Installation instructions for heating engineers VIESMANN Vitosol 200 Type SD2 Direct flow vacuum tube collector VITOSOL 200 5/2005 Dispose after installation.
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 gas appliances must only be carried out by a qualified gas engineer. & 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, & thecodeofpracticeofrelevant trade associations, & all current safety regulations as defined by DIN, EN, DVGW, TRGI, TRF, VDE and all locally applicable standards. Workingontheheatingsystem & Isolate the system from the power supply and check that it is no longer 'live', e.g. by removing a separate fuse or by means of a mains isolator. & Safeguard the system against unauthorised reconnection. & When using gas as fuel, also close the main gas shut-off valve and safeguard against unauthorised reopening. 2
Index Preparing the installation Earthing and lightning protection of the solar heating system... 4 Installation steps Horizontal rooftop installation... 5 & Component summary... 5 & Fitting the roof hooks or mounting brackets... 7 & Fitting mounting rails... 13 & Fitting the connecting chamber... 17 Vertical rooftop installation... 19 & Component summary... 19 & Fitting roof hooks or mounting brackets... 21 & Fitting the mounting rails... 27 & Fitting the connecting chamber... 30 Installation on flat roofs... 31 & Component summary... 31 & Fitting the mounting rails... 33 & Fitting the connecting chamber... 36 Installation on walls... 37 & Component summary... 37 & Fitting the mounting rails... 38 & Fitting the connecting chamber... 42 Water connections... 45 & Installing the connecting chamber... 45 & Fitting the vacuum tubes... 46 & Installing the connection set and collector temperature sensor... 48 Installation... 51 Commissioning and adjustment... 53 3
Earthing and lightning protection of the solar heating system Install an electrical conductor on the pipework of the solar circuit in the lower part of the building in compliance with VDE or local regulations. The connection of the collector system to a new or existing lightning protection system or the provision of local earthing must only be carried out by authorised trained personnel, who must take into account the site conditions. 4
Horizontal rooftop installation Component summary 5
Horizontal rooftop installation (cont.) Roof tile cover 1 Timber & 38 x 58 x 2430 mm & 30 x 100 x 2430 mm 2 Roof hooks 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 cover 5 Roof hooks 6 Zinc-plated countersunk chipboard screw (Spax-s) 6 x 30 mm Corrugated sheet cover 7 Roof hooks for corrugated roofing sheet profile 5 and 6 8 Roof hooks for corrugated roofing sheet profile 8 Plain tile cover 9 Roof hooks 4 Zinc-plated countersunk chipboard screw (Spax-s) 5 x 30 mm Fixing kit without roof hooks qp Mounting bracket For all forms of roof and roofing qq Clamping bracket qw T-slot bolt qe Washer qr Hexagon nit qt Mounting rail qz Mounting rail with tube holder qu Retaining plate qi Locking profile qo Spacer wp Connecting chamber wq Vacuum tube ww Retaining rubber Accessories for one collector array we Connecting pipe wr Retaining clip Connection set: wt Connecting pipe (short) wz Connecting pipe (long) wu Profile clip wi Locking ring fitting (elbow 90 ), 7 22 mm wo Support sleeve ep U-pipe eq Thermal insulation cap ew Fixing screws Accessories for a solar heating system wo Support sleeve ee Lockingringfitting(tee), 7 22 mm er Sensor well et Strain relief fitting ez Thermal insulation 6
Horizontal rooftop installation (cont.) Fitting the roof hooks or mounting brackets Overview Installation with roof hooks Dimension x according to the width of thetilehead.dimensionsatoesee tableonpage9. A Spacer B Connecting chamber C Mounting bracket D Mounting rail with tube holder E Mounting rail F Timber, 38 x 100 mm (only for roof tiles) G Timber, 30 x 58 mm (only for roof tiles) H Roof hooks 7
