Installation Manual - TitanPower-AL2DH

TitanPower-AL2DH Flush/Inclined Installation Manual
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WARNING!
For your safety, please read through this manual carefully before installation to minimize the risk of fire, property damage, and personal injury!
Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329 www.siliconsolar.com

Any work you perform must be adapted to suit conditions on site and must be in accordance with technical and local regulations. Installation must be carried out by technically qualified and authorized professional personnel who possess the required licensing, if applicable.
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SAFETY PRECAUTIONS
Only use components as intended and described in the Installation Manual; use other than described will void warranty and may cause property damage and personal injury. Working fluids can get very hot. Use care when handling/installing hydraulic components and filling/leak checking. Allow collectors to cool down if necessary. Ensure that hydraulic connections are water-tight. Keep components away from children and animals. Anti-freeze protection: The solar energy system may only be filled with antifreeze mixture. As it is not possible to empty the collectors completely, it is imperative that the system be filled with the antifreeze mixture, even for function tests. We recommend using premixed antifreeze mixtures; alternatively, the water and antifreeze must be mixed outside the solar energy system. Caution! As the collector can reach temperatures of over 200C, an antifreeze which is suitable for use in such conditions must be chosen (e.g. with a propylene glycol base).
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General
Bleeding of the solar circuit should be provided at the highest point of the hydraulic connection. If automatic bleed valves are used, it is imperative that additional ball valves be installed for manual closure of the system. These ball valves must be closed after filling the plant again. Otherwise, the antifreeze mixture might leak during high temperatures and steam build-up in the collector. The inclined mounting installation kit is for mounting the SunMaxx TitanPower-AL2DH type collectors vertically on a flat surface. It can also be used on roofs with a slight slope. Installation can be carried out with a variable tilt angle of between 45 and 60. Tilt angles of between 20 and 45 are also possible using additional components. The collectors must be mounted at an angle of more than 20. Installing the SunMaxx TitanPower-AL2DH type collectors flush vertically or horizontally on a roof can be used on roofs with slopes of 20 and above. The rafter anchors are available in variations for the following roof coverings: pan tiles and similar roof tiles, and plain tiles. Fastening elements are also available for corrugated slabs (e.g. corrugated sheeting, corrugated fibre cement). Alternatively, standing seam clamps for standing seam roofs or fastenings for other types of roofs can be combined with the system. These must be procured by the contractor from the local roofing supplier. Extra materials such as ventilation tiles for the roof opening for the collector array connections (available from specialist suppliers) and tin/lead sheets for sealing the rafter anchors on a plain tile covering may be required. Attention should be paid to the sealing of the roof. Drilling into the roof might not be permitted. If this is the case, concrete slabs must be laid as a foundation on the roof on site. These slabs must be heavy enough to withstand the wind loads at the location. In case of an uneven surface there is the option of using a continuous U-rail as a substructure (see parts list). Extra materials may be required for the roof opening for the collector array connections. This must be provided on site. In the case of a flat-roof installation, it is also necessary to plan a means of transporting the collectors onto the roof. When connected hydraulically, up to 10 collectors can be connected in series. If more than 10 collectors are connected, this must be done using a combination of series and parallel connection. An expansion joint kit must be used between every 2nd to 3rd collector of a series connection! If more

