Installation Instructions. Vitosol 100. Vitosol 100 Type w 2.5 Flat collector for flat roofs and freestanding installation Part No.

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1 Installation Instructions Vitosol 100 Type w 2.5 Flat collector for flat roofs and freestanding installation Part No Vitosol 100 8/99

2 Safety instructions This hazard symbol precedes all important notes on safety. Please follow these safety instructions closely to prevent possible risk of injury to persons and damage to property. Safety regulations Please observe all relevant safety requirements (GB: British Standards code of practice) (see also the enclosed red sheet headed Important safety information ). In certain countries, solar collectors must be registered or issued with a permit in accordance with national regulations. The entire solar heating system should be installed in accordance with the accepted rules of technology (GB: British Standards codes of practice), observing all relevant accident prevention regulations. Please note: Please read these instructions carefully before commencing with installation and start-up. Failure to observe the installation, operating and service instructions could invalidate the guarantee. The installation instructions for Viessmann accessories (where included in the scope of supply) must be followed when installing the complete system (comprising Viessmann modular system components). We organise regular training courses for installers. Use suitable safety measures to prevent falls, falling objects and roof damage due to insufficient load bearing capacity, e.g. by means of scaffolding, ladders, cable ties etc. Observe the maximum load for the understructure of the building and the distance from the roof edge as required by DIN Work on the solar heating system Installation, maintenance and repairs must be carried out by a competent person (heating engineer/service contractor). Before work is undertaken on the equipment/heating system/solar heating system, the mains voltage must be switched off (e.g. at the separate fuse or mains electrical isolator switch) and measures taken to prevent it from being switched on again. Potential equalization/lightning protection of the solar heating system An electrically conductive connection of the pipework system of the solar circuit should be implemented in the lower part of the building in accordance with I.E.E. regulations. Connection of the collector system to a new or existing lightning protection facility or the provision of local potential equalization should only be carried out by competent personnel, taking into account the conditions applicable on site. 2

3 Index Page Safety instructions... 2 General information Notes on using these installation instructions... Product information... Notes on installation... Overview of system components... 5 Installation Mounting the collector support frames... 7 Freestanding installation on understructure... 8 Freestanding installation with weight inserts... 9 Mounting the collectors Hydraulic connections Mounting the connection kit... Appendix Installation... 1 After installation Check list Service document ring binder

4 General information Notes on using these installation instructions The following headings and symbols are used in these instructions: Safety instruction: Caution! Important: Please note: This denotes an instruction which must be observed to safeguard persons and property. This denotes actions which must be avoided in the interests of the safety of persons and property. This denotes information which is important for ensuring the performance of the equipment. This denotes useful tips and important supplementary information. This indicates a reference to other instructions which must be observed. Product information Vitosol 100, Type w 2.5 Flat collector with 2.5 m 2 absorber surface area. Max. shutdown temperature ºC Max. operating pressure... 6 bar Type approval code Notes on installation The collectors must be securely mounted so that the mountings can reliably withstand gale-force winds. Although the glass covers are hailproof, we advise users to include storm cover in their buildings insurance as our materials warranty does not cover storm damage. The collectors should, as far as possible, be oriented towards the south. The collectors should be mounted level so that complete venting is assured. An air vent valve should be installed at the highest point of the system. Fill the solar heating system only with Viessmann heat transfer medium Tyfocor-HTL. Tyfocor-HTL is supplied in liquid form and must not be mixed. The piping inside the building should be insulated in accordance with the heating system regulations.

5 General information Overview of system components Collector Fig. 1 Overview of system components 5

6 General information Overview of system components (continued) Number of collectors Part Collector support frame 1, comprising: 6 Quantity Mounting plate Mounting plate Mounting plate Clamping bolt Washer 10 mm dia. Hexagon nut M 10 Support rail 2 (only for flat roofs with gravel filling) Hexagon screw M without support rail with support rail Washer 10 mm dia, without support rail with support rail Hexagon nut M 10 without support rail with support rail Collector support frame 2, comprising: Mounting plate Mounting plate Mounting plate Clamping bolt Washer 10 mm dia Hexagon nut M Support rail (only for flat roofs with gravel filling) Hexagon screw M without support rail with support rail Washer 10 mm dia, without support rail with support rail Hexagon nut M 10 without support rail with support rail Accessories for one collector panel (up to 6 collectors) Connecting pipe Connection kit, comprising: Connection pipe Stopper Profile clip Clamping ring connection, 22 mm dia Clamping ring connection elbow, 90º, mm dia. Accessories for one solar heating system Sensor well kit, comprising: Clamping ring connection (tee), mm dia. Sensor well Strain relief connection

