Viessmann Solar-Divicon-HX Dimensions and installation guide

Installation, Start-up
and Service Instructions
SOLAR-DIVICON-HX
5724 267 v1.0 08/2010
Solar-Divicon-HX
Solar heat transfer station
c/w double wall heat exchanger
Read and save these instructions
for future reference.
IMPORTANT
Please file in Service Binder

2
5724 267 v1.0
About these instructions
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the
instructions listed below and details printed in this manual can cause product/property damage, severe personal injury,
and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information found in
manual subsections).
General Information
The installation, service, and
maintenance of this equipment
must be performed by a licensed
professional heating contractor.
u Please see section
entitled “Important
Regulatory and
Installation
Requirements" in the
Installation Instructions.
Read all applicable documentation
before commencing installation.
Store documentation in a readily
accessible location for reference in
the future by service personnel.
u These instructions
describe the function,
installation, startup
and operation of the
Solar-Divicon-HX heat
transfer stations. For other
components of the solar system
such as collectors, storage tanks,
expansion tanks and controllers,
please observe the instructions
supplied with those components.
Vitosol solar collectors and pumping
stations are designed for use in
closed loop heating systems for
domestic hot water heating, space
heating and pool heating via a heat
exchanger. The use of Viessmann
heat transfer medium “Tyfocor-
HTL” is strongly recommended.
Other heat transfer fluids may be
suitable if they have the same
temperature range -35°F to 170°F
(-31°C to 77°C) and are non-toxic.
Information contained in
this and related product
documentation must be
read and followed.
Failure to do so may
render the warranty
null and void.
gWarranty
gApplicability
gProduct documentation gLicensed professional heating
contractor
gAdvice to owner
Once the installation work is
complete, the heating contractor
must familiarize the system
operator/ultimate owner with all
equipment, as well as safety
precautions/requirements,
shut-down procedure, and the need
for professional service annually
before the heating season begins.
uThis symbol indicates
that other instructions
must be referenced.
Take note of all symbols intended to
draw attention to potential hazards or
important product information. These
include “WARNING” and “CAUTION”.
gImportant Symbols
WARNING
Indicates an imminently hazardous
situation which, if not avoided,
could result in death, serious injury
or substantial product/property
damage.
CAUTION
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or product/
property damage.
Solar-Divicon-HX may only be used
as a heat transfer station between
the solar collector loop and storage
tank loop in closed loop solar thermal
systems taking into consideration
the technical limit values indicated in
these instructions. Improper usage
excludes any liability claims.

5724 267 v1.0
3
Table of Contents
About these Instructions............................................................................2
Important regulatory and safety requirements ..............................................4
Description..............................................................................................6
Primary and secondary loop.......................................................................7
Mounting the Solar-Divicon-HX...................................................................8
Connection fittings for primary (solar) loop...................................................9
Pipe and fitting connections........................................................................9
Connections...........................................................................................10
Controller connection...............................................................................11
Safety...................................................................................................12
Commissioning sequence.........................................................................12
Flushing and filling the storage tank loop...................................................13
Flushing and filling the solar loop..............................................................13
Flushing the heat exchanger......................................................................14
Air-scoop...............................................................................................15
Setting the flow rates..............................................................................16
Draining the solar circuit..........................................................................17
Parts.....................................................................................................18
Characteristics.......................................................................................20
Specifications........................................................................................22
General Information
Safety
Installation
Start-up
Service
Technical Data
Page