than 10 collectors are connected, this must be done using a combination of series and parallel connection. We recommend declaring the solar energy system to your insurer as added value to the building, and taking out insurance against lightning and possibly glass breakage
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Technical Instructions
Anti-freeze protection The solar energy system may only be filled with antifreeze mixture. As it is not possible to empty the collectors completely, it is imperative that the system be filled with the antifreeze mixture, even for function tests. We recommend using premixed antifreeze mixtures; alternatively, the water and antifreeze must be mixed outside the solar energy system. Caution! As the collector can reach temperatures of over 200C, an antifreeze which is suitable for use in such conditions must be chosen (e.g. with a propylene glycol base). Bleeding Bleeding of the solar circuit should be provided at the highest point of the hydraulic connection. If automatic bleed valves are used, it is imperative that additional ball valves be installed for manual closure of the system. These ball valves must be closed after filling the plant again. Otherwise, the antifreeze mixture might leak during high temperatures and steam build-up in the collector. Recycling We guarantee that we will take back and recycle our products once they have come to the end of their life cycle. We have already ensured that our products are suitable for recycling during the development stage. This is therefore guaranteed. Electrical connections A dedicated electrical circuit/circuit breaker should be provided for the solar system. Earthing and lightning protection If the building already has lightning protection, the solar system's metal pipes must be connected to the lightning protection by means of a green/yellow conductor of at least 6 mmCu (H07 V-U or R). Otherwise it is possible to earth the system to an earth rod.
Required Tools

10 mm masonry or wood drill bit and 13 mm socket wrench Spanners 13/ 17/ 19/ 20/ 22 Measuring tape
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Part 1: Inclined Mounting

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Components
No. Description Quantity basic kit 0 2 Quantity extension kit 0 2 Quantity expansion joint kit 0 2
Collector 1x supporting tube (K420) supporting tube 50 x 30 x 3 mm, L=1180 mm, aluminium (K420) supporting tube 50 x 30 x 3 mm, L=1180 mm, aluminium Ground fastening kit 2x U-piece, 60 x 60 x 5 mm, aluminium 4x 8 x 60 wood screw 4x 8.4 mm washer 4x 10 S-wall plug 1x protective cap, 50 x 30 mm 3x M10 x 85 hexagonal bolt 3x A10 spring washer 3x M10 hexagonal nut 1x 22 x 10.3 x 50 mm spacer sleeve 1.10 1.11 1.12 Collector fixing kit 4x T-piece, 60 x 40 x 6 mm, aluminium 8x M8 x 14 hexagonal bolt 2x 22 x 10.3 x 5 mm spacer sleeve 1.13 1x installation aid Connection kit 2x 22 mm x angle piece 2 x 2 mm end piece 4x 22 mm support sleeve Connection kit 2x 22 mm straight compression fitting 1.18 4x 22 mm support sleeve Expansion joint kit 4x 22 mm x angle piece 4x 22 mm support sleeve 2x 300 mm corrugated pipe with " union nuts and insulation tube 1.22 6x gasket 60 x 60 x 4 mm U-rail, L = 1180 mm * optional
1.14 1.15 1.16 1.17
1.19 1.20 1.21
2*
2*
2*
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Exploded View
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1. Preparing the Collectors
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A. Position the square nuts in the slot on the back of the collector with a screwdriver and secure them with the installation aid (4.4).
Using the installation aid, the nut can easily be positioned for further installation of the Tpieces when the collector (1) has been erected.
B. Preassemble four T-pieces (4.1) for each collector with M8 hexagonal bolts (4.2) on the square nuts in the slot on the rear of the collector. To do so, align the first square nut with the help of the long side of the installation aid (4.4). Attach the T-piece and screw in a hexagonal bolt. Align the second square nut by turning the installation aid and screw in another hexagonal bolt.
Pay attention to the orientation of the collector connections when installing the T-pieces.
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C. Determine the definitive lower spacing of the T-pieces (4.1) on the collector (1). As you do so, make sure you observe the spacing G of 40 mm from the bottom edge of the collector for the lower T-pieces. Screw the T-pieces tightly.
To avoid damage to the collector, the spacing G of 40 mm must be observed.
Tilt 45
Spacing H (K420) 1570 mm 1425 mm 1270 mm 1100 mm
Spacing H (K423) 1850 mm 1680 mm 1495 mm 1300 mm
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50 55 60
D. Determine the definitive upper spacing of the T-pieces (5.1/6.1) on the collector. The mounting angle is determined by the spacing H between the two T-pieces. Use the chart above for reference. Screw the T-pieces tightly.
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E.
To ensure that water can drain properly from the collector, it is absolutely essential that all drainage holes are punched at the bottom corners (depending on how the collector is mounted on the roof).
2. Installing the Collectors

