(PDF 3.1 MB)

(PDF 3.1 MB)
Installation instructions
Solar Collector
63043965.01-1.SD
For heating engineers
ON ROOF MOUNTING
Solar Thermal Systems
Please read carefully prior
to commissioning and
maintenance
7 747 019 101 (04/2006) UK
SKN 3.0 Series Flat Collector
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
SKN 3.0 Series - On roof mounting -We reserve the right to make any changes due to technical modifications.
Contents
1
General information
2
Specifications .
3
Safety
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1 Correct use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.2 Notes structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.3 Please observe these safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4
Before installation .
4.1
4.2
4.3
4.4
4.5
4.6
5
General notes . . . . . . . . . . . . . .
Component description . . . . . . . .
Other equipment . . . . . . . . . . . .
Transport and storage . . . . . . . . .
Technical documentation . . . . . . .
Determining space required on roof
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fitting the roof connection and profile rails
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Setting clearances . . . . . . . . . .
Pan tile roofs. . . . . . . . . . . . . .
Crown tile roofs . . . . . . . . . . . .
Corrugated sheet roofs . . . . . . .
Slate/shingle roofs . . . . . . . . . .
Sheet roofs . . . . . . . . . . . . . . .
Fitting additional rails (accessory) .
Installing profile rails . . . . . . . . .
Collector installation .
. . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.1 Preparing to install the collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2 Fastening the collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7
Collector sensor connection .
8
Header connection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.1 De-airing through pressure filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.2 De-airing through air vent (accessory) at highest point in the system . . . . . . . . . . . 35
9
Fitting the connection set for two rows (accessory) .
10 Final activities .
. . . . . . . . . . . . . . . . 37
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.1 Checking the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.2 Insulating the connection and header pipes . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
3
1
1
General information
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 roofs
The Health and Safety at Work etc
Act 1974
Connection of solar thermal
systems
Installation and equipment of DHW
cylinders
EN 12976: Thermal solar system and
their components (pre-fabricated
systems).
The Management of Health and Safety
at Work Regulations 1999
ENV 12977: Thermal solar system
and their components (bespoke
The Construction (Health Safety and
systems).
Welfare) Regulations 1996
BS 6795: Code of practice for solar
The Construction (Design and
thermal systems for swimming pools.
Management) Regulations 1994
BS5546: 2000 Specification for
installation of hot water supplies for
domestic purposes, using gas-fired
appliances of rated input not
exceeding 70 kW.
BS6700:1997 Specification for
design, installation, testing and
maintenance, of servicing supplying
water for domestic use within
buildings and their curtilages.
The Lifting Operations and Lifting
Equipment Regulations 1998
Tab. 1
Technical rules for the installation of solar thermal systems (selection) in UK
Lightning protection
USER NOTE
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 mm2 to the earth bonding.
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
Special measures regarding lightning protection are not
required for building heights (installation heights) of less
than 20 m.
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.
4
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Specifications
2
2
Specifications
SKN SERIES SOLAR collectorS
Certificates
0036
DIN
Length
Width
Height
Clearance between collectors
Fluid content, portrait version
Fluid content, landscape version
Gross absorber surface area
Net absorber surface area
Net weight, portrait version
Net weight, landscape version
Permissible operating pressure
of the collector
Tab. 2
Vf
Vf
AG
m
m
pmax
2070 mm
1145 mm
90 mm
25 mm
0.86 l
1.25 l
2.37 m²
2.23 m²
41 kg
42 kg
6 bar
Specifications
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
5
3
3
Safety
Safety
This chapter details how the notes for the installation
instructions, as well as the general safety instuctions,
necessary for safe and truoble-free operation, are
arranged in this manual.
Safety and user notes, which specifically refer to the
installation, in the installation manual immerdiately
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 instuctions.
3.1
Correct use
This installation set holds the thermal solar collectors,
which are installed on sloping roofs with a slope of 25°
to 60°. The collectors can be installed on corrugated and
sheet steel roofs with slopes of between 5° and 65°.
Operating conditions
Only erect the installation set on roofs whose
construction can support the weight. If necessary,
consult a structural engineer or a roofer.
The installation set is suitable for a max. standard wind
or snow load of 2.0 kN/m² and an installation height of
max, 20m. Using appropriate accessories, the
installation set can be used for a max. standard wind or
snow load of 3.1 kN/m² and a max. installation height of
100 m. See Chapter 5.8 "Installing profile rails".
The roof installation set must not be used for fixing any
other objects to the roof. The kit is intended exclusively
for the safe fixing of solar collectors.
6
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Safety
3.2
Notes structure
RISK OF INJURY
Two levels are identified by signal terms:
RISK TO LIFE
WARNING!
CAUTION!
CAUTION!
Identifies potentially dangerous situations,
which might lead to mild or slight injuries or
to material losses.
Further symbols identifying dangers and user notes:
RISK TO LIFE
from electric shock.
Injury and operating faults can result from
making changes to the system
construction.
z Never change the system construction.
Identifies possible dangers which might
lead to serious injury or death if appropriate
care is not taken.
RISK OF INJURY/SYSTEM DAMAGE
3
RISK OF INJURY
CAUTION!
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.
WARNING!
USER NOTE
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.
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
7
4
Before installation
4
Before installation
4.1
General notes
USER NOTE
It is recommended that the services of a
roofing company, who are experienced in
working on roofs and will be fully aware of
the risks of working at height are considered.
Make yourself familiar with the on-site conditions and local regulations before commencing the installation.
RISK OF INJURY
CAUTION!
If the collector and its installation material
is left exposed to the sunlight for a long period, the parts will become hot and may
cause burns.
z Wear protective clothing.
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.
63043965.02-1.SD
Fig. 1
General overview of collector pair — roof mounting
Check
z the delivery for completeness and perfect condition.
z the optimum arrangement of the solar collectors.
