VIESMANN. Installation instructions VITOSOL 200-T. for contractors. Vitosol 200-T Type SP2 Vacuum tube collector based on the heat pipe principle

Transcription

1 Installation instructions for contractors VIESMANN Vitosol 200-T Type SP2 Vacuum tube collector based on the heat pipe principle VITOSOL 200-T 6/2010 Dispose after installation.

2 Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained Danger This symbol warns against the risk of injury.! Please note This symbol warns against the risk of material losses and environmental pollution. Note Details identified by the word "Note" contain additional information. Target group These instructions are exclusively designed for qualified personnel. Work on electrical equipment must only be carried out by a qualified electrician. Regulations Observe the following when working on this system All legal instructions regarding the prevention of accidents, All legal instructions regarding environmental protection The Code of Practice of relevant trade associations, All current safety regulations as defined by DIN, EN, DVGW, VDE and all locally applicable standards. a ÖNORM, EN and ÖVE c SEV, SUVA, SVTI, SWKI and SVGW Gas Safety (Installation & Use) Regulations the appropriate Building Regulation either the Building regulations, the Building Regulation (Scotland), Building Regulations (Northern Ireland), the Water Fittings Regulation or Water Bylaws in Scotland, the current I.E.E. Wiring Regulations. Working on the system Isolate the system from the power supply and check that it is no longer 'live', e.g. by removing the separate fuse or by means of a main isolator. Safeguard the system against unauthorised reconnection. 2

3 Index Installation sequence Horizontal above roof installation... 4 Installation with roof hooks... 4 Installation with mounting brackets Vertical above roof installation Installation with roof hooks Installation with mounting brackets Installation on supports Components Determining collector row clearance z Installation Horizontal installation on flat roofs Components Installation Installation on walls Components Installation Making the hydraulic connections Connecting the header casing Fitting the connection set Fitting the vacuum tubes Fitting the collector temperature sensor Installation Commissioning

4 Horizontal above roof installation Installation with roof hooks Components /2148 Pantiled roof 1 Timber 38 x 58 x 2430 mm 30 x 100 x 2430 mm 2 Roof hook 3 Zinc-plated countersunk chipboard screw (Spax-s) 6 x 80 mm 4 Zinc-plated countersunk chipboard screw (Spax-s) 5 x 80 mm Slate roof 5 Roof hook 6 Zinc-plated countersunk chipboard screw (Spax-s) 6 x 80 mm Corrugated sheet roof 7 Roof hook for corrugated sheet roofs, profiles 5 and 6 8 Roof hook for corrugated sheet roofs, profile 8 4 Plain tiles 9 Roof hook 4 Zinc-plated countersunk chipboard screw (Spax-s) 5 x 80 mm For all types of roofing qw T-slot bolt qe Washer qr Hexagon nut qt Mounting rail qz Mounting rail with tube holders qu Mounting plate qi Locking bracket qo Spacer wp Retaining rubber

5 Horizontal above roof installation (cont.) Dimensions overview 102 a 81 b x 160 x 160 c d e Dimension x according to the width of the tile head. For dimensions a to e, see the following table. A Spacer B Header casing C Mounting bracket D Mounting rail with tube holders E Mounting rail F Timber, 38 x 100 mm (only for pantiles) G Timber, 30 x 58 mm (only for pantiles) H Roof hook 5

6 Horizontal above roof installation (cont.) Combination a mm b mm c mm d mm e mm 2 m m m 2 /2 m m 2 /3 m m 2 /2 m m 2 /3 m f Note f = 81 mm For installations without roof hooks, mounting brackets are used in place of roof hooks. Fitting roof hooks Roof tiles Observe dimensions in chapter "Dimensions overview". 6

7 Horizontal above roof installation (cont.) x x Continue with chapter "Fitting mounting rails". Slate roof Observe dimensions in chapter "Dimensions overview" Note Fit commercially available lead flashing to protect against the ingress of moisture. Continue with chapter "Fitting mounting rails". 5 7

8 Horizontal above roof installation (cont.) Corrugated sheet roof Observe dimensions in chapter "Dimensions overview". Continue with chapter "Fitting mounting rails". Ø8 A 2. 7,8 1. B A Sealing washer (on site) B Existing roof batten Plain tiles Observe dimensions in chapter "Dimensions overview"

9 Horizontal above roof installation (cont.) 30 Fitting mounting rails Information regarding fitting the rail Fit the mounting rails with tube holders offset against each other. This achieves a slope of the vacuum tubes towards the horizontal. Trim tile with angle grinder; cut off approx. 30 mm. a c b A A Header casing B B Mounting rail with tube holders Vitosol 200-T a mm b mm c mm 2 m m

