Silicon Solar Inc

Innovative Solar Solutions

TM

Solar Thermal Systems

SunMaxx

SunMaxx-M2 Flat Plate Collector

Instructions - Flush Mounting Installation System

EXPLOSION DRAWING

SunMaxx M2 Flush Mounting Installation System

PARTS LIST
Quantity basic kit 0 2 0 1 Quantity extension kit 0 0 2 1

No. Designation 1 2 3 4 Collector Rail, 1,155 mm Rail, 1,172 mm Collector fixing kit 4.1 4x M8 x 14 hexagonal bolt 4.2 4x mounting profile (Z-hooks) 4.3 4x 8.4 mm washer 4.4 1x installation aid 4.5 2x M8 x 10 hexagon socket head cap screw Rafter anchor for pantiles (variation A) Rafter anchor kit 6.1 4x 10 wood screw 6.2 2x M10 hexagonal bolt 6.3 6x 10.5 mm washer 6.4 2x M10 hexagonal nut 6.5 2x slot nut 6.6 4x wooden equalisation board (2 x 5 mm, 2 x 10 mm thick) Rail connection kit 7.1 2x rail connector 7.2 4x M8 x 50 hexagonal bolt 7.3 8x 8.4 mm washer 7.4 4x M8 hexagonal nut 7.5 2x 20 mm self-adhesive spacer Rail end set 8.1 4x rail connector 8.2 4x end piece 8.3 4x M8 x 50 hexagonal bolt 8.4 8x 8.4 mm washer 8.5 4x M8 hexagonal nut Corrugated pipe, 800 mm 9.1 1x 800 mm corrugated pipe with 12 mm compression fitting and insulation tube 9.2 1 x 12 mm support sleeve 9.3 2 x seal

5 6

4 2

2 1

10 Corrugated pipe, 250 mm 10.1 1x 250 mm corrugated pipe with 12 mm compression fittings and insulation tube 10.2 2 x 12 mm support sleeve 11 Rafter anchor for plain tiles (variation B) 12 Corrugated slab fastening (variation C) 12.1 1x hanger bolt 12.2 3x M10 hexagonal nut 12.3 1x seal 12.4 1x rail holder * optional

4* 4*

2* 2*

SunMaxx M2 Flush Mounting Installation System

GENERAL
The on-roof installation kit is for installing the K4-EM2S type collectors vertically or horizontally on a roof. It 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.

In some cases it is necessary to plan a means of transporting the collectors onto the roof. We recommend considering roof access near to the collectors so that checking and maintenance work can be carried out more easily. When connected hydraulically, up to 3 K4-EM2S collectors can be connected in series. If more than 3 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.

SAFETY INSTRUCTIONS
The installation and safety instructions must be observed and adhered to. The accident prevention regulations of the trade associations must be adhered to, particularly when working on the roof. Where there is a danger of falling, precautions must absolutely be taken. The entire solar energy system must be installed and operated in accordance with the recognised technical regulations. Due to snow and wind loads, extreme forces can be at work on the collector fixings. Attention should therefore be paid to carrying out the installation carefully. The roof construction (rafters) must be capable of withstanding the additional load. Furthermore, care must be taken that the snow and wind loads are discharged into the roof construction at certain points. It may be necessary to consult a structural engineer. In case of snow loads of zone 3 and above, and installation locations more than 600 m above sea level, we ask that you enquire with us about the static test. When installing the collectors towards the edges of the roof, a minimum gap of 1.5 m from the eave and of 1.2 m from the ridge must be observed. If this minimum gap cannot be observed, a structural engineer must be consulted.

SunMaxx M2 Flush Mounting Installation System

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
The solar circuit must generally be bled below the roof. 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 mm Cu (H07 V-U or R). Otherwise it is possible to earth the system to an earth rod.

Pictograms
Here you will find important instructions which must be observed under all circumstances. Here you will find notices regarding dangers concerning health, damage to equipment and financial losses.

Required tools
Cordless screw driver with 6 mm wood drill bit, 13 mm socket wrench and 14 mm masonry drill bit Angle grinder with stone cutoff wheel Spanners 13/ 17/ 19/ 20/ 22 Measuring tape 6 mm Allen key

SunMaxx M2 Flush Mounting Installation System

RAFTER ANCHOR AND HANGER BOLT INSTALLATION

Vertical

1. The collector array can be installed vertically or horizontally. For vertical installation, the rails (2/3) are installed horizontally. The distance A of the profile rail can be
A in m M2 1,2 1,5

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 3 collectors can be connected in series (1 basic kit and 2 extension kits).
Horizontal

2. 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 3 collectors can be connected in series (1 basic kit and 2 extension kits).
M2

A in m 0,9 1,5

A. Pan tiles and similar roof tiles

1. 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)

2. 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.

SunMaxx M2 Flush Mounting Installation System

RAFTER ANCHOR AND HANGER BOLT INSTALLATION

3. 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.

4. Fix each rafter anchor (5) to the roof rafters with 2 wood screws (6.1) and washers (6.3). The screws (6.1) must enter into the wood to a depth of at least 40 mm. 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).