Take account of the direction of the sunlight (angle of
inclination, southerly direction). Avoid the shade of
high trees or structures and match the collector array
to the shape of the building (e.g. aligned with windows, doors, etc.).
USER NOTE
Only use OEM components and replace
any damaged or faulty parts immediately.
USER NOTE
Remove broken tiles, shingles or plates in
the area of the collectors and replace
them.
8
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Before installation
4.2
4
Component description
4.2.1 Installation set for the collectors
USER NOTE
The installation sets are for mounting and
fixing the collectors in place.
1
8
3
2
4
3
5
7
6
63043965.03-1.SD
Fig. 2
Installation set for 2 collectors — 1 basic installation set, 1 extended installation set and 2 roof connection installation sets
Basic installation set for each collector array and
for the first collector (Fig. 2):
Item 1:
Item 3:
Item 7:
Item 8:
Profile rail
Single-sided collector clamp
Anti-slip protection
M8 screw
2×
4×
2×
4×
Extended installation set for each additional collector
(Fig. 2):
Item 1:
Item 2:
Item 7:
Item 6:
Item 8:
Profile rail
Double-sided collector clamp
Anti-slip protection
Rail connector with threaded studs
M8 screw
2×
2×
2×
2×
4×
Roof connection, pan tile roofs, per collector
(Fig. 2):
Item 4:
Item 5:
Roof hook, adjustable
Sliding nut
4×
4×
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
9
4
Before installation
4.2.2 Hydraulic connection
USER NOTE
One connection kit for each collector array
will be required. The collectors are connected together by solar hoses (connection set).
1
4
2
3
3
5
4
8
6
7
Fig. 3
63043965.04-1.SD
Connection kit and connection set (illustration shows 2 portrait collectors)
Connection kit, per collector array (Fig. 3)
Item 1:
Item 3:
Item 4:
Item 5:
Hose clip (1 x spare)
Solar hose, length 1000 mm
Dummy plug
Solar hose, length 55 mm
5×
2×
2×
2×
Item 6:
Item 7:
Item 8:
Clamped joint for collector sensor
Size 5 Allen key
Hose nozzle R¾ with 15 mm compression fittings
1×
1×
2×
Connection set between the collectors, for each
collector (in two corner protectors, Fig. 4)
Item 1:
Item 2:
Hose clip
Solar hose, length 95 mm
4×
2×
1
2
63043965.05-1.SD
Fig. 4
10
Two corner protectors with one connection set
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Before installation
4.3
4
Other equipment
— 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 pipework connection, the only tool required
is the size 5 Allen key from the connection
kit.
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 plastic caps.
SYSTEM DAMAGE
through damaged sealing faces.
CAUTION!
z Do not remove the plastic caps
(Fig. 5, Item 1) until immediately prior
to installation.
1
Storage
The collectors must be stored in dry conditions.
USER NOTE
Do not store collectors outside without protection from the rain.
63043965.06-1.SD
Fig. 5
Plastic caps on collector connections
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
11
4
4.5
Before installation
Technical documentation
The solar thermal system consists of various components (Fig. 6). Installation, operation and maintenance
documentation is provided for each component. Accessories may be accompanied by a separate document.
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 Controller: instructions are enclosed
with the controller.
Item 4:
DHW Cylinder: instructions enclosed with the
DHW cylinder.
4
1
3
2
6720613577.00-1.SD
Fig. 6
12
Solar thermal system components and technical
documentation
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Before installation
4.6
4
Determining space required on roof
Please note the following minimum space requirements.
Dimension A and B
Area required for the collector array.
H
Dimension C
At least two tiles to the roof or chimney. Otherwise there
is a risk of damaging the tiles, particularly if the tiles are
laid in mortar.
Dimension D
G
Roof overhang including gable wall thickness.
Dimension E
Minimum 30 cm for fitting the connection cables in
the attic.
63043965.09-1.SD
Fig. 7
Clearances to be observed
Dimension F
Minimum 40 cm for installing the connection cables in
the attic (if installing a vent, sufficient space must also be
allowed for in the vicinity of the flow outlet).
Please note that the air vent must be the highest point of
the system.
Dimension G
Minimum 50 cm left and right of the collector array for
the connection cables under the roof.
Dimension H
Dimension H is 1.900 mm (1.000 mm for landscape
collectors) and is the minimum distance from the upper
edge of the collector to the lower profile rail, which is installed first.
Space requirements for portrait collectors:
Space requirements for landscape collectors:
Number of collectors
Dimension A
Dim. B
Number of collectors
Dimension A
Dim. B
2
2.32 m
2.07 m
2
4.17 m
1.15 m
3
3.49 m
2.07 m
3
6.26 m
1.15 m
4
4.66 m
2.07 m
4
8.36 m
1.15 m
5
5.83 m
2.07 m
5
10.45 m
1.15 m
6
7.06 m
2.07 m
6
12.55 m
1.15 m
7
8.17 m
2.07 m
7
14.64 m
1.15 m
8
9.34 m
2.07 m
8
16.74 m
1.15 m
9
10.51 m
2.07 m
9
18.61 m
1.15 m
10
11.68 m
2.07 m
10
20.93 m
1.15 m
Tab. 3
Space requirement for portrait collectors
Tab. 4
Space requirement for landscape collectors
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
13
Fitting the roof connection and profile rails
5
5
Fitting the roof connection and profile rails
5.1
Setting clearances
The dimensions given are guide values that should be
approximately maintained.
USER NOTE
On pan tile roofs the tile troughs determine
the true distance between the roof hooks.
Distances of roof hooks
Every profile rail is fastened using two roof hooks
(Fig. 8). See the table for the approximate distance between the roof hooks.
Installation
type
portrait
Distance w
approx.
1 170 mm
landscape approx. 2090 mm
Tab. 5
Distance x
610 —
1030 mm
1520 —
1950 mm
Distance between roof hooks
z
x
Distance z
170 — 540 mm
170 — 540 mm
63043965.11-1.SD
Fig. 8
Distance between roof hooks
USER NOTE
Distances x and z should always be approximately equal to distance w.
