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Installation instructions
63043970.01-1.SD
Solar Collector
63043970.01-1.SD
SKS 4.0 Series Flat Collector
FLAT ROOF AND WALL MOUNTED
SOLAR THERMAL SYSTEMS
For heating engineers
Please read carefully prior
to commissioning and
maintenance
7 747 019 102 (04/2006) UK
Page 2
Foreword
About this manual
This installation manual contains important information
for the safe and appropriate installation of the roof
mounted solar collectors.
Notes are included with important information for
situations in which there is no danger for persons or
equipment.
These technical documents should be retained in a safe
place. These may also be inspected at the
manufacturer's premises.
The activities described in the installation manual
assume expertise based on completed vocational
training in gas or water-related installation. Only carry
out these installation steps, if you possess these skills.
— Hand these installation instructions to the customer.
— Explain to the customer the function and operation of
the related devices.
2
SKS 4.0 Series - Flat roof and wall mounting -We reserve the right to make any changes due to technical modifications.
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Contents
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.2 Notes structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.3 Please observe these safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4 Before installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.2 Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.3 Other equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.4 Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.5 Technical documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6 Determining the angle of incidence of the collectors . . . . . . . . . . . . . . . . . . . . . 12
4.7 Determining space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Installing flat roof and wall mounting supports . . . . . . . . . . . . . . . . . . . . 17
5.1 Distances between collector braces for on-site base anchoring . . . . . . . . . . . . . . 18
5.2 Clearances between the collector braces when using loading trays (accessory) . . . . 20
5.3 Stabilising the flat roof supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4 Wall mounting supports - installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.5 Installing the profile rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6 Collector installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1 Preparing to install the collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2 Fastening the collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7 Collector sensor connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8 Header connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.1 Fitting holder for flow line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2 Venting through pressure filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.3 De-airing through air vent (accessory) at highest point in the system . . . . . . . . . . . 37
8.4 Connecting two arrays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9 Final activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.1 Checking the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.2 Insulating the connection and header pipes . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10 Quick reference guide for base anchoring and pressure filling . . . . . . . . 41
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1
General information
1 General information
This chapter details which technical rules and
regulations apply to this installation.
USER NOTE
Observe all standards and guidelines
applicable to the installation and operation
of this system in your country.
UK
Installation work on roof
The Health and Safety at Work etc
Act
1974
The Management of Health and Safety
at Work Regulations 1999
The Construction (Health Safety and
Welfare) Regulations 1996
The Construction (Design and
Management) Regulations 1994
The Lifting Operations and Lifting
Equipment Regulations 1998
Tab. 1 Technical rules for the installation of thermal solar thermal systems (selection) in UK
Lightning protection
If the building height (installation height) exceeds 20 m,
and there is no lightning conductor installed, ask your
local electrical contractor to connect the components on
the roof which conduct electricity with an electrical earth
cable of at least 16
Special measures regarding lightning protection are not
required for building heights (installation heights) of less
than 20
Where there is a lightning conductor system installed,
ask your local electrical contractor to check the inclusion
of the solar thermal system into the lightning protection
system.
m.
mm2 to the earth bonding.
Connection of thermal solar
systems
EN 12976: Thermal solar thermal
system and their components (prefabricated systems).
ENV 12977: Thermal solar thermal
system and their components
(bespoke systems).
BS 6795: Code of practice for solar
thermal systems for swimming pools.
Installation and equipment of DHW
BS 5546: 2000 Specification for
installation of hot water supplies for
domestic purposes, using gas-fired
appliances of rated input not
exceeding 70
BS 6700: 1997 Specification for
design, installation, testing and
maintenance, of servicing supplying
water for domestic use within
buildings and their curtilages.
USER NOTE
The installation of the thermal Solar
System must be carried out in accordance
with the relevant requirements for safety,
current IEE wiring regulations, local
building regulations, building standards
(Scotland) (Consolidation) regulations and
by-laws of the local water company and
health and safety document No 635
(Electricity at Work Regulations 1989).
BS 6795: Latest version
cylinders
kW.
4
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2 Specifications
SKS Solar collectors
Certificates
0036
DIN
Length 2,070 mm
Width 1,145 mm
Height 90 mm
Clearance between collectors 25 mm
Fluid content, portrait version Vf1.43 l
Fluid content, landscape version Vf1.76 l
Gross absorber surface area AG2.37 m²
Net absorber surface area 2.1 m²
Net weight, portrait version m 46 kg
Net weight, landscape version m 47 kg
Permissible operating pressure of the
collector
Tab. 2 Specifications
p
max
10 bar
Specifications
2
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3
Safety
3 Safety
This chapter details how the notes for the installation
instructions, as well as the general safety instructions,
necessary for safe and trouble-free operation, are
arranged in this manual.
Safety and user notes, which specifically refer to the
installation, in the installation manual immediately
following the individual installation steps, are found here.
Carefully read the safety instructions before
commencing the installation.
Severe injury and even death, as well as material losses
and environmental damage, may follow if you ignore
safety instructions.
3.1 Correct use
Install components only on roofs with sufficient strength.
Please take the additional roof load per flat roof support,
including solar collector, into consideration. If necessa
ry, ask a structural engineer for assistance.
Only install this system on flat roofs or roofs with a shallow pitch (≤ 25°).
The wall mounting support must only be installed at a
maximum height of 20
snow load of 2.0
-
m and with a maximum wind or
kN/m².
If there is a risk that larger quantities of snow might accumulate behind the collectors (towards the roof ridge),
prevent this by fitting a suitable protective grille.
On roofs with a shallow pitch, attach the system to the
roof on site.
Application conditions for flat roof supports
Only erect the installation set on roofs whose construction can support the weight.
The installation set is suitable for a max. standard wind
or snow load of 2.0
max.
20 m. Using appropriate accessories, the installation set can be used for a max. standard wind or snow
load of 3.8 kN/m² and a max. installation height of 100 m.
The flat roof installation set must not be used for fixing
any other objects to the roof. The kit is intended exclusi
vely for the safe fixing of solar collectors.
Conditions at use for wall mounting supports
Only landscape panel orientations are suitable for
wall mounting
Install the wall mounting support only on wall structures
with sufficient structural strength. If necessary, ask a
structural engineer for assistance.
kN/m² and an installation height of
-
6
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Safety
3
3.2 Notes structure
Two levels are identified by signal terms:
RISK TO LIFE
Identifies possible dangers which might
WARNING!
CAUTION!
Further symbols identifying dangers and user notes:
WARNING!
lead to serious injury or death if appropriate
care is not taken.
