Viessmann Vitosol 100 User manual

VITOSOL 100
Installation instructions
for heating engineers
VitosolĂ100
TypeĂs2.5
Flat solar panels for pitched roofs, installation on top of roofs
5862Ă511 GBăăă /2003

2
Safety instructions
Please follow these safety instructions closely to prevent accidents and
material losses.
Safety regulations
Installation, initial start-up, inspection,
maintenance and repairs must only
be carried out by a competent
person (heating engineer/installation
contractor).
Observe all current safety
regulations as defined by DIN, EN,
DVGW and VDE or locally applicable
standards.
See also the safety instructions sheet
in the Vitotec technical documentation
folder.
Before working on the equipment/
heating/solar heating system, isolate
its mains electrical supply (e.g. by
removing a separate mains fuse or
by means of a mains electrical
isolator) and safeguard against
unauthorised reconnection.
Observe maximum load and
distance from roof edge for the
substructure installed on the roof to
DINĂ1Ă055.
Earthing/lightning protection of the
solar heating system
Install an electrical conductor on the
pipework system of the solar circuit
in the lower part of the building to
comply with VDE or local
regulations.
Connection of the collector system to
a new or existing lightning
protection facility or the provision of
local earthing should only be carried
out by authorised personnel, who
must take into account the
conditions applicable on site.
¨ĂSafety instructions
Denotes information which must be
observed to prevent accidents and
material losses.
5862Ă511 GB

3
Index
Page
Component summaryĂ 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the fixing frames
Installation with roof tiesĂ 6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation without roof ties (roofs with higher snow loads)Ă 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation without roof ties (e.g. on sheet steel roofs)Ă 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting mounting railsĂ 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing collectorsĂ18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ydraulic connectionsĂ
Installing the connection set and collector temperature sensorĂ 20
. . . . . . . . . . . . . . . . . . . . . . . .
InstallationĂ22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start-upĂ24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5862Ă511 GB

4
Component summary
ACollector
5862Ă511 GB
1 2
18 9
qR qT qZ qU qI qO wP
wQ wW wE wR wT wZ
wU wI
wO eP
A
3 54
6 7 qP qQ
qW qE

5
Component summary (cont.)
Roof tile integration
1Batten
38Ă×Ăă58Ă×Ă1Ă5 0 or 2Ă430Ămm
30Ă×Ă100Ă×Ă1Ă5 0 or 2Ă430Ămm
2Roof tie
3Zinc-plated countersunk chipboard
screw (SpaxĆs) 6Ă×Ăā80Ămm
4Zinc-plated countersunk chipboard
screw (SpaxĆs) 5Ă×Ăā30Ămm
Slate integration
5Roof tie
6Zinc-plated countersunk chipboard
screw (SpaxĆs) 6Ă×Ăā30Ămm
Plain tile integration
7Roof tie
4Zinc-plated countersunk chipboard
screw (SpaxĆs) 5Ă×Ăā30Ămm
Corrugated roofing sheet integration
8Roof tie with clamping bolt for cor-
rugated roofing sheet profileĂ5 and 6
9Roof tie with clamping bolt for
corrugated roofing sheet profileĂ8
On-site accessories (not shown):
Hexagon woodscrew ∅Ă8Ămm
(length according to the corrugated
roofing sheet profile)
Fixing without roof ties
e.g. on sheet steel roofs
qP Clamping bolt
Roof tile integration
(higher snow loads)
qQ Solar panel support with
clamping bolt
On-site accessories (not shown):
Zinc-plated countersunk chipboard
screw (Spax-s) 3Ă×Ă25Ămm
For all types of roof cover
qW Joining element
qE Mounting rail
1Ă1 5 or 2Ă330Ămm
qR Washer ∅Ă8.4Ămm
qT Hexagon screw MĂ8Ă×Ă10
qZ Mounting plate
qU Clamping bolt
qI Locking bolt with threaded stud
qO Hexagon nut
Accessories for one panel array
wP Connecting pipe
Connection set, comprising:
wQ Hose clip
wW Mounting rail cover
wE Connecting pipe
wR Plugs
wT Compression fitting (elbow)
∅Ă22Ămm, 90º
wZ Support sleeve
Accessories for one solar heating
system
Sensor well set, comprising:
wZ Support sleeve
wU Compression fitting (tee)
∅Ă22Ămm
wI Sensor well
wO Strain relief fitting
eP Thermal insulation
5862Ă511 GB

6
Installing the fixing frames
Install the panel array level or slightly inclined (approx. 10Ămm) towards the
connection side to ensure complete venting.
Installation with roof ties
Summary
ARoof tie
BCollector
CMounting rail
DAdditional batten, 38Ă×Ă58Ămm
(only for roof tile integration)
EAdditional batten, 30Ă×Ă100Ămm
(only for roof tile integration)
Dim.Ă"X" according to the width of
the tile head.
Roof integration Dim.ĂY
mm
Roof tiles 440
Slates 348
Plain tiles 380
Corrugated roofing sheets 20
5862Ă511 GB
ABCDE