Have the M10 hexagonal bolts (3.6), large spacer sleeves (3.9), spring washers (3.7) and M10 hexagonal nuts (3.8) ready for fastening the collector. If you lay the collector on the surface for a short time, it may be necessary to use an underlay to avoid damage to the frame. The help of a second person is required to position the collector and fix it in place.
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Installing One Collector
A. Attach the collector (1) to the front U-pieces (3.1). To do so, position the collector with the help of a second person. Attach the T-pieces (4.1) to the U-pieces using M10 hexagonal bolts (3.6), large spacer sleeves (3.9), spring washers (3.7) and M10 hexagonal nuts (3.8). B. Slowly tilt the collector (1) towards the supporting tubes (2). Attach the T-pieces using M10 hexagonal bolts (3.6), large spacer sleeves (4.3), spring washers (3.7) and M10 hexagonal nuts (3.8). Fasten all four T-pieces in place by tightening the M10 hexagonal bolts. Installing More Collectors
C. Insert one support sleeve (6.2) into the collector pipe of each basic kit collector to which another collector is to be connected. Next, attach compression fittings (6.1) to the collector pipes.

Have hexagonal bolts, small spacer sleeves, large spacer sleeves, spring washers and hexagonal nuts ready for the next collector.
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D. Fix the upper T-pieces (4.1) to the supporting tubes (2). To do so, preassemble the T-pieces using M10 hexagonal bolts (3.6), large spacer sleeves (4.3), spring washers (3.7) and M10 hexagonal nuts (3.8).
Keep supporting the collector until all M10 hexagonal bolts have been attached.
E.
Preassemble the lower T-pieces to the U-pieces using M10 hexagonal bolts (3.6), large spacer sleeves (3.9), spring washers (3.7) and M10 hexagonal nuts (3.8). Screw tight all M10 hexagonal bolts with spring washers and M10 hexagonal nuts.
Keep supporting the collector until all M10 hexagonal bolts have been attached.
F.
Screw the compression fittings (6.1) tight.

Make sure the fitting is snug to the collector pipes. Do not over tighten the connection (hand tight + spanner turn). Use two spanners so that there is no tension on the absorber.
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3. Hydraulic Connections
Because of its 4 connections, the collector offers a wide choice of connection options. Ensure that no part of the collector array or collector in the array is short circuited. When planning the collector array, the position of the various connection parts must be in accordance with the diagrams. The numbering in the diagrams corresponds with the numbering in the parts list. To ensure the full flowthrough of the collector array, the positions of the immersion sleeves must be observed! There are enough connectors supplied to arrange the collectors as shown in the diagrams. If other arrangements are chosen, extra connectors may be required.
A. B. C.
Diagram 1 shows the connections for connecting one collector. The immersion sleeves must be on the side of the end pieces (5.2). Diagram 2 shows how to connect 3 collectors with the positions of the parts of the connection and joining kit (5/6) (the position of the immersion sleeves must be observed here as well). For installing two collectors, the connections correspond with the outer collectors in diagram 2. The collector in the middle is omitted in this case. If more collectors are to be connected directly to the collector array, an expansion joint kit
must be used. Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329 www.siliconsolar.com
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Connecting More Collectors