RISK OF INJURY/SYSTEM DAMAGE
Identifies potentially dangerous situations,
which might lead to mild or slight injuries or
to material losses.
RISK TO LIFE
from electric shock.
USER NOTE
CAUTION!
CAUTION!
RISK OF INJURY
Injury and operating faults can result from
making changes to the system
construction.
z Never change the system construction.
RISK OF INJURY
Some parts may cause burns, if the
collector and installation materials are
exposed to solar radiation for longer
periods of time.
z Always wear your personal protective
clothing and safety equipment.
z Cover the collector (e.g. with a covering
sheet - available as an accessory) and
the installation material during the
installation as protection against high
temperatures resulting from solar
irradiation.
Tip for the optimum utilisation and setting
of the products plus other useful
information.
3.3 Please observe these safety
instructions
RISK TO LIFE
through a fall or falling parts.
WARNING!
z Ensure you have the correct safety
equipment for working on roofs.
z Take appropriate action to prevent
accidents when working on roofs.
z Whilst working on the roof, take all
necessary precautions against a
possible fall.
z Always wear your personal protective
clothing and safety equipment.
z After completing the installation, always
check the secure positioning of the
installed set and that of the collectors.
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Before installation
4 Before installation
4.1 General notes
USER NOTE
It is recommended that the services of a
roofing company, who are fully experi
enced in working on roofs and will be aware of the risk of working at height, are
considered.
Make yourself familiar with the on-site conditions and local regulations before commencing the installation.
Check
z the delivery for completeness and perfect condition.
z the roof structure for sufficient strength and possible
damage (e.g. leaks).
z the building height and determine the type of fixings
required for the flat roof supports (
see Chapter 5.3
"Stabilising the flat roof supports", page 22).
z the optimum arrangement of the solar collectors.
Take the solar radiation into consideration
(angle of incidence, southerly orientation). Avoid the
shade of high trees or structures and match the coll
ector array to the shape of the building (e.g. flush with
windows, doors, etc.).
z the stability of the support surface. Remove gravel or
similar material.
-
-
Fig. 1 General overview of collector pair — flat roof mounting
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USER NOTE
Only use OEM components and replace
any faulty parts immediately.
USER NOTE
Let a professional roofer carry out all difficult roof repairs, particularly weather-proofing of bitumen layers.
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Fig. 2 General overview of collector pair — wall mounted
installation
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4.2 Component description
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4.2.1 Installation set for the collectors
The installation sets are for mounting and fixing the collectors in place.
1
5
Before installation
3
2
4
4
5
6
8
Fig. 3 Installation set for 2 collectors - 1 basic installation set, 1 extended installation set
Basic installation set for each collector array and
for the first collector
Item 1: Profile rail 2 × Item 1: Profile rail 2 ×
Item 3: M8 screw × 20 6 × Item 2: Plug connector with threaded studs 2 ×
Item 5: Single-sided collector clamp 4 × Item 3: M8 screw × 20 3 ×
Item 6: M8 nut 4 × Item 4: Double-sided collector clamp 2 ×
Item 7: Collector brace 2 × Item 6: M8 nut 2 ×
Item 8: Anti-slip protection 2 × Item 7: Collector brace 1 ×
(Fig. 3):
Extended installation set for each additional
collector
Item 8: Anti-slip protection 2 ×
(Fig. 3):
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USER NOTE
3
7
Depending on the use of the flat roof support, auxiliary braces and additional profile
rails may be needed, and are dealt with in
the relevant sections.
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Before installation
4.2.2 Pipework connection
One connection kit for each collector array is required.
The collectors are connected together by a connection
set.
1
10
9
Fig. 4 Connection kit and connection set (illustration shows 2 portrait collectors)
8
7
6
Connection kit, per collector array (Fig. 4)
2
3
4
5
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Item 2: Bracket (spare) 2 × Item 7: Holder for header pipe 2 ×
Item 3: Elbow 2 × Item 8: Compression fitting for collector sensor 1 ×
Item 4: Olive 2 × Item 9: Size 5 spanner 1 ×
Item 5: Nut 2 × Item 10: End cap 2 ×
Item 6: Insulation for corrugated pipe connector
710 mm
1 ×
Connection set between the collectors, for each
collector (in two corner protectors,
Item 1: Corrugated pipe connector 2 ×
Item 2: Connector clip 4 ×
Fig. 5)
1
2
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Fig. 5 Two corner protectors with one connection set
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4.3 Other equipment
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— Spirit level
— Plumb line
— Filling pump
— Vest harness with safety rope
— Pipe insulation
— Scaffolding
— Roofing ladder
— Crane or mobile hoist
USER NOTE
When fitting the roof installation set and
water connection, the only tool reqiured is
the size 5 allen key
kit.
from the connection
Before installation
4
4.4 Transport and storage
Please ensure that the corner protectors are
retained. They contain pipework connection pieces
which are required for installation. All components
are protected by transport packaging.
USER NOTE
Dispose of the transport packaging in
an
environmentally friendly recycling
system.
Transport protection for collector connections
The collector connections are protected against damage
by rubber caps.
SYSTEM DAMAGE
through damaged sealing faces.
CAUTION!
Storage
z Do not remove the rubber caps (Fig. 6,
Item 1) until immediately prior to
installation.
1
The collectors must be stored in dry conditions.
USER NOTE
Do not store collectors outside without
protection from the rain.
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Fig. 6 Plastic caps on collector connections
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Before installation
4.5 Technical documentation
The solar thermal system consists of various components (Fig. 7). Installation, operation and maintenance
documentation is provided for each component. Accessories may be accompanied by a separate document.
Item 1:
Item 2:
Collector: instructions for roof installation
are
enclosed with the connection kit
Pump station: instructions enclosed with the
station
Item 3:
Solar Controller: instructions are enclosed
with the controller.
Item 4:
DHW Cylinder: instructions enclosed with the
DHW cylinder.
Fig. 7 Solar thermal system components and technical
documentation
4.6 Determining the angle of incidence of the collectors
4
1
3
2
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The collectors' angle of incidence to be selected depends on the desired area of application. It can be adjusted using the telescopic rails (Fig. 8).
4.6.1 Determining the area of application
The different areas of application of solar thermal systems provide angles of incidence that ensure an optimum solar yield for every season.
Applications Angle of incidence
range
DHW 30 — 45°
Domestic hot water + central heating 45 — 60°
Domestic hot water + swimming pool 30 — 45°
Domestic hot water + central heating +
swimming pool
Tab. 3 Area of application, angle of incidence range
45 — 60°
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Fig. 8 Angle of incidence of the collector on a flat roof
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4.6.2 Sloping roofs
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On roofs that slope slightly in a southerly direction, the
pitch angles are deducted from the angle of incidence.
