Installation Manual Logasol SKS 4.0 Mounting System for
Contents
1. 00 00 eeeeeeeeee 22 5 6 Sheet Metal Roof Surfaces 2 2 oes adaden edi bere eee eeieed eke beads 23 5 7 Installing high load rails accessory 00 0000 eee ee ee 24 5 8 Installing horizontal rails s 2e0e0ce cede cea eee dees eked eae ee we sana 25 6 Collector Installation 0000020 e ees 27 6 1 Preparing to install the collectors 2 2 ec ee 28 6 2 Mounting the collectors cicccteeded eee i are etbeew aden eaten en 29 Collector sensor 2c c ecu setee ete Sees anes eeegetensoedacuneees 33 8 Hydraulic connections 00 200 eee es 34 8 1 Installing an air vent accessory 0 000 eee es 35 9 Connecting Two Collector Arrays accessory 38 10 Final activities cc4cc07205 6562804 6044624 044556429 e2505884528 39 10 1 Checking the installation 0 0000 eee ee 39 10 2 Insulating the Pipes above the Roof 0 00 eee ee ee 40 11 Quick reference guide for tile roof and pressure filling 4 12 Spare parts 4222652 eV es beet Cee See ee ee CRE eek oes ee 42 13 Cenilicatlons c0 326652 acdsee ase eau oR REE be Ae bebe eee eee 54 Buderus 2 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 1 General This chapter details which technical rules and regulations apply to this installation NOTICE Observe all standards and guidelines applicable to the installation and operation of this system in your coun2. 7 va ay 63043965 43 1 SD Fig 38 Pushing on the single sided collector clamp Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 29 6 Collector Installation Placing the first collector onto the rack Lay the collector on the horizontal rails in such a way that the sensor well is at the top CAUTION RISK OF INJURY At least two people are required for installing collectors Place the first collector onto the horizontal rails and allow it to slide into the collector hangers Fig 39 The lower collector edge must engage evenly with the hooks of both collector hangers Fig 39 1 Carefully push collector Fig 39 1 up against the single sided collector clamp and align horizontally Tighten the screw on the single sided collector clamp Fig 39 2 using size 5 Allen key NOTICE When the screw is tightened the plastic spacer holding the clamp apart will break away Discard this piece The hook on the collector clamp Fig 39 2 now grips the lower collector edge Installing a double sided collector clamp Insert the double sided collector clamp nut first into the connector between two horizontal rails then turn 90 degrees clockwise and push down onto the rail with the plastic cover Fig 41 1 sitting on top of the horizontal rail Push double sided collector clamp against the collector frame
3. NOTICE Do not tighten the screw until the second collector has been pushed against the double sided collector clamp Buderus 63043966 13 1 SD Fig 39 Laying the first collector on the profile rails 63043965 45 1 SD Fig 40 Single sided collector clamp in place 63043966 14 1 SD Fig 41 Fitting a double sided collector clamp 30 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Installing the corrugated pipe connectors Remove the rubber caps from the connections Push corrugated pipe connectors Fig 42 1 onto the connections where the next collector will be connected Verify they are pushed in as far as they will go Slide clip sideways Fig 42 2 over the corrugated pipe connector and collector connection to secure it in place Sliding the second collector in place Place the second collector onto the horizontal rails and allow it to slide into the collector hangers SYSTEM DAMAGE A from damaged corrugated pipe caution Connectors Do not use any tools e g pliers Fig 43 2 These could render the corrugated pipe connector unusable Push the second collector toward the first in such a way that the collector
4. Buderus 20 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Tighten the nut Fig 21 2 so the gasket Fig 21 3 is pressed against the roof surface making a seal NOTICE Verify that the attachment block Fig 21 1 is screwed on tight and oriented horizontally Installing the horizontal rail Please also note Chapter 5 8 1 Connecting the horizontal rails Fasten each rail Fig 22 2 with two screws Fig 22 1 NOTICE The horizontal rails must not sag due to differences in height of the roof or the hanger bolts Use a cord to verify the horizontal rails do not sag To correct differences screw in the high hanger bolt until level Installing roof hooks and horizontal rails ea 63043965 25 1 SD Fig 21 Post screw installed to corrugated roof 1 Attachment block 2 Nut M12 3 Gaskets 63043965 26 1 SD Fig 22 Attaching the horizontal rail to the attachment blocks on the hanger bolts 1 Screw Horizontal rail Attachment block Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 21 Le Installing roof hooks and horizontal rails 5 5 Roof Hooks for Flat Shingles NOTICE It is recommended to consult a roofer when installing on slate or composite shingle roofs Fig 23 shows a typical installation of the roof hook on an asphalt shi
5. overhangs including the gable wall thickness NOTICE If access to the roof is limited consider installing the air vent in the attic Ensure that there is sufficient room and clearance in the attic to position this air vent above the top of the collectors Dimension H Dimension H is 75 in 1 900 mm for portrait collectors 39 4 in 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 63043965 09 1 SD Fig 7 Clearances to be observed Space requirements for landscape collectors Number of collectors Dimension A Dimension B Number of collectors Dimension A Dimension B 2 91 in 2 32 m 81 1 2 in 2 07 m 2 164 in 4 17 m 45 5 16 in 1 15 m 3 137 in 3 49 m 81 1 2 in 2 07 m 3 266 in 6 26 m 45 5 16 in 1 15 m 4 183 in 4 66 m 81 1 2 in 2 07 m 4 329 in 8 36 m 45 5 16 in 1 15 m 5 230 in 5 83 m 81 1 2 in 2 07 m 5 411 in 10 45 m 45 5 16 in 1 15 m 6 278 in 7 06 m 81 1 2 in 2 07 m 6 494 in 12 55 m 45 5 16 in 1 15 m 7 322 in 8 17 m 81 1 2 in 2 07 m 7 577 in 14 64 m 45 5 16 in 1 15 m 8 368 in 9 34 m 81 1 2 in 2 07 m 8 659 in 16 74 m 45 5 16 in 1 15 m 9 414 in 10 51 m 81 1 2 in 2 07 m 9 733 in 18 61 m 45 5 16 in 1 15 m 10 460 in 11 68 m 81 1 2 in 2 07 m 10 824 in 20 93 m 45 5
6. 16 in 1 15 m Tab 2 Space requirement for portrait collectors Buderus Tab 3 Space requirement for landscape collectors 12 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 5 WARNING WARNING Installing roof hooks and horizontal rails ea Installing roof hooks and horizontal rails RISK TO LIFE Use appropriate personal protective equipment whenever on a ladder lift or the roof A RISK OF INJURY from a fall or falling parts Take appropriate action to prevent accidents when working on roofs Always wear your personal protective clothing and safety equipment Four types of roof attachments are offered Adjustable roof hook gt 5 2 5 3 for installation on S tile roofs barrel tile roofs and similar roof tiles Hanger bolt gt 5 4 for corrugated sheet roofs asphalt shingle roofs flat shingle roofs slate roofs mission style pan roofs and similar roofing materials Roof hooks gt 5 5 for asphalt shingle slate or composite shingle roofs and similar roofing materials For metal roofs the hanger bolt gt 5 6 can be used or in case of a sufficiently strong standing seam a special seam clamp is recommended Please contact Buderus for details gt VL LY Ul ie 7 63043965 10 1 SD Fig 8 Installed horizontal rails for two collectors WARNING PROPERTY DAMAGE
7. 5 16 in 2090 mm 1520 1950 mm 170 540 mm Tab 4 Distance between attachment points NOTICE Distances x and z should always be approximately equal to distance w Distances between horizontal rails Set the distance between the top and bottom profile rails Fig 10 according to Tab 5 Collector Distance y type from to portrait 52 in 1320 mm 67 5 16 in 1710 mm landscape 23 5 8 in 600 mm 32 5 16 in 820 mm Tab 5 Distance center to center between bottom and top rail Buderus 63043965 11 1 SD Fig 9 Distance between roof hooks a Fig 10 Distance between profile rails 14 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 5 2 Adjustable Roof Hooks for Tile Roofs Step one is to install all roof hooks according to the guidelines shown in tables 4 and 5 on page 14 6 o 6 NOTICE Avoid modifying the roof surface and take care not to compromise a roofing membrane Consult a professional roofer to ensure proper installation NOTICE In the case of tiles laid in mortar leave clearances of at least 2 rows of tiles from any ridge or building feature NOTICE If roof hooks cause tiles to ride too high or not fit properly the conflicting areas of the tiles may have to be ground down to ensure a secure fit SYSTEM DAMAGE from gra