D.
Adding more collectors is carried out in the same way as the standard installation, with the measurements given in the base fastening chapter. Install the U-profiles of the expansion joint kit at a distance of 375 mm from the U-profile of the extension kit (measure from the middle of each U-profile) in order to create a spacing E of 250 mm between the collectors. Install the next collector (see chapter on collector installation) and connect it to the last collector.
E.
Install the expansion joints. To do so, attach the support sleeves (7.2) and 22 mm x " angle pieces (7.1) to the collector pipes. Screw the compression fitting, attach the corrugated pipe (7.3) with a gasket (7.4) and tighten. Push the previously pulled back insulation tube over the angle piece until it meets the collector frame.
Do not over tighten the compression fitting (hand tight + spanner turn). Use two spanners so that there is no tension on the absorber. Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329 www.siliconsolar.com
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F.
Install connection parts (5).To do so, attach the support sleeves (5.3) and 22 mm x " angle pieces (5.1) to the corresponding collector connections. Screw the compression fitting.
A bleed valve (to be provided on site) should be planned at the highest point of the hydraulic connection to ensure that the solar power system can be completely bled.
G.
Attach the end pieces (5.2) with support sleeves (5.3) to the open collector connections and tighten.
Do not overtighten the compression fitting (hand tight + spanner turn). Use two spanners so that there is no tension on the absorber.
4.
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Installing the Sensor
A. Carefully remove the plugs from the collector housing.
B. Slide the plugs over the temperature sensor (included with the solar controller).
C. Coat the temperature sensor with heat-conducting paste (included with the solar controller).
Part 1: Inclined Mounting

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Components
Silicon Solar Inc, Solar Park, Bainbridge, NY 13733 USA Ph: 607-563-7865 Fax: (866) 746-5508 www.siliconsolar.com
No.
Designation
Quantity basic kit
Collector Rail, 1,155 mm Rail, 1,242 mm Collector fixing kit 1.23 4x M8 x 14 hexagonal bolt 1.24 4x mounting profile (Z-hooks) 1.25 4x 8.4 mm washer 1.26 1x installation aid 1.27 2x M8 x 10 hexagon socket head cap screw
Page | 20 Rafter anchor for pantiles (variation A)
Quantity Quantity extension expansio kit n joint kit TitanPower-AL2DH 0 0 0 2 0 2Flush/Inclined Installation 2 0 Manual 0 1 1
4 2
2 1
4 2
Rafter anchor kit 1.28 4x 10 wood screw 1.29 2x M10 hexagonal bolt 1.30 6x 10.5 mm washer 1.31 2x M10 hexagonal nut 1.32 2x slot nut 1.33 4x wooden equalisation board (2 x 5 mm, 2 x 10 mm thick) Rail connection kit 1.34 2x rail connector 1.35 4x M8 x 50 hexagonal bolt 1.36 8x 8.4 mm washer 1.37 4x M8 hexagonal nut 1.38 2x 90 mm self-adhesive spacer Rail end set 1.39 4x rail connector 1.40 4x end piece 1.41 4x M8 x 50 hexagonal bolt 1.42 8x 8.4 mm washer 1.43 4x M8 hexagonal nut Corrugated pipe, 800 mm 1.44 1x 800 mm corrugated pipe with union nuts and insulation tube 1.45 3x seal Connection kit 1.46 2x 22 mm x angle piece 1.47 2 x 22 mm end piece 1.48 4x 22 mm support sleeve Connection kit 1.49 2x 22 mm straight compression fitting 1.50 4x 22 mm support sleeve
Expansion joint kit 0 0 1 1.51 4x 22 mm x angle pieces 1.52 4x 22 mm support sleeve 1.53 2x 300 mm corrugated pipe with Silicon nuts and insulation tube union Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329 www.siliconsolar.com 1.54 6x seal Rafter anchor for plain tiles (variation B) 4* 2* 4*
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Rafter Anchor and Hanger Bolt Installation

