Viessmann VITOSOL 200 Installation Instructions Manual

VIESMANN

Installation instructions

for heating engineers

Vitosol 200

Type SD2

Direct flow vacuum tube collector

VITOSOL 200

5862 788 GB 5/2005 Dispose after installation.

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 isola-

tor.

&Safeguard the system against

unauthorised reconnection.

&When using gas as fuel, also close

the main gas shut-off valve and

safeguard against unauthorised

reopening.

Safety instructions

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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

Index

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Install an electrical conductor on the

pipework of the solar circuit in the

lower part of the building in compli-

ance with VDE or local regulations.

The connection of the collector sys-

tem to a new or existing lightning pro-

tection system or the provision of

local earthing must only be carried out

by authorised trained personnel, who

must take into account the site condi-

tions.

Earthing and lightning protection of the solar heating system

4

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Component summary

Horizontal rooftop installation

5

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Roof tile cover

1Timber

&38 x 58 x 2430 mm

&30 x 100 x 2430 mm

2Roof hooks

3Zinc-plated countersunk chip-

board screw (Spax-s) 6 x 80 mm

4Zinc-plated countersunk chip-

board screw (Spax-s) 5 x 30 mm

Slate cover

5Roof hooks

6Zinc-plated countersunk chip-

board screw (Spax-s) 6 x 30 mm

Corrugated sheet cover

7Roof hooks for corrugated roofing

sheet profile 5 and 6

8Roof hooks for corrugated roofing

sheet profile 8

Plain tile cover

9Roof hooks

4Zinc-plated countersunk chip-

board 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°),

722 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),

722 mm

eR Sensor well

eT Strain relief fitting

eZ Thermal insulation

Horizontal rooftop installation (cont.)

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Fitting the roof hooks or mounting brackets

Overview —Installation with roof hooks

Dimension x according to the width of

thetilehead.Dimensionsatoesee

tableonpage9.

ASpacer

BConnecting chamber

CMounting bracket

DMounting rail with tube holder

EMounting rail

FTimber, 38 x 100 mm

(only for roof tiles)

GTimber, 30 x 58 mm

(only for roof tiles)

HRoof hooks

Horizontal rooftop installation (cont.)

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Overview —Installation with mounting brackets

(e.g. on sheet steel roofs)

ASpacer

BConnecting chamber

CMounting bracket

DMounting rail with tube holder

HMounting rail

Horizontal rooftop installation (cont.)

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5862 788 GB

Combination

(tubes)

ammbmmcmmdmme mm

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.

Horizontal rooftop installation (cont.)

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For installations without roof hooks, mounting brackets are used in place of roof

hooks.

Centre the mounting rails, maintaining dimension f = 26 mm.

Horizontal rooftop installation (cont.)

10

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Fitting roof hooks for roof tile cover

1. Push up the roof tiles in accor-

dance 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

tilesinaccordancewiththedimen-

sions 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 protru-

sions from the roof tiles in the roof

hook area.

5. Secure the roof hooks and position

the roof tiles.

Continue with "Mounting rail instal-

lation" on page 13.

Horizontal rooftop installation (cont.)

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Fitting roof hooks for slate 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 instal-

lation" on page 13.

Fitting roof hooks for corrugated sheet cover

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

78 mm and sealing washers (on-

site provision) to the battens.

Continue with "Mounting rail instal-

lation" on page 13.

Horizontal rooftop installation (cont.)

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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 bat-

tens and position and align on top

of the tile below.

4. Secure the roof hooks to the bat-

tens.

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.

Horizontal rooftop installation (cont.)

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ARoof hooks or mounting brackets

1. Secure the mounting rails to the

roof hooks or mounting brackets;

align vertically and horizontally.

Horizontal rooftop installation (cont.)

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2. Secure the retaining plates to the

mounting rails.

3. Secure the mounting brackets to

the mounting rails.

Horizontal rooftop installation (cont.)

15

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4. Align the mounting rails with the

tube holders and secure to the

mounting bracket.

Note

Tube holders must be aligned later-

ally to the opposite rail.

5. Screw the mounting bracket to the

other side of the mounting rail.

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.)

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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.

Horizontal rooftop installation (cont.)

17

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ACentering groove

3. Mark the fixing points at the back of

the connecting chamber.

Use centering groove as a tem-

plate.

4. Drill 79 mm holes.

5. Tighten the connecting chamber.

6. Where several collectors are

installed above each other, con-

tinue with "Installing the connecting

chamber" on page 45, otherwise

continue with "Fitting the vacuum

tubes" on page 46.

Horizontal rooftop installation (cont.)

18

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Component summary

Vertical rooftop installation

19

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Roof tile cover

1Timber

&38 x 58 x 2430 mm

&30 x 100 x 2430 mm

2Roof hooks

3Zinc-plated countersunk chip-

board screw (Spax-s) 6 x 80 mm

4Zinc-plated countersunk chip-

board screw (Spax-s) 5 x 30 mm

Slate cover

5Roof hooks

6Zinc-plated countersunk chip-

board screw (Spax-s) 6 x 30 mm

Corrugated sheet cover

7Roof hooks for corrugated roofing

sheet profile 5 and 6

8Roof hooks for corrugated roofing

sheet profile 8

Plain tile cover

9Roof hooks

4Zinc-plated countersunk chip-

board 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°),

722 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),

722 mm

eR Sensor well

eT Strain relief fitting

eZ Thermal insulation

Vertical rooftop installation (cont.)

20

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Viessmann VITOSOL 200 Installation Instructions Manual

Viessmann VITOSOL 200 Installation Instructions Manual

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