Horizontal rooftop installation (cont.) Overview Installation with mounting brackets (e.g. on sheet steel roofs) A Spacer B Connecting chamber C Mounting bracket D Mounting rail with tube holder H Mounting rail 8
Horizontal rooftop installation (cont.) Combination a mm b mm c mm d mm e mm (tubes) 20 1439 850 30 2149 1260 20/20 1439 1439 850 1465 2315 20/30 1439 2149 850 1820 2875 30/20 2149 1439 1260 1820 2875 30/30 2149 2149 1260 2175 3435 Secure the mounting brackets to the substructure in accordance with the dimensions given in the illustration on page 8 and 10. 9
Horizontal rooftop installation (cont.) For installations without roof hooks, mounting brackets are used in place of roof hooks. Centre the mounting rails, maintaining dimension f = 26 mm. 10
Horizontal rooftop installation (cont.) Fitting roof hooks for roof tile cover 1. Push up the roof tiles in accordance with the dimensions shown in the illustrations on page 7 and 10. 2. Secure the timber to the joists at the head of the exposed rows of tilesinaccordancewiththedimensions shown in the illustration on page 7. 3. Hook the roof hooks into the timber in accordance with the dimensions shownintheillustrationsonpage7 and 10. 4. Remove the drip tabs and protrusions from the roof tiles in the roof hook area. 5. Secure the roof hooks and position the roof tiles. Continue with "Mounting rail installation" on page 13. 11
Horizontal rooftop installation (cont.) Fitting roof hooks for slate cover Fitting roof hooks for corrugated sheet cover 1. Mark the position of the roof hooks in accordance with the dimensions shownintheillustrationsonpage7 and 10. 2. Remove slates from the roof hook area. 3. Secure the roof hooks on the roof surface. Fit commercially available lead flashing to protect against ingress of moisture. 4. Cover the roof. Continue with "Mounting rail installation" on page 13. 1. Mark the position of the roof hooks in accordance with the dimensions shownintheillustrationsonpage7 and 10. 2. Position the roof hooks at the level ofabattenontotheridgeofthe roofing sheet and, through the hole in the roof hook, drill a further hole into the apex of the corrugation. 3. Secure the roof hooks with screws 7 8 mm and sealing washers (onsite provision) to the battens. Continue with "Mounting rail installation" on page 13. 12
Horizontal rooftop installation (cont.) Fitting roof hooks for plain tile cover 1. Mark the position of the roof hooks in accordance with the dimensions shownintheillustrationsonpage7 and 10. 2. Remove tiles from the roof hook area. 3. 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. 5. Cover the roof; trim tiles to suit with an angle grinder; trim approx. 30 mm off the tiles. Fitting mounting rails Turn T-slot bolts 90 for all installation steps. 13
Horizontal rooftop installation (cont.) 1. Secure the mounting rails to the roof hooks or mounting brackets; align vertically and horizontally. A Roof hooks or mounting brackets 14
Horizontal rooftop installation (cont.) 2. Secure the retaining plates to the mounting rails. 3. Secure the mounting brackets to the mounting rails. 15
Horizontal rooftop installation (cont.) 4. Align the mounting rails with the tube holders and secure to the mounting bracket. Note Tube holders must be aligned laterally to the opposite rail. 5. Screw the mounting bracket to the other side of the mounting rail. 16 6. Secure the locking profile at the bottom of the mounting rails. 7. If a second collector is fitted above the first, fit a spacer. Proceed as per points 2 to 5.