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A in m K420 K423 1,2 1,5 1,5 1,8
Vertical Installation For vertical installation, the rails (2/3) are installed horizontally. The distance A of the profile rail can be taken from the adjoining table. The distances B and C from the rails to the outer edge of the collector must be between 150 and 350 mm.
Up to 10 collectors can be connected in series (1 basic kit and 9 extension kits).
A in m K420 K423 0,9 1,5 1,2 1,8
Horizontal Installation For horizontal installation, the rails (2/3) are installed vertically. The distance A of the profile rail can be taken from the adjoining table. The distances B and C from the rails to the outer edge of the collector must be between 150 and 500 mm.
Up to 10 collectors can be connected in series (1 basic kit and 9 extension kits). Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329 www.siliconsolar.com
1. Pan tiles and similar roof tiles:

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A. Remove one (or more) roof tiles above the planned installation position of each rafter anchor (5). The horizontal spacing is derived from the rafter spacing and the vertical spacing is derived from the roof tiles. The number of rafter anchors is derived from the size of the collector array (basic kit: 4 rafter anchors, extension kit: 2 rafter anchors)
A. Fix each rafter anchor (5) to the roof Page | 25
rafters with 2 wood screws (6.1) and washers (6.3).
The rafter anchors (5) must not rest on the roof tiles! A spacing of 5 mm must be kept between the rafter and the roof tile. If necessary, underlay the rafter anchors with equalisation boards (6.6).
The screws (6.1) must enter into the wood to a depth of at least 40 mm
B. Cut a recess in the upper tile with an angle
grinder at the point where the rafter anchor (5) comes through.
A. Determine the position of the rafter anchor (5) so that it is located in the trough of the roof tile. Mark two fixing points on the rafter for each rafter anchor and pre-drill them with a 6 mm wood drill bit.
B. If necessary, cut a recess in the lower tile with an angle grinder at the point where the rafter anchor (5) comes through. Pay particular attention to the leak-tightness of the roof at the position where the rafter anchor comes through. The roof hook must not exert any pressure on the roof tile.
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C. Replace the upper roof tile
Pay particular attention to the leak-tightness of the roof at the position where the rafter anchor comes through. The roof tile must not be pushed up by the rafter anchor (5).
B. Plain Tiles
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A. Remove several roof tiles above the planned installation position of each rafter anchor (13). The spacing to the side is derived from the rafter spacing and the number of rafter anchors. The spacing between the rails must be observed as described on Page 6.
B. Determine the position of the rafter anchor (13) so that it is located on a roof rafter directly above a roof batten. Mark two fixing points on the roof rafter for each rafter anchor and pre-drill them with a 6 mm wood drill bit.
A. Fix the rafter anchors (13) to the roof rafters using wood screws (6.1) and the washers which go with these (6.3).
The wood screws must enter into the wood to a depth of at least 40 mm.

B. Using an angle grinder, at the point where the rafter anchor (13) comes through, cut a recess in the upper tile which overlaps the crown of the rafter anchor.
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C. Replace the roof tiles.

Pay particular attention to the leaktightness of the roof at the position where the rafter anchor comes through.
D. Cover each rafter anchor (13) with a metal sheet.
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A. As you do so, hang the plate with the standing seam edge on the upper edge of the roof tiles and fix it here. Replace the roof tiles.
2. Corrugated Slabs
A. In accordance with the planning, pre-drill
the corrugated slabs at the crest with a 14 mm drill bit. Remove existing hanger bolts as an alternative. The spacing to the side is derived from the rafter spacing and the number of rafter anchors. The spacing between the rails must be observed as described on Page 9.
Do not drill the rafters! B. Pre-drill the rafters through the hole in the
corrugated slab with an 6 mm wood drill bit.
C. Insert the hanger bolt (14.1) though the Page | 30
hole in the corrugated sheet and screw it into the pre-drilled rafter.
The hanger bolt must not exert any pressure on the corrugated slab!
D. Seal the hole on the crest of the roof
covering with seal (14.3). To do so, slide the seal with the flat side facing upwards onto the hanger bolt (14.1) up to the level of the fibre cement corrugated slab. Next, carefully secure the seal with an M10 hexagonal nut (14.2).
E. Attach the rail holder (14.4) to the hanger bolt (14.1) using two M10 hexagonal nuts (14.2).
3. Assembling The Rails

