Buderus SKR6.1R, SKR12.1R Installation And Maintenance Instructions Manual
Installation and
maintenance instructions
Vacuum tube
collectors
6 720 647 042-00.1ITL
SKR6.1R, SKR12.1R
Rooftop installation
6 720 647 057 (2011/05) GB
For contractors
Read carefully
prior to installation
and maintenance.
Table of contents
Table of contents
1 Key to symbols and safety instructions . . . . . 3
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . 3
1.2 General safety information . . . . . . . . . . . . . . 3
2 Product information . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Components and instructions . . . . . . . . . . . 4
2.2 Correct usage . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 EU Declaration of Conformity . . . . . . . . . . . 5
2.4 Standard delivery . . . . . . . . . . . . . . . . . . . . . 6
2.4.1 Mounting bracket . . . . . . . . . . . . . . . . . . . . . 6
2.4.2 Installation set . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4.3 Connection sets (hydraulic connection) . . . 7
2.4.4 Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Specification . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Before installation . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Determining space requirements . . . . . . . . 9
4.2 Planning the hydraulic connection . . . . . . 10
4.3 General notes . . . . . . . . . . . . . . . . . . . . . . . 11
4.4 Required tools and accessories . . . . . . . . 11
4.5 Lightning protection . . . . . . . . . . . . . . . . . . 11
4.6 Installation order . . . . . . . . . . . . . . . . . . . . . 11
7 Rail installation . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.1 Installing the vertical rails . . . . . . . . . . . . . . 20
7.2 Installing horizontal rails and clamps . . . . . 21
7.3 Installing the clampings onto the
vertical rails . . . . . . . . . . . . . . . . . . . . . . . . . .22
8 Installing the collectors . . . . . . . . . . . . . . . . . . 23
8.1 Fitting the first collector . . . . . . . . . . . . . . . 23
8.2 Fitting the second collector . . . . . . . . . . . . 24
8.3 Installing the collector sensor . . . . . . . . . . 24
8.4 Fitting the bridging set (accessory) . . . . . . 25
9 Hydraulic connection . . . . . . . . . . . . . . . . . . . . 26
10 Final steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.1 Checking the installation . . . . . . . . . . . . . . 28
10.2 Pressure filling, flushing, venting . . . . . . . . 28
10.3 Adjusting the pre-charge pressure of
the expansion vessel . . . . . . . . . . . . . . . . . .28
10.4 Determining and setting the operating
pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
10.5 Adjusting the flow rate . . . . . . . . . . . . . . . . 28
10.6 Insulating piping . . . . . . . . . . . . . . . . . . . . . 28
11 Replacing individual tubes . . . . . . . . . . . . . . . 29
5 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Fitting the mounting bracket . . . . . . . . . . . . . 13
6.1 Determining distances . . . . . . . . . . . . . . . . 13
6.1.1 Vertical distances for the mounting
brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1.2 Horizontal distances for the mounting
brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2 Installing mounting brackets on roof
tile roofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.3 Installing mounting brackets on plain
tile roofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.4 Installing mounting brackets on roofs
with monk/nun tiles . . . . . . . . . . . . . . . . . . . 17
6.5 Installing mounting brackets on slate
roofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
12 Environmental protection/disposal . . . . . . . 30
13 Maintenance/inspection . . . . . . . . . . . . . . . . . 31
2
SKR6.1R, SKR12.1R - Subject to technical modifications.
Key to symbols and safety instructions
1 Key to symbols and safety instructions
1
1.1 Explanation of symbols
Warning symbols
Safety instructions in this document are
framed and identified by a warning triangle
which is printed on a grey background.
Electrical hazards are identified by a lightning
symbol surrounded by a warning triangle.
Signal words indicate the seriousness of the hazard in
terms of the consequences of not following the safety
instructions.
• NOTICE indicates possible damage to property or
equipment, but where there is no risk of injury.
• CAUTION indicates possible injury.
• WARNING indicates possible severe injury.