Horizontal rooftop installation (cont.) Fitting the connecting chamber Turn T-slot bolts 90 for all installation steps. 1. Position the connecting chamber onto the mounting rails and click it into the retaining plates. 2. Align the connecting chambers. Note The tube holders on the mounting rails must be in line with those in the connecting chambers; where necessary, align with a piece of string. 17
Horizontal rooftop installation (cont.) 3. Mark the fixing points at the back of the connecting chamber. Use centering groove as a template. 4. Drill 7 9 mm holes. 5. Tighten the connecting chamber. 6. Where several collectors are installed above each other, continue with "Installing the connecting chamber" on page 45, otherwise continue with "Fitting the vacuum tubes" on page 46. A Centering groove 18
Vertical rooftop installation Component summary 19
Vertical rooftop installation (cont.) Roof tile cover 1 Timber & 38 x 58 x 2430 mm & 30 x 100 x 2430 mm 2 Roof hooks 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 cover 5 Roof hooks 6 Zinc-plated countersunk chipboard screw (Spax-s) 6 x 30 mm Corrugated sheet cover 7 Roof hooks for corrugated roofing sheet profile 5 and 6 8 Roof hooks for corrugated roofing sheet profile 8 Plain tile cover 9 Roof hooks 4 Zinc-plated countersunk chipboard screw (Spax-s) 5 x 30 mm Fixing kit without roof hooks qp Mounting bracket For all forms of roof and roofing qq Clamping bracket qw T-slot bolt qe Washer qr Hexagon nut qt Mounting rail qz Mounting rail with tube holder qu Retaining plate wp Connecting chamber wq Vacuum tube ww Retaining rubber Accessories for one collector array we Connecting pipe wr Retaining clip Connection set: wt Connecting pipe (short) wz Connecting pipe (long) wu Profile clip wi Locking ring fitting (elbow 90 ), 7 22 mm wo Support sleeve ep U-pipe eq Thermal insulation cap ew Fixing screws Accessories for a solar heating system wo Support sleeve ee Lockingringfitting(tee), 7 22 mm er Sensor well et Strain relief fitting ez Thermal insulation 20
Vertical rooftop installation (cont.) Fitting roof hooks or mounting brackets Overview Installation with roof hooks Dimension x according to the width of thetilehead. A Vacuum tube B Clamping bracket C Mounting rail with tube holder D Mounting rail E Roof hooks F Timber, 38 x 58 mm (only for roof tiles) G Timber, 30 x 100 mm (only for roof tiles) H Retaining plate K Connecting chamber 21
Vertical rooftop installation (cont.) Overview Installation with mounting brackets (e.g. on sheet steel roofs) A Vacuum tube B Clamping bracket C Mounting rail with tube holder D Mounting bracket E Mounting rail F Retaining plate G Connecting chamber 22
Vertical rooftop installation (cont.) Secure the mounting brackets to the substructure in accordance with the dimensions given in the illustrations on page 22 and 24. 23
Vertical rooftop installation (cont.) For installations without roof hooks, mounting brackets are used in place of roof hooks. Centre the mounting rails, maintaining dimension f = 26 mm. Combination a mm b mm c mm d mm e mm (tubes) 20 850 30 1260 20/20 850 1465 850 2315 615 20/30 850 1820 1260 2875 765 30/30 1260 2175 1260 3435 915 24
Vertical rooftop installation (cont.) Fitting roof hooks for roof tile cover 1. Push up the roof tiles in accordance with the dimensions shown in the illustration on page 21. 2. Secure the timber to the joists at the head of the exposed rows of tilesinaccordancewiththedimensions shown in the illustration on page 21. 3. Hook the roof hooks into the timber in accordance with the dimensions shownintheillustrationon page 24. 4. Remove the drip tabs and protrusions from the roof tiles in roof hook area. 5. Secure the roof hooks and position the roof tiles. Continue with "Mounting rail installation" on page 27. 25
Vertical rooftop installation (cont.) Fitting roof hooks for slate cover Fitting roof hooks for corrugated sheet cover 1. Markthepositionofeachroofhook in accordance with the dimensions shownintheillustrationon page 24. 2. Remove slates from the roof hook area. 3. Secure the roof hooks to the roof surface. Fit commercially available lead flashing to protect against ingress of moisture. 4. Cover the roof. Continue with "Mounting rail installation" on page 27. 1. Markthepositionofeachroofhook in accordance with the dimensions shownintheillustrationon page 24. 2. Position each roof hook at the level ofabattenontotheridgeofthe roofing sheet and, through the hole in the roof hook, drill a further hole into the apex of the corrugation. 3. Secure the roof hook with a screw 7 (8mm)andasealingwasher (on-site provision) to the batten. Continue with "Mounting rail installation" on page 27. 26
