Buderus SKS 4.0 Series Installation Instructions Manual Download Page 2

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Foreword

SKS 4.0 Series - Flat roof and wall mounting -We reserve the right to make any changes due to technical modifications.

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.

Summary of Contents for SKS 4.0 Series

Page 1: ...r Collector 63043970 01 1 SD 63043970 01 1 SD SKS 4 0 Series Flat Collector FLAT ROOF AND WALL MOUNTED SOLAR THERMAL SYSTEMS 7 747 019 102 04 2006 UK For heating engineers Please read carefully prior to commissioning and maintenance ...

Page 2: ...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...

Page 3: ...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...

Page 4: ...ealth 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 EN 12976 Thermal solar thermal system and their components pre fabricated systems ENV 12977 Thermal solar thermal system an...

Page 5: ...ors Certificates Length 2 070 mm Width 1 145 mm Height 90 mm Clearance between collectors 25 mm Fluid content portrait version Vf 1 43 l Fluid content landscape version Vf 1 76 l Gross absorber surface area AG 2 37 m Net absorber surface area 2 1 m Net weight portrait version m 46 kg Net weight landscape version m 47 kg Permissible operating pressure of the collector pmax 10 bar DIN 0036 ...

Page 6: ...ch 25 If there is a risk that larger quantities of snow might ac cumulate 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 construc tion can support the weight The installation set is suitab...

Page 7: ...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 CAU...

Page 8: ...r 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 USER NOTE It is recommended that the services of a roofing company who are fully experi enced in working on roofs and ...

Page 9: ...llation set for each collector array and for the first collector Fig 3 Extended installation set for each additional collector Fig 3 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...

Page 10: ...ollector in two corner protectors Fig 5 Fig 4 Connection kit and connection set illustration shows 2 portrait collectors 63043969 03 1 SD 63043969 03 1 SD 1 2 5 6 3 8 4 7 9 10 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 p...

Page 11: ...g Transport protection for collector connections The collector connections are protected against damage by rubber caps Storage The collectors must be stored in dry conditions USER NOTE When fitting the roof installation set and water connection the only tool reqiured is the size 5 allen key from the connection kit USER NOTE Dispose of the transport packaging in an environmentally friendly recyclin...

Page 12: ... application of solar thermal sys tems provide angles of incidence that ensure an opti mum solar yield for every season Fig 7 Solar thermal system components and technical documentation 6720613577 00 1 SD 6720613577 00 1 SD 2 1 3 4 Item 1 Collector instructions for roof installation are enclosed with the connection kit Item 2 Pump station instructions enclosed with the station Item 3 Solar Control...

Page 13: ... SD 63043970 07 1 SD 30 45 30 15 15 45 1 2 3 WARNING RISK TO LIFE If there is a risk that larger quantities of snow might accumulate behind the collec tors towards the roof ridge prevent this by fitting a suitable protective grille on site CAUTION SYSTEM DAMAGE through strong wind On sloping flat roofs the flat roof supports must be secured on site z Ask a roofing contractor to carry out the insta...

Page 14: ...opic rails into each other and fasten with M8 20 screw Fig 11 Fig 11 Connecting telescopic rails 63043970 08 1 SD 63043970 08 1 SD 1 Fig 12 Adjust angle of inclination for portrait collectors 63043970 39 1 SD 63043970 39 1 SD 60 55 50 45 40 35 30 25 140 mm 1 2 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 ...

Page 15: ...ower 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 WARNING RISK TO LIFE from falling collectors due to incorrect use z For wall mounted installation use only the positions for the collector angles of inclination 30 35 40 and 45 Fig 13 Item 1 Fig 14 Shadow clearance X 63043970 09 1 SD...

Page 16: ...mencing the installation ensure that at least one metre is allo wed between the flat roof supports and the edge of the roof Fig 15 Fig 16 Space requirements collector array portrait version 63043970 10 1 SD 63043970 10 1 SD A B Space requirements for portrait collectors Space requirements for landscape collectors Number of collectors Dimension A Angle of inclination Dimension B Number of collector...

Page 17: ...Portrait flat roof supports for 2 collectors 63043970 11 1 SD 63043970 11 1 SD WARNING RISK TO LIFE Whilst working on the roof take all neces sary precautions against a possible fall WARNING 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 USER NOTE Please observ...

Page 18: ...r brace is required Fig 19 For every additional landsca pe collector two further collector braces are required Fig 21 The basic version can be used for the following loads building height max 20 m installation height max 2 0 kN m wind or snow load Fig 19 Basic version for 2 portrait collectors Fig 20 Basic version for 3 10 portrait collectors Fig 21 Basic version for 2 landscape collectors 6304397...

Page 19: ...installation for the second and all further collectors Fig 22 This ver sion can be used for the following loads Building height max 100 m installation height max 3 8 kN m wind or snow load Fig 22 Auxiliary braces for 3 portrait collectors 63043970 14 1 SD 63043970 14 1 SD 63043970 14 1 SD 980 980 980 190 190 USER NOTE For landscape installation a max building height of 100 m and a max wind or snow...

Page 20: ...r the 4th 7th and 10th collectors Fig 23 Item 1 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 m wind or snow load Tab 7 Distances between auxiliary braces USER NOTE Strictly observe the clearances between the collector braces so that the profile rails can be installed Number of collectors Dim A Dim B Dimension C 4 ...