8. Ensure the building substructure is capable of carrying the load of the panels including the required snow and wind loads Only attach to framing that is properly supported Do not connect to less than 2x6 framing Follow the local building code and use best practice methods NOTICE Observe all national and local safety regulations as well as the safety instructions in this manual when working on roofs NOTICE Always use personal protective equipment and ensure it is in good working order NOTICE Take measures to protect the roof membrane when working on the roof It is recommended to consult a professional roofer to ensure the membrane is not damaged Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 13 Le Installing roof hooks and horizontal rails 5 1 Rail and hook spacing Use the dimensions given as guidelines for a proper installation NOTICE On tile roofs the tile valleys determine the true distance between the roof hooks Distances between roof attachments Every horizontal rail is fastened using two roof attachments Fig 9 per collector See the table for the approximate distance between the attachment points Installation 7 3 type Distance w Distance x Distance z ortrait approx 46 in 24 51 in 6 5 8 25 1 4 in P 1170 mm 610 1030 mm 170 540 mm approx 60 77 in 6 5 8 21 1 4in landscape 82
9. Extreme caution must be taken when a system is in stagnation SYSTEM DAMAGE Avoid scratching or sudden shocks to the glass of a solar panel Never step or walk on collectors Never braze or solder in close proximity of a solar panel Install a heat exchanger to separate pool water or potable water from the collector system The use of heat transfer fluid Tyfocor L Tyfocor LS and Tyfocor L G is strongly recommended For more detailed information about suitable solar heat transfer fluids refer to the installation instruction of the KS pump stations This system is not suitable for drain back installations Only closed loop pressurized systems are permitted 6 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Before installation Ee 4 Before installation 4 1 General notes NOTICE It is recommended to consult a roofing company as they are experienced in working on roofs and are equipped with the necessary personal safety equipment Roofers also are experienced with attaching equipment to the roof and making proper penetrations Make yourself familiar with the on site conditions and local regulations before commencing the installation Check the delivery for completeness and perfect condition the roof structure for sufficient strength and possible damage e g leaks the building height and determine the type and number of attachment points r
10. Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Collector Ta Item Part Number Description Weight 40 7747021975 SKS 4 0 S Solar Flat Plate Collector Portrait vertical 104 1 2 50 7747021976 SKS 4 0 W Solar Flat Plate Collector Landscape horizontal 106 1 2 Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 43 12 On roof installation material 67910060 00 On roof mounting hardware vertical horizontal Buderus 44 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications On roof installation material 12 Item Part Number Desciption in Ib 10 63045246 Single sided collector clamp 0 2 20 63045239 Horizontal rail Portrait collector 3 1 21 63045240 Horizontal rail Landscape collector 5 5 30 63045243 Collector hanger 0 22 40 63045241 Connector rail connector 0 25 50 63045244 Double sided collector clamp 0 26 60 63045233 Roof hooks adjustable kpl 0 66 Available individual part 70 63045237 Threaded clip M8 0 06 80 x Screw M8x25 m Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 45 12 On roof installation material 67910165 00 Slate roof mounting hardware Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Buder
11. Single sided collector clamp 4x 2 Double sided collector clamp 2x 7 Collector hanger 2x 7 Collector hanger 2x 8 M8 nut 4x 6 Rail connector 2x 8 M8 nut 4x Roof hook for tile roofs per collector Fig 2 4 Roof hook for tile roofs adjustable 4x 5 Sliding nut 4x NOTICE For higher snow and wind loads additional horizontal rails and roof hooks may be needed Buderus 8 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 4 2 2 Hydraulic connection For the hydraulic connections the connection kit is needed The parts are included in two of the corner protectors of each collector s packaging Before installation Ee B 7 G bB 2 ger a 1 jn amp A aes 5 63043966 03 1 SD Fig 3 Connection kit and connection set Connection kit per collector array Fig 3 1 Flexible connector 2x 2 Safety clip 4x 3 Flexible pipe 2x 4 Closed cell insulation 1x Connection set between the collectors for each collector in two of each collector s protective corners Fig 4 1 Flexible connector 2x 2 Safety clip 4x 5 Collector sensor strain relief 6 5 Allen wrench 1x 7 Dummy plug 2x 63043966 04 1 SD Fig 4 Two of the four protective corners of each collector carry parts for interconnecting collectors Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 9 zal Be
12. the hydraulic collector connection set with its flexible corrugated pipes to connect the collectors to the supply and return piping It is not permitted to hook a rigid pipe directly to the collector NOTICE The corrugated connector connection pipes can be cut to length if needed 63043966 18 1 SD NOTICE Fig 49 Routing connection pipes under the roof For the roof penetration use special tiles 1 Supply line shown without insulation n flashings ey aliable Tor this purpose or 2 Return line shown without insulation roof jacks If a job requires a custom solution consult a professional roofing 3 Sensor cable contractor NOTICE Feed the sensor cable together with the supply pipe under the roof NOTICE It is recommended to install an automatic air vent at the highest point of the installation The air vent can be installed directly on the collector where the supply line connects or in the attic where the connection set hooks up to the supply piping toward the pump station In either case in order to work properly the air vent must be positioned perfectly vertically Buderus 34 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 8 1 Installing an air vent accessory Automatic air vents accessory simplify filling commissioning and servicing of solar thermal systems In order for the air vent to work properly it must be installed at the highest poi
13. use any other grease 6 1 1 Hydraulics Each collector has a sensor well which must be at the top when installed on the roof Fig 34 1 NOTICE i Supply and return pipes can be connected from the right Fig 33 the left Fig 34 or diagonally Fig 35 across The pipework in the collector is designed as a double meander which allows two different hydraulic setups NOTICE It is recommended to have the roof penetration for the hydraulic piping as close to the collector as it is feasible and run as little piping above the roof as possible Single sided connection of up to 5 collectors Up to 5 collectors can be connected from one side of a collector array Fig 33 and Fig 34 Diagonal connection of up to 10 collectors If piped in a diagonal fashion Fig 35 up to 10 SKS 4 0 collectors can be combined to one consecutive array Diagonal connections are also encouraged if there are fewer than 6 collectors Fig 35 Buderus 3 lt gt 2 63043966 09 1 SD Fig 33 Hydraulic connection right up to max 5 collectors 1 Corrugated pipe connector 2 Supply line 3 Return line 4 Endcap 63043966 10 1 SD Fig 34 Hydraulic connection left up to max 5 collectors 63043966 08 1 SD Fig 35 Diagonal water connections 28 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 6 1 2 Ins
14. 1652 S Ka 1 0 0 17 S Linear Fit lt r TAX Oo This award of certification is subject to all terms and conditions of the Program Agreement and the documents incorporated therein by reference It must be renewed annually Any change in collector design materials specifications parts or construction must be reported to SRCC for evaluation of continued certification TRA SF A iy LX TENG LN 77 S November 20 2007 SZ O ZIN LS 7 O k 7 ZS A Min TI LL SESE SLE EEE SEE ME SE SE NIA Spee WOMEN ila LE SESSLER 7 DISTDIR DIDI _ 06 100 SRCC COLLECTOR CERTIFICATION PARVINA CE Solar Rating and Certification Corporation c o FSEC 1679 Clearlake Road Cocoa FL 32922 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Buderus 55 United States and Canada Bosch Thermotechnology Corp 50 Wentworth Avenue Londonderry NH 03053 Tel 603 552 1100 Fax 603 584 1681 www buderus us U S A Products manufactured by Bosch Thermotechnik GmbH Sophienstrasse 30 32 D 35576 Wetzlar www buderus com Bosch Thermotechnology Corp reserves the right to make changes without notice due to continuing engineering and technological advances Buderus