Distances of profile rails
Set the distance between the top and bottom profile rails
Installation
(Fig.
9). Use the table values. Distance y
type
from
to
portrait
1320 mm
1710 mm
landscape
600 mm
820 mm
Tab. 6
y
Distance (centre-centre) between bottom
and top profile rail
USER NOTE
Landscape installation is only possible
if roof battens are max. 420 mm apart.
63043965.12-1.SD
Fig. 9
14
Distance between profile rails
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Fitting the roof connection and profile rails
5
RISK TO LIFE
WARNING!
Whilst working on the roof, take all necessary precautions against a possible fall.
RISK OF INJURY
through a fall or falling parts.
WARNING!
z Take appropriate action to prevent accidents when working on roofs.
z Always wear personal protective clothing and safety equipment.
63043965.10-1.SD
Fig. 10
Fitted profile rails for two collectors
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
15
5
5.2
Fitting the roof connection and profile rails
Pan tile roofs
Fit all roof hooks according to the guide values shown in
tables 5 and 6 on page 14.
USER NOTE
Do not modify the roof construction and
avoid damaging the roof covering. In the
case of roof tiles laid in mortar, lift the tiles
starting with the 3rd row under the ridge.
USER NOTE
Carefully cut away the base of the tile if necessary to ensure the tile lies correctly
over the roof hook.
63043965.13-1.SD
Fig. 11
Fitted roof hooks for two collectors
SYSTEM DAMAGE
CAUTION!
1
2
through subsequent loosening of the long
hexagon nut on the roof hook. When the
nut is tightened, adhesive is activated
which bonds the joint securely after one
hour.
z If the nut becomes loose after this time,
it must be tightened on-site (e.g. lock
washer).
5.2.1 Attaching the roof hooks over the roof batten
63043965.14-1.SD
In its packaged state, the lower part of the roof hook is
folded.
z Loosen the long hexagon nut (Fig. 12, Item 2) on the
roof hook and move the lower part of the roof hook
(Fig. 12, Item 1) to the correct position.
Fig. 12
Turning the lower part of the roof hook
z Push the tile upwards according to the roof hook positions shown in (Tab. 5 and Tab. 6, page 14).
1
z Attach in the roof hook in such a way that the front
brace lies in a tile trough (Fig. 13, Item 4).
5
z Push the lower part of roof hook (Fig. 13, Item 3) upwards until it touches the roof batten
(Fig. 13, Item 2).
4
z Tighten the long hexagon nut (Fig. 13, Item 1). To do
this, insert the size 5 Allen key into one of the holes
in the hexagon nut and turn.
3
USER NOTE
The serated washer (Fig. 13, Item 5) must
grip the teeth on the lower part of the roof
hook.
16
2
4
63043965.15-1.SD
Fig. 13
Roof hook located in place (some tiles have been
removed to show the example in more detail)
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Fitting the roof connection and profile rails
5.2.2 Fastening roof hooks to joists
5
1
Alternatively, the roof hook can also be used for fastening to the joist.
2
3
According to the roof hook positions shown in (Tab. 5
and Tab. 6, page 14), sufficiently strong boards must be
attached to the joists so that the roof hook can be fitted
between the joists.
USER NOTE
With some roof coverings it may be necessary to pack the lower part of the roof hook
(Fig. 14, Item 4) with boards so that the
upper part of the roof hook lies on top of
the tile.
4
5
63043965.16-1.SD
Fig. 14
Fastening roof hooks to joists
z Loosen the long hexagon nut (Fig. 14, Item 2).
Item 1: Lower part of roof hook
z Insert bolt into upper hole (Fig. 14, Item 3).
Item 2: Long hexagon nut
z Loosely fasten lower part of roof hook
(Fig. 14, Item 1). Do not tighten the connection yet.
Item 3: Upper hole for fastening the lower part
Item 4: Pack if necessary
Item 5: Cut off if necessary
SYSTEM DAMAGE
CAUTION!
through breakage of the roof hook if the
bolt is not positioned in the upper hole, resulting in uneven load distribution.
z Lay front brace onto the tile so that when subjected
to a load it lies in a tile trough (Fig. 15, Item 3).
5
The roof hook must have some clearance along the upper edge of the tile (Fig. 15, Item 4). Adjust the top of the
tile if necessary.
6
1
4
z Push the lower part of the roof hook down until it lies
on the joist or on the boards (Fig. 15, Item 6).
USER NOTE
3
The serated washer (Fig. 15, Item 5) must
grip the teeth on the lower part of the roof
hook.
z Tighten the long hexagon nut (Fig. 15, Item 1). To do
this, insert the size 5 Allen key into the hole in the hexagon nut and turn.
z Using suitable screws, fasten the lower part of the
roof hook into the first (Fig. 15, Item 2) and second
holes (at least) of the joist.
3
2
63043965.17-1.SD
Fig. 15
Roof hook fitted (some tiles have been removed for a
better view)
Item 1: Long hexagon nut
Item 2: Screw for fastening roof hook
Item 3: Front brace
Item 4: Adjust the tile as necessary to fit the roof hook
Item 5: Serated washer
Item 6: Board
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
17
5
5.3
Fitting the roof connection and profile rails
Crown tile roofs
USER NOTE
1
Consult a roofer when installing on a roof
with crown tiles.
During installation, please maintain the required distances (w, x and y) between the roof hooks as detailed
in (Tab. 5 and Tab. 6, page 14).
According to the roof hook positions shown in (Tab. 5
and Tab. 6, page 14), sufficiently strong boards
(Fig. 16, Item 1) must be attached to the joists (cut out
counter-battens) so that the roof hook can be fitted between the joists.
1
63043965.18-1.SD
Fig. 16
Fit boards/planks if necessary
USER NOTE
If the roof has been fitted with boards, the
same roof hook as with pan tile roofs can
be used (page 16). It may also be possible
to fit the roof hooks over battens.