On roofs that slope slightly in a northerly direction, the
pitch angles are added to the angle of incidence
(Fig. 9).
RISK TO LIFE
If there is a risk that larger quantities of
WARNING!
snow might accumulate behind the collec
tors (towards the roof ridge), prevent this
by fitting a suitable protective grille on site.
SYSTEM DAMAGE
through strong wind. On sloping flat roofs
CAUTION!
the flat roof supports must be secured on
site.
z Ask a roofing contractor to carry out the
installation on sloping flat roofs.
4.6.3 Walls
Before installation
4
1
45°
-
30°
15°
15°
45°
2
30°
3
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Fig. 9 Angle of incidence of the collector on a flat roof
Item 1: Angle of incidence (absolute angle to the horizontal
plane)
Item 2: Collector angle of inclination
Item 3: Roof pitch
The landscape collector braces can be used as flat roof
supports or wall-mounting supports.
RISK TO LIFE
from falling collectors, due to incorrect use.
WARNING!
z The collector angle of incidence
(Fig. 10, Item 1) to the horizontal must
be between 45° and 60° (or the angle of
inclination
Fig. 10, Item 2 of the collec-
tors must be between 30° and 45°)
45°
30°
45°
2
1
60°
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Fig. 10 Angle of incidence of the collector on a wall
Item 1: Angle of incidence (absolute angle to the horizontal
plane)
Item 2: Collector angle of inclination
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Before installation
4.6.4 Fitting telescopic rails
Different angles of incidence can be set using the telescopic rails.
z Select holes on the upper and lower telescopic rails
as shown in
Fig. 12 and Fig. 13.
z Insert telescopic rails into each other and fasten with
M8
× 20 screw (Fig. 11).
1.
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Fig. 11 Connecting telescopic rails
USER NOTE
For vertical installation of a collector with
an angle of inclination of 30° to 60°, use
the uppermost hole on the lower telescopic
rail
(Fig. 12, Item 1).
For an angle of inclination of 25°, you must
shorten the top of the lower rail by 140 mm
and use the lower hole
(Fig. 12, Item 2).
30°
35°
40°
45°
50°
55°
60°
25°
140 mm
1
2
14
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Fig. 12 Adjust angle of inclination for portrait collectors
Page 15
Before installation
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4
USER NOTE
For landscape installation of a collector
with an angle of inclination of 35° to 60°,
use the uppermost hole on the lower tele
scopic rail (Fig. 13, Item 3).
For an angle of inclination of 25° and 30°,
you must shorten the top of the lower rail
by 140 mm and use the lower hole
(Fig. 13, Item 2).
RISK TO LIFE
from falling collectors, due to incorrect use.
WARNING!
z For wall-mounted installation, use only
the positions for the collector angles of
inclination 30°, 35°, 40° and 45°
(Fig. 13, Item 1).
4.7 Determining space requirements
4.7.1 Ascertaining the clearance between collector
arrays
35°
40°
45°
-
50°
55°
60°
1
1
1
25°
30°
1
140 mm
3
2
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Fig. 13 Adjusting angle of inclination for landscape collectors
The minimum spacing between the collector arrays is
determined by the angle of inclination of the collector.
USER NOTE
When using multi-row arrays, note that the
clearance X
(Fig. 14) between the arrays
must be large enough to avoid shadows
falling over adjacent collectors.
Maintain the clearance stated in the tables or calculate
the require clearance (Technical Guide).
Angle of inclina-
tion — collector
installation
25° 4.74 m 2.63 m
30° 5.18 m 2.87 m
35° 5.58 m 3.09 m
40° 5.94 m 3.29 m
45° 6.26 m 3.46 m
50° 6.52 m 3.61 m
55° 6.74 m 3.73 m
60° 6.90 m 3.82 m
Tab. 4 Dependency of clearance X on the angle of
incidence and the minimum altitude of the sun (17°)
Portrait
Clearance X
Landscape
installation
X
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Fig. 14 Shadow — clearance X
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Before installation
4.7.2 Estimating your space requirements
SYSTEM DAMAGE
through wind, eddies and pressure peaks
CAUTION!
around the roof edges.
z Before commencing the installation,
ensure that at least one metre is allo
wed between the flat roof supports and
the edge of the roof
(Fig. 15).
Allow sufficient installation space for the different forms
of installation (landscape, portrait).
These dimensions (Tab. 5 and Tab. 6) relate to the roof
surface area which must be available.
>1 m
>1 m
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Fig. 15 Distance from the edge of the roof
The quoted dimensions are simply the width of the collector array. In addition, allow at least 0.5 m on either
side of the collector array for pipework.
A
Fig. 16 Space requirements — collector array — portrait
version
B
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Space requirements for portrait collectors: Space requirements for landscape collectors:
Number
of collectors
2 2.34 m 25° 1.84 m 2 4.18 m 25° 1.06 m
3 3.51 m 30° 1.75 m 3 6.28 m 30° 1.02 m
4 4.68 m 35° 1.68 m 4 8.38 m 35° 0.96 m
5 5.85 m 40° 1.58 m 5 10.48 m 40° 0.91 m
6 7.02 m 45° 1.48 m 6 12.58 m 45° 0.85 m
7 8.19 m 50° 1.48 m 7 14.68 m 50° 0.85 m
8 9.36 m 55° 1.48 m 8 16.78 m 55° 0.85 m
9 10.53 m 60° 1.48 m 9 18.88 m 60° 0.85 m
10 11.70 m 10 20.98 m
Tab. 5 Space requirement for portrait installed collectors Tab. 6 Space requirements for landscape installed
Dimension
A
Angle of
inclination
Dimension
B
Number
of collectors
collectors
Dimension
A
Angle of
inclination
Dimension
B
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Installing flat roof and wall mounting supports
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5 Installing flat roof and wall mounting supports
RISK TO LIFE
Whilst working on the roof, take all neces-
WARNING!
WARNING!
sary precautions against a possible fall.
RISK OF INJURY
through a fall or falling parts.
z Take appropriate action to prevent ac-
cidents when working on roofs.
z Always wear your personal protective
clothing and safety equipment.
5
USER NOTE
Please observe all national and local accident prevention regulations, as well as the
safety instructions in this manual when
working on roofs.
Ensure sufficient stability at the installation surface, and
removing any gravel and similar material.
USER NOTE
To protect the roof skin, lay commercially
available building protection mats, onto
which you can position the profiles. The
sealing membrane must not be damaged.
This installation method also applies to the flat roof
support for landscape collectors.
The following describes the installation of flat roof supports for portrait collectors. The landscape version is installed in the same way.