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A. According to the number of rafter anchors (5/13/14), feed an M10 hexagonal bolt (6.2) with a slot nut (6.5) into the rail (2/3).
The rails can be pre-assembled on the ground.
B. Extend the rail (2/3) with a rail connector (7.1). To do so, slide the rail connector into the ends of two rails (2/3) and screw it in place with two M8 hexagonal bolts (7.2) and M8 hexagonal nuts (7.4) with washers (7.3).
C. Fix two rail end pieces (8) to one side of the collector array. Attach one rail end piece consisting of a rail connector (8.1) and the end piece (8.2) per rail string as a stop for the first collector (1).
To do so, slide the assembled end piece into the rail (2/3) and screw it in place with an M8 x 50 hexagonal bolt (8.3), a washer (8.4) and an M8 hexagonal nut (8.5).
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4A. Installing the Rails on the Roof (Vertically)
A. Lock the lower rail (2/3) with the studs into the mounting profiles (4.2); mount the rail facing
upwards. To do so, position the M10 hexagonal bolt (6.2) with slot nut (6.5) in the rail according to the positions of the rafter anchors and fix it to the rafter anchor (5/13/14) by hand with a washer (6.3) and an M10 hexagonal bolt (6.4).
B. Attach the upper rail (2/3) as described in steps 1 to 5 and position it sideways.

To do so, position the rails with respect to each other so that the diagonals D and E are of equal length. Mark the correct position before installing them. Next, fasten both rails in place by tightening the M10 hexagonal bolts (6.4).
Page | 33 The rail end pieces (8) must be on the side where the first collector is to be installed. 4A.
Installing the Rails on the Roof (Horizontally)
A. Mount the first rail (2/3). Lock the stud into the mounting profiles (4.2), align to a side. To do so, position the M10 hexagonal bolt (6.2) with slot nut (6.5) in the rail according to the positions of the rafter anchors and fix it to the rafter anchor (5/13/14) by hand with a washer (6.3) and an M10 hexagonal bolt (6.4).
B. Attach the second rail (2/3) as described in steps 1 to 4.1 and position it vertically. To do so, position the rails with respect to each other so that the diagonals D and E are of equal length. Mark the correct position before installing them. Next, fasten both rails in place by tightening the M10 hexagonal bolts (6.4).
The rail end pieces (8) must be at the bottom end of the rails. Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329 www.siliconsolar.com
5. Installing the Collectors

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A. Position the square nuts in the slot on the back of the collector with a screwdriver and secure them with the installation aid (4.4).
Using the installation aid, the square nut can easily be positioned for further installation of the fixing profile (4.2) when the collector (1) has been erected.
B.Preassemble the mounting profile (4.2) with an M8 hexagonal bolt (4.1) and washer (4.3) on the square nuts on the rear side of the collector.
C. Determine the lower spacing C of the mounting profiles (4.2) on the collector. To do so, keep a distance of 150-350 mm between the lower edge of the collector and the lower mounting profile for vertical installation and 150-500 mm for horizontal installation. Attach the upper mounting profiles in accordance with the spacing A of the rails (2/3) to the lower mounting rails. The distance B to the top edge of the collector must also be within the range given above. The mounting profiles must be facing downwards. Preassemble the securing screw (4.5) 100 mm beneath the lower mounting profiles.