• DANGER indicates possible risk to life.
Important information
Notes contain important information in cases
where there is no risk of personal injury or
material losses and are identified by the
symbol shown on the left. They are bordered
by horizontal lines above and below the text.
1.2 General safety information
Danger of falling when working on the roof
B If there are no general anti-fall safety devices, wear
personal protective clothing or safety equipment.
B Take appropriate action to prevent accidents during all
work on roofs.
B Observe accident prevention regulations.
Danger when installing collectors above walk/
driveways
Should the glass tubes be shattered, there is a risk of
injury through glass splinters if anyone is below the
collector array.
B Avoid installation above walkways.
Risk of burns on the collectors
Some parts may cause burns, if the vacuum tube collector
and installation materials are exposed to solar radiation for
prolonged periods of time.
B Wear personal safety equipment.
B Protect the collector and installation materials from
solar radiation (e.g. with a tarpaulin).
Installation
Installation and maintenance must only be carried out by
an authorised contractor. Never modify components.
Additional symbols
Symbol Meaning
B a step in an action sequence
Æ a reference to a related part in the
document or to other related documents
• a list entry
– a list entry (second level)
Tab. 1
B Please read these instructions carefully.
B Install the installation set only on roofs with sufficient
load-bearing capacity. If necessary, consult a structural
engineer and/or roofer.
B Collectors must never be walked on and must never be
subject to loads from other objects.
B After completing the installation, check that the
installation set and the collectors are securely
positioned.
Function checks
The operator is responsible for the safety and
environmental compatibility of the system.
B Customers are recommended to arrange a
maintenance and inspection contract with an approved
contractor.
B Only original spare parts must be used.
Instructing the customer
B Instruct customers in the functions and operation of the
appliance as well as the operation of the system as a
whole.
B Inform customers that they must not carry out any
modifications or repairs.
B Hand over the installation instructions to the customer
and inform him/her that these are to be retained and
passed on to any future owner/user.
SKR6.1R, SKR12.1R - Subject to technical modifications.
3
2
Product information
2 Product information
Regarding these instructions
On the following pages, the vacuum tube collector will
simply be referred to as the collector. Roofing in the form
of pantiles, roof tiles, stone tiles, etc. will be uniformly
referred to as roof tiles.
These instructions describe the installation of collectors
(including their hydraulic connection) for the following
covers on pitched roofs:
• Roof tiles, plain tiles, monk/nun tiles and slate shingles.
2.1 Components and instructions
A solar thermal system for heating domestic hot water
and/ or central heating backup comprises various
components (Æ Fig. 1). These are supplied with
instructions regarding their installation, operation and
maintenance. Some accessories are supplied with
separate instructions. The following subjects are
described in the component instructions:
Collectors (Æ Fig. 1, [1])
• Installing the roof connections
• Securing collectors
• Hydraulic collector connection
• Collector maintenance
Solar pump station (Æ Fig. 1, [2])
• Installation of the solar pump station
• Pipework installation
• Commissioning the overall system
• Maintenance of the solar pump station
• Maintenance of the overall system
Cylinder (Æ Fig. 1, [3])
• Siting and installing the cylinder
• Commissioning the cylinder
• Cylinder maintenance
Solar controller (Æ Fig. 1, [4])
• Controller installation
• Operation of the controller and the overall system
6 720 647 042-11.1ITL
Fig. 1 Schematic diagram of a solar thermal system
1 Collectors
2 Solar pump station
3 Cylinder
4 Solar controller
4
6 720 647 042-01.1ITL
Fig. 2 Vacuum tube collector layout; here: SKR6.1R =
6 tubes (type SKR12.1R = 12 tubes)
1 Header box
2 CPC mirror for optimum sunlight utilisation
3 Heat transfer medium tubes
4 Double glass tubes with vacuum for optimum thermal
insulation (tubes can be replaced without draining the
system)
SKR6.1R, SKR12.1R - Subject to technical modifications.