Notes identify any variations.
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Fig. 17 Portrait flat roof supports for 2 collectors
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Fig. 18 Landscape flat roof supports for 2 collectors
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Installing flat roof and wall mounting supports
5.1 Distances between collector braces
for on-site base anchoring
The distances between the collector braces (middle/middle, in mm) depend on:
— the collector version (portrait, landscape)
— and the maximum wind or snow loads
USER NOTE
You must strictly observe the clearances
between the collector braces so that the
profile rails can still be installed at a later
stage.
5.1.1 Basic version
Two collector braces are required for the first collector.
For every additional portrait collector, another collector
brace is required
pe collector, two further collector braces are required
(Fig. 21).
(Fig. 19). For every additional landsca-
980 980
63043970.44-1.SD
Fig. 19 Basic version for 2 portrait collectors
The basic version can be used for the following loads:
— building height max. 20 m (installation height)
— max. 2.0 kN/m² wind or snow load
9801170980
last
x collectors
collector
Fig. 20 Basic version for 3 — 10 portrait collectors
275
first
collector
63043970.13-1.SD
18201820
18
SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
63043970.42-1.SD
Fig. 21 Basic version for 2 landscape collectors
Page 19
5.1.2 Version with auxiliary brace (accessory)
63043970.14-1.SD
For greater loads, an auxiliary brace (and additional profile rails, page 27) is required for portrait installation for
the second and all further collectors (Fig. 22). This version can be used for the following loads:
— Building height max. 100 m (installation height)
— max. 3.8 kN/m² wind or snow load
USER NOTE
For landscape installation, a max. building
height of 100 m and a max. wind or snow
lo
ad of 3.8 kN/m² are permitted using the
basic version (
Fig. 21, provided that an ad-
ditional rail is fitted, page 27).
Installing flat roof and wall mounting supports
980980 980190 190
63043970.14-1.SD
Fig. 22 Auxiliary braces for 3 portrait collectors
5
SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
19
Page 20
5
63043970.15-1.SD
Installing flat roof and wall mounting supports
5.2 Clearances between the collector
braces when using loading trays
(accessory)
The distances between the collector braces (middle/middle, in mm) depend on:
— the collector version (portrait, landscape)
— and the maximum wind or snow loads.
For portrait installation, an auxiliary brace must be erected for the 4th, 7th and 10th collectors (Fig. 23, Item 1).
USER NOTE
Strictly observe the clearances between
the collector braces so that the profile rails
can be installed.
5.2.1 Basic version
The basic version can be used for the following loads:
— Building height max. 20 m (installation height)
— max. 2.0 kN/m² wind or snow load
Number of
collectors
4 381 mm - -
5 381 mm - -
6 571 mm - -
7 571 mm 381 mm -
8 571 mm 381 mm -
9 571 mm 571 mm -
10 571 mm 571 mm 381 mm
Tab. 7 Distances between auxiliary braces
Dim. A Dim. B Dimension C
11
980980980980980980980
1
1.2.3.4.5.6.7.8.9.10.
ABC
980980980
Fig. 23 Basic version for up to 10 portrait collectors (in mm)
20
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63043970.15-1.SD
Page 21
63043970.16-1.SD
USER NOTE
63043970.14-1.SD
Landscape installation can be carried out
using only the auxiliary brace (accessory).
For landscape installation, 3 collector braces must be fitted for each collector (Fig. 24).
5.2.2 Version for maximum loads (accessory,
Fig. 25)
For greater loads, ropes (page 23) and additional rails
(page 27) are also required. This version can be used
for the following loads:
— Building height max. 100 m (installation height)
Installing flat roof and wall mounting supports
980 980 135 980 980
63043970.16-1.SD
Fig. 24 Basic version for 2 landscape collectors
5
— max. 3.8 kN/m ²wind or snow load
USER NOTE
For distances between the landscape collector braces for maximum loads, refer to
Fig. 24.
980980 980190 190
63043970.14-1.SD
Fig. 25 Version for maximum loads, 3 portrait collectors
SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
21
Page 22
5
Installing flat roof and wall mounting supports
5.3 Stabilising the flat roof supports
The following details refer to a single collector. These
details are based on DIN
buildings".
Individual flat roof supports may be secured in the following three ways to prevent slippage or tipping of the
structure due to the effect of the wind:
— Securing flat roof supports with anchor bolts (on-si-
te).
— Weigh down flat roof supports with concrete slabs,
gravel or similar material (loading trays required).
— Weigh down flat roof supports with concrete slabs,
gravel or similar material (loading trays required) and
make more secure using rope as necessary.
For all methods, please consider the structural integrity
of the roof.
USER NOTE
1055, part 4 "Design loads for
Using gravel in the loading trays, a maximum load of 320 kg is possible per collector (Tab. 8).
USER NOTE
For the following table, please also consider the clearances and number of additional collector braces (Chapter 5.1
"Distances between collector braces for
on-site base anchoring").
Stabilising a collector
Height of building Wind velocity Base anchor Weighting Ropes
Securing against
tipping
Number and type
screws
of
0 m to 8 m 102 km/h 2 × M8/8.8 270 kg 180 kg 1.6 kN
above 8 m up to 20 m 129 km/h 2 × M8/8.8 450 kg 320 kg 2.5 kN
above 20 m up to
1
100 m
Tab. 8 Values to stabilise one collector
1
With additional rail only
2
Per collector brace
151 km/h 3 × M8/8.8 — 450 kg 3.3 kN
2
Weight
(e.g. concrete slabs)
Weight
(e.g. concrete
slabs)
Securing against
slippage
Maximum rope
tension
22
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Page 23
5.3.1 Securing flat roof supports on site with base
63043970.46-1.SD
563
563
63043970.19-1.SD63043970.19-1.SD
63043970.20-1.SD
anchoring
Installing flat roof and wall mounting supports
5
You can fasten the flat roof supports with anchor bolts.
As an example, we describe fastening onto girders
(Fig. 26, Item 3).
Design the substructure so that the collectors can withstand the wind or snow loads and wind forces placed up-
on them.
In addition, a means of fixing should be provided on site
that
stabilises the structure and prevents damage to the
roof.
SYSTEM DAMAGE
through modifications to the design of the
CAUTION!
flat roof supports
.
z For example, never drill the flat roof
support profiles.
z Transfer the lower profile hole clearances (Fig. 26,
Item 2) onto the girders, and drill the corresponding
holes.
z Insert screws (see Tab. 8 and Fig. 26, Item 1) th-
rough the profiles and girders and screw tight with
nuts and washers.