15. 3045263 Connector SKS FKT 18 G3 4 kpl 0 21 Available individual parts 130 63045301 O Ring 25x3 0 Shore70 0 02 Set 5 pieces 150 63045264 O Ring 15x3 SHORE70 EPDM291 0 01 Set 5 pieces Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 53 Buderus 54 DENNEN NONON NUNU NUNU NUNU NUNU NUNT A Ze O je a O Q 0 Q Q Q QO fe je QO Q O Q Oe ESI ISIS TSS LISS IISSISSISSTSSIISISA TIT I S a SOLAR RATING amp CERTIFICATION CORPORATION AWARD OF COLLECTOR CERTIFICATION The solar collector listed below has been evaluated by the Solar Rating and Certification Corporation SRCC in accordance with SRCC Document OG 100 Operating Guidelines and Minimum Standards for Certifying Solar Collectors and has been certified by the SRCC as specified in SRCC Standard 100 94 Test Methods and Minimum Standards for Certifying Solar Collectors Certification and thermal performance ratings are based on the successful durability and performance testing of a sample unit where said tests have been conducted by an independent laboratory accredited by the SRCC Collector Certification Number 100 2007006A Date Certified November 14 2007 Expiration Date October 24 2019 Report Number 06 08 0533 2 Report Date October 24 2007 Test Laboratory Bodycote lt Product Glazed Flat Plate Certified Model SKS 4 0 s w Vert Horiz Mo
16. 7182237050 Connecting pipe VL RL SKS FKT kpl 2 46 Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 51 12 Air vent set SKN SKS On roof Connection SKS FKT Under roof Connection SKS FKT 130 80 160 m 80 160 67910064 00 Air Vent Set SKN SKS Buderus 52 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Air vent set SKN SKS 12 Item Part Number Description Weight 20 63045247 Hose clip DN30 Steel tape 0 19 Set 5 pieces 30 85336132 Solar hose 3 4 x1000 1 54 40 63015362 Air Vent Valve autom R3 8 Solar 0 86 50 85103282 Ball valve 3 8 I A Wing grasp 0 55 60 63012692 Cover D17x24x2 AFM34 5x 0 04 70 63045299 Air vent body 0 88 80 87182237060 Double nipple 18 Clamp G3 4 kpl 0 17 Available individual parts 130 63045301 O Ring 25x3 0 Shore70 0 02 Set 5 pieces 160 63020599 Compression ring DN16x1 5 0 033 Set 10 pieces 90 x Solar hose 3 4 x55 see Pos 30 Part accordingly cut to length 100 87182237070 Hose clip 18 G3 4xD21 kpl 0 02 Available individual parts 130 63045301 O Ring 25x3 0 Shore70 0 02 Set 5 pieces 110 63045249 Hose clip 18 G3 4xD21 kpl 0 2 Available individual parts 130 63045301 O Ring 25x3 0 Shore70 0 02 Set 5 pieces 140 87182237740 Compression ring 1 2 16 mm 0 05 Set 5 pieces 140 63045250 Compression ring 3 4 18 mm Set 5 pieces 120 6
17. Le Installing roof hooks and horizontal rails Installing the hanger bolts NOTICE With corrugated roofs it is recommended to install the hanger bolts at the peak of the corrugation to reduce the pressure on the gasket from rain water Determine the length of the drill bit for the wood drill as follows 3 1 2 in 90 mm Height of peak of corrugation Thickness of roofing material 63043965 24 1 SD j Fig 20 Installing the hanger bolt sequence Required depth of hole to be drilled 1 Attachment block BUILDING DAMAGE 2 M12 nut A 3 Washer caused by leaks e Hib 5 M12 stud Determine the hole locations for the hanger bolts see Tab 4 and Tab 5 Drill a 1 2 13 mm hole through the roofing surface Do not drill into the wood Use the 1 4 6 mm bit and drill a hole of the depth determined above Clean off shavings Use a caulking gun and fill the hole with appropriate sealant When installing the hanger bolt note the sequence of the individual parts Fig 20 Install the stud Fig 20 5 as far as it will go into the attachment block Fig 20 1 Screw the preassembled hanger bolt into the roof using a size 15 wrench according to the measured depth of the hole Tighten the attachment block and turn horizontally Use a level to ensure all attachment blocks are at the same height Use a cord across all blocks to confirm
18. N in uneven load distribution SYSTEM DAMAGE The roof hooks must be positioned in tile valleys and directly bolted to the building substructure with sufficient capacity to carry the load of the solar system including required snow and wind loads Fig 13 3 Allow for expansion and contraction by keeping some clearance along the upper edge of the tile Fig 13 4 Push the L shaped part of the roof hook down until it lies flat on the sheathing or on the board shim if needed Fig 13 6 Tighten the long hex nut Fig 13 1 To do this insert the size 5 Allen wrench into the hole in the hex nut and turn NOTICE The toothed washer Fig 13 5 must grip the teeth on the lower part of the roof hook Using suitable screws Fig 13 2 secure the L shaped part of the roof hook to the building substructure The sheathing alone will not offer sufficient support Buderus 63043965 16 1 SD Fig 12 Adjusting the roof hook 1 Lower part of roof hook Long hex nut Upper hole for fastening the lower part L shaped attachment piece a fF ND Cut off if necessary 63043965 17 1 SD _ Fig 13 Roof hook installed some tiles have been removed for a better view Long hex nut Screw for fastening roof hook Front brace Adjust the tile as necessary to install the roof hook Toothed washer our OD Sheathing or board shim if needed 16 Logasol
19. ON Do not remove the plastic caps on the collector connections until immediately prior to installation NOTICE Use a boom truck scissor lift or similar for accessing the roof For carrying the collectors use equipment used by window installers NOTICE Unsecured collectors may fall during handling and installation NOTICE Two of the protective corners of each collector s packaging hold connectors and clips needed for installation Do not throw those out before removing those parts Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 27 6 Collector Installation 6 1 Preparing to install the collectors Before beginning the installation on the roof preassemble the end caps on the ground to make work on the roof easier Push the end cap onto the collector connection until it hits the stop Slide a clip sideways over the notches to secure the cap in place The clip must snap into place gt 6 1 2 caution The collector connections end caps corrugated pipe connectors and collector connection sets must be clean and free from any sign of damage in order to be able to establish a good seal SYSTEM DAMAGE from leaks in the collector connections Inspect the inside of each connector for the double O rings seated properly before installation The collector connections have had special grease applied at the factory to make installation easier Do not
20. S 4 0 We reserve the right to make any changes due to technical modifications 17 Le Installing roof hooks and horizontal rails Installing the roof hook Push the lower part of the hook down until it lies flat on the sheathing Fig 16 1 NOTICE The toothed washer Fig 16 2 must engage with the teeth on the lower part of the roof hook Tighten the long hex nut Fig 17 1 To do this insert the size 5 Allen wrench into the hole in the hex nut and turn Using suitable screws attach the upper part of the roof hook Fig 18 through the sheathing to the building substructure f necessary cut adjacent shingles tiles Fig 18 1 to size dashed line Fig 18 2 Buderus Fig 16 Installed roof hook Fig 17 Toothed washer must engage with the toothed hook when tightening the nut 1 Long hex nut 2 Toothed washer 63043965 65 1 SD Fig 18 Tiles shingles may have to be trimmed to size 18 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 5 4 Hanger Bolt Installation It is recommended to consult a roofer when installing on corrugated roofs WARNING RISK TO LIFE from inhalation of fibers containing asbestos Work with materials containing asbestos must only be carried out by trained and certified professionals Hanger bolts are designed for asphalt shingle roofs flat shingle roofs