Preparing roof hook
1
Before installing, the lower part must be moved to the
correct position.
2
z Loosen the long hexagon nut (Fig. 17, Item 2).
3
z Insert bolt into upper hole (Fig. 17, Item 3).
z Loosely fasten lower part of roof hook
(Fig. 17, Item 1). Do not tighten the connection yet.
SYSTEM DAMAGE
CAUTION!
through breakage of the roof hook if the
bolt is not positioned in the upper hole, resulting in uneven load distribution.
4
63043965.16-1.SD
Fig. 17
Repositioning lower part of roof hook
Item 1: Lower part of roof hook
Item 2: Long hexagon nut
Item 3: Upper hole for fastening the lower part
Item 4: Cut off if necessary
18
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Fitting the roof connection and profile rails
5
Fitting the roof hook
BUILDING DAMAGE
caused by leaks.
CAUTION!
z Fit each roof hook centrally on a crown
tile.
1
USER NOTE
If the roof battens are too close together,
remove the lower part of the roof hook between the second and third holes.
z Push the lower part of the hook down until it lies on
the joist or on the board (Fig. 18, Item 1).
63043965.20-1.SD
USER NOTE
Fig. 18
Fitted roof hook
The serated washer (Fig. 19, Item 2) must
grip the teeth on the lower part of the roof
hook.
1
2
z Tighten the long hexagon nut (Fig. 19, Item 1). To do
this, insert the size 5 Allen key into the hole in the hexagon nut and turn.
z Using suitable screws, fasten the lower part of the
roof hook into the first (Fig. 19, Item 3) and second
holes (at least) of the joist or board.
3
63043965.21-1.SD
Fig. 19
Fitted roof hook — cross section showing shortened
lower part of roof hook
Item 1: Long hexagon nut
Item 2: Serated washer
Item 3: Screw for fastening roof hook
z Cut the adjacent crown tiles (Fig. 20, Item 1) to size
(dashed line, Fig. 20, Item 2).
2
1
63043965.65-1.SD
Fig. 20
Roof hook with covered roof
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
19
5
5.4
Fitting the roof connection and profile rails
Corrugated sheet roofs
Carriage bolts must be used instead of roof hooks for fastening the profile rails.
1
Standard delivery (Fig. 21):
Item 1:
Item 2:
Item 3:
Item 4:
Item 5:
Item 6:
M8 screw
Holding bracket
M12 nut
Washer
Sealing disc
Carriage bolts
2
4×
4×
4×
4×
4×
4×
3
4
5
6
On corrugated roofs, the peaks determine the true distance between the carriage bolts. During installation,
please maintain the required distances (w, x and y) between carriage bolts as detailed in (Tab. 5 and Tab. 6,
page 14).
63043965.22-1.SD
Fig. 21
SYSTEM DAMAGE
due to an insufficiently strong subframe.
CAUTION!
z Check that the subframe is strong
enough. To fasten the carriage bolts,
timber supports of at least 40 × 40 mm
thickness are required.
z If necessary, fit additional timber supports to maintain the measurements
shown in Tab. 5 and Tab. 6.
20
Roof connector for corrugated sheets
Additional tools required
— Cordless screwdriver
— Tape measure
— Wood drill, Ø 6 mm (drill bit length see
Chapter "Fitting the carriage bolts", page 21)
— Metal drill, Ø 13 mm
— Spanner size 15 and 19
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Fitting the roof connection and profile rails
5
Fitting the carriage bolts
USER NOTE
Using the wood drill, drill precisely at a 90°
angle through the roof subframe to obtain
a flat, level surface between the holding
bracket and profile rail.
BUILDING DAMAGE
caused by leaks.
CAUTION!
z Never drill into a tile trough.
z Drill through the corrugated metal roof using a metal
drill (Ø 13 mm) taking note of the positions of the carriage bolt (see Tab. 5 and Tab. 6). Do not drill into the
wood beneath!
63043965.23-1.SD
Fig. 22
Creating a drilling template
z Feed wood drill (Ø 6 mm) through the hole and drill
vertically into the subframe (timber support).
1
z When fitting the carriage bolts, note the sequence of
the individual parts (Fig. 23).
2
3
4
z Turn holding bracket (Fig. 23, Item 1) until it touches
the carriage bolt (Fig. 23, Item 5).
z Screw the pre-assembled carriage bolt into the roof
using a size 15 spanner until distance B is reached.
5
USER NOTE
When screwing in carriage bolts, ensure
that the distance B (Fig. 24) is the same
for all carriage bolts.
63043965.24-1.SD
Fig. 23
Fitting the carriage bolts — sequence
Item 1: Holding bracket
Item 2: M12 nut
Item 3: Washer
Item 4: Sealing disc
Item 5: M12 carriage bolt
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
21
5
Fitting the roof connection and profile rails
z Tighten the nuts (Fig. 24, Item 2) until the sealing
disc (Fig. 24, Item 3) is lying completely flush on the
roof.
1
USER NOTE
2
3
z The holding bracket must be screwed
fully onto the carriage bolt.
Height of peak, dimension A
35 mm
40 mm
45 mm
50 mm
55 mm
60 mm
Dim. B
70 mm
65 mm
60 mm
55 mm
50 mm
45 mm
63043965.25-1.SD
Fig. 24
Carriage bolt fitted to corrugated roof
Item 1: Holding bracket
Item 2: Nut, M12
Item 3: Sealing disc
Fastening the profile rail
1
Please also note Chapter 5.8.1 "Connecting profile
rails".
2
z Fasten each profile rail (Fig. 25, Item 2) with two
bolts (Fig. 25, Item 1).
3
USER NOTE
The profile rails must not sag due to differences in level of the joists.
z Use a plumb line to check. If necessary,
pack the profile rails at the holding bracket.
63043965.26-1.SD
Fig. 25
Fastening the profile rail to the holding bracket
Item 1: Screw
Item 2: Profile rail
Item 3: Holding bracket
22
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Fitting the roof connection and profile rails
5.5
5
Slate/shingle roofs
USER NOTE
1
A roofer must carry out the installation on
slates or shingles.