Vertical rooftop installation (cont.) Fitting roof hooks for plain tile cover 1. Markthepositionofeachroofhook in accordance with the dimensions shownintheillustrationon page 24. 2. Remove tiles from the roof hook area. 3. 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. 5. Cover the roof; trim tiles to suit with an angle grinder; trim approx. 30 mm off the tiles. Fitting the mounting rails Turn T-slot bolts 90 for all installation steps. 27
Vertical rooftop installation (cont.) 1. Secure the mounting rails to the roof hooks or mounting brackets; align vertically and horizontally. A Roof hooks or mounting brackets 2. Secure the retaining plates to the mounting rails. 28
Vertical rooftop installation (cont.) Centre the mounting rails, maintaining dimension f = 26 mm. 3. Fit clamping brackets onto the mounting rails; do not yet tighten the bolts. 4. Click mounting rails with tube holders into the clamping brackets, align and fasten. Note Tube holders must be aligned laterally to the opposite rail. 29
Vertical rooftop installation (cont.) Fitting the connecting chamber Turn T-slot bolts 90 for all installation steps. 1. Position the connecting chamber onto the mounting rails and click it into the retaining plates. 2. Align the connecting chambers. Note The tube holders on the mounting rails must be in line with those in the connecting chambers; where necessary, align with a piece of string. 3. Tighten the mounting rails with the clamping brackets. 4. Where several collectors are installed side-by-side, continue with "Installing the connecting chamber" on page 45, otherwise continue with "Fitting the vacuum tubes" on page 46. 30
Installation on flat roofs Component summary 31
Installation on flat roofs (cont.) 1 Rawl plug S10 2 Washer 3 Hexagon screw 8x70 mm qq Clamping bracket qw T-slot bolt qe Washer qr Hexagon nut qt Mounting rail qz Mounting rail with tube holder qu Retaining plate wp Connecting chamber wq Vacuum tube ww Retaining rubber Accessories for one collector array we Connecting pipe wr Retaining clip Connection set: wt Connecting pipe (short) wz Connecting pipe (long) wu Profile clip wi Locking ring fitting (elbow 90 ), 7 22 mm wo Support sleeve ep U-pipe eq Thermal insulation cap ew Fixing screws Accessories for a solar heating system wo Support sleeve ee Lockingringfitting(tee), 7 22 mm er Sensor well et Strain relief fitting ez Thermal insulation Protection against slippage Installation height above ground level m <8 8-20 20-100 Type SD2 2 m 2 3m 2 2m 2 3m 2 2m 2 3m 2 Foot A kg/piece 22 33 44 65 66 98 Foot B kg/piece 26 39 46 69 67 101 Protection against lifting Installation height above ground level m <8 8-20 20-100 Type SD2 2 m 2 3m 2 2m 2 3m 2 2m 2 3m 2 Foot A kg/piece 15 22 31 46 48 72 Foot B kg/piece 18 27 32 49 48 73 32
Installation on flat roofs (cont.) Fitting the mounting rails Turn T-slot bolts 90 for all installation steps. Position the collector array as far south as possible; longitudinal tube axis aligned east-west. Centre the mounting rails, maintaining dimension d = 26 mm. A Foot A B Foot B 33
Installation on flat roofs (cont.) Combination a mm b mm c mm (tubes) 20 850 30 1260 20/20 850 1465 2315 20/30 850 1820 2875 30/20 1260 1820 2875 30/30 1260 2175 3435 1. Position feet on a solid surface on protective mats. A Foot A 2. Fix clamping brackets to the feet A and B, do not yet tighten the bolts. B Foot B 3. Click the mounting rails into the clamping brackets, align and tighten. 34
Installation on flat roofs (cont.) 4. Secure the retaining plates to the mounting rails. 5. Fit the clamping brackets onto the mounting rails; do not yet tighten the bolts. 6. Click the mounting rails with tube holders into the clamping brackets, align and tighten. Note Tube holders must be aligned laterally to the opposite rail. 35
Installation on flat roofs (cont.) Fitting the connecting chamber Turn T-slot bolts 90 for all installation steps. 1. Position the connecting chamber onto the mounting rails and click it into the retaining plates. 2. Align the connecting chambers. 36 Note The tube holders on the mounting rails must be in line with those in the connecting chambers; where necessary, align with a piece of string. 3. Tighten the connecting chamber with the clamping brackets. 4. Where several collectors are installed side-by-side, continue with "Installing the connecting chamber" on page 45, otherwise continue with "Fitting the vacuum tubes" on page 46.