7
Installing the fixing frames (cont.)
The illustration shows dimensions for the installation of four panels.
Number 1 2 3 4 5 6
Dim.ĂA mm 1Ă050 1Ă050 1Ă050 1Ă050 1Ă050 1Ă050
Dim.ĂB mm ćć ćć 900 900 900 900
Dim.ĂC mm ćć 150 150 150 150 150
Dim.ĂD mm ćć ćć ćć 300 300 ćć
Dim.ĂE*1 mm 1Ă050
A
2Ă250
A+C+A
3Ă300
A+C+B
+C+A
4Ă500
A+C+B+D+B
+C+A
5Ă00
A+C+B+D+B
+D+B+C+A
6Ă50
A+C+B+C
+A+C+A+C
+B+C+A
Dim.ĂF mm 1Ă1 5 2Ă330 3Ă505 4Ă660 5Ă835 6Ă990
Dim.ĂG mm 62.5 40 102.5 80 6 .5 120
Dim.Ă mm 8 .5 88 98.5 99 109.5 110
*1Dim.ĂE comprises dimensions A to D;
For static reasons maintain the stated sequence.
5862Ă511 GB

8
Installing the fixing frames (cont.)
Fitting roof ties in the case of roof tile integration
1. Push up the roof tiles in accordance
with the dimensions shown in the
illustration on pageĂ6 and .
2. Secure the battens to the joists at
the head of the exposed rows of
tiles in accordance with the
dimensions shown in the
illustration on pageĂ6 (maintain
dimension 185Ămm).
3. Hook the roof ties into the battens
in accordance with the dimensions
shown in the illustration on
pageĂ .
4. Remove the drip tab and profiling
from the roof tiles in the area of
the roof ties.
5. Secure the roof ties and roof tiles.
Continue with mounting rail
installation on pageĂ1 .
5862Ă511 GB
3.
5.2.
4.
42
1
1
30 x 100
38 x 58
3
3

9
Installing the fixing frames (cont.)
Fitting roof ties for slate integration
1. Mark the position of the roof ties
in accordance with the dimensions
shown in the illustration on
pageĂ .
2. Remove slates from the roof tie
location.
3. Secure the roof ties to the roof
face.
Utilise commercial lead flashing to
prevent the ingress of moisture.
4. Cover the roof.
Continue with mounting rail
installation on pageĂ1 .
5862Ă511 GB
5
6
2.
3.

10
Installing the fixing frames (cont.)
Fitting roof ties in the case of plain roof tile integration
1. Mark the position of the roof ties
in accordance with the dimensions
shown in the illustration on
pageĂ .
2. Remove tiles from the roof tie
location.
3. Hook the roof ties onto the
battens, locate and align on top of
the tile below.
4. Secure the roof ties to the battens.
5. Cover the roof; trim tiles to suit
with an angle cutter. Trim approx.
35Ămm off the tiles.
Continue with mounting rail
installation on pageĂ1 .
5862Ă511 GB
7
2.
3.
4.
4

11
Installing the fixing frames (cont.)
Fitting roof ties in the case of corrugated roofing sheet integration
1. Mark the position of the roof ties
in accordance with the dimensions
shown in the illustration on
pageĂ .
2. Position the roof ties at the level of
a batten onto the ridge of the plate
and drill a hole into the ridge of
the plate through the hole in the
roof tie.
3. Secure the roof ties with hexagon
woodscrews ∅Ă8Ămm (on-site
provision) to the battens.
4. Secure the top of the roof ties and
mounting brackets.
Continue with mounting rail
installation on pageĂ1 .
5862Ă511 GB
3.3.
2.
4.
8,9

12
Installing the fixing frames (cont.)
Installation without roof ties (roofs with higher snow loads)
Summary
APlastic tile (on site), made by
Klöber
BCollector
CSolar panel support
DMounting rail
EAdditional battens (on-site)
Dim.Ă"X" according to the width of
the tile head.
Reduce dim. "Y" on site.
5862Ă511 GB
ABC DE

13
Installing the fixing frames (cont.)
The illustration shows dimensions for the installation of five panels.
Number 1 2 3 4 5 6
Dim.ĂA mm 900 900 900 900 900 900
Dim.ĂB mm ćć 300 300 300 300 300
Dim.ĂC mm ćć ćć ćć ćć 600 600
Dim.ĂD*1 mm 900
A
2Ă100
A+B+A
3Ă300
A+B+A
+B+A
4Ă500
A+B+A+B+A
+B+A
4Ă500
A+B+C+B+A
+B+C+B+A
6Ă600
A+B+A+B
+A+B+C+B
+A+B+A
Dim.ĂE mm 13 .5 115 102.5 80 21 .5 195
Dim.ĂF mm 8 .5 88 98.5 99 109.5 110
Dim.ĂG mm 1Ă1 .5 2Ă330 3Ă505 4Ă660 5Ă835 6Ă990
*1Dim.ĂD comprises dimensions A to C;
For static reasons maintain the stated sequence.
5862Ă511 GB