6
Here is an example of the installation of the special roof
hooks and the watertight seal with custom flashing
(Fig. 26, Item 1 and 2) with a shingle/slate roof.
4
5
4
3
During installation, please maintain the required distances (w, x and y) between the special roof hooks as
detailed in (Tab. 5 and Tab. 6, page 14).
2
z Fit special roof hook (Fig. 26, Item 5) and gasket
(Fig. 26, Item 4) to the slate/shingle roofs using
screw (Fig. 26, Item 6).
z To ensure that the installation is watertight, flashing
(Fig. 26, Item 1, 2) must be installed on the building
above and below the special roof hooks.
USER NOTE
The special roof hooks must be positioned
on the front of a multiple roof
(Fig. 26, Item 3).
5.6
63043965.27-1.SD
Fig. 26
Mounting on slate/shingle roof
Item 1: Flashing (on building)
Item 2: Flashing (on building)
Item 3: Multiple roofs
Item 4: Gasket (on building)
Item 5: Special roof hooks
Item 6: Screw
Sheet roofs
USER NOTE
1
2
3
4
A roofer must carry out the installation on
a sheet roof.
1
5
Carriage bolts (Fig. 27, Item 5) must be used instead of
roof hooks for fastening the profile rails. During installation, please observe the distances (w, x and y) between
carriage bolts as detailed in (Tab. 5 and Tab. 6,
page 14).
6
4
To ensure the roof is water tight, sleeves for the carriage
bolts (Fig. 27, Item 5) must be soldered onto the sheet
roof.
USER NOTE
For the fitting sequence for carriage bolts
and profile rails, and the relevant instructions, see Chapter 5.4 "Corrugated sheet
roofs".
2
3
5
63043965.29-1.SD
Fig. 27
Mounting on sheet roof
Item 1: Holding bracket
Item 2: M12 nut
Item 3: Washer
Item 4: Sealing disc
Item 5: M12 carriage bolt
Item 6: Sleeve (not supplied)
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
23
5
5.7
Fitting the roof connection and profile rails
Fitting additional rails (accessory)
Additional measures are needed for installation heights
of 20 to 100 m and/or with standard wind or snow loads
of 2.0 to 3.1 kN/m2.
USER NOTE
The example here shows an installation
on pan tile roofs. The additional rails can
also be installed on other types of roof described in this manual.
1
Fitting additional roof hooks
Additional roof hooks must be fitted for attaching the
wind or snow load profiles.
z Fasten additional roof hooks (Fig. 28, Item 1) as
centrally as possible between the upper and lower
roof hooks already fitted.
63043965.30-1.SD
Fig. 28
Additional roof hooks for the wind or snow load profile
(here: for two collectors)
USER NOTE
1
There must be at least one free row of tiles
between the upper, middle and lower roof
hooks.
Fastening the wind or snow load profile to the roof
hooks
z Push sliding nut (Fig. 29, Item 1) onto the roof hook
in the direction of the arrow.
3
2
z Place the wind or snow load profile (Fig. 29, Item 2)
onto the roof hooks and tighten using an M8 bolt
(Fig. 29, Item 3).
z Make sure wind or snow load profiles are level and
flush (use string line).
63043965.31-1.SD
Fig. 29
Fastening the wind or snow load profile
Installing the profile rails
The profile rails must be joined before they are fastened.
Please see Chapter 5.8.1 "Connecting profile rails".
z Place the profile rails (Fig. 30, Item 1) into the indentations (Fig. 30, Item 2) on the wind or snow load
profiles and loosely fasten using bolt and sliding nut
(Fig. 30, Item 3) so that the profile rails can still be
aligned.
1
2
3
z Carry out the same procedure for the other profile
rails.
To continue with the installation, see Chapter 5.8.3
"Aligning the profile rails".
63043965.32-1.SD
Fig. 30
24
Fitting landscape profile rails
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Fitting the roof connection and profile rails
5.8
5
Installing profile rails
The profile rails must be joined together using rail connectors. Each collector has been provided with an upper
and lower profile rail.
5.8.1 Connecting profile rails
1
z Push rail connector (Fig. 31, Item 1) as far as it will
go into both profile rails (Fig. 31, Item 2).
2
z To lock, tighten both fitted M10 threaded studs
(Fig. 31, Item 3) in the rail connector using a
size 5 Allen key.
3
63043965.33-1.SD
Fig. 31
Connecting profile rails
Item 1: Rail connector
Item 2: Profile rail
Item 3: M10 threaded stud
5.8.2 Installing profile rails
z Push sliding nut (Fig. 32, Item 1) onto the roof hook
in the direction of the arrow.
3
z Place the lower profile rails (Fig. 32, Item 2) onto the
roof hooks and loosely fasten M8 bolt
(Fig. 32, Item 3) so that the profile rails can still be
aligned.
1
z Carry out the same procedure for the upper profile
rails.
USER NOTE
To check the distance between the profile
rails, we recommend that you make a tool
out of battens.
2
63043965.34-1.SD
Fig. 32
Fastening profile rails to the roof hook
Item 1: Sliding nut
Item 2: Profile rail
Item 3: Bolt
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
25
5
Fitting the roof connection and profile rails
5.8.3 Aligning the profile rails
z Align the upper and lower profile rails to the side flush
with each other and level them (Fig. 33, use a spirit
level).
1
USER NOTE
90°
Measure the diagonals or place a roof batten (Fig. 33, Item 1), for example, at the
ends of the profile rails. The angle between roof batten and profile rail must be
90°. Align the profile rails over the slotted
holes.
90°
1
z Tighten the screws.
USER NOTE
63043965.35-1.SD
Fig. 33
Aligning the profile rails
The profile rails must not sag due to differences in level of the joists.
Check using a plumb line.
5.8.4 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.