Product information
2
2.2 Correct usage
The collectors are designed as the heat source for DHW
heating and central heating backup.
B Only operate these collectors in conjunction with
suitable solar controllers and in fail-safe sealed
unvented solar thermal systems.
These systems must be equipped with a suitable,
adequately sized expansion vessel.
Permissible roof pitch
The self-cleaning effect for the glass tubes and CPC
mirror will only work if the roof has a pitch of at least 15°.
The maximum roof pitch is 65°.
Permissible loads
The installation set is suitable for the following:
• a standard snow load of 1.5 kN/m
(Æ Tab. 4) and
• wind speeds of max. 129 km/h (corresponds to a
stagnation pressure of 0.8 kN/m
B Find out about the local standard snow loads.
B To determine the maximum wind speed, take into
account the following factors:
– the location of the solar thermal system
– the geographic height [above seal level]
– the topography
– the building height
2
or 2.0 kN/m2
2
)
• The following values in the installation and
maintenance instructions of the solar pump station
refer to flat-plate collectors:
– the pre-charge pressure to be set for the expansion
vessel
– the operating pressure to be set
– the flow rate to be set
For the values applicable to vacuum tube
collectors, see the chapter "Final steps"
(Æ page 28) in these instructions.
Apart from the information in the solar pump station
instructions, observe the following:
• The distance between the solar pump station
(expansion vessel connection) and the bottom edge of
the collector array must be at least 2 m (Æ Fig. 3).
• The minimum pipe length (straight length) between the
solar pump station (expansion vessel connection) and
the collector array must be at least 10 m.
If necessary, consult a building structural engineer.
Heat transfer medium
To protect the collectors against damage through frost
and corrosion, operate them with LS solar heat transfer
medium. This must never be mixed with other fluids.
Other applicable instructions and important notes
The installation and maintenance instructions for the solar
pump station include vital information regarding the use of
collectors in a solar thermal system. Observe particularly
the information on the following subjects:
• Never braze pipework near the collectors.
• If system is used for central heating backup or covers
more than 60 % of the DHW demand, install a precooling vessel upstream of the expansion vessel.
• Install the expansion vessel (EV) with a tee 20-30 cm
above the solar pump station in the return (Æ Fig. 3).
• Flush and fill the system with LS solar heat transfer
fluid, by using a filling pump (never use water, as the
collectors cannot be drained). Consequently, there is
no need for an air vent above the roof.
> 200 cm
20-30 cm
6 720 647 042-14.1ITL
Fig. 3 Minimum clearances
2.3 EU Declaration of Conformity
This product conforms in design and operation to the
European Directives and the supplementary national
requirements. Its conformity is demonstrated by the CE
designation.
The Declaration of Conformity can be requested from the
manufacturer (see the back cover for the address).
SKR6.1R, SKR12.1R - Subject to technical modifications.
5
2
Product information
2.4 Standard delivery
B Check that the delivered material is complete and
undamaged.
2.4.1 Mounting bracket
1
4
2.4.2 Installation set
7
4
3
2
3
2
6
Fig. 4 Standard delivery, roof connection for tiles
Item 1 Mounting bracket 4 6 4
Item 2 M10 nut 4 6 4
Item 3 Washer 4 6 4
Item 4 T-head bolt 4 6 4
Item 5 Screw 8 x 120 12 18 12
Item 6 Wooden support
100 x 150 x 8 mm
Tab. 2 Standard delivery, roof connection for roof tiles
subject to number of collectors
5
6 720 647 042-16.1ITL
2 x
SKR6
12 18 12
3 x
SKR6
1 x
SKR12
L
8
9
6 720 647 042-17.1ITL
Fig. 5 Standard delivery for installation set
2 x
SKR6
Item 2 M10 nut 24 36 6
Item 3 Washer 24 36 6
Item 4 T-head bolt 24 36 6
Item 7 Rail L=1300 mm 2 -- --
Item 7 Rail L=1953 mm 2 3 --
Item 7 Rail L=2007 mm -- 2 --
Item 7 Rail L=2022 mm -- -- 2
Item 8 L connector 4 6 --
Item 9 Clamp top/bottom 4 6 2
Tab. 3 Installation set subject to number of collectors
3 x
SKR6
1 x
SKR12
3 x SKR6.1
2 x SKR6.1
1300
1953
Standard snow load: max. 1.5 kN/m2Standard snow load: max. 1.5 kN/m
Tab. 4 Using the rails (Item 7) and maximum standard snow load (dimensions in mm)
6
(or 1xSKR6.1 + 1xSKR12.1)
2007
SKR6.1R, SKR12.1R - Subject to technical modifications.