10 Horizontal above roof installation (cont.) qrqe qw A qt A Roof hook 10

11 Horizontal above roof installation (cont.) 2. 2x x

12 Horizontal above roof installation (cont.) If several collectors are fitted above each other 90 2x 7. qw qeqrqo Installing the header casing Use the centring nut on the back of the header casing as a drilling guide. 12

13 Horizontal above roof installation (cont.) Continue with chapter "Making the hydraulic connections". qr qe Ø9 90 qw qu 8. Installation with mounting brackets Components For example, installation on sheet steel roofs. Use on-site fixings to secure the brackets (e.g. for box profiles). 13

14 Horizontal above roof installation (cont.) /2148 qp Mounting bracket qq Clamping bracket qw T-slot bolt qe Washer qr Hexagon nut qt Mounting rail qz Mounting rail with tube holders qu Mounting plate qi Locking bracket qo Spacer wp Retaining rubber 14

15 Horizontal above roof installation (cont.) Dimensions overview 102 a 81 b e c d A Spacer B Header casing C Mounting bracket D Mounting rail with tube holders H Mounting rail Combination a mm b mm c mm d mm e mm 2 m m m 2 /2 m m 2 /3 m m 2 /2 m m 2 /3 m

16 Horizontal above roof installation (cont.) Installation Fit mounting rails offset against each other (see page 9) Screws for mounting brackets to be supplied on site. Proceed as follows: See chapter "Fitting mounting rails". See chapter "Making the hydraulic connections". 16

17 Vertical above roof installation Installation with roof hooks Components /2148 Pantiled roof 1 Timber 38 x 58 x 2430 mm 30 x 100 x 2430 mm 2 Roof hook 3 Zinc-plated countersunk chipboard screw (Spax-s) 6 x 80 mm 4 Zinc-plated countersunk chipboard screw (Spax-s) 5 x 30 mm Slate roof 5 Roof hook 6 Zinc-plated countersunk chipboard screw (Spax-s) 6 x 80 mm Corrugated sheet roof 7 Roof hook for corrugated sheet roofs, profiles 5 and 6 8 Roof hook for corrugated sheet roofs, profile 8 Plain tiles 9 Roof hook 4 Zinc-plated countersunk chipboard screw (Spax-s) 5 x 80 mm For all types of roofing qq Clamping bracket qw T-slot bolt qe Washer qr Hexagon nut qt Mounting rail qz Mounting rail with tube holders qu Mounting plate qi Locking bracket qo Spacer wp Retaining rubber 17

18 Vertical above roof installation (cont.) Dimensions overview AB C D E F G B C H K B x x Dimension x according to the width of the tile head. A Vacuum tube B Clamping bracket C Mounting rail with tube holders D Mounting rail E Roof hook F Timber, 38 x 58 mm (only for pantiles) G Timber, 30 x 100 mm (only for pantiles) H Mounting plate K Header casing 18

19 Vertical above roof installation (cont.) d a 2 b a e c c Note For installations without roof hooks, mounting brackets are used in place of roof hooks. Combination a mm b mm c mm d mm e mm 2 m m m 2 /2 m m 2 /3 m m 2 /3 m Fitting roof hooks Roof tiles Observe dimensions in chapter "Dimensions overview". 19

20 Vertical above roof installation (cont.) x x Continue with chapter "Fitting mounting rails". Slate roof Observe dimensions in chapter "Dimensions overview" Note Fit commercially available lead flashing to protect against the ingress of moisture. Continue with chapter "Fitting mounting rails". 5 20

21 Vertical above roof installation (cont.) Corrugated sheet roof Observe dimensions in chapter "Dimensions overview". Continue with chapter "Fitting mounting rails". Ø8 A 2. 7,8 1. B A Sealing washer (on site) B Existing roof batten Plain tiles Observe dimensions in chapter "Dimensions overview"

22 Vertical above roof installation (cont.) Trim tile with angle grinder; cut off approx. 30 mm. 230 Fitting mounting rails ,5 A Roof hook 22

23 Vertical above roof installation (cont.) 4. f qr qe qq qw qt 90 qq qz qq 3. 4x Note f = 81 mm Tube holders on opposite rails must be aligned. 23

24 Vertical above roof installation (cont.) Installing the header casing Note The tube holders on the mounting rails must be aligned with those in the header casing; where necessary, align with a piece of string. Continue with chapter "Making the hydraulic connections". Installation with mounting brackets Components For example, installation on sheet steel roofs. Use on-site fixings to secure the brackets (e.g. for box profiles). 24

25 Vertical above roof installation (cont.) /2148 qp Mounting bracket qq Clamping bracket qw T-slot bolt qe Washer qr Hexagon nut qt Mounting rail qz Mounting rail with tube holders qu Mounting plate qi Locking bracket qo Spacer wp Retaining rubber 25