1
2
3
63043970.46-1.SD
Fig. 26 Flat roof support on girders, dimensions in mm
(value in brackets = landscape version)
1
2
563
(353)
3
563
(353)
5.3.2 Securing flat roof supports with weights
z Erect collector braces (see Chapter 5.1 "Distances
between collector braces for on-site base anchoring").
z Insert loading trays (Fig. 27, Item 2) into lower profi-
les (Fig. 27, Item 1) and into each other (Fig. 27,
Item 3).
z Insert concrete slabs or similar into loading trays
(for
required weight, see Tab. 8).
5.3.3 Providing extra security for the flat roof
supports using rope
You may also additionally secure the weighted flat roof
support with ropes.
Select the rope depending on the expected loads
(see
Tab. 8).
z Fasten each collector on site to the screw on the lo-
wer profile and to a suitable point on the roof, using
at least 2 wire ropes
(Fig. 28, Item 1).
63043970.19-1.SD
Fig. 27 4 loading trays per collector
1
1
SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
63043970.20-1.SD
Fig. 28 Flat roof support with ropes
23
Page 24
5
Installing flat roof and wall mounting supports
5.4 Wall mounting supports - installation
The landscape collector braces can also be used for
wall-mounted installation.
RISK TO LIFE
from falling collectors, due to incorrect use.
WARNING!
z Only landscape collector braces are al-
lowed for wall-mounted installation.
z Collectors may only be installed on
walls of buildings with a height up to
20
m (wind velocity = 129 km/h) and a
wind or
snow load of up to 2.0 kN/m².
z Each collector brace must be fastened
to the holes provided, using 3 screws
(provided by customer)
(Tab. 9).
z Install only on a sealed, windproof out-
side wall.
z Before installing the wall mounting sup-
port, check the load-bearing capability
of the fixing wall (i.e. of the wall base).
If necessary, ask a structural engineer
for assistance.
z Never modify the wall mounting struc-
ture.
z Never place objects in the space under-
neath the wall mounting support.
z Never fit facing to the collectors.
63043970.05-1.SD
Fig. 29 Wall mounting support
z Fasten as follows:
Wall structure
Steel-reinforced concrete min. B25
(min. 120 mm)
Steel base structure (e.g. girder) 3 × M8 (4.6) and 2 × washers
Tab. 9 Fasteners
1
A tensile strength of 1.63 kN or a shear strength of at least 1.56 kN must be able to be applied to each fixing.
2
3 × Screw diameter = outside diameter of washer.
3
Brickwork on request
3
3 × UPAT MAX Express anchors, type MAX 8 (A4)1 or similar
and 3 × washers
3 × Hilti HST-HCR-M8 1 or HST-R-M8
3 × washers
Fixings per collector brace Distance from the edge
2
1
2
2
or similar and
z Use 3 screws to fasten each collector brace to the
wall
(see Tab. 9, Fig. 30, Item 1).
of the wall
> 100 mm
> 100 mm
—
24
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Page 25
Installing flat roof and wall mounting supports
63043970.30-1.SD
5
980
980
135
1
Fig. 30 Fastening collector braces to the wall (for 2 collectors, dimensions in mm)
980
980
63043970.30-1.SD
SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
25
Page 26
5
63043965.33-1.SD
63043970.43-1.SD
63043970.45-1.SD
Installing flat roof and wall mounting supports
5.5 Installing the profile rails
The profile rails must be joined together using plug connectors. Each collector is provided with an upper and lower profile rail.
5.5.1 Connecting profile rails
z Push plug connector (Fig. 31, Item 1) as far as it will
go into both profile rails (Fig. 31, Item 2).
z To lock, tighten both fitted M10 threaded studs
(Fig. 31, Item 3) in the plug connector using a size
5 spanner.
5.5.2 Installing profile rails
Positioning the profile rails depends on
— whether they are being installed portrait or landscape
3
Fig. 31 Connecting profile rails
1
1
2
63043965.33-1.SD
3
2
— and on the clearances between the collector braces.
If using base anchoring, begin fastening the profile rails
as follows:
Base anchoring
Basic version Auxiliary brace
portrait: Align with middle hole
on plug connector
(Fig. 32, Item 1)
landscape: Align with third slotted
hole from right
(Fig. 32, Item 2)
Tab. 10 Aligning the lower and upper profile rails when using
base anchoring
Align with second
slotted hole from right
(Fig. 32, Item 3)
--
If using loading trays, begin fastening the profile rails as
follows:
Loading trays
2 collectors 3 to 10 collectors
portrait: Align with middle hole
on plug connector
(Fig. 33, Item 1)
landscape: Align with second slot-
ted hole from right
(Fig. 33, Item 3)
Tab. 11 Aligning the lower and upper profile rails when using
loading trays
Align with sixth slotted hole from right
(Fig. 33, Item 2)
Align with second
slotted hole from right
(Fig. 33, Item 3)
63043970.43-1.SD
Fig. 32 Aligning the profile rails for on-site base anchoring
1
Fig. 33 Aligning the profile rails for loading trays
2
3
63043970.45-1.SD
26
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Page 27
z Lightly tighten the pre-assembled profile rails
63043970.21-1.SD
63043970.25-1.SD
63043970.24-1.SD
(Fig. 34, Item 2) with M8 x 20 bolts (Fig. 34, Item 1)
so that the profile rails can still be aligned.
z Align the sides of the upper and lower profile rails.
z Tighten bolts.
5.5.3 Fitting additional profile rails (accessory)
If the collector array is exposed to greater loads (building
or installation height of over 20 m and/or wind or
load
of over 2.0 kN/m²), additional rails must be fitted.
snow
z Fasten additional profile rails as described in
Chapter 5.5.2 "Installing profile rails", using the middle hole on the profile (Fig. 35, Item 1).
z Align sides of the profile rails.
z Tighten bolts.
Installing flat roof and wall mounting supports
1
63043970.21-1.SD
Fig. 34 Fitting profile rails (for two portrait collectors in this
example)
1
5
2
5.5.4 Installation of anti-slip protection
To prevent the collectors from slipping, you must fasten
two anti-slip protectors to the lower profile rails for each
collector.
z Push each anti-slip protector (Fig. 36, Item 3) into
the innermost slotted holes (Fig. 36, Item 1) over the
profile rails until it clicks into place (Fig. 36, Item 2).
63043970.25-1.SD
Fig. 35 Fitting additional profile rails
1
3
2
63043970.24-1.SD
Fig. 36 Attaching anti-slip protection
Item 1: Fixing holes for the anti-slip protection
Item 2: Clicking the anti-slip protection into place
Item 3: Anti-slip protection
SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
27
Page 28
6
63043970.02-1.SD
Collector installation
6 Collector installation
Observe the following safety and user instructions when
commencing the collector installation.