Installation on walls Component summary 37
Installation on walls (cont.) 1 Rawl plug S10 2 Washer 3 Hexagon screw 8x70 mm qp Mounting bracket qw T-slot bolt qe Washer qr Hexagon nut qt Mounting rail qz Mounting rail with tube holder qu Retaining plate qi Locking profile wp Connecting chamber wq Vacuum tube ww Retaining rubber Accessories for one collector array we Connecting pipe wr Retaining clip Connection set: wt Connecting pipe (short) wz Connecting pipe (long) wu Profile clip wi Locking ring fitting (elbow 90 ), 7 22 mm wo Support sleeve ep U-pipe eq Thermal insulation cap ew Fixing screws Accessories for a solar heating system wo Support sleeve ee Lockingringfitting(tee), 7 22 mm er Sensor well et Strain relief fitting ez Thermal insulation Fitting the mounting rails Turn T-slot bolts 90 for all installation steps. 38
Installation on walls (cont.) Centre the mounting rails, maintaining dimension d = 26 mm. Combination a mm b mm c mm (tubes) 20 850 30 1260 20/20 850 1465 2315 20/30 850 1820 2875 30/20 1260 1820 2875 30/30 1260 2175 3435 39
Installation on walls (cont.) 1. Fix the mounting brackets to the wall according to the dimensions on page 39. 2. Align the mounting rails and secure to the mounting brackets. 40
Installation on walls (cont.) 3. Secure the retaining plates to the mounting rails. 4. Secure the mounting brackets to the mounting rails. 5. Align the mounting rails with the tube holders and secure to the mounting bracket. Note Tube holders must be aligned laterally to the opposite rail. 41
Installation on walls (cont.) 6. Securethemountingbrackettothe other side of the mounting rail. 7. Secure the locking bracket at the bottom of the mounting rails with thetubeholders. Fitting the connecting chamber Turn T-slot bolts 90 for all installation steps. 42
Installation on walls (cont.) 1. Position the connecting chamber onto the mounting rails and click into the retaining plate. 2. Align the connecting chambers. Note The tube holders on the mounting rails must be in line with those in the connecting chambers; where necessary, align with a piece of string. 43
Installation on walls (cont.) 3. Mark the fixing points at the back of the connecting chamber. Use the centering groove as a template. 4. Drill 7 9 mm holes. 5. Secure the connecting chamber. 6. Where several collectors are installed above each other, continue with "Installing the connecting chamber" on page 45, otherwise continue with "Fitting the vacuum tubes" on page 46. A Centering groove 44
Water connections Installing the connecting chamber Interconnecting pipes should not cause any damage. Lubricate all plug-in connections (Oring seals) on the collectors only with the special lubricating grease included in the connection set. 1. Insert the interconnecting pipes into the flow and return connectors. 2. Push the next connecting chambers carefully onto the first and insert the interconnecting pipes. 3. Align and secure the connecting chambers. 4. Click the retaining clips into position. 45
Water connections (cont.) Fitting the vacuum tubes Danger The vacuum tubes can become hot or break if insufficient care is taken.this can lead to severe burns or injury. Wear gloves and safety goggles. A Template B Locking spring 1. Remove protective caps from the tubes. 46
Water connections (cont.) 2. Push the tubes into the tube holders until they click and push them into the header as far as possible. The tubes will lock into the locking spring. 3. For south-facing roofs, adjust the angle of inclination of the absorber with the enclosed template. Thecoatedsideoftheabsorber should be turned towards the sun. 4. Secure the tubes with the retaining rubber. Removing tubes If a tube must be removed, proceed as follows: 1. Remove the rubber seal from the groove of the casing cover and open the casing. 2. Push the locking spring upwards out of the tube holders on the header. 3. Carefully remove the tubes. 47
