Viessmann Vitosol 100 Installation Instructions Manual

Brand: Viessmann

Model: Vitosol 100

Type: Installation Instructions Manual

Viessmann Vitosol 100

Overview of the System Components The Viessmann Vitosol 100 consists of a flat collector with an absorber surface area of 2.5 m2, mounting plates, and various accessories. It has a maximum shutdown temperature of 211 degrees Celsius and a maximum operating pressure of 6 bar.

Applications

The Vitosol 100 is designed to work in conjunction with a complete system of Viessmann modular components. It is suitable for both flat roofs and freestanding installations.

Mounting

The Vitosol 100 can be mounted on flat roofs using mounting plates and support rails. For freestanding installations, weight inserts can be used to secure the system.

Viessmann Vitosol 100

Applications

The Vitosol 100 is designed to work in conjunction with a complete system of Viessmann modular components. It is suitable for both flat roofs and freestanding installations.

Mounting

The Vitosol 100 can be mounted on flat roofs using mounting plates and support rails. For freestanding installations, weight inserts can be used to secure the system.

Installation Instructions

Vitosol 100

Type w 2.5

Flat collector for flat roofs and freestanding installation

Part No. 3001 970

Vitosol 100

5492 780 GB 8/99

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 prop-

erty.

Safety regulations

Please observe all relevant safety re-

quirements (GB: British Standards code

of practice) (see also the enclosed red

sheet headed ”Important safety in-

formation”).

In certain countries, solar collectors

must be registered or issued with a

permit in accordance with national re-

gulations.

The entire solar heating system should

be installed in accordance with the ac-

cepted rules of technology (GB: British

Standards codes of practice), observing

all relevant accident prevention regula-

tions.

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 un-

derstructure of the building and the dis-

tance from the roof edge as required by

DIN 1055.

Work on the solar heating system

Installation, maintenance and repairs

must be carried out by a competent

person (heating engineer/service con-

tractor).

Before work is undertaken on the equip-

ment/heating system/solar heating sys-

tem, 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 sys-

tem

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 fa-

cility or the provision of local potential

equalization should only be carried out

by competent personnel, taking into ac-

count the conditions applicable on site.

Please note:

Please read these instructions care-

fully before commencing with installa-

tion and start-up.

Failure to observe the installation, op-

erating and service instructions could

invalidate the guarantee.

The installation instructions for Viess-

mann accessories (where included in

the scope of supply) must be fol-

lowed when installing the complete

system (comprising Viessmann

modular system components).

We organise regular training courses

for installers.

5492 780 GB

Index

Page

Safety instructions 2

................................................ ..................

General information Notes on using these installation instructions 4.............

Product information 4.................................................. .............

Notes on installation 4................................................. .............

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 11................................................ ........

Hydraulic connections Mounting the connection kit 12...............................................

Appendix Installation 14................................................ .................................

After installation ... 17................................................ ..................

Check list 17............................................... ......................................

Service document ring binder 17.............................................. ...

5492 780 GB

General information

Notes on using these installation instructions

The following headings and symbols are used in these instructions:

Safety instruction: This denotes an instruction which

must be observed to safeguard per-

sons and property.

Caution! This denotes actions which must be

avoided in the interests of the safety

of persons and property.

Important: This denotes information which is im-

portant for ensuring the performance

of the equipment.

Please note: This denotes useful tips and impor-

tant supplementary information.

This indicates a reference to other in-

structions which must be observed.

Product information

Vitosol 100, Type w 2.5

Flat collector with 2.5 m2absorber surface

area.

Max. shutdown temperature 211 ºC

......

Max. operating pressure 6 bar................

Type approval code. 06-328-117..............

Notes on installation

The collectors must be securely

mounted so that the mountings can re-

liably withstand gale-force winds.

Although the glass covers are hail-

proof, 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 pos-

sible, 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 ”Tyfo-

cor-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 heat-

ing system regulations.

5492 780 GB

General information

Overview of system components

Collector

5492 780 GB

Fig. 1

Overview of system components

General information

Overview of system components (continued)

Number of collectors 1 2 3 4 5 6

Part Quantity

Collector support frame 1, comprising:

Mounting plate 1 2 2 2 2 2 2

Mounting plate 2 2 2 2 2 2 2

Mounting plate 3 2 2 2 2 2 2

Clamping bolt 4 4 4 4 4 4

Washer 10 mm dia. 4 4 4 4 4 4

Hexagon nut M 10 4 4 4 4 4 4

Support rail

(only for flat roofs with gravel filling)

2 4 4 4 4 4

Hexagon screw M 10×20

– 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 1 1 2 3 4 5

Mounting plate 2 1 2 3 4 5

Mounting plate 3 1 2 3 4 5

Clamping bolt 4 8 12 16 20

Washer 10 mm dia. 4 8 12 16 20

Hexagon nut M 10 4 8 12 16 20

Support rail

(only for flat roofs with gravel filling)

2 4 6 8

Hexagon screw M 10×20

– without support rail

– with support rail

2 4

Washer 10 mm dia,

– without support rail

– with support rail

2 4

Hexagon nut M 10

– without support rail

– with support rail

2 4

Accessories for one collector panel (up to 6 collectors)

Connecting pipe 2 4 6 8 10

Connection kit, comprising:

Connection pipe 2 2 2 2 2 2

Stopper 2 2 2 2 2 2

Profile clip 4 4 4 4 4 4

Clamping ring connection, 22 mm dia. 1 1 1 1 1 1

Clamping ring connection elbow, 90º,

22 mm dia.