RISK TO LIFE
through a fall or falling parts.
WARNING!
z Take appropriate action to prevent acci-
dents when working on roofs.
z Whilst working on the roof, take all ne-
cessary precautions against a possible
fall.
z Always wear your personal protective
clothing and safety equipment.
z After completing the installation, always
check that the installed set and the col
lectors are fastened securely.
RISK OF INJURY
-
Fig. 37 Flat roof installation: 2 collectors
63043970.02-1.SD
CAUTION!
CAUTION!
through interruption of work.
z Secure the collectors against falling.
z Stabilise the collector array.
SYSTEM DAMAGE
through damaged sealing faces.
z Do not remove the rubber caps on the
collector connections until immediately
prior to installation.
USER NOTE
Use lifting equipment as used by roofing
contractors, sufficiently strong 3-point suc
tion handles or special carry handles for
the installation (for easier lifting).
USER NOTE
Unsecured collectors may fall during handling and installation.
63043970.05-1.SD
Fig. 38 Wall mounted installation
-
28
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Page 29
Collector installation
63043966.09-1.SD
63043966.10-1.SD
63043966.08-1.SD
6
6.1 Preparing to install the collectors
Before beginning actual installation on the roof, preassemble the locking caps on the ground to make work on
the roof easier.
To secure the locking caps (and later the corrugated
pipe connectors and connecting pipes as well), attach
brackets to the connections.
SYSTEM DAMAGE
through leaks in the collector connections.
CAUTION!
6.1.1 Pipework connections
The collectors must be installed in such a way that the
sensor bushs for taking up the collector sensor
Item 1) are at the top.
The corrugated pipe connectors, connecting pipes and collector connections must
not display any signs of damage or conta
mination.
z The collector connections have had
special grease applied in the factory to
make installation easier. Do not use
any other grease.
(Fig. 40,
1
4
4
-
Fig. 39 Water connection (right) up to max. 5 collectors
Item 1: Corrugated pipe connector
Item 2: Flow line
Item 3: Return line
Item 4: Locking cap
1
3
63043966.09-1.SD
2
1
USER NOTE
The water connection pipes can be connected on the right (Fig. 39) or left
(Fig. 40). In this manual, the connection pipes are shown on the right.
The pipework in the collector is designed as a double
meander, which enables you to carry out two different
water connections:
Single-sided connection of up to 5 collectors
Up to 5 collectors can be connected to one side of a collector array (Fig. 39 and Fig. 40).
Two-way connection of up to 10 collectors
If there are more than 5 collectors installed in one
collector array, the water connection must be two-way
(Tichelmann principle,
Fig. 41).
The two-way connection can also be made if there are
fewer than 6 collectors
(Fig. 41).
If more than10 collectors are required then a further
AGS pump station is required.
63043966.10-1.SD
Fig. 40 Water connection (left) up to max. 5 collectors
63043966.08-1.SD
Fig. 41 Two-way pipework connections
SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
29
Page 30
6
63043966.12-2.SD
63043970.26-1.SD
63043970.31-1.SD
Collector installation
6.1.2 Fitting the end cap
Not all the connections are needed when connecting a
collector array, so those that are not used must be
closed.
z Remove rubber caps (transport protection) from the
relevant collector connections.
z Push end cap with the O-rings (Fig. 42, Item 3) onto
the collector connection.
z Push bracket (Fig. 42, Item 2) over the end cap and
collector connection to secure the connection.
3
1
SYSTEM DAMAGE
from unsecured end caps.
CAUTION!
z Secure each end cap with a bracket
(Fig. 42, Item 1).
6.2 Fastening the collectors
The collectors are fastened to the profile rails using the
single-sided collector clamps
ginning and end of a collector array, and double-sided
clamps
(Fig. 43, Item 1) between each collector.
In addition, the anti-slip protectors (Fig. 43, Item 3) prevent the collector from slipping.
USER NOTE
The plastic parts on the collector clamps
do not have any support function. They are
simply intended to make installation ea
sier.
(Fig. 43, Item 2) at the be-
-
2
63043966.12-2.SD
Fig. 42 Securing end cap with bracket
1
3
Fig. 43 Fasteners for the collector
2
63043970.26-1.SD
Fitting the single-sided collector clamp on the right
z Push single-sided collector clamps (Fig. 44, Item 1)
into the profile rails at the right-hand end of the collector array until they click into place in the first slotted
hole on the profile rails.
USER NOTE
Do not fit the single-sided collector clamps
to the left-hand side of the collector array
until the last collector has been installed.
30
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1
63043970.31-1.SD
Fig. 44 Pushing on the single-sided collector clamp
Page 31
Putting the first collector in place
63043970.32-1.SD
63043965.45-1.SD
63043969.02-1.SD
Lay the collector on the profile rails in such a way that
the sensor bush to receive the collector sensor is at the
top. Begin by laying the collectors on the right-hand side
of the profile rails.
Collector installation
6
RISK OF INJURY
Install collectors with at least one assis-
CAUTION!
tant.
z Place the first collector onto the profile rails and allow
it to slide into the anti-slip protectors
(Fig. 45, Item 2)
(Fig. 45).
The lower collector edge must lie in the opening of the
anti-slip protector
(Fig. 45, Item 1).
z Carefully push collector (Fig. 46, Item 1) up against
the single-sided collector clamp and align horizontally.
z Screw in single-sided collector clamp using size 5
spanner
(Fig. 46, Item 2).
USER NOTE
When the screw is tightened, the plastic
guide at the pre-determined cut-off points
breaks away and can be discarded.
The grip (Fig. 46, Item 2) on the collector clamp now
grips the lower collector edge.
1
2
63043970.32-1.SD
Fig. 45 Laying the first collector on the profile rails
1
2
63043965.45-1.SD
Inserting a double-sided collector clamp
z Insert the double-sided collector clamp, nut first, into
the opening made by the profile rail and plug connec
tor so that the plastic spacer (Fig. 47, Item 1) surrounds the profile rail.
z Push double-sided collector clamp up against the
collector frame.
USER NOTE
Do not tighten the screw until the second
collector has been pushed up against the
double-sided collector clamp.
Fig. 46 Single-sided collector clamp screwed in place
-
1
1
63043969.02-1.SD
Fig. 47 Fitting a double-sided collector clamp
SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
31
Page 32
6
63043966.11-1.SD
63043966.15-1.SD
63043966.16-1.SD
Collector installation
Fitting corrugated pipe connectors to the first
collector
z Remove the rubber caps from the connections.
z Push corrugated pipe connectors (Fig. 48, Item 1)
onto the left-hand connections on the first collector.
z Push bracket (Fig. 48, Item 2) over the corrugated
pipe connector and collector connection to secure
the connection.