Water connections (cont.) Installing the connection set and collector temperature sensor Observe the following when fitting the locking ring fitting: & All pipes must be right-angled and must be deburred. & Push the union nut and the locking ring onto the pipe and lightly lubricate the threads with oil. & Pushthepipeintothelockingring fitting as far as it will go. & Initially turn the union nut by hand, thentightenwithanopenended spanner by a further ¾ turn. Do not fit any annealed copper pipes onto the locking ring fitting. Connection to the right RL Return (short connection pipe) 48 VL Flow (long connection pipe)
Water connections (cont.) 1. Insert the connection pipes as far as possible, then secure them with hose clips. 2. Fit the elbow onto the return connector. 3. Fit the tee onto the flow connector. 4. Insert the sensor well into the tee, holding the tee tightly. 5. Insert the strain relief fitting into the sensor well. 6. Insert the collector temperature sensor as far as possible into the sensor well and secure with PG thread. 7. Insert the U-pipe as far as possible, then secure it with profile clips. 8. Insert the support sleeves into the pipework of the solar circuit. Make the connection between the collector array and pipework of the solar heating circuit. 9. Check the system pressure and test for leaks. "Vitosol" service instructions. 10. Fit the thermal insulation and join its cut faces with adhesive. 11. Fit and secure on the thermal insulation cap. 49
Water connections (cont.) Connection to the left RL Return (short connection pipe) 50 1. Insert the connection pipes as far as possible, then secure them with profile clips. VL Flow (long connection pipe) 2. Fit the elbow onto the return connector.
Water connections (cont.) 3. Fit the tee onto the flow connector. 4. Insert the sensor well into the tee, holding the tee tightly. 5. Insert the strain relief fitting into the sensor well. 6. Insert the collector temperature sensor as far as possible into the sensor well and secure with PG thread. 7. Insert the U-pipe as far as possible, then secure with profile clips. 8. Insert the support sleeves into the pipework of the solar circuit. Make the connection between the collector array and pipework of the solar heating circuit. 9. Check the system pressure and test for leaks. "Vitosol" service instructions. 10. Fit the thermal insulation and join its cut faces with adhesive. 11. Fit and secure the thermal insulation cap. Installation! Please note Incorrect installation can lead to collector damage. Use only gunmetal and brass fittings and copper pipes for the installation. Use hemp only in conjunction with pressure and temperature-resistant sealants (e.g. Viscotex Solarpaste from Locher, CH-9450 Altstätten). Never step onto solar panels. Never solder near or on the collector. 51
Installation (cont.) A Collector B Solar-Divicon C Collecting tank D Expansion vessel E Pre-cooling vessel (if required) F Shut-off valve G Fill set H Manual solar fill pump K Fill valve (F, G, H) L Drain M Air separator N DHW cylinder O Solar control unit P Air vent valve 52
Installation (cont.) 1. Route pipes so that they can be completely vented. Install at least oneairventvalvewithshut-off facility at the highest point of the system. Install an air separator at an accessible point in the pipework (see illustration on page 52). 2. Equip the system to EN 12975 with expansion vessel, safety valve and circulation pump. 3. The expansion vessel must be approved to DIN 4807 and must be arranged with a heat insulating loop. The diaphragms and seals of the expansion vessel and the safety valve must be suitable for the process medium. For the calculation of the inlet pressure, see the "Vitosol" service instructions. 4. When operating without Solar-Divicon, only use safety valves designed for 120 C and a maximum of 6 bar which carry the "S" (Solar) designation. 5. Make connections pressure and temperature-resistant (observe the max. idle temperature of the collector). Commissioning and adjustment For commissioning of the solar heating system, see "Vitosol" service instructions. 53
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Printed on environmentally-friendly, chlorine-free bleached paper Viessmann Limited Hortonwood 30, Telford, TF1 7YP, GB Telephone: +44 1952 675000 Fax: +44 1952 675040 www.viessmann.com Subject to technical modifications. 56