Page 21: ...so required This version can be used for the following loads Building height max 100 m installation height max 3 8 kN m wind or snow load Fig 24 Basic version for 2 landscape collectors 63043970 14 1 SD 63043970 16 1 SD 63043970 16 1 SD 980 980 135 980 980 USER NOTE Landscape installation can be carried out using only the auxiliary brace accessory Fig 25 Version for maximum loads 3 portrait collec...

Page 22: ...ing trays required and make more secure using rope as necessary For all methods please consider the structural integrity of the roof USER NOTE Using gravel in the loading trays a maxi mum load of 320 kg is possible per collec tor Tab 8 USER NOTE For the following table please also consi der the clearances and number of additio nal collector braces Chapter 5 1 Distances between collector braces for...

Page 23: ...aces see Chapter 5 1 Distances between collector braces for on site base ancho ring 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 s...

Page 24: ... 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 sup...

Page 25: ...KS 4 0 Series Flat roof and wall mounting We reserve the right to make any changes due to technical modifications 25 Fig 30 Fastening collector braces to the wall for 2 collectors dimensions in mm 63043970 30 1 SD 63043970 30 1 SD 980 980 135 980 980 1 ...

Page 26: ...llows Tab 10 Aligning the lower and upper profile rails when using base anchoring If using loading trays begin fastening the profile rails as follows Tab 11 Aligning the lower and upper profile rails when using loading trays Fig 31 Connecting profile rails 63043965 33 1 SD 63043965 33 1 SD 1 2 3 Fig 32 Aligning the profile rails for on site base anchoring Fig 33 Aligning the profile rails for load...

Page 27: ...ter 5 5 2 Installing profile rails using the midd le hole on the profile Fig 35 Item 1 z Align sides of the profile rails z Tighten bolts 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...

Page 28: ...ways 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 Fig 38 Wall mounted installation 63043970 05 1 SD CAUTION RISK OF INJURY through interruption of work z Secure the collectors against falling z Stabilise the collector array CAUTION SYSTEM DAMAGE through damaged sealing f...

Page 29: ...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 Fig 39 Water connection right up to max 5 collectors Item 1 Corrugated pipe connector Item 2 Flow line Item ...

Page 30: ...collector In addition the anti slip protectors Fig 43 Item 3 pre vent the collector from slipping 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 coll ector array until they click into place in the first slotted hole on the profile rails Fig 42 Securing end cap with bracket 63043966 12 2 SD...

Page 31: ... Item 2 The grip Fig 46 Item 2 on the collector clamp now grips the lower collector edge 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 sur rounds the profile rail z Push double sided collector clamp up against the collector frame Fig 45 Laying the fi...

Page 32: ...hat 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 Fig 48 Fitting corrugated pipe connectors to the first collector 63043966 11 1 SD 63043966 11 1 SD 2 1 Fig 49 Pushing second collector towards the first 2 63043966 15 1 SD 6304...

Page 33: ... 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 Fig 51 Double sided collector clamp between two collectors 63043965 48 1 SD 63043965 48 1 SD 1 USER NOTE When the...

Page 34: ... 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 Fig 53 Collector sensor installation location schematic Item 1 Return line Item 2 Flow line B A 63043966 25 1 SD 63043966 25 1 SD 2 1 2 1 USER NOTE The collector sensor is supplied with the solar controller Observe the installat...

Page 35: ... header pipes to the collector array Item 1 Flow line Item 2 Return line 63043969 01 1 SD 63043969 01 1 SD 1 2 1 CAUTION SYSTEM DAMAGE from leaks in the collector connection due to movements caused by heat z Feed the on site flow line Fig 55 Item 1 alongside the collector rather than vertically downwards Fig 56 Fastening holder to the collector frame Item 1 Hose clamp on building Item 2 M8 thread ...

Page 36: ...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 Perform the same procedure with the return connection Fig 57 Fitting flow line with no vent on roof Item 1 Connector clip Item 2 Elbow Item 3 Olive Item ...

Page 37: ...rub 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 Open the air vent valve by unscrewing the grub screw one full revolution Universal air vent set Fig 59 Fig 58 View air pot with vent valve for flow connection Item 1 Collector sensor Item 2 Automa...

Page 38: ...5 mm Fig 60 Item 2 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 Fig 60 Connecting the air vent Item 1 Connector clip Item 2 Union nut for 15 mm compression fitting Item 3 Olive I...

Page 39: ...s Otherwise carry out flushing pressure test later USER NOTE Do not carry out the final insulating work until the appropriate checks have been performed 1 Corrugated pipe connector end caps and connecting pipe bends secured with clips 2 All collector braces connected to profile rails 3 Anti slip protection installed and clicked into place in profile rails 4 Sensor inserted as far as it will go and...

Page 40: ... 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...

Page 41: ...ctors into the two inner slotted ho les on the lower profile rails p 27 Preparing to install the collectors 7 Push end caps onto those connections that are not required and secure using brackets p 30 Fastening the collectors 8 Push single sided collector clamp right into profile rails p 30 9 Place first collector right onto profile rails and push onto collector clamp p 31 10 Screw up collector cla...

Page 42: ...Notes SKS 4 0 Series Flat roof and wall mounting We reserve the right to make any changes due to technical modifications 42 ...

Page 43: ...Notes SKS 4 0 Series Flat roof and wall mounting We reserve the right to make any changes due to technical modifications 43 ...

Page 44: ... 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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