5. Cut a recess in the upper tile with an angle grinder at the point where the rafter anchor (5) comes through.

6. 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).

SunMaxx M2 Flush Mounting Installation System

RAFTER ANCHOR AND HANGER BOLT INSTALLATION

B. Plain tiles
1. Remove several roof tiles above the planned installation position of each rafter anchor (11). 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.

2. Determine the position of the rafter anchor (11) 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.

3. Fix the rafter anchors (11) to the roof rafters using wood screws (6.1) and the washers which go with these (6.3). The wood screws (6.1) must enter into the wood to a depth of at least 40 mm.

4. Using an angle grinder, at the point where the rafter anchor (11) comes through, cut a recess in the upper tile which overlaps the crown of the rafter anchor.

SunMaxx M2 Flush Mounting Installation System

RAFTER ANCHOR AND HANGER BOLT INSTALLATION

5. Replace the roof tiles.

Pay particular attention to the leak-tightness of the roof at the position where the rafter anchor comes through.

6. Cover each rafter anchor (11) with a metal sheet.

7. 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. Once all the roof tiles have been replaced, check the leak-tightness of the roof!

C. Corrugated slabs
1. 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 6. Do not drill the rafters!

SunMaxx M2 Flush Mounting Installation System

RAFTER ANCHOR AND HANGER BOLT INSTALLATION

2. Pre-drill the rafters through the hole in the corrugated slab with an 6 mm wood drill bit.

3. Insert the hanger bolt (12.1) though the hole in the corrugated sheet and screw it into the pre-drilled rafter. The hanger bolt (12.1) must not exert any pressure on the corrugated slab!

4. Seal the hole on the crest of the roof covering with seal (12.3). To do so, slide the seal with the flat side facing upwards onto the hanger bolt (12.1) up to the level of the fibre cement corrugated slab. Next, carefully secure the seal with an M10 hexagonal nut (12.2).

5. Attach the rail holder (12.4) to the hanger bolt (12.1) using two M10 hexagonal nuts (12.2).

SunMaxx M2 Flush Mounting Installation System

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ASSEMBLING THE RAILS

1. According to the number of rafter anchors (5/11/12), 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.

2. 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).

3. 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) 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).

SunMaxx M2 Flush Mounting Installation System

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INSTALLING THE RAILS ON THE ROOF

Vertical

4. 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 (5/11) by hand with a washer (6.3) and an M10 hexagonal bolt (6.4).

Vertical

5. Attach the upper rail (2/3) as described in steps 1 to 3 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). The rail end pieces (8) must be on the side where the first collector is to be installed.

Horizontal

4.1 Mount the first rail (2/3). Lock the stud into the mounting profiles (4.2), align towards the planned position of the collector connections. 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 (5/11) by hand with a washer (6.3) and an M10 hexagonal bolt (6.4).

Horizontal

5.1 Attach the second rail (2/3) as described in steps 1 to 3 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.

SunMaxx M2 Flush Mounting Installation System

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PREPARING THE COLLECTORS

1. 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.

2. 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.

3. Determine the definitive lower spacing C of the mounting profiles (4.2) on the collector. To do so, keep a distance from the lower edge of the collector of 150350 mm for vertical installation and 150-500 mm for horizontal installation. Attach the upper mounting profiles (4.2) in accordance with the spacing A of the rails (2/3) to the lower mounting rails (4.2). 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.

4. 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).

SunMaxx M2 Flush Mounting Installation System

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INSTALLING THE COLLECTORS ON THE ROOF

5. 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!
Vertical

6. Carefully lift the 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.

Horizontal

6.1 Carefully lift the 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.

7. 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. Install another collector as described in subsection 5 and 6 or 6.1. This collector must be positioned next to the spacers. After installing the last collector, attach two rail end pieces (8) to the open ends of the rails (2/3).

SunMaxx M2 Flush Mounting Installation System

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HYDRAULIC CONNECTION
1. Replace one roof tile with a ventilation tile above each connecting pipes (9.1) feed-through.

2. 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.

3. Install the connecting pipes (9.1) to each of the external collector connections. To do so, insert the support sleeve (9.2) into the connecting pipe. Push the screw connection until it meets the collector connections. Tighten the nut by hand first, then tighten by one turn with the spanner. Push the previously pulled back insulation tube over the connection until it meets the collector frame. When tightening, make sure you keep the screw fitting tight with a second spanner in order to prevent damage to the collector!

4. Connect the collectors together in series. To do so, attach the connection pipe (10.1) to the appropriate collector connection. Insert the support sleeves (10.2) into the connecting pipes. Push the screw connection until it meets the collector connections. Tighten the nut by hand first, then tighten by one turn with the spanner. Push the previously pulled back insulation tube over the connection until it meets the collector frame.

SunMaxx M2 Flush Mounting Installation System

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INSTALLING THE SENSOR

1. Carefully remove the plugs from the collector frame.

2. Slide the plugs over the temperature sensor (included with the solar controller).

3. Coat the temperature sensor with heat-conducting paste (included with the solar controller).

4. 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.

SunMaxx M2 Flush Mounting Installation System

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