21. SKS 4 0 We reserve the right to make any changes due to technical modifications 5 3 Adjustable Roof Hooks on Flat Shingle and Slate Roofs NOTICE It is recommended to consult a roofer when installing on shingle or slate roofs Ensure the required distances w x and y between the roof hooks as detailed in Tab 4 and Tab 5 page 14 Remove the needed number of shingles tiles to gain access to the sheathing where to mount the roof hook Fig 14 1 The roof hooks must be directly bolted to the building substructure with sufficient capacity to carry the load of the solar system including required snow and wind loads Preparing roof hook Before installing the lower part must be moved to the correct position Loosen the long hex nut Fig 15 2 and disassemble the unit Insert bolt into upper hole Fig 15 3 Reassemble with the L shaped piece Fig 15 center facing away and down Do not tighten the nut Fig 15 2 until the hook is installed and properly adjusted SYSTEM DAMAGE A from failure of the roof hook if the bolt is caution Ot positioned in the upper hole resulting in uneven load distribution Installing roof hooks and horizontal rails ea Fig 14 Remove the needed number of shingles tiles Fig 15 Repositioning lower part of roof hook 1 L shaped attachment piece 2 Long hex nut 3 Upper hole 4 Cutoff if necessary Buderus Logasol SK
22. arious components Fig 6 Installation operation and maintenance documentation is provided for each component Accessories may be accompanied by a separate document 1 Collector instructions for roof installation are enclosed with the connection kit 2 Pump station instructions enclosed with the pump station 3 DHW storage tank instructions enclosed with the DHW storage tank 63043965 07 1 SD Fig 6 Solar thermal system components and technical documentation Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 11 zal Before installation 4 6 Determining space required on roof Please observe the following minimum space requirements for roof stability reasons safe access during installation and to reduce wind load Dimension A and B Area required for the collector array Dimension C On tile roofs keep a minimum clearance of two rows of tiles to the ridge dormers a chimney or other building features On asphalt shingle roofs metal roofs or similar keep at least 3 feet 1m clearance to the ridge to dormers a chimney or other building features Dimension D Keep clear of roof overhangs on the gable end of the house Dimension E Minimum 12 in 30 cm for making the connection in the attic Dimension F Minimum 16 in 40 cm for making the connection in the attic Dimension G Keep at least 3 feet 1 m clearance from roof edges and
23. connections are pushed into the corrugated pipe connectors Fig 43 1 of the first collector You may have to push the connector by hand the last 1 4 until it hits the stop Verify it is engaged properly Place second clip Fig 43 3 over the corrugated pipe connector and collector connection SYSTEM DAMAGE A from unsecured corrugated pipe caution Connectors and end caps Verify each end cap is secured with one clip and each corrugated pipe connector with two clips Fig 44 1 Collector Installation Se 63043966 11 1 SD Fig 42 Fitting corrugated pipe connectors to the first collector 63043966 15 1 SD Fig 43 Pushing second collector toward the first 63043966 16 1 SD Fig 44 Corrugated pipe connector secured with clips Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 31 Ps Collector Installation Tighten the screw on the double sided collector clamp using the size 5 Allen key Verify the clamp engages with the lower edge of the collector It may be necessary to slightly adjust the position of the second collector NOTICE When the screw is tightened the plastic spacers holding the clamp apart will break away Discard this piece The hook Fig 45 1 on the collector clamp now grips the lower collector edg
24. ctions before commencing the installation Severe injury and even death as well as property damage and environmental damage may follow if you ignore safety instructions About this manual This installation manual contains important information for the safe and intended installation of sloped roof mounted systems as well as plumbing connections The illustrations in this manual show the portrait collectors Instructions for landscape collectors are the same as for portrait unless stated otherwise These technical documents should be retained in a safe place The activities described in the installation manual assume expertise based on completed vocational training in plumbing Only carry out these installation steps if you possess these skills Hand these installation instructions to the building owner Explain to the customer the function and operation of the related devices 3 1 Intended use Install components only on roofs with sufficient strength and capacity Take the additional roof load per roof rack including solar collector into consideration If necessary ask a structural engineer for assistance This mounting system holds the solar thermal collectors portrait and landscape on pitched roofs with a slope of 25 to 65 The collectors can be installed on different roof surfaces including asphalt shingle ceramic tile slate composite shingle corrugated or standing seam or other metal roofs with slop
25. d pressure filling These instructions are only intended as an overview of the work to be carried out You MUST follow the detailed descriptions for the work on the pages mentioned and observe all safety and user instructions Fitting roof hooks and horizontal rails 1 Turn lower part of roof hook upward Determine p 16 locations for the roof hooks while observing the distances given in Chapter 5 1 Rail and hook spacing page 14 2 Determine settings of the roof hook p 16 3 Connect horizontal rails together using rail p 25 connectors 4 Fasten horizontal rails to roof hook p 25 1 2 5 Align horizontal rails horizontally and laterally flush p 26 with each other E 6 Install collector hangers p 26 Preparing to install the collectors 7 Push end caps onto those connections that are not p 29 needed and secure using clips Fastening the collectors 8 Push single sided collector clamp into horizontal rails p 29 9 Place first collector onto horizontal rails and push onto p 29 collector clamp 10 Tighten single sided collector clamps p 29 11 Place double sided collector clamp into horizontal rail p 30 and push onto first collector 12 Push corrugated pipe connectors onto the p 31 connections on the first collector and secure with clips 13 Push second collector towards the first and fit second p 31 bracket 63043966 31 1 SD 14 Tighten screws on the double si
26. d unscrew the bleeder screw one full revolution Close both after completing the operation Automatic air vent kit SKS 4 0 Fig 51 1 Weather protection cap 1x 2 Automatic air vent 1x 3 Ball valve 1x 4 Gasket 1x 5 Vent body 1x 6 Double nipple with O ring 1x 7 Nipple R with collector connection 1x 8 Union nut 2x 9 Gasket 1x 10 Large diameter washer 1x 11 Split compression washer 1x Hydraulic connections se 63043966 20 1 SD Fig 50 Air vent installed on the supply connection 1 Collector sensor 2 Automatic air vent 1 o _ b 9 __v T a o 1 4 63043966 21 1 SD Fig 51 Automatic air vent SKS 4 0 Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 35 8 Hydraulic connections 8 1 1 Installing the air vent valve under the roof Installing the air vent in the attic allows servicing the system without accessing the roof j In order for it to work properly it is essential to position i the air vent above the collectors Push connection pipe Fig 52 3 onto the supply connection of the collector and secure in place using ZOU the clip Fig 52 5 Feed connection pipe together with the sensor cable through the penetration Fig 52 4 into the attic The supply piping must be sloped away from the collectors toward the air vent Perform the same procedure with the return connecti
27. ded collector clamp 31 f 3 7 i j P Fig 59 Hydraulic connections 15 Repeat the procedure for all other collectors p 32 it single si i 32 16 Fit single sided collector clamps on outside p g 7 3 17 o s Header connection dome p 17 Insert collector sensor as far as it will go into p 33 the sensor well on the collector with the supply 12 connection and secure 18 Install connection pipes on the supply and return p 36 connections and secure with clips 19 Feed supply connection pipe together with sensor p 36 cable through roof penetration 18 19 20 Perform installation checks p 39 12 21 Insulate header pipes and corrugated pipe connectors p 40 A amt with UV and high temperature resistant material amp ai K 18 fe N Fig 60 Fitting the collector sensor and header pipes 63043966 30 1 SD Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 41 Le Collector Buderus 50 4 Buderus SKS 4 0 s Pra 6 bar 87 psi Ag 2 41m 25 96 yd me 9 bar 131 psi tag 188 C 370 F Fluid H O PP Glycol Vr 0 86 1 0 227 gal 50 50 amp 70 30 mM 41 kg 91 pound Made in Germany Reg Nr 011 7S050 F 82999340 00 5241 00017 A SKS 4 0 w Dimensions 2070x1145x90mm Pmax 10 bar Pe 13 bar Fluid H O PP Glycol 50 50 amp 70 30 Reg Nr 011 7S052 F Made in Germany Year of production 2010 315100 111 123456 82999364 42
