VIESMANN. Installation instructions VITOSOL 300-T. for contractors. Vitosol 300-T Type SP3A Vacuum tube collector based on the heat pipe principle

Transcription

1 Installation instructions for contractors VIESMANN Vitosol 300-T Type SP3A Vacuum tube collector based on the heat pipe principle VITOSOL 300-T 9/2009 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. 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. 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 and SWKI 2

3 Index Installation sequence Vertical rooftop installation... 4 Component overview... 4 Fitting roof hooks or mounting brackets... 6 Fitting mounting rails Fitting the header casing Installation on flat roofs Component overview Determining the collector row distance z Adjusting the angle of inclination α Fitting the collector supports Fitting the mounting rails and header casing Making the hydraulic connections Connecting the header casing Fitting the connection set Fitting the vacuum tubes and collector temperature sensor Installation Commissioning and adjustment

4 Vertical rooftop installation Component overview qp qq qw qe qr qt qz qu /2149 qi qo wp Roof tiles 1 Timber 38 x 58 x 2140 mm 30 x 100 x 2140 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 30 mm Corrugated sheet roof 7 Roof hook for corrugated roofing sheet, profiles 5 and 6 8 Roof hook for corrugated roofing sheet, profile 8 4

5 Vertical rooftop installation (cont.) Plain tiles 9 Roof hook 4 Zinc-plated countersunk chipboard screw (Spax-s) 5 x 30 mm Fixing without roof hooks qp Mounting bracket 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 Retaining bracket qi Header casing qo Vacuum tube wp Retaining rubber Accessories for one collector array wq ww we wr wt wz wu wi wo ep eq ew wq Connection pipe ww Thermal insulation Connection set: we Connecting pipe (short) wr Connecting pipe (long) wt Locking ring fitting (elbow 90 ), 7 22 mm wz Support sleeve wu U-pipe wi Thermal insulation cap wo Fixing screws ep Strain relief fitting eq Sensor retainer ew Installation pipe 5

6 Vertical rooftop installation (cont.) Fitting roof hooks or mounting brackets Overview Installation with roof hooks 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 roof tiles) G Timber, 30 x 100 mm (only for roof tiles) H Retaining bracket K Header casing 6

7 Vertical rooftop installation (cont.) Overview Installation with mounting brackets (e.g. on sheet steel roofs) Use on-site fixing elements to secure the brackets (for example, standing seams). 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 Retaining bracket G Header casing 7

8 Vertical rooftop installation (cont.) For installations without roof hooks, mounting brackets are used in place of the roof hooks. qt qu a 2 a d b e c c f qz Note Centre the mounting rails; maintain dimension f = 81 mm. 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

9 Vertical rooftop installation (cont.) Fitting the mounting brackets Secure the mounting brackets to the substructure on site in accordance with the dimensions given in the illustrations on pages 7 and 8. Fitting roof hooks for roof tiles x x Push up the roof tiles in accordance with the dimensions shown in the illustration on page Secure the timber to the joists at the head of the exposed rows of tiles in accordance with the dimensions shown in the illustration on page 6. 9

10 Vertical rooftop installation (cont.) 3. Hook the roof hooks into the timber in accordance with the dimensions shown in the illustration on page Remove the drip tabs and protrusions from the roof tiles where the roof hooks are to be fitted. 5. Secure the roof hooks and position the roof tiles. Continue with "Mounting rail installation" on page Cover the roof. Continue with "Mounting rail installation" on page 11. Fitting roof hooks for corrugated sheet roofs 3. Fitting roof hooks for slate roof , Mark the position of the roof hooks in accordance with the dimensions shown in the illustration on pages 6 and Mark the position of the roof hooks in accordance with the dimensions shown in the illustration on pages 6 and Remove slates from the roof at the hook contact points. 3. Secure the roof hooks to the roof surface. Fit commercially available lead flashing to protect against the ingress of moisture. 2. Position each roof hook at the level of a batten onto the ridge of the roofing sheet and, through the hole in the roof hook, drill a further hole into the apex of the corrugation. 3. Secure each roof hook with screw 7 8 mm and a sealing washer (onsite provision) to the battens. Continue with "Mounting rail installation" on page