4
5724 267 v1.0
Safety
Important regulatory and safety requirements
Instructing the system user
The installer of the system is responsible to ensure the
system operator/ultimate owner is made familiar with
the functioning of the system, its activation, and its
shut-down.
Initial start-up
Initial start-up must be performed by a qualified heating
contractor. Completion of the Maintenance Record by the
heating contractor is also required.
Working on the equipment
The installation, adjustment, service, and maintenance of
this equipment must be done by a licensed professional
heating contractor who is qualified and experienced in the
installation, service, and maintenance of hot water heating
systems. There are no user serviceable parts on this
equipment.
Ensure main power supply to equipment, the heating
system, and all external controls has been deactivated.
Take precautions in all instances to avoid accidental
activation of power during service work.
Technical literature
Literature applicable to all aspects of the Vitosol 100-F,
200-F or Vitosol 200-T, Vitosol 300-T:
- Technical Data Manual
- Installation Instructions
- Start-up, Service and Operating Instructions
- System Design Guidelines
u The following topics must be covered:
Proper system operation sequence.
Explain the equipment.
Demonstrate an emergency shut-down, what to do
and what not.
Explain that there is no substitute for proper
maintenance to help ensure safe operation.
u The Maintenance Record is located in the Vitosol
Start-up, Service and Operating Instructions.
u Please carefully read this manual prior to attempting
start-up, maintenance or service. Any warranty is null
and void if these instructions are not followed.
For information regarding other Viessmann System
Technology componentry, please reference
documentation of the respective product.
Viessmann offers frequent installation and service
seminars to familiarize our partners with our products.
Please inquire.
u The completeness and functionality of field supplied
electrical controls and components must be verified
by the heating contractor. These include low water
cut-offs, flow switches (if used), staging controls,
pumps, motorized valves, air vents, thermostats, etc.
u Leave all literature at the installation site and advise
the system operator/ultimate owner where the
literature can be found. Contact Viessmann for
additional copies.
In the lower part of the building, install an electrical
conductor on the solar circuit’s piping system in
compliance with local regulations.
Connection of the solar system to a new or existing
lightning protection or the provision of local grounding
should only be carried out by a licensed professional, who
must take into account the prevailing conditions on site.
gGrounding/lightning protection of the solar system
The installation and startup of the solar station as well as the connection of electrical components require technical
knowledge commensurate with recognized vocational qualification as a fitter for plumbing, heating and air conditioning
technology, or a profession requiring a comparable level of knowledge [specialist].
The following must be observed during installation and startup:
»Relevant local and national regulations
»Accident prevention regulations of the professional association
»Instructions and safety instructions mentioned in this manual

5724 267 v1.0
5
Safety
Important regulatory and safety requirements (continued)
Pool water or potable water cannot be pumped directly
through the Vitosol collectors. Damage to collectors
caused by corrosion or scaling will void warranty.
IMPORTANT
WARNING
Check system pressure frequently. Excessive system
pressure may result in damage to the equipment,
personal injuries or loss of life.
WARNING
With pressure relief valves there is danger of scalding
due to vapor escape. A discharge line must be connected
to the pressure relief valve leading off-blowing solar fluid
and vapor to an adequate heat-resistant container.
Observe the instructions regarding the pressure relief
valve.
CAUTION
Install the station at a sufficient distance to the
collector field, since the solar fluid may be very hot
near the collector.
It may be necessary to install an intermediate tank in
order to protect the expansion tank.
CAUTION
It is imperative to prevent that the EPDM seals of the
station get in contact with substances containing mineral
oils. Mineral oil products cause lasting damage to the
material, whereby its sealant properties are lost.
If necessary, ask the manufacturer whether the solar
fluid, fats or installation aids contain mineral oils.
We do not assume liability nor provide warranty for
damage to property resulting from sealants damaged in
this way.
Repairing components which fulfil a safety function can
compromise the safe operation of your heating system.
Replace faulty components only with original Viessmann
replacement parts.
IMPORTANT
IMPORTANT
Replacement and wear parts which have not been
tested together with the solar system can compromise
its function. Installing non-authorized components and
non-approved modifications/conversion can compromise
safety and may infringe our warranty conditions.
For replacement, use only original Viessmann replacement
parts or those which are approved by Viessmann.

6
5724 267 v1.0
Installation
Description
Solar-Divicon-HX is a premounted group of fittings and
components used to transfer the heat from the primary or
solar loop to the secondary or storage tank loop. The
primary and secondary loop are separated with a generously
sized stainless-steel double wall heat exchanger with
visable leak detection. The heat exchanger is UL certified
for use with potable water. The fittings in the secondary
side are approved for potable water applications and are
made of lead free brass so the station can be directly
connected to potable water tanks.
The station contains a preset controller and the valves,
fittings, pumps and safety equipment necessary to operate
a Vitosol solar thermal system.
The expansion tank required for operation is not part of
the transfer station and must be ordered separately. The
expansion tank must be sized for the number of collectors
in the system. Refer to the Vitosol System Design Guide
for sizing details.
An ASME stamped pressure relief valve must be field
supplied and mounted on site to protect the transfer
station from overpressure in the secondary loop.
Note:
Field piping not exactly as shown. Refer to layout drawing
on page 10 for piping and wiring details.
Fig. 2 Typical piping connection
Fig. 1 Solar-Divicon-HX components