28. del Tested SKS 4 0 s ae X On aga pet ye Sy Londonderry NH 03053 USA 603 216 3449 LN RI LX Y o je S SO LOMO Description Fiberglass frame Low Iron Tempered Glass glazing Copper absorber with Selective Coating coating Mineral Wool side insulation and Mineral Wool back insulation Water was the fluid for performance tests Gross Area 2 41 m 25 95 ft Aperture Area 2 09 m 22 49 ft ZN O RAR NL YASS GLAZED COLLECTOR THERMAL PERFORMANCE RATING Megajoules Per Panel Per Da Thousands of Btu Per Panel Per Da Category CLEAR MILDLY CLOUDY Category CLEAR CLOUDY Ti Ta CLOUDY Ti Ta CLOUDY2 23 MJ m d 17 MJ m d 11 MJ m d 2 kBtu ft d 1 5 kBtu ft d 1 kBtu ft d E A ee Om T Zs SF AX ES A A T O DX WLS LY amp EEEE A a a ASE Vog vX BROSES e T HY SA vod Eo aa aea a E o a XK a A Pool Heating Warm Climate B Pool Heating Cool Climate C Water Heating Warm Climate D Water Heating Cool aN SUA Climate E Air Conditioning V N N ZIN Efficiency Equation NOTE P Ti Ta Y Intercept Slope WY NA SI Units n 0 709 3 2609 PI 0 0120 P I 0 715 3 97 W m C NOA IP Units n 0 709 0 5747 P I 0 0012 PI 0 715 0 700 Btu hr ft F aS Incident Angle Modifier NOTE S 1 cos 6 1 Ss K Kim 1 0 0 0058 S 0
29. dual loosening of the hex nut on the roof hook When the nut is tightened adhesive is activated which bonds the joint securely after one hour f the roof hook requires adjustment after this time the adhesive may be compromised It must then be secured on site e g lock washer Installing roof hooks and horizontal rails ea DD a 63043965 13 1 SD Fig 11 Installed roof hooks for two collectors Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 15 Le Installing roof hooks and horizontal rails 5 2 1 Attaching roof hooks to the substructure NOTICE Roof hooks must be attached to the building substructure Sheathing alone will not support the load of the solar collectors Minimum 2x6 framing required to attach the roof hooks to Follow the local building code and use best practice methods NOTICE With some roof coverings it may be necessary to suspend the roof hook using a board or shims Fig 13 6 to get the upper part of the roof hook to rest on top of the tile Loosen the long hex nut Fig 12 2 and disassemble the unit Insert bolt into upper hole Fig 12 3 Reassemble with the L shaped piece Fig 12 4 facing away and down Do not tighten the nut Fig 12 2 until the hook is installed and properly adjusted from failure of the roof hook if the bolt is not positioned in the upper hole resulting CAUTIO
30. e nipple and compression fitting from Fig 56 Connection set between two collector rows connection pipe Insert gasket Fig 56 2 into union nut Insert elbow Fig 56 3 into union nut G1 align and tighten Push connection pipe Fig 56 1 onto the collector connections and fix in place using clips Fig 56 4 1 from the connection kit Extending the connection set with rigid copper pipe Slide union nut and compression ring Fig 57 2 over the copper pipe 3 4 18 mm Fig 57 1 Cut copper pipe to required length Insert pipe into both compression fittings and tighten aED Fig 57 Extending the length of the connection pipe Buderus 38 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Final activities 10 10 Final activities 10 1 Checking the installation SYSTEM DAMAGE A from freezing or corrosion if pure water CAUTION without antifreeze remains in the solar system for an extended period after flushing or after a pressure test Commission the solar system immediately after flushing pressure test with solar fluid for instructions on flushing pressure test see pump station instructions Otherwise do not carry out flushing pressure testing until ready to commissioning right away NOTICE Carry out the final insulating work only once all necessary checks have been performed Checks 1 Corrugated p
31. equired the optimal arrangement of the solar collectors Take into consideration the orientation of the building toward the sun any tall trees adjacent buildings building features etc g 63043965 02 1 SD where the penetration s into the building envelope are located and arrange the collector array accordingly Fig 1 General overview of two collectors if the collector array can be arranged symmetrically with the building and building features NOTICE Only use OEM components and replace any defective or damaged parts immediately NOTICE It is recommended to consult a professional roofer if roof repairs are necessary Have the work completed before installing the solar equipment Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 7 Fal Before installation 4 2 Component description 4 2 1 Collector racks The collectors are attached to horizontal rails that are mounted on roof hooks or standoffs A variety of attachment methods are available to match different roof types and surfaces 63043965 03 1 SD Fig 2 Mounting system for 2 collectors 1 basic system 1 extension system and 2 sets of roof hooks hooks for tile roofs shown Basic mounting system for each collector array Extension mounting system for each additional including the first collector Fig 2 collector Fig 2 1 Horizontal rail 2x 1 Horizontal rail 2x 3
32. es Repeat the procedure for all the other collectors Installing the single sided collector clamp on the last collector Once all collectors are installed the two remaining single sided collector clamps can be attached Push the single sided collector clamp Fig 46 1 into all profile rails Push collector clamp up against the collector frame and screw in place using size 5 Allen key Fig 46 2 NOTICE When the screw is tightened the plastic spacer holding the clamp apart will break away Discard this piece Buderus 63043965 48 1 SD Fig 45 Double sided collector clamp between two collectors 63043966 17 1 SD Fig 46 Single sided collector clamp left 32 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 7 Collector sensor NOTICE The collector sensor is included with the solar controller Observe the installation location for single or dual row collector systems Fig 47 SYSTEM DAMAGE 4 N from damaged sensor cable CAUTION Protect the cable from possible damage e g by birds and rodents Sensor location The collector sensor must be installed in the collector connected to the supply line Fig 47 2 Location Fig 47 A for single row collector systems Location Fig 47 B for multi row collector systems Installing
33. es between 5 and 65 Application conditions The mounting system is suitable for a max standard snow load of 42 lbs saqft 2 0 kN m and an installation height of max 66 ft 20 m Using appropriate accessories the system can be used for a max standard snow load of 65 Ibs saft 3 1 kN m and a max installation height of 328 ft 100 m See Chapter 5 7 Installing high load rails accessory Do not attach any other devices e g antennas to collector racks Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 5 E Safety 3 2 Guideline of Notices Two levels of safety are identified by the following symbols DANGER Denotes a possible severely dangerous situation where without proper caution WARNING bodily injury or loss of life may result gt RISK OF INJURY SYSTEM DAMAGE BUILDING DAMAGE Identifies a possible dangerous situation that can lead to mild to moderate bodily injury or property damage gt CAUTION Additional symbol for designating user notes NOTICE Application comment for optimum use of equipment and adjustment as well as useful information 3 3 Please observe these safety instructions RISK TO LIFE from a fall or falling tools and parts Take appropriate action to prevent accidents when working on roofs While working on the roof take all necessary precautions against a possible fall Always wear protec