7 Installation Mounting the collector support frames 1. Position the mounting plates, or,. 2. Shorten the mounting plates or according to the required angle of inclination. Angle of inclination 25º 30º 35º 0º 5º Length of rail 510 mm 580 mm 652 mm 72 mm 797 mm 3. Screw the mounting plates or to the plates or with hexagon screw, washer and hexagon nut.. Tighten all screws. Fig. 2 Shortening and assembly the mounting plates 7

8 Installation Freestanding installation on understructure Understructure Support frame arrangement END/END END/ERW ERW/END ERW/ERW Dimension X mm END ERW End support frame Extension support frame Number of collectors Dimension Y mm Fig. 3 Assembling the collector support frames 1. Mount the understructure (to be provided on site), e.g. U-channels at right angles to and level with the installation orientation of the collectors according to the dimensions in Fig Assemble, align and bolt the collector support frames to the understructure according to the dimensions in Fig. 3 use the mounting plates or as a template for drilling (provide screws on site). Go to Mounting the collectors on page 11. 8

9 Installation Freestanding installation with weight inserts Weight inserts Support frame arrangement END/END END/ERW ERW/END ERW/ERW Dimension X mm END ERW End support frame Extension support frame Number of collectors Fig. Assembling the collector support frames Dimension Y mm Clear the surface on which it is intended to install the collectors so that it is free from gravel etc. and place protective matting on the area cleared. 2. Position concrete slabs on the protective matting. 3. Assemble, align and bolt the collector support frames to the concrete slabs according to the dimensions in Fig. ; use the mounting plates or as a template for drilling (provide screws on site).. Screw the rear support rails or with the fastening screws of the collector support frames. Screw the front support rails or to the mounting plates or with hexagon screw, washer and hexagon nut. 5. Place the weights in position (see tableonpage10). Go to Mounting the collectors on page 11. 9

10 Installation Freestanding installation (continued) with weight inserts Installation height above ground level Weight required per collector Zone Height above mean sea level m Snow load S 0 N/m 2 m kg up to 8 92 Snow load on understructure kg to to

11 Installation Mounting the collectors Important: Install the collector panel so that the nameplate side of the first and last collector is on the outside (note sticker). If only one collector is to be installed, connect the piping opposite the nameplate side. The connecting pipes must not be damaged or dirty. All plug-in connections (O ring seal) on the collectors may only be lubricated with the special lubricating grease supplied in the connection kit. The connections must not come into contact with conventional oils, greases or other lubricants. Collector connection Spacer fold Sticker Fig. 5 Mounting the collectors 1. Place the first collector on the collector support frames and push up against the spacer fold. 2. Screw the collector to the mounting plates / with clamping bolts, washer and hexagon nut. 3. Insert the connecting pipes as far as they will go into the collector connections.. Position the next collector and carefully push it up against the first collector so that the connecting pipes can be inserted fully into the collector connections (collector must butt up against the spacer fold). 5. Screw on collector as described under point Mount the rest of the collectors as described under points 3 to Remove the sticker from the glass cover. 11

12 Hydraulic connections Mounting the connection kit Flow connection (top); to domestic hot water cylinder Return connection (bottom); to collector Flared coupling of collector connection Nameplate Fig. 6 Mounting the connection kit and the collector temperature sensor

13 Hydraulic connections Mounting the connection kit (continued) Important: The procedure for installing the clamping ring connection is as follows: Ensure that all pipe ends are rectangular and free from burring. Push the union nut and the clamping ring onto the pipes and moisten thread with a little oil. Push the pipe as far as it will go into the clamping ring connection. First tighten the union nut by hand, then tighten by a 3 / turn with an open-end wrench. Do not use annealed copper pipes on clamping ring connections. 1. Fully insert the connection pipes on the side of the collector panel on which the hydraulic connections are to be installed. 2. Fully insert the stopper on the other side of the collector panel. 3. Screw the profile clips onto the flared couplings, stopper and pipes to secure the stopper and connection pipes.. Mount the clamping ring connection or on the return connection. 6. Screw the sensor well into the tee ; apply countergrip on tee. 7. Screw the strain relief connection into the sensor well. 8. Fully insert the collector temperature sensor into the sensor well and secure with the strain relief connection. 9. Make the connection between the collector panel and the piping of the solar circuit. 5. Mount the clamping ring connection (tee) on the flow connection. 13