Putting the second collector in place
z Place the second collector onto the profile rails and
allow it to slide into the anti-slip protectors.
1
2
63043966.11-1.SD
Fig. 48 Fitting corrugated pipe connectors to the first
collector
SYSTEM DAMAGE
through damaged corrugated pipe
CAUTION!
connectors.
z Do not use any tools, e.g. pliers
(Fig. 49, Item 2). These could render
the corrugated pipe connector
unusable.
z Push the second collector on to the first in such a way
that the collector connections are pushed into the
preassembled corrugated pipe connectors
(Fig. 49,
Item 1) on the first collector.
z Place second bracket (Fig. 49, Item 3) over the
corrugated pipe connector and collector connection.
SYSTEM DAMAGE
through unsecured corrugated pipe
CAUTION!
connectors and end caps.
z Secure each end cap with one bracket
and each corrugated pipe connector
with two brackets
(Fig. 50, Item 1).
1
2
3
Fig. 49 Pushing second collector towards the first
2
63043966.15-1.SD
32
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1
63043966.16-1.SD
Fig. 50 Corrugated pipe connector secured with brackets
Page 33
z Tighten the screw on the double-sided collector
63043965.48-1.SD
63043970.34-1.SD
clamp using the size 5 spanner.
USER NOTE
When the screw is tightened, the plastic
lugs at the pre-determined cut-off points
break away.
The grip (Fig. 51, Item 1) on the collector clamp now
grips the lower collector edge.
Repeat the procedure for all the other collectors.
Fitting the single-sided collector clamp on the left
Once all collectors are fitted, the two remaining one-sided collector clamps can be attached.
z Push single-sided collector clamp (Fig. 52, Item 1)
into upper and lower profile rails.
z Push collector clamp up against the collector frame
and screw in place using size 5 spanner
(Fig. 52,
Item 2).
The grip (Fig. 52, Item 2) on the collector clamp now
grips the lower collector edge.
Collector installation
6
1
63043965.48-1.SD
Fig. 51 Double-sided collector clamp between two collectors
2
1
USER NOTE
When the screw is tightened, the plastic
guide at the pre-determined cut-off points
breaks away and can be discarded.
63043970.34-1.SD
Fig. 52 Single-sided collector clamp (left)
SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
33
Page 34
7
63043966.25-1.SD
63043966.26-1.SD
Collector sensor connection
7 Collector sensor connection
USER NOTE
The collector sensor is supplied with the
solar controller.
Observe the installation location for single
or dual row collector systems
(Fig. 53).
SYSTEM DAMAGE
through faulty sensor cable.
CAUTION!
z Protect the cable from possible dama-
ge.
Insertion point
The collector sensor must be fitted in the collector
nearest to the flow connection
(Fig. 53, Item 2).
— Insertion point (Fig. 53, Item A) for single row collec-
tor systems.
— Insertion point (Fig. 53, Item B) for dual row collector
systems.
Installing the collector sensor
B
A
1
2
63043966.25-1.SD
Fig. 53 Collector sensor installation location (schematic)
Item 1: Return line
Item 2: Flow line
1
2
For perfect functioning of the solar thermal system, the
collector sensor
(Fig. 54, Item 1) needs to be inserted
into the sensor guide tube as far as it will go
(approx.
250 mm).
z Using the collector sensor or screwdriver, push th-
rough the sealing membrane on the sensor bushing
(Fig. 54, Item 3).
z Screw compression fitting (Fig. 54, Item 2) into sen-
sor bushing.
z Insert collector sensor approx. 250 mm into the sen-
sor guide tube (as far as it will go).
z Tighten compression fitting (Fig. 54, Item 2), coun-
terhold if necessary.
USER NOTE
If you accidentally push through the sensor
bushing
(Fig. 54, Item 3) on the wrong collector, it can be resealed using the plug
from the connection kit. You must first re
move the nut in the sensor bushing using
the cable gland
(Fig. 54, Item 2).
3
2
Fig. 54 Inserting the collector sensor into the collector
Item 1: Collector sensor
Item 2: Compession fitting
Item 3: Sensor bushing
1
Kollektor
250 mm
63043966.26-1.SD
34
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Page 35
8 Header connection
63043969.01-1.SD
63043970.35-1.SD
Information on laying the header pipes can be found in
the complete station installation instructions.
SYSTEM DAMAGE
from leaks in the collector connection, due
CAUTION!
to movements caused by heat.
z Feed the on-site flow line (Fig. 55,
Item 1) alongside the collector, rather
than vertically downwards.
Header connection
1
63043969.01-1.SD
Fig. 55 Feeding header pipes to the collector array
Item 1: Flow line
Item 2: Return line
8
2
1
8.1 Fitting holder for flow line
Use the holder to fasten the insulated flow line to the collector.
USER NOTE
We recommend commercially available
hose clamps
the header to the M8 thread on the holder
(Fig. 56, Item 2).
Select the diameter on the hose clamp according to the outside diameter of the flow
line, incl. insulation.
z Place holder (Fig. 56, Item 3) onto collector frame
and tighten with size 5 spanner.
z Fasten insulated header to holder on site.
(Fig. 56, Item 1) for fastening
2
3
Fig. 56 Fastening holder to the collector frame
Item 1: Hose clamp (on building)
Item 2: M8 thread
Item 3: Holder
1
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8
63043969.04-1.SD
Header connection
8.2 Venting through pressure filling
If venting of the solar thermal system is carried out using
a pressure filling pump, no vent is required on the roof.
z Remove rubber caps (transport protection) from the
relevant collector connections.
z Push elbow (Fig. 57, Item 2) with olive and union nut
onto collector connection.
z Secure elbow with bracket (Fig. 57, Item 1).
1
2
Perform the same procedure with the return connection.
3
4
63043969.04-1.SD
Fig. 57 Fitting flow line (with no vent on roof)
Item 1: Connector clip
Item 2: Elbow
Item 3: Olive
Item 4: Nut
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Page 37
Header connection
63043966.20-1.SD
63043966.21-1.SD
8.3 De-airing through air vent (accessory) at highest point in the system
8
If you intend to vent the solar thermal system with an
automatic air-vent valve (accessory) at the highest point
of the system, run the flow line rising to the air-vent valve
(Fig. 58, Item 2) and the return line rising to the collector
array (Fig. 58).
Avoid frequent changes in direction.
USER NOTE
For each change of direction downwards
and each new rise, install an additional air
pot with air vent.
