Viessmann VITOSOL 200 User 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
2
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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
3
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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.)
6
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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.)
7
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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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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.)
9
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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.)
11
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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.)
12
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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.)
13
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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.)
14
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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.)
16
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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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