Buderus SKS 4.0 Series Installation Instructions Manual
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
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.
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SKS 4.0 Series - Flat roof and wall mounting -We reserve the right to make any changes due to technical modifications.
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
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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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.
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SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
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
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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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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
SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
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.
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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4
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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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SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
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.
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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4
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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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SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
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.
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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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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SKS 4.0 Series - Flat roof and wall mounting - We reserve the right to make any changes due to technical modifications.
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
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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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
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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Fig. 12 Adjust angle of inclination for portrait collectors
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