1 x SKR12.1 or 1 x SKR6.1
1953
2
Standard snow load: max. 2.0 kN/m
2022
2
Product information
2
2.4.3 Connection sets (hydraulic connection)
5
6720648182-02.1ST
Fig. 6 Standard delivery, connection set, rooftop
Item 1 Cap, thermal insulation 1 x
Item 2 Installation and maintenance
instructions
Item 3 Return feed bend 1 x
Item 4 Connection pipe, fully assembled
(incl. corrugated stainless steel pipe,
thermal insulation and 18 mm locking
ring fitting for connection to the
common pipeline)
Item 5 Reducer 18 x 15 mm 2 x
Tab. 5 Standard delivery, connection set, rooftop
1 x
2 x
2.5 Data plate
The data plate is mounted on the header box and contains
all important information in the form of symbols.
Symbol Meaning Explanation
A
G
A
a
A
A
Dimensions Measurements
V
f
m mass Weight
t
stg
p
max
p
pr
y
prod
Tab. 7 Data plate information
area
gross
area
aperture
area
absorber
volume
fluid
temperature
pressure
pressure
year
maximum
test
production
stagnation
Gross area
Aperture area
Absorber area
Collector contents
Stagnation
temperature, max.
Max. operating
pressure
Test pressure
Year of manufacture
2.4.4 Collector
6 720 647 042-08.1ITL
Fig. 7 Collector with pre-assembled male connectors
Item 1 Male connectors to join the collectors 2 x
Item 2 Collector SKR6.1R/SKR12.1R
1 x
comprising: vacuum tubes,
CPC mirror and header box
Tab. 6 Standard delivery, collector
SKR6.1R, SKR12.1R - Subject to technical modifications.
7
3
Regulations
2.6 Specification
SKR6.1R SKR12.1R
Certificates
Width 0.70 m 1.39 m
Depth 0.10 m 0.10 m
Length 2.08 m 2.08 m
Collector connection,
flow and return
Collector contents 1.19 l 2.36 l
Gross area 1.46 m
Aperture area 1.28 m
Absorber area 1.29 m
Net weight 24 kg 44 kg
Permissible operating
pressure collector (p
max
Test pressure (ppr) 13 bar 13 bar
Stagnation temperature,
max.
Number of glass tubes 6 12
Glass tube: tube length /
external Ø / internal Ø
Tab. 8 Specification
180
160
140
120
100
80
60
40
20
0
012345678
Fig. 8 Collector pressure drop
1 Pressure drop curve for SKR12.1R
2 Pressure drop curve for SKR6.1R
15 mm 15 mm
10 bar 10 bar
)
301 °C 301 °C
1920 mm /
47 mm / 37 mm
2
2
2
2.90 m
2.57 m
2.58 m
6 720 647 042-15.1ITL
DIN
3 Regulations
B Observe all standards and guidelines applicable to the
installation and operation of the system in your country
and region.