5724 267 v1.0
7
Primary and secondary loop
Installation
The primary (solar) loop comprises:
a– ball valve with integrated temperature gauge and check
valve, solar supply
b– ball valve with integrated temperature gauge and check
valve, solar return
c– pressure relief valve - 87 psig
d– drain valve for flushing / filling
e– pressure gauge and connection for expansion tank
f– solar 3-speed circulation pump
g– flowmeter to display and balance the flow rate
h– fill valve for flushing / filling
i– double-wall heat exchanger
j– air-scoop with discharge line
The secondary (DHW storage tank) loop comprises:
A– ¾“ male nipple for connection of an ASME
stamped pressure relief valve (PRV ordered
separately, maximum 150 psig)
B– DHW 3-speed bronze circulation pump
C– isolation valve in the storage tank return
D– isolation valve in the storage tank supply
E– temperature sensor DHW return
F– temperature sensor DHW supply
abc
d
e
f
g
h
i
j
A
B
F
E
D C
Fig. 3 Primary solar loop components
Fig. 4 Secondary tank loop components
The solar ball valves (a and b)
are equipped with spring-
charged check valves to
prevent gravity circulation.

8
5724 267 v1.0
Installation
Mounting the Solar-Divicon-HX
The discharge line of the pressure relief valve must lead
into a heat-resistant collecting tank with corresponding
size. The jug for the “Tyfocor-HTL“ solar fluid can be used
for this purpose. This allows you to easily refill the circuits
and to avoid undesired discharge into the environment!
1. Copy the holes to be drilled to the mounting
surface. The cardboard under the station may serve
as a template.
2. Drill the holes and insert the enclosed wall anchors.
3. Turn in the screws so that about 1“ of each screw
still sticks out.
4. Pull off the insulating front shell. Hang the station
onto the screws and tighten the screws.
5. Connect the transfer station to the system by
pipework:
»1 supply from solar panel
»2 return to solar panel
»3 storage tank supply
»4 storage tank return
All pipe connections are ¾“. The actual size of the
supply and return piping will vary depending on the type
and number of collectors used and the total length of the
pipe run. Please call Viessmann for sizing assistance.
12
34
Mounting
screw
locations
The location of installation must be dry, load-carrying and
frost-proof. Future access to the controller and the safety
equipment must be always guaranteed!
CAUTION
The mounting location must be able to carry the full
weight of the Solar-Divicon-HX. Take into account the
full weight of the unit. Damage or injury could occur if
not mounted securely.
Fig. 5 Pipe connections and mounting plate

5
4
3
1
2
min. d”
5724 267 v1.0
9
Installation
Connection fittings for primary (solar) loop
1. Mount the solar safety equipment to the connection
above the return ball valve using the gasket supplied
in the accessory kit.
2. Connect the expansion tank below the pressure gauge
using c“ piping.
3. Mount the expansion tank.
Note: The expansion tank must not be connected, or
must be isolated during flushing and filling in order to
avoid that dirt particles are washed in.
4. Connect a discharge line to the pressure relief valve in
the solar circuit. The jug for the “Tyfocor-HTL“ solar
fluid can be used for this purpose.
5. Connect an ASME stamped pressure relief valve
(not part of delivery) to the NPT male nipple (A) in
the storage tank loop. Maximum pressure is 150 psig.
6. Connect a discharge line to the pressure relief valve
in the storage tank circuit and pipe to a floor drain.
7. Before connecting the expansion tank, pressurize the
air cushion of the expansion tank according to the
instructions in the Vitosol manual.
connection for
discharge line
drain valve
connection for
expansion tank
A
Expansion
tank
For additional information, follow the
procedures in the Vitosol Start-up,
Service and Operating Instructions.
Pipe and fitting connections
Sp1
Fig. 7 Connection details
The connection to the solar thermal system is carried
out fast, pressure-proof and without soldering with the
supplied compression fittings.
1. Push the union nut 2and the cutting ring 3onto
the copper pipe 1. The pipe must protrude at least
d“ from the cutting ring in order to ensure the force
transmission and the sealing.
2. Insert the support sleeve 4(supplied with the Solar-
Divicon-HX) into the copper pipe.
3. Insert the copper pipe with the plugged-on individual
parts 2, 3and 4all the way into the housing of
the compression fitting (5) mounted on the ball valves
of the Solar-Divicon-HX.
4. Tighten the union nut 2manually to start.
5. Tighten the union nut 2by rotating with wrench one
full turn. Secure the housing of the compression fitting
5with a second wrench against distortion in order to
avoid damaging the sealing ring. Fig. 6 Primary loop piping connection