34. fore installation 4 3 Other equipment Level Rope High head filling pump Personal protective equipment for on the roof Pipe insulation with UV protective coating Scaffolding Ladder Bucket truck or scissor lift NOTICE When installing the roof mounting set and water connection the only tool you will need is the size 5 Allen wrench from the connection kit plus some adjustable pipe wrenches 4 4 Transport and storage All components are protected by transport packaging NOTICE Dispose of the transport packaging in an environmentally friendly manner Transport protection for collector connections The collector connections are protected against damage by rubber caps WARNING Do not remove the rubber caps Fig 5 1 until immediately prior to installation SYSTEM DAMAGE from damaged gaskets Storage The collectors must be stored in dry conditions NOTICE protection from the weather The Do not store collectors outside without packaging is not designed to be all weather proof Protect the collectors using a tarp during transport in wet weather in an open truck Buderus 63043966 05 1 SD Fig 5 Rubber caps on collector connections 10 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Before installation Ee 4 5 Technical documentation The solar thermal system consists of v
35. g 1 2 16 mm 0 05 Set 5 pieces 20 63045250 Compression ring 3 4 18 mm Set 5 pieces 40 63045256 End plug kpl 0 1 Available individual parts 0 1 15 63045264 O Ring 15x3 SHORE70 EPDM291 0 008 Set 5 pieces 50 63045255 Retaining clip f Corrugated pipes SKS FKT 0 05 Set 5 pieces 60 x Isolation f Corrugated connector SKS FKT 80 87182237050 Connecting piece VL RL SKS FKT kpl 2 6 Available individual parts 15 63045264 O Ring 15x3 SHORE70 EPDM291 0 008 Set 5 pieces 90 63045258 Corrugated connector SKS FKT 0 05 Available individual parts 15 63045264 O Ring 15x3 SHORE70 EPDM291 0 1 Set 5 pieces 50 63045255 Clip SKS FKT 0 05 Set 5 pieces Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 49 Le Row connection set SKS FKT SKS Extension SKS Reduction 120 100 gt AS NA 150 aad 90 67910167 00 Row connection set SKS FKT Buderus 50 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Row connection set SKS FKT 12 Item Part Number Description Weight Row connecting set SKS FKT 90 63045266 Elbow FKT SKS 18 Clamp G3 4 kpl 0 3 Available individual parts 100 63045264 O Ring 15x3 SHORE70 EPDM291 0 008 Set 5 pieces 110 87182237740 Compression ring 1 2 16 mm 0 05 Set 5 pieces 110 63045250 Compression ring 3 4 18 mm Set 5 pieces 120 63045255 Clip FKT SKS 0 04 Set 5 pieces 130 8
36. ipe connector end caps and connection pipes secured with clips Horizontal rails connected to roof hook and threaded clip Collector hanger installed and snapped in horizontal rails 4 Sensor inserted as far as it will go and secured with strain relief Pressure test carried out and all connections leak proof see pump station instructions NOTICE Ensure the ball valve on the automatic air vent is closed after commissioning Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 39 10 Final activities 10 2 Insulating the Pipes above the Roof Cut provided insulation 28 710 mm into 3 5 88 mm pieces and wrap around the corrugated pipe connectors between the collectors Insulation of the pipework in internal or external installations For the insulation of external pipework use only UV and high temperature resistant insulating materials For the insulation of internal pipework use only high temperature resistant insulating materials Use only material that is bird and rodent proof Verify all penetrations are weather proof and discourage critters from entering the building Buderus 40 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Quick reference guide for tile roof and pressure filling E 11 Quick reference guide for tile roof an
37. lar Thermal i Plate Collectors Installation Manua 4 R COCA M A CCC o OO neea T RURA O COCCCCCRES ATE CA Co oS RT For Contractors iis d carefully prior Mountin soe for gin ieee Mounting Sloped Roofs 6 720 614 828 02 2010 US erus Q E Bud EI Contents Genelal o een ne eon h eis E en hese ee eee E eenewasees 3 Specifications 5 s ccccsoceeeve eee eiuneredeetetasarnewne ead 4 Safety Seer el ooo eee es oe Gee ee oe Bete es eee ee eee 5 Sl Intended USE sos talent eS Poel ee eee Eee bee Bae Bae oo 5 3 2 Guideline of Notices 2 2 6 252k age duas doPib dante esaewc bad edee ds 6 3 3 Please observe these safety instructions 0 000 eee ee 6 4 Before installation i026 ees auauna aaa 7 41 General Notes mesai tee eee ee Se Sk eK eK ee EE REE See E E Ee 7 4 2 Componentdescription 0 0000 ee 8 4 3 Otherequipment 0 000 ce ee 10 4 4 Transport and storage aaao 10 4 5 Technical documentation 2 20 cs d 0a4 602 iv eee cea cada de eden eb sa4a a 11 4 6 Determining space required on roof aaoo 12 5 installing roof hooks and horizontal rails 13 5 1 Rail and hook Spacing 202464c e005 8 bea ee eee ee eee ee ee ee 14 5 2 Adjustable Roof Hooks for Tile RoofS 0 000 eee eee ee es 15 5 3 Adjustable Roof Hooks on Flat Shingle and Slate Roofs 17 5 4 Hanger Bolt Installation 2 2 0 19 5 5 Roof Hooks for Flat Shingles
38. lease see Chapter 5 8 1 Connecting the horizontal rails Place the horizontal rails Fig 27 1 into the indentations Fig 27 2 on the vertical rails and loosely fasten using screw and counter plate Fig 27 3 so that the rails can still be aligned Repeat the same procedure for the other rails To continue with the installation see Chapter 5 8 3 mateo Aligning the horizontal rails Fig 27 Installing horizontal rails Buderus 24 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 5 8 Installing horizontal rails The horizontal rails must be joined together using connectors For standard installations each collector is equipped with one upper and one lower horizontal rail 5 8 1 Connecting the horizontal rails Push connector Fig 28 1 as far as it will go into both rails Fig 28 2 To lock tighten both installed M10 threaded studs Fig 28 3 using a size 5 Allen wrench 5 8 2 Installing the horizontal rails Push threaded clip Fig 29 1 onto the roof hook in the direction of the arrow Place the lower horizontal rails Fig 29 2 onto the roof hooks and loosely fasten M8 bolt Fig 29 3 so that the rails can still be aligned Carry out the same procedure for the upper rails NOTICE Use a tape measure and a level to verify the rails are plumb and properly aligned Imprope
39. ng face Double nipple Gasket Z2 63043966 23 1 SD Fig 54 Fitting the air vent insulation not shown a A OND Air vent body Connection pipe Compression fitting 3 4 18 mm Roof penetration Nipple R Clip oa hr OD Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 37 es Connecting Two Collector Arrays accessory 9 Connecting Two Collector Arrays accessory The collector array connection set Fig 55 9 is available as an accessory and allows connecting two collector arrays in series that are located in close vicinity of each other NOTICE It is recommended to assemble these pipes on the ground to make work easier and avoid loss of parts Scope of delivery Fig 55 1 End cap 2x 2 Connection pipe 1x 3 Elbow 1x 4 Gasket 1x 63043966 27 1 SD 5 Large diameter washer 1x i 6 Split compression washer ix Fig 55 Schematic diagram and scope of supply 7 Compression ring 2x 8 Union nut G1 1x Fitting additional end caps Use the end caps to close any collector connections not in use Fig 55 1 see Chapter 6 1 2 Installing the end cap page 29 NOTICE If the connection pipe is too long shorten it by following the installation steps described in Making the sealing face page 37 Installing the connection set as is 63043966 29 1 SD Remove doubl
40. nger bolts are maintained as described in Tab 4 and Tab 5 page 14 The number of hanger bolts per panel must be based on the required snow and wind load Minimum four 4 bolts per panel The roofer will install means to keep water from penetrating the roof e g sleeves brazed to the roof Fig 24 6 have been used successfully for this purpose NOTICE For the sequence of installation for hanger bolts and horizontal rails please refer to the instructions given in Chapter 5 4 Hanger Bolt Installation SYSTEM DAMAGE CAUTION Ensure the building substructure is capable of carrying the load of the panels including the required snow and wind loads due to an insufficient substructure Only attach to framing that is properly supported Do not install hanger bolts in less than 2x6 framing Follow the local building code and best practice when installing hanger bolts Installing roof hooks and horizontal rails E 63043965 29 1 SD Fig 24 Mounting on sheet steel roof 1 Attachment block 2 M12 nut 3 Washer 4 Gasket 5 M12 stud 6 Sleeve example for a sealing method provided by roofer Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 23 es Installing roof hooks and horizontal rails 5 7 Installing high load rails accessory The standard racks as described so far are suitable for installation heights up to 66 ft 20 m