26 Vertical above roof installation (cont.) Dimensions overview A B C D E B CF G D B A Vacuum tube B Clamping bracket C Mounting rail with tube holders D Mounting bracket E Mounting rail F Mounting plate G Header casing 26

27 Vertical above roof installation (cont.) Installation qt qp qw qe qr Screws for mounting brackets to be supplied on site. Proceed as follows: See chapter "Fitting mounting rails". See chapter "Making the hydraulic connections". 27

28 Installation on supports Components A 50 Ø qz 1439/2148 wp A Collector supports for angles of inclination α 25 to 50, pre-assembled with screws, washers, nuts and clamping brackets 1 Collector support 2 Base rail 3 Adjustable support, lower part 4 Adjustable support, upper part 5 Cross brace 6 Hexagon bolt M 8 x 20 7 Washer mm 8 Hexagon nut M 8 qz Mounting rail with tube holders qi Header casing qo Vacuum tube wp Retaining rubber Determining collector row clearance z If several collectors are installed behind each other, maintain distance z to prevent shading. 1. Determine angle β of insolation on 21 December (the shortest day of the year) at midday. In Germany, this angle lies between 11.5 (Flensburg) and 19.5 (Konstanz), subject to latitude. 28

29 Installation on supports (cont.) Example: Würzburg is approximately located on latitude 50 north. In the northern hemisphere, this value is deducted from a fixed angle of β = = Calculating dimension z: h = 2165 mm α = 45 β = 16.5 h h α z β α z sin (180 (α+β)) = h sin β 2165 mm sin ( ) z = sin 16.5 z = 6700 mm z Collector row distance h Collector height α Collector angle of inclination β Angle of the sun Installation Installation information Observe max. load and distance from the edge of the roof for the on-site substructure to DIN Remove any gravel or similar from the installation location, cover the surface with protective building mats and position foot support slabs A and B on top of these mats. Where possible, orient the collector array due south. Calculation of ballast and max. load on the substructure according to DIN /1986 and DIN /1975. Two foot support slabs each A and B are required respectively for each collector. For the calculation, the Viessmann "SOLSTAT" calculation program is available at 29

30 Installation on supports (cont.) Adjusting the angle of inclination α Adjust the required angle of inclination (see chapter "Components") x Fitting the collector supports Use the cross braces as drilling template. For calculating dimension z, see chapter "Determining collector row clearance z". 30

31 Installation on supports (cont.) A 3. 8x z B a b A Foot support A B Foot support B Combination a mm b mm 2 m 2 /2 m 2 900/ m 2 /3 m 2 900/ m 2 /3 m /

32 Installation on supports (cont.) Ø

33 Installation on supports (cont.) Fitting the mounting rails and header casing 8. 4x qi qz qz 7. 4x Note The tube holders on the mounting rails must be in line with those in the header casing; where necessary, align with a piece of string. Continue with chapter "Hydraulic connections". 33

34 Horizontal installation on flat roofs Components / Rawl plug S10 2 Washer 3 Hexagon screw 8 x 70 mm qq Clamping bracket qw T-slot bolt qe Washer qr Hexagon nut qt Mounting rail qz Mounting rail with tube holders qu Mounting plate wp Retaining rubber wq Mounting bracket Installation Installation information Observe max. load and distance from the edge of the roof for the on-site substructure to DIN Remove any gravel or similar from the installation location, cover the surface with protective building mats and position foot support slabs A and B on top of these mats. Where possible, orient the collector array due south. Calculation of ballast and max. load on the substructure according to DIN /1986 and DIN /1975. Two foot support slabs each A and B are required respectively for each collector. For the calculation, the Viessmann "SOLSTAT" calculation program is available at 34

35 a b c f Horizontal installation on flat roofs (cont.) Dimensions overview Note f = 81 mm A Foot support A B Foot support B Combination a mm b mm c mm 2 m m m 2 /2 m m 2 /3 m m 2 /2 m m 2 /3 m

36 Horizontal installation on flat roofs (cont.) Fitting mounting rails 4x A Foot support A B Foot support B 36

37 Horizontal installation on flat roofs (cont.) 2x x Note Tube holders on opposite rails must be aligned. 37

38 Horizontal installation on flat roofs (cont.) Installing the header casing x 6. Note The tube holders on the mounting rails must be in line with those in the header casing; where necessary, align with a piece of string. Continue with chapter "Making the hydraulic connections". 38

39 Installation on walls Components / Rawl plug S10 2 Washer 3 Hexagon screw 8 x 70 mm qp Mounting bracket qw T-slot bolt qe Washer qr Hexagon nut qt Mounting rail qz Mounting rail with tube holders qu Mounting plate qi Locking bracket wp Retaining rubber 39