1
3
z Push each anti-slip protector (Fig. 34, Item 3) into
the innermost slotted holes (Fig. 34, Item 1) over the
profile rails until it clicks into place (Fig. 34, Item 2).
2
Fig. 34
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
26
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
6
6
Collector installation
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
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.
63043965.37-1.SD
Fig. 35
View of roof mounting with collectors
z Ensure that the correct equipment is
used for working on roofs.
RISK OF INJURY
through interruption of work.
CAUTION!
z Secure the collectors against falling.
z Stabilise the collector array.
USER NOTE
Use lifting equipment as used by roofing
contractors or sufficient suction handles for
the installation.
USER NOTE
Unsecured collectors may fall during
handling and installation.
27
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Collector installation
6.1
6
Preparing to install the collectors
Before beginning actual installation on the roof, preassemble the short solar hoses and dummy plugs on the
ground to make work on the roof easier.
To secure the solar hoses, the hose clips must be fitted
with the release ring.
SYSTEM DAMAGE
through leaks in the solar hoses.
CAUTION!
z The hose clip MUST be positioned correctly BEFORE the release ring
(Fig. 36, Item 1) is removed (Fig. 36,
Item 2). Subsequent loosening using
pliers can impair resilience.
2
1
Fig. 36
RISK OF INJURY
CAUTION!
63043965.38-1.SD
Hose clip with release ring, also shown fitted to the
pre-assembled dummy plug
2
1
The release ring must only be pulled away
when the hose clip is positioned over the
solar hose.
6.1.1 Water connection according to the
Tichelmann principle
1
2
The collector array must be connected according to the
Tichelmann principle. This ensures that each collector
receives the same flow rate (Fig. 37).
The flow line can be fitted to the top right
(Fig. 37) or top left (Fig. 38). In this manual, the flow line is shown on the right.
3
4
USER NOTE
63043965.39-1.SD
Fig. 37
Water connection — right-hand flow line
Item 1: Solar hose 95 mm
Item 2: 55 mm solar hose and dummy plug
The collectors must be installed in such a way that the
sensor pockets that receive the collector sensor
(Fig. 38, Item 1) are at the top.
Item 3: Flow line
Item 4: Return line
1
USER NOTE
If you intend to vent the solar thermalthermalthermal system with an automatic airvent valve (accessory) at the highest point
of the system, run the flow line rising to the
air-vent valve and the return line rising to
the collector array.
63043965.19-1.SD
Fig. 38
Water connection — left-hand flow line
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
28
6
Collector installation
6.1.2 Preassembling connection set
The pipework connection between two collectors is
made using the 95 mm solar hoses and hose clips from
the connection set in the collector corner protectors.
USER NOTE
To make installation easier, we recommend that you place the solar hoses in hot
water, especially when the ambient temperature is low.
1
2
3
USER NOTE
The illustrations show the connection set
when the first collector to be installed is on
the right.
63043965.40-1.SD
Fig. 39
Pre-assembling the connection set on the second
collector
z Remove plastic caps (transport protection) from the
relevant collector connections.
z Push 95 mm solar hoses (Fig. 39, Item 2) onto the
right-hand connections on the second and any subsequent collector.
z Push hose clips (Fig. 39, Item 1) over the solar hose
(the second clip will enable the other collector to be
connected later).
z Once the hose clip is sitting correctly, pull the quick
release ring to secure the connection (Fig. 39,
Item 3).
6.1.3 Dummy plug installation
Not all the connections are needed when connecting
a collector array, so those that are not used must be
closed.
z Remove plastic caps (transport protection) from the
relevant collector connections.
z Put 55 mm solar hoses (Fig. 40, Item 2) together
with the pre-assembled dummy plug onto the two
free connections on the collector array.
3
z Once the hose clips are sitting correctly, pull the
quick release rings to secure the connection.
1
2
63043965.41-1.SD
Fig. 40
Fitting the dummy plug and hose clip
Item 1: Hose clip
Item 2: Solar hose 55 mm
Item 3: Dummy plug
29
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Collector installation
6.2
6
Fastening the collectors
The collectors are fastened to the profile rails using the
single-sided collector clamps (Fig. 41, Item 2) at the beginning and end of a collector array, and double-sided
clamps (Fig. 41, Item 1) between each collector.
In addition, the anti-slip protectors prevent the collector
from slipping.
1
2
1
2
USER NOTE
The plastic parts on the collector clamps
do not have any support function. They are
simply intended to make installation easier.
63043965.42-1.SD
Fig. 41
Fasteners for the collector
Pushing on the single-sided collector clamp
on the right
z Push single-sided collector clamps (Fig. 42, 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.
1
1
2
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.
63043965.43-1.SD
Fig. 42
Pushing on the one-sided collector clamp
Putting the first collector in place
Lay the collector on the profile rails in such a way that
the sensor pocket is at the top to receive the collector
sensor. Begin by laying the collectors on the right-hand
side of the profile rails.
1
2
RISK OF INJURY
CAUTION!
11
Install collectors with at least one assistant.
z Place the first collector onto the profile rails and allow
it to slide into the anti-slip protectors (Fig. 43).
The lower collector edge must lie in the opening of the
anti-slip protector (Fig. 43, Item 1).
63043965.44-1.SD
Fig. 43
Laying the first collector on the profile rails
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
30
6
Collector installation
z Carefully push collector (Fig. 44, Item 1) up against
the single-sided collector clamp and align horizontally.
1
z Screw in single-sided collector clamp using size 5 Allen key (Fig. 44, Item 2).
USER NOTE
2
When the screw is tightened, the plastic
guide at the pre-determined cut-off points
breaks away and can be discarded.
The grip (Fig. 44, Item 2) on the collector clamp now
grips the lower collector edge.
63043965.45-1.SD
Fig. 44
One-sided collector clamp screwed in place
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
connector so that the plastic spacer (Fig. 45, Item 1)
surrounds the profile rail.
z Push double-sided collector clamp up against the
collector frame.