41. ngle flat shingle or slate roof The long part of the hook faces upward and is covered by the adjacent rows of shingles Ensure the required distances w x and y between the two roof hooks as detailed in Tab 4 and Tab 5 page 14 Install roof hook Fig 23 3 and gasket Fig 23 2 not supplied to the shingles using 63043985 27 1 SD screw Fig 23 1 Fig 23 Mounting on shingle roof It is recommended to apply generous amounts of 1 Screws caulking on the underside of the roof hook and into 2 Gaskets not supplied the screw holes to establish a tight seal 3 Roof hook 4 SYSTEM DAMAGE A due to an insufficient substructure CAUTION Ensure the building substructure is capable of carrying the load of the panels including the required snow and wind loads Bottom tile Only attach to framing that is properly supported Do not install hanger bolts in less than 2x6 framing Follow the local building code and best practice when installing roof hooks Buderus 22 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 5 6 Sheet Metal Roof Surfaces 5 6 1 Seamless metal roofs NOTICE These types of roofs require hiring a professional roofing company to ensure long term leak free operation Hanger bolts Fig 24 must be used for attaching the horizontal rails to the roof Ensure the distances w x and y between ha
42. nt of the system and all supply and return piping should be sloped toward the collectors Fig 50 Avoid frequent changes in direction NOTICE If the system requires significant dips in the pipework it may be necessary to install If an automatic air vent can not be installed due to space restrictions use a manual air vent valve additional air vents in order to be able to remove all the air during commissioning Description of the automatic air vent NOTICE When using corrugated stainless steel piping for extended lengths of the supply and return lines an automatic air vent is required NOTICE Only use air vents that are rated for the temperatures and glycol fluids of solar systems The automatic air vent contains a float that opens a valve if air is collecting and releases the air to the outside The valve closes once the air was released and liquid reaches the float The air vent must be positioned perfectly vertically Otherwise the float may not work properly During stagnation steam is generated which would escape through the air vent Therefore a ball valve is installed before the air vent which must be closed after the system is commissioned Only during servicing may the ball valve be opened The air vent has a bleeder screw at its top protected by a weather cap Fig 51 1 In order to prevent contamination this weather cap must always be installed To bleed air from the system open the ball valve an
43. on except that the return piping should be sloped toward the collector array 63043966 22 1 SD Fig 52 Fitting the air vent valve under the roof e i i Remove union nut and compression washer from Insulation no shown connection pipe Double nipple with O ring Firmly screw connection pipe Fig 52 3 and double nipple Fig 52 1 into air vent body O ring gasket Air vent body Connection pipe Roof penetration Hook the connection pipe to double nipple with o lip compression fitting Fig 52 1 a fF WON Buderus 36 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 8 1 2 Installing the air vent valve on the collector above the roof With the air vent mounted directly on the collector the flexible connection pipe is used to bring the supply pipe into the attic and hook up to the supply piping to the pump station The flexible return pipe is used as described in Chapter 8 1 1 To connect the connection pipe to the air vent supply connection its elbow must be replaced with a double nipple Cut elbow Fig 53 1 from connection pipe using pipe cutters Step 1 Cut in the valley of the corrugation Establish a clean cut without a rough edge Push union nut over the connection pipe Step 2 Making the sealing face Separate one of the cuts of the split compression washer and bend it open Slide over the first valley of the c
44. orrugated pipe and close it again Fig 53 2 The closed compression washer must be positioned evenly on the collar of the union nut once pulled forward Place large diameter washer Fig 53 3 into the union nut in front of the cut surface of the connection pipe Firmly screw double nipple Fig 53 4 into union nut which will create a flat sealing surface on the connection pipe Remove double nipple and large diameter washer and verify that a flat sealing surface has been created Remove any burrs as required Insert gasket Fig 53 5 and reassemble double nipple Connection to the collector Firmly screw nipple Fig 54 5 and connection pipe Fig 54 2 into vent body Fig 54 1 O ring gasket Push vent body and nipple onto collector connection as far as it will go and secure with a clip Fig 54 6 Feed connection pipe together with the sensor cable through the penetration Fig 54 4 into the attic Ensure that the air vent is positioned perfectly vertically otherwise the float will not work properly Connect the supply piping from the pump station to the compression fitting Fig 54 3 NOTICE Install return connection as described in Chapter 8 1 1 Hydraulic connections se haw 2 CC 9 aw e 63043966 24 1 SD Fig 53 Preparing the connection pipe Elbow Split compression washer Large diameter washer for making seali
45. re snapped into the lower horizontal rail Install the collector hanger Fig 31 8 at the innermost slotted holes Fig 31 1 on the lower horizontal rails until it snaps into place Fig 31 2 Buderus 63043965 35 1 SD Fig 30 Aligning the horizontal rails high load rails not shown Sooo n FFY 63043965 36 1 SD Fig 31 Attaching collector hanger 1 Slots reserved for the hanger 2 Both teeth must engage with the rail 3 Collector hanger 26 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Collector Installation Se 6 Collector Installation Observe the following safety and user instructions when commencing the collector installation RISK TO LIFE 4 from a fall or falling tools and parts WARNING Installing collectors requires at least two people Take appropriate action to prevent accidents when working on roofs While working on the roof take all necessary precautions against a possible fall Always wear protective clothing and use your personal protective equipment PPE 63043965 37 1 SD Fig 32 View of roof mounting with collectors After completing an installation always verify that all components are installed according to the instructions and are securely attached SYSTEM DAMAGE 4 from damaged connections CAUTI
46. rly aligned rails not only reflect poorly on the installer but also may put stress onto the collectors causing premature failure Installing roof hooks and horizontal rails ea 1 2 we F7 we S 63043965 33 1 SD Fig 28 Connecting horizontal rails 1 Connector 2 Horizontal rail 3 M10 threaded stud 4 A 63043965 34 1 SD Fig 29 Fastening profile rails to the roof hook 1 Threaded clip 2 Horizontal rail 3 Screw Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 25 Le Installing roof hooks and horizontal rails 5 8 3 Aligning the horizontal rails Align the upper and lower horizontal rails evenly side to side and to each other using a level and a cord Fig 30 NOTICE Use a tape measure or a cord to compare the diagonal distances across which must be identical for the installation to be square Fig 30 1 Correct it before proceeding if this is not the case Tighten all screws NOTICE Ensure the horizontal rails do not sag Use a cord to confirm Install spacers to correct for differences in height Uneven or sagging profile rails may put stress on collectors and connections and may result in leaks and reduced service life 5 8 4 Installation of collector hangers To carry the weight of the collectors two collector hangers are used which a