1 1 1 1 1 1

Accessories for one solar heating system

Sensor well kit, comprising:

Clamping ring connection (tee),

22 mm dia.

1 1 1 1 1 1

Sensor well 1 1 1 1 1 1

Strain relief connection 1 1 1 1 1 1

5492 780 GB

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

Length of rail

25º

30º

35º

40º

45º

510 mm

580 mm

652 mm

724 mm

797 mm

3. Screw the mounting plates or

to the plates or with hexagon

screw , washer and hexagon

nut .

4. Tighten all screws.

5492 780 GB

Fig. 2

Shortening and assembly the mounting plates

Installation

Freestanding installation on understructure

Understructure

Support frame

arrangement

END/END END/ERW ERW/END ERW/ERW

Dimension X mm 1990 1990 1990 2182

Number of

collectors

1 2 3 4 5 6

Dimension Y mm 2189 4398 6799 9200 11602 14004

1. Mount the understructure (to be pro-

vided on site), e.g. U-channels at

right angles to and level with the in-

stallation orientation of the collectors

according to the dimensions in

Fig. 3.

2. Assemble, align and bolt the collec-

tor support frames to the understruc-

ture 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.

5492 780 GB

END End support frame

ERW Extension support frame

Fig. 3

Assembling the collector support frames

Installation

Fig. 4

Assembling the collector support frames

END End support frame

ERW Extension support frame

Freestanding installation with weight inserts

Weight inserts

Support frame

arrangement

END/END END/ERW ERW/END ERW/ERW

Dimension X mm 1990 1990 1990 2182

Number of

collectors

1 2 3 4 5 6

Dimension Y mm 2189 4398 6799 9200 11602 14004

1. Clear the surface on which it is in-

tended 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 pro-

tective matting.

3. Assemble, align and bolt the collec-

tor support frames to the concrete

slabs according to the dimensions in

Fig. 4; use the mounting plates or

as a template for drilling (provide

screws on site).

4. Screw the rear support rails or

with the fastening screws of the col-

lector 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.

5492 780 GB

Installation

Freestanding installation (continued) with weight inserts

Installation height above ground level m

Weight required per collector kg

up to 8

492

8to20

845

20 to 100

1198

Zone Height above

mean sea level

Snow load S0

N/m2

Snow load on understructure

1500

600

700

800

736

834

1030

1226

762

775

800

825

1173

1186

1211

1237

1584

1597

1623

1648

2400

500

600

700

800

900

736

883

1128

1471

1815

2256

762

781

813

857

902

959

1173

1192

1224

1269

1313

1371

1584

1603

1635

1680

1725

1782

3300

400

500

600

700

800

900

1000

736

981

1226

1570

1962

2502

3041

3728

762

794

825

870

921

991

1061

1151

1173

1205

1237

1282

1332

1403

1473

1562

1584

1616

1648

1693

1744

1814

1884

1973

4200

300

400

500

600

700

800

900

1000

981

1128

1521

2060

2551

3188

3826

4562

5396

794

813

864

934

998

1081

1163

1259

1368

1205

1224

1275

1345

1409

1492

1575

1670

1779

1616

1635

1686

1756

1820

1890

1986

2085

2190

5492 780 GB

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

1. Place the first collector on the collec-

tor 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 con-

nections.

4. Position the next collector and care-

fully push it up against the first col-

lector so that the connecting pipes

can be inserted fully into the col-

lector connections (collector must

butt up against the spacer fold).

5. Screw on collector as described under

point 2.

6. Mount the rest of the collectors as

described under points 3 to 5.

7. Remove the sticker from the glass

cover.

5492 780 GB

Fig. 5

Mounting the collectors

Hydraulic connections

Fig. 6

Mounting the connection kit and the collector temperature sensor

Mounting the connection kit

Flow connection (top); to domestic hot water cylinder

Return connection (bottom); to collector

Flared coupling of collector connection

Nameplate

5492 780 GB

Hydraulic connections

Mounting the connection kit (continued)

Important:

The procedure for installing the clamping ring connection is as follows:

HEnsure that all pipe ends are rectangular and free from burring.

HPush the union nut and the clamping ring onto the pipes and moisten thread with

a little oil.

HPush the pipe as far as it will go into the clamping ring connection.

HFirst tighten the union nut by hand, then tighten by a 3/4turn 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 con-

nection pipes .

4. Mount the clamping ring connection

or on the return connection.

5. Mount the clamping ring connection

(tee) on the flow 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 con-

nection .

9. Make the connection between the

collector panel and the piping of the

solar circuit.

5492 780 GB

Appendix

Installation

Please refer to the technical

guide ”Solar heating sys-

tems” 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 galva-

nized pipes, galvanized fittings or gra-

phitized gaskets.