D. Optional Extension kit collectors For Vertical Installation: Installing the mounting profiles for vertical installation. Use the dimensions from the basic kit collectors for the spacings C. The mounting profiles (4.2) must be facing outwards so that the collector can be positioned onto the rails (2/3). Preassemble the upper mounting profiles as for security. The spacing A is derived from the rail spacing plus 5 mm. The upper mounting profiles must be pointing downwards and are only put in their final position once they are on the roof. Preassemble the securing screw (4.5) beneath the lower mounting profiles.
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E. Punch the two drainage holes at each bottom corner of the collector, according to how it is positioned on the roof, with the aid of a slotted screwdriver. To do so, punch at the bottom edge.
To ensure that water can drain properly from the collector, it is absolutely essential that all drainage holes are punched at the bottom of the collector (depending how it is oriented on the roof).
F. Hoist the collectors (1) onto the roof. For hoisting onto the roof, fix two sufficiently sturdy ropes to the collector as shown in the diagram. When doing so, make sure that the ropes are not fed over the plastic edges of the collector. We recommend using a crane for doing the lifting. If necessary, carefully hoist the collector up onto the roof via a ladder. Work as a pair: one installer secures the collector, the second guides it.
Observe the labour safety regulations! Do not walk under suspended loads. Secure the collectors (1) to prevent them falling! Silicon Solar Inc, 56 Broome Corp. Pkwy, Conklin, NY 13748 USA Ph: 877-786-6299 Fax: 800-786-0329 www.siliconsolar.com

G. Carefully lift the basic kit collector (1) onto the rails (2), remove the hoisting guys and position the collector. To do so, position the collector against the rail end pieces (8) and slowly let it slide downwards until the mounting profiles (4.2) lock into the rails (2). Next, position the securing screws (4.5) against the rail from underneath and tighten it. H. Carefully lift the basic kit collector (1) onto the rails (2), remove the hoisting guys and position the collector. To do so, let the collector slowly slide downwards against the rail end pieces (8) and move it sideways until the mounting profiles (4.2) lock into the rails (2). Next, position the securing screws (4.5) against the rail from the side and tighten it.
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I. Installing More Collectors: For both horizontal and vertical installation, first stick the spacer (7.5) onto the rails with the stopper against the first collector. The next collector must be positioned next to the spacers. Insert 2 support sleeves (11.2) into the collector pipes of the basic kit collector which are to be connected. Attach the compression fitting (11.1) to the collector pipes.
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J1.
(Vertical installation Only). Position another collector (1) with the lower, outward-facing mounting profiles (4.2) on the lower rail (3) and feed it onto the compression fitting by moving the collector on the rails (3). Before doing so, insert 2 support sleeves (11.2) into the collector pipes.
J2.
(Horizontal Installation Only). Position another collector (1) on the rails (3) and move it sideways until the mounting profiles (4.2) lock into the rails. Let the collector slowly slide downwards and insert the collector pipes into the compression fitting. Before doing so, insert 2 support sleeves into the collector pipes. Next, position the securing screws (4.5) against the rail from the side and tighten it.
6. Hydraulic Connection
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Because of its 4 connections, the collector offers a wide choice of connection options. Ensure that no part of the collector array or collector in the array is short circuited. When planning the collector array, the position of the various connection parts must be in accordance with the diagrams. The numbering in the diagrams corresponds with the numbering in the parts list.
To ensure the full flow-through of the collector array, the positions of the immersion sleeves must be observed! There are enough connectors supplied to arrange the collectors as shown in the diagrams. If other arrangements are chosen, extra connectors may be required.
A. Diagram 1 shows the connections for connecting a collector. The immersion sleeves must be on the side of the end pieces (10.2). B. Diagram 2 shows how to connect 3 collectors with the positions of the parts of the connection and joining kit (10/11) (the position of the immersion sleeves must be observed here as well). C. For installing two collectors, the connections correspond with the outer collectors in diagram 2. The collector in the middle is omitted in this case. If more collectors are to be connected directly to the collector array, an expansion joint kit must be used.
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D. Connecting more collectors: attach the rails of the expansion joint kit (2) alongside the rails of the extension kit with a spacing E of 250 mm (see chapter on rafter anchor and hanger bolt installation). Install the joint expansion kit collector (see chapter on on-roof installation of basic kit collector) and connect to the extension kit collector. E. Install the expansion joints. To do so, attach the support sleeves (12.2) and 22 mm x angle pieces (12.1) to the collector pipes. Screw on the compression fitting, attach the corrugated pipe (12.3) with a gasket (12.4) and tighten. Push the previously pulled back insulation tube over the angle piece until it meets the collector frame.