11 Vertical rooftop installation (cont.) Fitting roof hooks for plain tile roofs Mark the position of the roof hooks in accordance with the dimensions shown in the illustration on pages 6 and Remove tiles from the roof at the hook contact points Hook the roof hooks onto the battens and position and align on top of the tile below. 4. Secure the roof hooks to the battens Cover the roof; trim tiles to suit with an angle grinder; trim approx. 30 mm off the tiles. Fitting mounting rails Turn the tee bolts 90 for all installation steps. 11

12 Vertical rooftop installation (cont.) Secure the mounting rails to the roof hooks or mounting brackets; align vertically and horizontally ,5 A Roof hooks or mounting brackets 2. Align and fix the retaining plates to the mounting rails

13 Vertical rooftop installation (cont.) qqqz qq qz qu qt qz qu qt 4. f qr qe qq qw 90 qq qz qq 3. 4x Note Centre the mounting rails; maintain dimension f = 81 mm. 3. Fit clamping brackets onto the mounting rails; do not tighten the bolts yet. 4. Click the mounting rails with tube holders into the clamping brackets; align and fasten. Note Tube holders on opposite rails must be aligned. 13

14 Vertical rooftop installation (cont.) Fitting the header casing Turn the tee bolts 90 for all installation steps. qr qe qq qw qi qt qz qu qi 1. Position the header casing onto the mounting rails and click into the retaining brackets. 2. Align the header casing. 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. 3. Tighten the header casing with the clamping brackets. 4. Where several collectors are installed side-by-side, continue with "Connecting the header casing" on page 22, otherwise continue with "Fitting the connection set" on page

15 Installation on flat roofs Component overview A 50 Ø qz 1439/2149 qi qo wp A Collector supports for angles of inclination α 25 to 50, pre-assembled with screws, washers, nuts and clamping brackets 15

16 Installation on flat roofs (cont.) 1 Collector support 2 Base rail 3 Adjustable support, lower part 4 Adjustable support, upper part 5 Cross brace 6 Hexagon screw 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 Accessories for one collector array wq ww we wr wt wz wu wi wo ep eq ew wq Connection pipe ww Thermal insulation Connection set: we Connecting pipe (short) wr Connecting pipe (long) wt Locking ring fitting (elbow 90 ), 7 22 mm wz Support sleeve wu U-pipe wi Thermal insulation cap wo Fixing screws ep Strain relief fitting eq Sensor retainer ew Installation pipe Determining the collector row distance z When installing several collectors in series, maintain distance z (see page 19). Example: Würzburg is located at approx. latitude 50 north. 16

17 Installation on flat roofs (cont.) 1. Determine the angle of the sun β. In Germany, this angle (subject to latitude) lies between 12 (Flensburg) and 20 (Freiburg). Angle of the sun: latitude (23.5 can be assumed as a constant value) = 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 Adjusting the angle of inclination α Position the collector array as far south as possible; linear tube axis aligned eastwest. 17

18 Installation on flat roofs (cont.) x 1. Secure the adjustable support with the base rail. 2. Secure the upper and lower adjustable supports in accordance with the required angle of inclination (see page 15). Fitting the collector supports Information regarding ballast and max. load on the substructure Calculation in accordance with DIN /1986 and DIN /1975. Two foot supports A and two foot supports B are required for each collector (see the following diagram). For the calculation, the Viessmann calculation program "SOLSTAT" is available at 18

19 Installation on flat roofs (cont.) A 3. 8x z B a b Note To calculate dimension z, see page 16. 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 /

20 Installation on flat roofs (cont.) 1. Observe the max. load and distance from the edge of the roof for the onsite substructure in accordance with DIN Secure the base rails (use as drilling template) to the foot supports. 2. Clear the position for installation, for example of gravel, lay out the protective mats and position foot supports A and B in accordance with the dimensions on page Ø Secure the cross brace diagonally to the inside of the adjustable supports. 5. Secure the cross brace diagonally to the outside of the adjustable supports. 20

21 Installation on flat roofs (cont.) 6. Drill 8.5 mm 7 holes in the cross braces and join together. Fitting the mounting rails and header casing 2. 4x qi qz qz 1. 4x 1. Click and fasten the mounting rails into clamping brackets. 2. Click the header casing into the clamping brackets. 21

22 192 Installation on flat roofs (cont.) 3. Align the header casing. 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. 5. Where several collectors are installed side-by-side, continue with "Connecting the header casing" on page 22, otherwise continue with "Fitting the connection set" on page Tighten all screws. Making the hydraulic connections Connecting the header casing qi ww wqaqi A Groove for the retaining clip 22