10
5724 267 v1.0
Installation
Connections
Fig. 8 Typical system layout

5724 267 v1.0
11
Installation
Controller Connection
WARNING
Prior to commencing electrical work on the controller,
disconnect the mains plug to avoid possible electric
shock! Only after completing all installation work,
plug the mains plug of the controller into an outlet.
This avoids an unintentional start of the motors.
Refer to the separate instructions
regarding the controller.
Fig. 9 Possible connection diagram
1. Connect the temperature sensors:
- Collector sensor (TCOL) to S1. Install the sensor in
the sensor well kit provided with Vitosol collectors.
Connect to the control using 18/2 thermostat wire.
- Tank return (TSEC) to S2. The sensor is preinstalled in
the isolation valve in the storage tank return live. Use the
quick-connect plug to join together the sensor wire and
pre-wired sensor cable from the control.
- Storage tank sensor (TST) to S3. Install sensor at the
same level as the tank supply inlet. Install in an
immersion sensor well, if possible.
- Solar return line sensor (TPRI) to S4. This sensor is
pre-installed in the Solar-Divicon-HX.
2. Tighten all union nuts and screw connections.
The assembly of the heat transfer station is now
completed and you can put the station into operation.

12
5724 267 v1.0
Safety
Start-up
WARNING
The valves and fittings can heat to temperatures of more
than 212° F (100° C) due to the solar fluid. Therefore,
do not flush or fill the system with the collectors heated
(intense sunshine).
Please note that hot solar fluid can leak from the
pressure relief valves in case of excessive system
pressure!
During venting hot solar fluid or vapor may escape and
cause scalding!
CAUTION
It is often the case that the solar system cannot be
completely drained after flushing. Thus, there is
risk of frost damage when flushing with water. It is
recommended to only use the solar fluid to flush and
fill the solar system.
Use “Tyfocor HTL“ solar fluid.
For commissioning flush and fill in the following sequence:
1. Flush the solar storage tank (to remove scale residues)
2. Fill the solar storage tank circuit
3. Flush and fill the solar heat exchanger
4. Flush and fill the collector field and primary solar loop
5. Flush and fill the complete solar circuit
This guarantees that dirt particles are not flushed into the
heat exchanger and that eventually absorbed heat can also
be dissipated.
IMPORTANT
Failure to follow flushing and filling sequence can lead to
heat exchanger blockage.
Observe the following safety instructions regarding the startup of the station:
Commisioning Sequence

5724 267 v1.0
13
Start-up
Flushing and filling the storage tank loop
Flushing and filling the solar loop
0o45o90o
Check valve is operating,
flow only in flow direction.
Check valve is not operating,
flow in both directions.
Ball valve closed, no flow.
The valves and fittings required to flush and fill are integrated in the heat transfer station.
Make sure not to wash dirt particles from the solar loop into the heat exchanger and the expansion tank.
Therefore only use flush and fill stations with fine filters.
The solar loop is flushed opposite to the normal direction of flow.
Make sure that an unintentional start of the solar pump is not possible by de-energizing the pump.
Check valve bypassing
The storage tank loop is filled with potable water by
means of the valves and fittings of the tank. To avoid that
dirt particles are washed into the heat exchanger, close
the ball valves of the station and wash the dirt particles
and scale residues out of the tank.
1. Open the piston valves (B) (C).
2. Fill the storage tank loop using the valves and fittings
of the tank.
3. Vent the storage tank loop by opening and closing
the pressure relief valve (A) installed in the secondary
circuit.
Fig. 10 Secondary tank loop components
Fig. 11 Check valve and shut off valve operation
A
B
C
mm wrench