F. Replace one roof tile with a ventilation tile above each connecting pipes (9.1) feed-through.
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Page | 41
G. Feed the connecting pipes (9.1) through the ventilation tile into the interior of the building. Next, if necessary, seal the sarking membrane with suitable adhesive tape.
The piping (9.1) should be laid so that it rises upwards in order to allow ventilation at the highest point of the solar energy system.
H. Install the connecting pipes (9.1) to each of the external collector connections. To do so, attach the support sleeves (10.3) and 22mm x angle pieces (10.1) to the collector pipes. Screw on the compression fitting, attach the corrugated pipe (9.2) with a gasket. Tighten the screw fitting. Push the previously pulled back insulation tube over the connection until it meets the collector frame. Attach the end pieces (10.2) with support sleeves (10.3) to the open collector pipe ends and tighten.
7. Installing The Sensor

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A. Carefully remove the plugs from the collector frame.
B. Slide the plugs over the temperature sensor (included with the solar controller).
C. Coat the temperature sensor with heatconducting paste (included with the solar controller).
D. Insert the temperature sensor fully into the immersion sleeve. Seal the collector frame with plugs. To do so, make sure that the plugs are positioned correctly.

Installation Manual - TitanPower-AL2DH

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Installation Manual - TitanPower-AL2DH

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TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

Part 1: Inclined Mounting

1.14 1.15 1.16 1.17

1.19 1.20 1.21

TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

1. Preparing the Collectors

TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

Spacing H (K420) 1570 mm 1425 mm 1270 mm 1100 mm

Spacing H (K423) 1850 mm 1680 mm 1495 mm 1300 mm

TitanPower-AL2DH Flush/Inclined Installation Manual

2. Installing the Collectors

TitanPower-AL2DH Flush/Inclined Installation Manual

Installing One Collector

TitanPower-AL2DH Flush/Inclined Installation Manual

Screw the compression fittings (6.1) tight.

TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

Connecting More Collectors

TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

Installing the Sensor

A. Carefully remove the plugs from the collector housing.

TitanPower-AL2DH Flush/Inclined Installation Manual

Part 1: Inclined Mounting

Quantity basic kit

TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

Rafter Anchor and Hanger Bolt Installation

A in m K420 K423 1,2 1,5 1,5 1,8

TitanPower-AL2DH Flush/Inclined Installation Manual

1. Pan tiles and similar roof tiles:

TitanPower-AL2DH Flush/Inclined Installation Manual

A. Fix each rafter anchor (5) to the roof Page | 25

rafters with 2 wood screws (6.1) and washers (6.3).

TitanPower-AL2DH Flush/Inclined Installation Manual

C. Replace the upper roof tile

TitanPower-AL2DH Flush/Inclined Installation Manual

TitanPower-AL2DH Flush/Inclined Installation Manual

C. Replace the roof tiles.

D. Cover each rafter anchor (13) with a metal sheet.

TitanPower-AL2DH Flush/Inclined Installation Manual

corrugated slab with an 6 mm wood drill bit.

TitanPower-AL2DH Flush/Inclined Installation Manual

C. Insert the hanger bolt (14.1) though the Page | 30

D. Seal the hole on the crest of the roof

TitanPower-AL2DH Flush/Inclined Installation Manual

3. Assembling The Rails

TitanPower-AL2DH Flush/Inclined Installation Manual

4A. Installing the Rails on the Roof (Vertically)

TitanPower-AL2DH Flush/Inclined Installation Manual

Installing the Rails on the Roof (Horizontally)

TitanPower-AL2DH Flush/Inclined Installation Manual

5. Installing the Collectors