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Safety instructions
2
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
3
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
4
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
6
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
4
8
4
12
4
12
4
12
4
12
4
12
Washer 10 mm dia,
– without support rail
– with support rail
4
8
4
12
4
12
4
12
4
12
4
12
Hexagon nut M 10
– without support rail
– with support rail
4
8
4
12
4
12
4
12
4
12
4
12
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
8
6
14
8
20
10
26
Washer 10 mm dia,
– without support rail
– with support rail
2 4
8
6
14
8
20
10
26
Hexagon nut M 10
– without support rail
– with support rail
2 4
8
6
14
8
20
10
26
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
7
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
8
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
9
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
10
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
m
Snow load S0
N/m2
Snow load on understructure
kg
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
11
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
13
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
14
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
5m
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
15
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
16
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
17
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
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
20
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chlorine-free bleached paper
5492 780 GB Subject to technical modifications!
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