40 a b c Installation on walls (cont.) Installation Dimensions overview f Note f = 81 mm Combination a mm b mm c mm 2 m m m 2 /2 m m 2 /3 m m 2 /2 m m 2 /3 m

41 Installation on walls (cont.) Fitting mounting rails Fit mounting rails offset against each other (see page 9) x x

42 Installation on walls (cont.) 5. qrqe qp qw qz qt qw qu qe qr x 90 4x x

43 Installation on walls (cont.) qz qi 2x 7. qw qeqr Installing the header casing Ø9 mm

44 192 Making the hydraulic connections Connecting the header casing Components Viesmann Armaturenfett Graisse pour robinetterie Instrument grease Lubrication Unisilkon L250L! Please note Connection pipes should not show any signs of damage. Lubricate all O-ring seals on the collectors only with the special grease provided. Installation information Click retaining clips into the groove in the connection pipes through the holes in the collector connectors. Align the header casing

45 Making the hydraulic connections (cont.) Fitting the connection set Components Viesmann Armaturenfett Graisse pour robinetterie Instrument grease Lubrication Unisilkon L250L Installation information All pipes must be cut at a right angle and deburred. Lubricate all O-ring seals only with the special grease provided. Initially turn the union nut by hand, then tighten with an open ended spanner by a further ¾ turn. Never fit annealed copper pipes onto the locking ring fittings. 45

46 Making the hydraulic connections (cont.) x x 8. 2x 1. VL RL VL RL 4. 4x 7. 2x Use the U-pipe with air vent valve only for horizontal collector installations. Click retaining clips into the groove through the holes in the collector connectors. After joining the collector array to the pipework of the solar circuit, fill the system, check the system pressure and test for leaks. "Vitosol-T" service instructions. 46

47 Making the hydraulic connections (cont.) Fitting the vacuum tubes Danger The vacuum tubes can break if insufficient care is taken. This can result in injuries. The condenser becomes very hot under insolation. Wear gloves and safety goggles. Installation information Pull the gasket only from the top of the casing cover groove. Direct the coated side of the absorber towards the sun. Ensure that no part of the thermal insulation becomes trapped. The surface of the condenser must be clean. Position the condenser centrally into the fitting inside the twin-pipe heat exchanger. For roofs deviating from due south, adjust the angle of inclination of the absorber using the template provided. max. 25! Please note Never align (turn) the tubes in their locked state. This would lead to tube damage x 47

48 Making the hydraulic connections (cont.) Fitting the collector temperature sensor Installation information The first and last tubes of a collector must be secured to the twin-pipe heat exchanger with a clip. Fit the sensor near the hydraulic connections.! Please note Route the sensor lead so that it does not come into contact with the hot tubes. Route the lead through the slot in the thermal insulation. 48

49 Fitting the collector temperature sensor (cont.) x ! Please note The collectors may be damaged if the solar thermal system is not filled with heat transfer medium immediately after installation. Therefore, protect the collectors against solar irradiation by covering them up. 49

50 Installation Please note! Incorrect installation can lead to collector damage. Use only gunmetal or brass fittings and copper pipes for the installation. Never step on the collectors. Never solder on or near the collector. Position pipes so that complete ventilation is guaranteed. Install an air separator at an accessible point in the pipework (see the following diagram). Generally, copper lines in solar circuits are hard soldered or joined by press fittings. Soft solder could be weakened, particularly near the collectors, due to the max. temperatures that may occur there. Metal seal connections, locking ring fittings or Viessmann plug-in connections with double O-rings are the most suitable. If other seals such as flat gaskets are used, adequate glycol, pressure and temperature stability must be guaranteed by the manufacturer. Make all connections pressure and temperature-resistant (observe the maximum idle temperature of the collector). Never use: Teflon (inadequate glycol stability) Hemp connections (not sufficiently gas-tight) Equip systems to EN with an expansion vessel, safety valve and circulation pump. The expansion vessel must be approved in accordance with DIN The diaphragms and seals of the expansion vessel and safety valve must be suitable for the heat transfer medium. To calculate the pre-charge pressure, see the "Vitosol" service instructions. When operating without a Solar-Divicon, only use safety valves designed for 120 C, a maximum pressure of 6 bar, and which carry the "S" (Solar) designation. 50

51 Installation (cont.) P O A E B P E M D D C T F N L K G H A Collector B Solar-Divicon C Drip container D Expansion vessel E Stagnation heat sink F Shut-off valve G Filling H Manual solar fill pump K Fill valve (F, G, L) L Drain M Air separator N DHW cylinder O Solar control unit P Air vent valve Commissioning For commissioning the solar thermal system, see the "Vitosol" service instructions. 51