If you cannot provide an automatic air vent valve due to
space restrictions, install a manual air vent valve.
Function of the grub screw and weather protection
cap on the automatic air vent valve
The solar thermal system is vented through the opened
grub screw. When in operation, the weather protection
cap
(Fig. 59, Item 1) must always be positioned over
the grub screw to prevent moisture entering through the
opened grub screw into the solar thermal system).
1
63043966.20-1.SD
Fig. 58 View — air pot with vent valve for flow connection
Item 1: Collector sensor
Item 2: Automatic air vent valve on roof
11
10
9
2
1
2
Open the air vent valve by unscrewing the grub screw
one full revolution.
Universal air vent set (Fig. 59):
Item 1: Weather protection cap 1 ×
Item 2: Automatic air vent 1 ×
Item 3: Ball valve 1 ×
Item 4: Gasket 1 ×
Item 5: Vent pot 1 ×
Item 6: Double threaded fitting with O-ring 1 ×
Item 7: Threaded fitting 1 ×
Item 8: Union nut 2 ×
Item 9: Gasket 1 ×
Item 10: Large diameter washer 1 ×
Item 11: Clamping disc 1 ×
8
7
63043966.21-1.SD
Fig. 59 Universal air vent set
3
4
5
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8
63043969.05-1.SD
63043969.06-1.SD
Header connection
Fitting the air vent
z Firmly screw threaded fitting (Fig. 60, Item 6) and
double threaded fitting (Fig. 60, Item 4) into air pot
(O-ring gasket).
z Push air pot (Fig. 60, Item 5) and fitting onto collector
connection and secure with clip.
z Connect header pipe to the compression fitting
(15
mm) (Fig. 60, Item 2).
1
4
3
6
Fig. 60 Connecting the air vent
Item 1: Connector clip
Item 2: Union nut for 15 mm compression fitting
Item 3: Olive
Item 4: Double threaded fitting with O-ring
Item 5: Air pot
Item 6: Threaded fitting
5
2
63043969.05-1.SD
8.4 Connecting two arrays
If connecting two collector arrays (Fig. 61, Item 1) you
will need a second connection kit.
z Fit individual parts as described in Chapter 8.2 "Ven-
ting through pressure filling".
z Make on-site connection between collector arrays
using copper pipe.
1
1
63043969.06-1.SD
Fig. 61 Two collector arrays, one behind the other
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Page 39
9 Final activities
9.1 Checking the installation
SYSTEM DAMAGE
through corrosion if water remains in the
CAUTION!
solar thermal system for an extended peri
od after it has been flushed or after a pressure test.
z Start up the solar thermal system im-
mediately after flushing/pressure test
with solar fluid (for instructions on flus
hing/pressure test see pump station instructions). Otherwise, carry out
flushing/pressure test later.
USER NOTE
Do not carry out the final insulating work
until the appropriate checks have been
performed.
Final activities
-
-
9
Checks
Corrugated pipe connector, end caps and
1.
connecting pipe bends secured with clips?
All collector braces connected to profile
2.
rails?
Anti-slip protection installed and clicked into
3.
place in profile rails?
Sensor inserted as far as it will go and secu-
4.
red with compression fitting?
Pressure test carried out and all connections
5.
leak-proof (see pump station instructions)?
USER NOTE
If you are venting the solar thermal system
with an automatic air-vent valve (accesso
ry), you must close the ball valve after the
venting procedure (see pump station in
stallation instructions).
-
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39
Page 40
9
Final activities
9.2 Insulating the connection and header
pipes
z Cut enclosed insulation (710 mm long) into 88 mm
lengths and place around the corrugated pipe con
nectors between the collectors.
Insulation of the header pipes in internal or external
installations
— For the insulation of external pipework, use only UV
and high temperature resistant insulating materials,
rated to 150 °C.
— For the insulation of internal pipework, use only high
temperature resistant insulating materials, rated to
150 °C.
— Make the insulation bird-proof.
-
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Page 41
Quick reference guide for base anchoring and pressure filling
63043970.48-1.SD
63043966.31-1.SD
63043969.07-1.SD
10 Quick reference guide for base anchoring and pressure filling
These instructions are only intended as an overview of
the work to be carried out. You MUST follow the detailed
descriptions for the work on the pages mentioned, and
obey all safety and user instructions.
16
10
Fitting braces and profile rails
Insert telescopic rails into each other according to
1.
the
selected angle of inclination, and fasten.
Drill holes in girder (or similar), and fasten collector
2.
braces with screws.
Connect profile rails together using plug connectors. p. 26
3.
Fasten profile rails to collector braces. p. 27
4.
Align sides of the profile rails. p. 27
5.
Install anti-slip protectors into the two inner slotted ho-
6.
les on the lower profile rails.
Preparing to install the collectors
Push end caps onto those connections that are not
7.
required and secure using brackets.
Fastening the collectors
Push single-sided collector clamp (right) into profile
8.
rails.
Place first collector (right) onto profile rails and
9.
push
onto collector clamp.
Screw up collector clamp on the right. p. 31
10.
Place double-sided collector clamp into profile rail
11.
and push onto first collector.
Push corrugated pipe connectors onto the connec-
12.
tions on the first collector and secure with brackets.
Push second collector towards the first and fix in
13.
place with brackets.
Tighten screws on the double-sided collector clamp. p. 31
14.
Repeat the procedure for all other collectors. p. 33
15.
Fit single-sided collector clamps on the left. p. 33
16.
Header connection
Insert collector sensor as far as it will go into the coll-
17.
ector with the flow line to be connected,
and
screw tight.
Place holder for flow line onto collector frame and
18.
screw in place.
Fasten pipe bend to flow and return connections
19.
using clamping ring and nut.
Fix pipe bend with clips. p. 36
20.
Perform installation checks. p. 39
21.
Insulate header pipes with UV and high
22.
temperature
resistant material.
p. 14
p. 23
p. 27
p. 30
p. 30
p. 31
p. 31
p. 32
p. 32
p. 34
p. 35
p. 36
p. 40
11,14
6
3
Fig. 62 Installing on a flat roof
13
7
7
12
12
Fig. 63 Water connections
7
12
17
8,10
4
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1
2
9
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20
18
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63043969.07-1.SD
Fig. 64 Fitting the collector sensor and connection parts
41
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Notes
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Page 43
Notes
SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
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Buderus
Cotswold Way, Warndon, Worcester WR4 9SW
Customer service: 0870 421 5933
Technical support: 0870 421 5944
Fax: 01905 753130
www.buderus.co.uk
In the UK and IE, Buderus is a brand name of
Bosch Thermotechnology Ltd.
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