Hemp should be used only in conjunc-

tion with pressure and temperature-re-

sistant sealants*1.

The components used must be resis-

tant to the heat transfer medium (see

Service Instructions for composition).

The insulation*2 of external piping must

be resistant to temperature, UV radi-

ation 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!

HAt least one air vent valve should be

installed at the highest point of the

system.

Install an air separator at an acces-

sible point in the piping (e.g. in the

flow of the solar circuit, upstream of

the inlet to the indirect coil of the do-

mestic hot water cylinder).

HThe system should be equipped with

an expansion vessel, safety valve and

circulation pump.

HUse only a diaphragm expansion

vessel that is suitable for the applica-

tion as an expansion vessel.

HThe expansion vessel must be ap-

proved to DIN 4807 and must be con-

nected via a heat insulating loop.

The diaphragms and seals of the ex-

pansion vessel and safety valve must

be suitable for the heat transfer me-

dium.

Please refer to the ”Service

Instructions” in order to

calculate the inlet pressure

of the diaphragm expansion

vessel.

HFill the solar heating system with

Viessmann heat transfer medium ”Ty-

focor-HTL”. The blow-off and dis-

charge pipes must be run to an open

container capable of accommodating

the total capacity of the collectors.

HThe Solar-Divicon is equipped with a

safety valve designed for 120 ºC and

max. 6 bar.

HFor operation without the Solar-Divi-

con, use only safety valves rated for

120 ºC and max. 6 bar with a part des-

ignation containing the code letters

”D/G/H”, ”F” or ”H”.

On smaller solar heating systems

with a collector surface area up to

2, Vitocell 300 cylinders with a pe-

ripheral heating system and a capacity

of 200 litres may also be used as solar

storage cylinders for preheating pur-

poses.

In this case, the Solar-Divicon must be

equipped with a 3 bar safety valve (ac-

cessory). 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 ex-

pansion vessel with a capacity of 33

litres.

HTo guarantee the satisfactory oper-

ation of the solar heating system, in-

stall the pipes so that complete vent-

ing is assured.

HThe connecting lines must be pres-

sure and temperature-resistant (ob-

serve the max. shutdown tempera-

ture of the collector).

*1E.g. Viscotex solar paste supplied by Locher, CH-9450 Altstätten.

*2E.g. HT/Armaflex (temperature resistant up to 175 ºC) supplied by Armstrong Insulation Products GmbH, Robert-Bosch-Str. 10,

*2D-48153 Münster.

5492 780 GB

Appendix

Fig. 7

Installation example

Installation (continued)

VL Flow

RL Return

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 recom-

mend the provision of a heat insulat-

ing loop or the installation of an

additional check valve in the flow of

the solar circuit.

5492 780 GB

Appendix

Installation (continued)

Nameplate side

Meander-shaped copper pipe

Flow

Air vent valve

Piping side

Return

Carry out the installation of the piping in reverse return.

Nameplate side

Meander-shaped copper pipe

Flow

Air vent valve

Piping side

Return

5492 780 GB

Fig. 8

Installation of the collectors, single row

Fig. 9

Installation of the collectors, double row

Appendix

After installation ...

Check list

jHas the solar circuit been installed in

accordance with the circuit diagram

and all relevant standards?

jHave the flow and return connec-

tions been carried out?

jHave the electrical connections been

carried out correctly?

jHave the sensors been installed cor-

rectly?

jHave 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 sys-

tem has been started up.

jHave all screws, screwed pipe con-

nections and covers been securely

tightened?

jHas the domestic hot water cylinder

been filled with water?

jDoes the maximum capacity of the

expansion vessel correspond to the

value stated in the Technical Guide?

jHas the inlet pressure of the expan-

sion vessel been adjusted to the sys-

tem pressure?

Service document ring binder

1. File all parts lists, operating and ser-

vice instructions in the ”Operating

and service document” ring binder.

2. Keep the ring binder in its protective

box (accessory).

5492 780 GB

Bauartzulassung

5492 780 GB

Bauartzulassung (Fortsetzung)

5492 780 GB

Viessmann Werke GmbH & Co

D-35107 Allendorf

Tel: (0 64 52) 70-0

Fax: (0 64 52) 70-27 80

Internet: www.viessmann.de

Viessmann Limited

Hortonwood 32

Telford, Shropshire TF1 4EU

Tel.: (01952) 670261

Fax: (01952) 670103

Printed on environmentally friendly,

chlorine-free bleached paper

5492 780 GB Subject to technical modifications!

Viessmann Vitosol 100 Installation Instructions Manual

Brand: Viessmann

Model: Vitosol 100

Type: Installation Instructions Manual

Viessmann Vitosol 100

Applications

The Vitosol 100 is designed to work in conjunction with a complete system of Viessmann modular components. It is suitable for both flat roofs and freestanding installations.

Mounting

The Vitosol 100 can be mounted on flat roofs using mounting plates and support rails. For freestanding installations, weight inserts can be used to secure the system.

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Viessmann Vitosol 100 Installation Instructions Manual

Viessmann Vitosol 100 Installation Instructions Manual

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