47. slate roofs corrugated sheet roofs mission style pan roofs and similar roofing materials The following procedure describes installation on a corrugated roof Installation on flat roof surfaces should be performed in a similar fashion Standard delivery Fig 19 1 M8 screw 4x 2 Attachment block 4x 3 M12 nut 4x 4 Washer 4x 5 Gasket 4x 6 M12 stud 4x The number of hanger bolts per panel must be based on the required snow and wind load Minimum four 4 bolts per panel On corrugated roofs the peaks in the corrugation determine the true distance between the post screws Maintain the required distances w x and y between hanger bolts as shown in Tab 4 and Tab 5 page 14 CAUTION Ensure the building substructure is capable of carrying the load of the panels including the required snow and wind loads SYSTEM DAMAGE due to an insufficient substructure Only attach to framing that is properly supported Do not install hanger bolts in less than 2x6 framing Follow the local building code and best practice when installing hanger bolts Installing roof hooks and horizontal rails ea 63043965 22 1 SD Fig 19 Hanger bolt Additional tools required Cordless screwdriver Tape measure Wood drill bit 1 4 6 mm Metal drill bit 1 2 13 mm Wrench size 15 and 19 Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 19
48. standard snow loads up to 42 Ibs sqft 2 1 kN m and wind speeds up to 81 mph 129 km h ila Vy Additional measures are needed for installation heights up to 328 ft 100 m standard snow loads up to 65 Ibs sqft 3 1 kN m2 and wind speeds up to 94 mph e LLA 150 km h F Tah G L NOTICE KY The example here shows an installation on la i tile Procedures are similar for other a roofing materials and surfaces Refer to the relevant sections 5 2 to 5 6 for details 63043965 30 1 SD Fig 25 Additional roof hooks for the accessory rails here for two collectors Installing additional roof hooks or hanger bolts Additional hooks or bolts and vertical support rails must be installed for attaching a third row of horizontal profiles The third row Fig 25 1 should be centered between the upper and lower rows already installed NOTICE On tile roofs there must be at least one free row of tiles between the upper middle and lower roof hooks or hanger bolts Mounting the high load rails Push threaded clip Fig 26 1 onto the roof hook in the direction of the arrow FP 63043965 31 1 SD Place the vertical rail Fig 26 2 onto the roof hooks and tighten the M8 screws Fig 26 3 Verify the high load rails are level and plumb use cord l S Installing the horizontal rails The horizontal rails must be joined together before they are installed P
49. talling the end cap Not all the connections are needed when connecting a collector array Those that are not used must be capped Remove rubber caps transport protection from the relevant collector connections Push end cap with the O rings Fig 36 1 onto the collector connection Push clip sideways Fig 36 2 over the end cap and collector connection to secure it in place 6 2 Mounting the collectors The collectors are attached to the horizontal rails using single sided collector clamps Fig 36 2 at the two ends of a collector array and double sided clamps Fig 36 1 between two collectors The clamps hold the collectors in place while the collector hangers are carrying their weight NOTICE The collector clamps are spread apart using small plastic pieces that break off when tightening the Allen screw Discard this piece Installing a single sided clamp Push single sided collector clamp Fig 37 1 onto each horizontal rail at one end of the collector array until it clicks into the first slot NOTICE Do not install clamps on the opposite side of the array until the last collector has been installed Collector Installation Se 63043966 12 1 SD Fig 36 Securing end cap with clip DV VIS 63043965 42 1 SD Fig 37 Single and double sided collector clamps
50. the collector sensor The collector sensor Fig 48 1 must be inserted into the sensor well as far as it will go approx 10 250 mm Using a pointy device penetrate the membrane on the outside of the sensor well Fig 48 3 Screw strain relief Fig 48 2 into sensor well Insert collector sensor approx 10 250 mm into the sensor well until it bottoms out Tighten strain relief by hand Fig 48 2 NOTICE If by accident the membrane Fig 48 3 of the wrong collector was penetrated cap it by pushing a black collector connection cap onto the well For that the nut installed at the outside of the well must be removed Route the sensor cable along the pipework using zip ties Collector sensor 4 63043966 25 1 SD Fig 47 Collector sensor installation location schematic 1 Return line 2 Supply line 63043966 26 1 SD Fig 48 Inserting the collector sensor into the sensor well 1 Collector sensor 2 Strain relief 3 Sensor well Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 33 8 Hydraulic connections 8 Hydraulic connections Details on how to route the supply and return piping and how to pipe multiple collector arrays can be found in the installation instructions of the Solar Pump Station and the Solar Technical Design Guide Use
51. tive clothing and use your personal protective equipment PPE gt WARNING Ifyou are not comfortable working ona ladder a lift or the roof hire a roofing contractor to install the equipment After completing an installation always verify that all components are installed according to the instructions and are securely attached RISK OF INJURY Personal injury and system faults can result from altered construction CAUTION Never modify structural elements Never drill additional holes Never attach non system related components e g antennas Buderus gt CAUTION gt o gt e zZ gt ce gt a zZ gt ce gt zZ gt o gt a fe zZ gt o gt a e zZ gt CAUTION gt CAUTION RISK OF INJURY Solar system components can become very hot even when a system is decommissioned Always wear protective clothing and safety equipment Cover the collector collector covers are available as an accessory during installation to prevent high temperatures resulting from solar radiation Observe maximum load and distance from edges before installing the substructure supports to the roof If necessary consult a structural engineer to determine if the structure is suitable for installing solar collectors including expected snow and wind loads Solar pipes and solar fluid can cause severe burns
52. try Installations must be made in accordance with all codes and regulations applicable to the installation site Lightning protection If the solar equipment protrudes above the roof ridge or the building height installation height exceeds 66 ft 20 m it is recommended to have lightning arrestors installed on the tallest equipment including the solar collectors Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 3 ea Specifications 2 Specifications SKS 4 0 C 0036 Certificates 81 1 2 in ae 2070 mm i 45 1 8 in ag 1145 mm 3 1 2 in Depth aan 1in Clearance between collectors Bs mi Absorber contents Portrait version Vi ean Absorber contents Landscape version V eran 2 Gross absorber surface area Ac T Le 2 Net absorber surface area eae Net weight Portrait version m ae a Net weight Landscape version m ay Permissible operating pressure of the 145 psi collector Pmax 10 bar Tab 1 Specifications Buderus 4 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 3 Safety This chapter explains the meaning of the notes you will find in this manual and provides general safety instructions for safe and trouble free operation You will find the installation specific safety and user notes next to the appropriate installation steps Carefully read the safety instru
53. us 46 On roof installation material 12 Item Part Number Description Weight Mounting kits for heavy snow and wind loads 10 63045254 High load rail vertical 5 5 Hanger bolt kit 30 63020003 Hanger bolt kit 0 44 consists of 40 x Screw 8x16 10 9 A2 i 2 pieces 50 63020008 Attachment block M8 M12 f 0 1 60 x Hex nut DIN439 M12 A2 1 piece 70 x Washer DIN125 13 A2 i 1 piece 80 63020009 Gasket 0 02 90 63020010 Stud M12x180 0 3 Mounting kits for Slate and Shingle roofs 100 63017467 Mounting Set for Roof hooks for slate roofs 0 88 consists of 110 x Roof hooks for slate roofs i 1 piece 120 x Screw M8x25 s 1 piece 130 x Washer DIN125 8 4 V2A 1 piece 140 x Hex nut DIN985 M8 A4 3 1 piece 150 x Wood screw 6x70 1 piece Buderus Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications 47 12 Connection Set FKT amp PS 40 qd 5 50 Pitched roof N 7 15 7 S ee 50 50 SN ae 90 2S 50 2 DA p l z 5 ae 2 Sy 1577 15 50 b 10 8 67910063 00 Connection set Buderus 48 Logasol SKS 4 0 We reserve the right to make any changes due to technical modifications Connection Set FKT 12 Item Part Number Description Weight 10 87182237030 Elbow 18 Clamp G3 4 kpl 0 3 Available individual parts 15 63045264 O Ring 15x3 SHORE70 EPDM291 0 008 Set 5 pieces 20 87182237740 Compression rin
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