1
2
1
USER NOTE
1
Do not tighten the screw until the second
collector has been pushed up against the
double-sided collector clamp.
63043965.46-1.SD
Fig. 45
Fitting a double-sided collector clamp
Putting the second collector in place
1
z Place second collector along with the pre-assembled
solar hoses (Fig. 46, Item 1) onto the profile rails and
let it slide into the anti-slip protectors.
z Push the second hose clip (Fig. 46, Item 3) onto the
solar hose.
2
z Push the collector towards the first collector (Fig. 46,
Item 2) in such a way that the pre-assembled solar
hoses are pushed onto the left-hand connections on
the first collector.
3
2
63043965.47-1.SD
Fig. 46
31
Pushing second collector towards the first
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Collector installation
6
z Push the hose clip over the bead on the collector
connection and pull the locking ring.
SYSTEM DAMAGE
CAUTION!
through unsecured solar hoses and dummy plug.
z Secure every solar hose to the collector
connection using a hose clip (Fig. 47).
63043965.49-1.SD
Fig. 47
Solar hose with hose jubilee clips
z Tighten the screw on the double-sided collector
clamp using the size 5 Allen key.
USER NOTE
When the screw is tightened, the plastic
lugs at the pre-determined cut-off points
break away.
1
The grip (Fig. 48, Item 1) on the collector clamp now
grips the lower collector edge.
Repeat the procedure for all the other collectors.
63043965.48-1.SD
Fig. 48
Double-sided collector clamp between two 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.
2
z Push single-sided collector clamp (Fig. 49, 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. 49,
Item 2).
USER NOTE
1
When the screw is tightened, the plastic
lug at the pre-determined cut-off points
breaks away and can be discarded.
63043965.50-1.SD
Fig. 49
One-sided collector clamp (left)
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
32
7
7
Collector sensor connection
Collector sensor connection
B
USER NOTE
The collector sensor is supplied with the
solar controller.
A
Observe the installation location for single
or dual row collector systems (Fig. 50).
SYSTEM DAMAGE
through faulty sensor cable.
CAUTION!
z Protect the cable from possible
damage.
1 2
2 1
Insertion point
63043965.54-1.SD
The collector sensor must be fitted in the collector
nearest to the flow connection (Fig. 50, Item 2).
— Insertion point (Fig. 50, Item A) for single row collector systems with right-hand flow line.
Fig. 50
Collector sensor installation location (schematic)
Item 1: Return line
Item 2: Flow line
— Insertion point (Fig. 50, Item B) for double row collector systems with left-hand flow line.
Installing the collector sensor
For perfect functioning of the solar thermalt system,
the collector sensor (Fig. 51, 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 through the sealing membrane on the sensor pocket
(Fig. 51, Item 3).
3
z Insert collector sensor approx. 250 mm into the sensor guide tube (as far as it will go).
z Tighten clamped joint (Fig. 51, Item 2), counterhold if
necessary.
USER NOTE
1
2
z Screw clamped joint (Fig. 51, Item 2) into sensor pocket.
250 mm
Kollektor
63043965.55-1.SD
Fig. 51
Pushing the collector sensor into the collector
Item 1: Collector sensor
Item 2: Clamped joint
If you accidentally push through the sensor
bush (Fig. 51, Item 3) on the wrong collector, it can be resealed using the plug from
the connection kit. However, you must first
remove the nut in the sensor bush using
the cable gland (Fig. 51, Item 2).
33
Item 3: Sensor pocket
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
8
8
Header connection
Header connection
Information on laying the header pipes can be found in
the pump station installation instructions.
1
The pipework connection to the header pipes is made
using the long flexible solar hoses. It is not permitted to
connect a fixed header pipe directly to the collector.
USER NOTE
Use standard ventilation tiles or pipe conduits when laying the connection pipes
(solar hoses) under the roof.
Use a specialist company to route the header pipes under the roof.
2
3
63043965.56-1.SD
8.1
USER NOTE
Fig. 52
Feed the sensor cable together with the
flow line through the ventilation tile under
the roof.
Item 1: Flow line
Routing connection pipes under the roof
Item 2: Return line
Item 3: Sensor cable
De-airing 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
for installations of less than 20 collectors.
1
z Push the long solar hose (1000 mm, Fig. 53, Item 3)
onto the flow connection on the collector array and
fix in place using hose clip (Fig. 53, Item 4).
z Insert hose nozzle with compression fitting (Fig. 53,
Item 2) into the solar hose as far as it will go, and
fix in place with hose clip.
4
z Feed solar hose together with the sensor cable through the ventilation tile (Fig. 52, Item 1) and through the roof insulation.
3
z Connect header pipe to the R¾ hose nozzle with
compression fitting (15 mm) (Fig. 53, Item 2).
Repeat the same procedure with the return connection.
2
63043965.57-1.SD
Fig. 53
Fitting flow line (with no vent on roof)
Item 1: Ventilation tile
Item 2: R¾ hose nozzle with compression fitting
Item 3: Solar hose 1000 mm
Item 4: Hose clip with quick release ring
34
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Header connection
8.2
8
De-airing through air vent (accessory) at highest point in the system
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. 54, Item 2) and the return line rising to the collector
array (Fig. 54).
1
2
Avoid frequent changes in direction.
USER NOTE
For each change of direction downwards
and each new rise, install an additional air
vent.
63043965.58-1.SD
Fig. 54
View — air pot with vent valve for flow connection
Item 1: Collector sensor
Item 2: Automatic air vent valve on roof
Function of the weather protection cap and weather
protection cap on the automatic air vent valve
1
The solar thermal system is vented through the opened
weather protection cap. When in operation, the weather
protection cap (Fig. 55, Item 1) must always be positioned over the weather protection cap to prevent moisture
entering through the opened weather protection cap into
the solar thermal system).
3
Open the air-vent valve by unscrewing the weather protection cap one full revolution.