14 Appendix Installation Please refer to the technical guide Solar heating systems for supplementary notes on installation examples and system types. Important! For installation purposes, use red bronze fittings, brass fittings and copper piping. Do not use galvanized pipes, galvanized fittings or graphitized gaskets. Hemp should be used only in conjunction with pressure and temperature-resistant sealants *1. The components used must be resistant to the heat transfer medium (see Service Instructions for composition). The insulation *2 of external piping must be resistant to temperature, UV radiation and to destruction by birds (e.g. through the use of metal sheathing). Caution! Do not stand on the collectors! Do not carry out soldering work at or near the collector! At least one air vent valve should be installed at the highest point of the system. Install an air separator at an accessible point in the piping (e.g. in the flow of the solar circuit, upstream of the inlet to the indirect coil of the domestic hot water cylinder). The system should be equipped with an expansion vessel, safety valve and circulation pump. Use only a diaphragm expansion vessel that is suitable for the application as an expansion vessel. The expansion vessel must be approved to DIN 807 and must be connected via a heat insulating loop. The diaphragms and seals of the expansion vessel and safety valve must be suitable for the heat transfer medium. Please refer to the Service Instructions in order to calculate the inlet pressure of the diaphragm expansion vessel. Fill the solar heating system with Viessmann heat transfer medium Tyfocor-HTL. The blow-off and discharge pipes must be run to an open container capable of accommodating the total capacity of the collectors. The Solar-Divicon is equipped with a safety valve designed for 0 ºC and max. 6 bar. For operation without the Solar-Divicon, use only safety valves rated for 0 ºC and max. 6 bar with a part designation containing the code letters D/G/H, F or H. On smaller solar heating systems with a collector surface area up to 5m 2, Vitocell 300 cylinders with a peripheral heating system and a capacity of 200 litres may also be used as solar storage cylinders for preheating purposes. In this case, the Solar-Divicon must be equipped with a 3 bar safety valve (accessory). The static head should be 7 metres max., the overpressure in the collectors approx. 1 bar and the inlet pressure of the diaphragm expansion vessel approx. 1.5 bar. In such cases, we recommend an expansion vessel with a capacity of 33 litres. To guarantee the satisfactory operation of the solar heating system, install the pipes so that complete venting is assured. The connecting lines must be pressure and temperature-resistant (observe the max. shutdown temperature of the collector). *1 E.g. Viscotex solar paste supplied by Locher, CH-950 Altstätten. *2 E.g. HT/Armaflex (temperature resistant up to 175 ºC) supplied by Armstrong Insulation Products GmbH, Robert-Bosch-Str. 10, *2 D-8153 Münster. 1

15 Appendix Installation (continued) VL Flow RL Return Fig. 7 Installation example Collector Solar-Divicon Collecting vessel Expansion vessel Solar manual filling pump Filling valve Shut-off valve Drain Filling device (,, ) Domestic hot water cylinder Air separator Solar control unit Air vent valve Heat insulating loop To avoid recirculation, we recommend the provision of a heat insulating loop or the installation of an additional check valve in the flow of the solar circuit. 15

16 Appendix Installation (continued) Nameplate side Meander-shaped copper pipe Flow Air vent valve Piping side Return Fig. 8 Installation of the collectors, single row Carry out the installation of the piping in reverse return. Nameplate side Meander-shaped copper pipe Flow Air vent valve Piping side Return Fig. 9 Installation of the collectors, double row 16

17 Appendix After installation... Check list Has the solar circuit been installed in accordance with the circuit diagram and all relevant standards? Have the flow and return connections been carried out? Have the electrical connections been carried out correctly? Have the sensors been installed correctly? Have air vent valves been installed at the highest points of the system and are they open? Important: It is absolutely essential to close the air vent valves again when the system has been started up. Have all screws, screwed pipe connections and covers been securely tightened? Has the domestic hot water cylinder been filled with water? Does the maximum capacity of the expansion vessel correspond to the value stated in the Technical Guide? Has the inlet pressure of the expansion vessel been adjusted to the system pressure? Service document ring binder 1. File all parts lists, operating and service instructions in the Operating and service document ring binder. 2. Keep the ring binder in its protective box (accessory). 17

18 Bauartzulassung 18

19 Bauartzulassung (Fortsetzung) 19

20 Printed on environmentally friendly, chlorine-free bleached paper Viessmann Werke GmbH & Co D Allendorf Tel: (0 6 52) 70-0 Fax: (0 6 52) Internet: Viessmann Limited Hortonwood 32 Telford, Shropshire TF1 EU Tel.: (01952) Fax: (01952) Subject to technical modifications! 20

VIESMANN. Installation instructions VITOSOL-F. for contractors

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