• The Health and Safety at Work Act 1974
• Control of substances hazardous to health regulations
(COSHH) 1994
• The pressure equipment regulations 1999
• Construction (Design and Management) Regulation
(CDM) 2007
• The Work at Height Regulations 2005
• Manual Handling Operations Regulations 1992
2
2
2
• The Lifting Operations and Lifting Equipment
Regulations (LOLER) 1999
• Reporting of injuries, diseases or dangerous
occurrences regulations (RIDDOR) 1995
• Confined spaces regulations 1997
• Personal protective equipment at work regulations
1992
• Electricity at work regulations 1989
• Provision and uses of work equipment regulations
(PUWER) 1998
• BS 6795:1986 Code of practice for solar heating
systems for swimming pools for swimming pool
• BS5918: A code of practice for the installation of
DSHW systems for domestic hot water
• BS5546: 2000 Specification for installation of hot
water supplies for domestic purposes, using gas-fired
appliances of rated input not exceeding 70 kW
• BS6700: 2006 Specification for design, installation,
testing and maintenance, of servicing supplying water
for domestic use within buildings and their curtilages
• EN 12976: Thermal solar heating system and their
components (prefabricated systems)
• ENV 12977: Thermal solar heating system and their
components (bespoke systems)
• BS 6920: Suitability of non-metallic products for use in
contact with water intended for human consumption
with regards to their effect on the quality of water
• BSEN 12831:2003: Heating systems in buildings.
Methods for calculation of the design heat load
• BS 8000-15: 1990: Workmanship on building sites.
Code of practice for hot and cold water services
(domestic scale)
8
SKR6.1R, SKR12.1R - Subject to technical modifications.
4 Before installation
b
a
a
Before installation
4
4.1 Determining space requirements
Also take account of the details concerning the optimum
arrangement of the collectors and the prevention of
shading (Æ chapter 4.3).
The clearance between the collector arrays
must be at least 15 cm to enable the correct
installation of the hydraulic connections.
The space requirement is determined by the installation
area of the collector array (Æ Tab. 9). When siting the
collector array ensure that the minimum are maintained
(Æ Fig. 9).
DANGER: Risk of fatal injury through
collectors that cannot withstand peak wind
and suction values.
B Maintain the minimum clearance to the
edge of the roof.
h
a =
10
C, a
b
a =
b
10
Number of
collectors
1 0.70 m 2.08 m 1.40 m 2.08 m
2 1.40 m 4.32 m* 2.80 m 4.32 m*
3 2.10 m 6.55 m* 4.20 m 6.55 m*
4 2.80 m -- -- --
5 3.50 m -- -- --
6 4.20 m -- -- --
Tab. 9 Space requirement (* for dimension B:
collectors arranged one above the other)
SKR6.1R SKR12.1R
Dim. A Dim. B Dim. A Dim. B
a
a
6720646203-10.1ST
Fig. 9 Minimum clearances of the collector array
• Dimension a: Use a formula, both are possible
• Dimensions A and B: Æ Tab. 9
• Dimension C: At least 3 rows of tiles to ridge or
chimney
• Dimension D: At least 0.5 m to the right and left of the
collector array as well as to the ridge for connection
lines below the roof.
h
SKR6.1R, SKR12.1R - Subject to technical modifications.
9
4
Before installation
4.2 Planning the hydraulic connection
Please refer to the solar technology technical
guide for detailed information on planning the
hydraulic system and components.
Before you install the collectors you will need to know
how you can arrange the collectors.
Fit the collector sensor [1] in the collector
connected to the flow and return pipes [2]
and [3].
Maximum number of collectors per row:
• SKR6.1R: 6 collectors
• SKR12.1R: 3 collectors
The following shows two examples of hydraulic layouts for collectors:
1
6 720 647 042-03.1ITL
Fig. 10 Connection in a single row
1 Collector sensor (always on the connection side)
2 Flow pipe (to the cylinder)
3 Return pipe (from the cylinder)
4 Return U-bend
4
32
Fig. 11 Triple row connection (with shut-off valve)
1 Collector sensor (always on the connection side)
2 Flow pipe (to the cylinder)
3 Return pipe (from the cylinder)
4 Shut-off valve (accessory)
5 Return U-bend
6 720 647 042-04.1ITL
10
SKR6.1R, SKR12.1R - Subject to technical modifications.
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