5
Universal air vent set scope of supply (Fig. 55):
Item 1:
Item 2:
Item 3:
Item 4:
Item 5:
Item 6:
Item 7:
Item 8:
Item 9:
Weather protection cap
Automatic air vent
Ball valve
Gasket
Vent pot
Double threaded fitting
Hose nozzle with O-ring
Hose clip
Solar hose 55 mm
2
4
9
1×
1×
1×
1×
1×
1×
2×
2×
1×
8
7
7
6
63043965.59-1.SD
Fig. 55
Universal air vent set
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
35
8
Header connection
8.2.1 Fitting the air vent valve under the roof
z Push long solar hose (1000 mm, Fig. 56, Item 2)
onto the flow connection on the collector array and
fix in place using hose clip.
1
2
z Feed solar hose together with the sensor cable through the ventilation tile (Fig. 56, Item 1) and through the roof insulation.
Repeat the same procedure with the return connection.
z Firmly screw R¾ hose nozzle with O-ring (Fig. 56,
Item 5) and double threaded fitting with O-ring
(Fig. 56, Item 3) into the air pot (Fig. 56, Item 4).
z Push hose nozzle onto the solar hose as far as it will
go and fix in place using hose clip (Fig. 56, Item 6).
6
5
4
63043965.60-1.SD
USER NOTE
Fig. 56
For the return connection, you must fit
the hose nozzle and compression fitting
(from the connection kit) into the long solar
hose.
3
Fitting the solar hose to the flow connection
Item 1: Ventilation tile
Item 2: Solar hose 1000 mm
Item 3: Double threaded fitting with O-ring
Item 4: Air pot
z Connect header pipe to the compression fitting
(Fig. 56, Item 3).
Item 5: R¾ hose nozzle with O-ring
Item 6: Hose clip
8.2.2 Fitting the air vent valve on the roof
2
1
z Push short solar hose (55 mm, Fig. 57, Item 1) onto
the flow connection on the collector array and fix in
place using hose clip.
3
z Firmly screw R¾ hose nozzles with O-rings (Fig. 57,
Item 3) into the air pot (Fig. 57, Item 4).
3
z Insert hose nozzles (Fig. 57, Item 3) into the solar
hoses (Fig. 57, Item 1 and 5) as far as they will go,
and fix in place using hose clips (Fig. 57, Item 2).
4
5
7
2
z Insert hose nozzle with compression fitting (Fig. 57,
Item 6) into the solar hose as far as it will go, and fix
in place with hose clip.
z Feed solar hose together with the sensor cable through the ventilation tile (Fig. 57, Item 7) and through the roof insulation.
z Connect header pipe to the hose nozzle with compression fitting (15 mm) (Fig. 57, Item 6).
USER NOTE
For the return connection, you must fit the
hose nozzle and compression fitting (from
the connection kit) into the long solar hose.
36
6
Fig. 57
Connecting the air vent valve on roof
Item 1: Solar hose 55 mm
Item 2: Hose clip
Item 3: R¾ hose nozzle with O-ring
Item 4: Air pot
Item 5: Solar hose 1000 mm
Item 6: Hose nozzle with compression fitting 15 mm
Item 7: Ventilation tile
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
9
9
Fitting the connection set for two rows (accessory)
Fitting the connection set for two rows (accessory)
The serial connection set (Fig. 58, Item 8) is available
as an accessory, and connects two rows of collectors.
USER NOTE
6
Fit all connection parts to the collectors on
the ground.
7
1
Scope of supply (Fig. 58)
Item 1:
Item 2:
Item 3:
Item 4:
Item 5:
Item 6:
Item 7:
Angled nozzle
Hose clip
Dummy plug
Solar hose 55 mm
Solar hose 1000 mm
Union nut G1
Clamping disc
2×
2×
2×
2×
1×
2×
2×
8
2
5
4
9
9
3
63043965.51-1.SD
Fig. 58
Fitting additional dummy plugs
Schematic diagram and scope of supply
1
Use the dummy plugs to close up any collector connections not in use (Fig. 59, Item 1).
z Place 55 mm solar hoses (Fig. 59, Item 3) together
with the preassembled dummy plugs onto the two
free connections.
1
z Once the hose clips are sitting correctly, pull the locking rings to secure the connection.
2
4
3
Installing the connection set
z Remove plastic caps (transport protection) from the
relevant collector connections.
z Push union nut (Fig. 60, Item 1) over the collector
connections.
63043965.52-1.SD
Fig. 59
z Place the clamping disc (Fig. 60, Item 2) behind the
bead on the collector connection and press together.
Fitting the preassembled dummy plugs
1
z Press angled nozzle with O-ring (Fig. 60, Item 3)
onto connection, align and bolt together with union
nut.
z Measure distance between the angled nozzles
(dim. X) once the collectors are installed, and cut the
solar hose (Fig. 60, Item 5) to size accordingly.
2
3
4
X
5
z Attach solar hose to the angled nozzles and secure
using hose clips (Fig. 60, Item 4).
63043965.53-1.SD
Fig. 60
37
Connection set between two collector rows
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
10
Final activities
10 Final activities
10.1 Checking the installation
USER NOTE
Carry out the final insulating work only
once the appropriate checks have been
performed.
Checks
1.
Solar hoses secured with hose clips
(quick release ring pulled)?
2.
Screws on the collector clamp (single-sided
and double-sided) tightened?
3.
Profile rails connected to roof hook and sliding nut?
4.
Anti-slip protection installed and clicked into
place in profile rails?
5.
Sensor inserted as far as it will go and secured with clamped joint?
6.
Pressure test carried out and all connections
leak-proof (see pump station instructions)?
USER NOTE
If you are venting the solar thermal system
with an automatic air vent valve (accessory), you must close the ball valve after the
venting procedure (see pump station installation instructions).
10.2 Insulating the connection and
header pipes
Insulation of the manifolds 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.
38
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
Notes
SKN 3.0 Series - On roof mounting - We reserve the right to make any changes due to technical modifications.
39
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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