23 Making the hydraulic connections (cont.)! Please note Connection pipes should not show any signs of damage. Lubricate all O-ring seals only with the special grease provided. 1. Remove the retaining clips. 2. Insert the connecting pipes. 3. Push the next connecting chamber carefully against the first and insert the connecting pipes. 4. Secure the connecting pipes with retaining clips; click clips into the groove in the connecting pipes through the holes in the collector connectors. 5. Align and secure the connecting chamber (see page 21). 6. Cut the thermal insulation lengthways, fit it and join its cut faces with adhesive. Fitting the connection set Observe the following when installing the locking ring fitting: 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. 23

24 Making the hydraulic connections (cont.) VL RL A Groove for the retaining clip VL Flow (short connecting pipe) 1. Remove the retaining clips. 2. Push the connecting pipes in as far as possible. 3. Push the U-pipe in as far as possible. 4. Secure the connecting pipes and U- pipe with the retaining clips; click clips into the groove in the connecting pipes through the holes in the collector connectors. RL Return (long connecting pipe) 6. Insert the support sleeves into the connecting pipes of the solar circuit. Make the connection between the collector array and pipework of the solar heating circuit. 7. Check the system pressure and test for leaks. "Vitosol" service instructions. 8. Fit the thermal insulation cap. 5. Thread the locking ring fittings onto the connecting pipe. 24

25 Making the hydraulic connections (cont.) Fitting the vacuum tubes and collector temperature sensor Danger The vacuum tubes can become hot and break if insufficient care is taken. This can lead to burns and injuries. Wear gloves and safety goggles qi 2. 2x 01. Pull the gasket only from the casing lid groove. 03. Flip the lid back. 02. Pull out pin as far as possible. 25

26 Making the hydraulic connections (cont.) 8. B wp ew 8. wp qo A C qz qz A Twin-pipe heat exchanger B Condenser 04. Note When installing the tubes, make sure that the locking pins for each tube are opened and closed separately. Turn the locking pin together with the installation pipe 90. C Template 05. Click the tubes into the tube holders on the mounting rails and insert the condenser into the twin-pipe heat exchanger. Observe the following: 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. The condenser must be positioned centrally inside the heat exchanger retainer. 26

27 Making the hydraulic connections (cont.) 06.! Please note Never align (turn) the tubes in their locked state. This would lead to tube damage. 07. Move the locking pin. 08. Secure the tubes with the retaining rubber. For roofs deviating from due south, adjust the angle of inclination of the absorber using the template provided. max

28 Making the hydraulic connections (cont.) 10. BA A Twin-pipe heat exchanger 09. The first and last tubes of a collector must be secured to the twin-pipe heat exchanger with a clip. 10. Fit the sensor retainer inside the connection casing near the hydraulic connections. 11. Cut out aperture in the connection casing. 12. Insert the collector temperature sensor into the sensor retainer. 28 D Clip 13. Route the lead inside the slot of the thermal insulation so that it does not come into contact with the hot tubes and pipes. 14. Secure the sensor with a PG thread on the chamber. 15. Close the lid, turn the locking pin inwards and push the gasket into place.

29 Installation! Please note Incorrect installation can lead to collector damage. Use only gunmetal or brass fittings and copper pipes for the installation. Use hemp only in conjunction with pressure and temperatureresistant sealants (e.g. Viscotex Solarpaste from Locher, CH-9450 Altstätten, Switzerland). Never step on the collectors. Never solder near or on the collector. 1. Position pipes so that complete ventilation is guaranteed. Install an air separator at an accessible point in the pipework (see the following diagram). 2. Equip systems to EN with an expansion vessel, safety valve and circulation pump. 3. The expansion vessel must be approved to DIN 4807 [or local regulations] and must be installed with a thermal insulating loop. 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. 4. 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. 5. Make all connections pressure and temperature-resistant (observe the maximum idle temperature of the collector). 29

30 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 facility 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 and adjustment For commissioning the solar thermal system, see the "Vitosol" service instructions. 30

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32 Printed on environmentally friendly, chlorine-free bleached paper 32 Viessmann Werke GmbH&Co KG D Allendorf Telephone: Fax: Viessmann Limited Hortonwood 30, Telford Shropshire, TF1 7YP, GB Telephone: Fax: Subject to technical modifications.