14
Installing the fixing frames (cont.)
Fitting solar supports
1. Secure the solar supports to the
plastic tile (screws supplied with
the tile).
2. Mark the position of the plastic tile
in accordance with the dimensions
shown in the illustration on
pageĂ13.
3. Extract the marked roof tiles. Push
up tiles above and alongside.
4. Position and nail down additional
battens (on-site provision) to the
top side of the next lower row of
tiles.
5. Hook in plastic tile.
Please note:
For roofs with
Hsmall batten cross-section
Hmissing counter battens
Hboarding
Bend the plastic tile claw out of
the way (see fig. on the back of the
plastic tile).
6. Cover the areas alongside with
tiles.
7. Secure the plastic tile with
countersunk chipboard screws
3Ă×Ă25Ămm (on-site provision).
8. Drill two holes ∅Ă6Ămm into the
plastic tile below the existing
screws at the height of an
additional batten. Protect the holes
against ingress of moisture by
filling them with silicone, and
secure the tile with stainless steel
screws (supplied with the tile) to
the additional roof batten.
9. Cover the remaining roof area
with tiles.
Continue with mounting rail
installation on pageĂ1 .
5862Ă511 GB
qQ
8.
4.
.
1.

15
Installing the fixing frames (cont.)
Installation without roof ties (e.g. on sheet steel roofs)
Summary
AMounting bracket
BCollector
CMounting rail
5862Ă511 GB
A CB

16
Installing the fixing frames (cont.)
The illustration shows dimensions for the installation of four panels.
Secure the clamping bolts to the
substrate in accordance with the
dimensions shown in the illustration.
Do not yet tighten the screws.
Number 1 2 3 4 5 6
Dim.ĂA mm 1Ă050 1Ă050 1Ă050 1Ă050 1Ă050 1Ă050
Dim.ĂB mm ćć ćć 900 900 900 900
Dim.ĂC mm ćć 150 150 150 150 150
Dim.ĂD mm ćć ćć ćć 300 300 ćć
Dim.ĂE*1 mm 1Ă050
A
2Ă250
A+C+A
3Ă300
A+C+B
+C+A
4Ă500
A+C+B+D+B
+C+A
5Ă00
A+C+B+D+B
+D+B+C+A
6Ă50
A+C+B+C
+A+C+A+C
+B+C+A
Dim.ĂF mm 1Ă1 5 2Ă330 3Ă505 4Ă660 5Ă835 6Ă990
Dim.ĂG mm 62.5 40 102.5 80 6 .5 120
Dim. mm 8 .5 88 98.5 99 109.5 110
*1Dim.ĂE comprises dimensions A to D;
For static reasons maintain the stated sequence.
5862Ă511 GB
qP

17
Installing the fixing frames (cont.)
Fitting mounting rails
1. Secure the joining elements into
the mounting rails.
2. Secure the mounting rails
Hto the roof ties; the locking bolt
must be turned 90Ăº
or
Hinto the clamping bolts of the
roof ties or the solar supports.
Hook in, align and tighten.
3. Hook the mounting plates into
lower mounting rails in
accordance with the dimensions
shown in the illustrations on
pagesĂ , 13, and 16.
5862Ă511 GB
qE
qR
qT
qW
1.
qE
2.
2,5,7qO qIqR
qE 2.
89qQ
qE qZ
3.

18
Installing collectors
AType plate
BPipework
CLabel
Number 1 2 3 4 5 6
Dim.ĂK mm 18.5 19 29.5 30 40.5 41
5862Ă511 GB
wP
qU
qR
qO
qZ wP
qI
2.
3.
3.
4.
8.
1.
C
B
A
5.
qE
4x
wW
9.

19
Collector installation (cont.)
Interconnecting pipes must be free
from damage and contamination.
Lubricate all plug-in joints (OĆring
seals) on the collectors only with the
special grease supplied with the
connection set.
On the first and last collector, the
side to which the type plate is
affixed, must be on the outside.
Route the piping on only one
collector opposite the type plate
side.
1. Hook the collector into its
mounting plates and lay down
onto the mounting rails.
2. Secure the collector with four
clamping bolts onto the mounting
rails; only tighten the two outer
clamping bolts.
Turn the grooved bolt 90Ăº.
3. Insert the connecting pipe until it
bottoms out inside the collector
connections.
4. Position the second collector as
described under itemĂ1.
5. Carefully push the second
collector against the first and
insert the connecting pipes until
they bottom out.
Distance from the lower edge of
the installed collector 16Ămm.
6. Install additional collectors.
7. Tighten all clamping bolts.
8. Remove the label.
9. Press the cover caps (part of the
connection set) into the mounting
rails.
5862Ă511 GB

20
ydraulic connections
Installing the connection set and collector temperature sensor
AType plate
BFlared coupling
5862Ă511 GB
wQ
wR
1.
3.1.
wT
wE
wQ
wU
eP
wI
wO
6.
.
4.
9.
2.
3.3.
3.2.
wQ
wE
B
A
wZ
8.
5.