14
5724 267 v1.0
Flushing the heat exchanger
Start-up
1. Disconnect the expansion tank from the solar system
and temporarily plug expansion tank pipe connection.
This avoids that the dirt particles in the pipes are
washed into the expansion tank.
2. Put the check valve temporarily out of operation by
turning the solar supply ball valve (a) to position 45°
(see page 13).
3. Close the solar return ball valve (b) (position 90°).
4. Connect the flush and fill station
- pressure hose to the fill valve (d)
- flush hose to the drain valve (c)
5. Open the fill and drain valves (d) (c) and put the flush
and fill charge station into operation.
6. Slowly open the return ball valve (b) during flushing
in order to vent the pump section.
7. Flush the solar installation until the solar fluid exits
without bubbles or debris.
8. Close the drain valve (c) with the filling pump running
and increase the system pressure to about
72 psi / 5 bars. The system pressure can be read on
the pressure gauge.
9. Close the fill valve (d) and switch off the pump of the
flush and fill station.
10. Check the pressure gauge to see whether the system
pressure reduces and eliminate leaks where necessary.
11.Reduce the pressure on the drain valve (c) to the
final fill pressure.
12.Connect the expansion tank to connection (e) and set
the final fill pressure of the solar system using the flush
and fill station.
Refer to the Vitosol Start-up, Service and
Operating Instructions for recommended
expansion tank cold fill and system final
fill pressures.
Fig. 12 Primary solar loop components
ab
c
d
e

13. Close the fill and drain valves (d) (c).
14. Put the check valves into operating position by turning
the ball valves (a) (b) to position 0° (see page 10).
15. Connect the controller to the power supply. Set the
solar circuit pump in the manual mode to ON.
16. Let the solar circuit pump run at maximum rotation
speed for at least 15 minutes.
17. If necessary, increase the system pressure to the
final fill pressure again.
18. Remove the hoses of the flush and fill station and
screw the sealing caps onto the fill and drain valves.
The sealing caps only serve to protect the valves
against dirt. They are not designed to take up high
system pressures, the valves must be closed.
5724 267 v1.0
15
Start-up
Fig. 13 Fill and drain valve positions after start-up
IMPORTANT
After commissioning, vent the solar system daily and then
weekly or monthly, depending on the vented air quantity.
Thus, an optimum operation of the solar installation is
ensured. Check the system pressure after venting and
increase it to the specified operating pressure, if necessary.
WARNING
Open the vent plug carefully. The escaping medium can
have a temperature of more than 212° F (100° C) and
cause scalding.
The air-scoop with manual vent valve (shown as (j) on
page 7) is used to vent the solar system. To ensure perfect
deaeration of the solar loop, the flow velocity must be at
least 0.3 m/s in the flow line.
Pipe diameter Min. flow rate at 0.3 m/s
(US gpm)
b”0.63
c”1.49
Fig. 14 Cutaway of air-scoop
CORRECT
INCORRECT
Refer to the separate instruction regarding
the controller
Air-scoop
Flushing the heat exchanger (continued)

16
Start-up
5724 267 v1.0
Setting the flow rates
IMPORTANT
The system must be clean and free of air and contaminants
to ensure a correct measurement.
Refer to the Vitosol Start-up, Service and
Operating Instructions for the correct
adjustment of the flow rate.
1. Switch on the pumps at the controller in manual mode.
[ Main menu \ Manual operation \ All relays: ON ]
2. Set the desired speed level (I to III) of the solar pump
to obtain the required flow rate. The current flow rate
can be read at the Flowmeter.
3. Set the speed level of the storage tank circuit pump to
obtain at most the same flow rate as in the solar loop.
4. Switch the relays at the controller to automatic mode.
[Main menu \ Manual operation \ All relays: AUTO ]
5. Mount the insulating front shell.
Fig. 15 DN 20 Flowmeter
Scale: 0.1 - 4 US gpm
Reading edge = Top edge of the turbine

5724 267 v1.0
Draining the solar circuit
17
Service
WARNING
The escaping medium may be very hot. Place the
collecting container so that anyone standing nearby are
not in danger of scalding when the solar system is being
emptied.
1. Disconnect power supply to the controller and make
sure that an accidental restart is not possible.
2. Open the check valves in the supply and return ball
valves (a) (b) by turning them to position 45° (see
page 13).
3. Connect a heat-resistant hose to the fill valve (h).
Make sure that the solar fluid being drained is collected
in a heat-resistant container.
4. Open the fill valve (c) of the solar station.
5. Open a vent valve that may be present at the highest
point of the solar system.
6. Dispose of the solar fluid observing the local
regulations.
ab
c
Fig. 16 Primary solar loop components

18
5724 267 v1.0
Service
Parts
Solar-Divicon-HX
Model No. Order No.
DN20 7834 370
DN25 7834 371
Ordering Replacement Parts:
Order replacement components from
your Viessmann distributor.
Parts
100 Wall-mount bracket,
559 x 185 x 2 mm
110 Hose, transparent,
d= 10 x 2 mm
200 Insulation jacket
210 Mounting kit, SCU 123
220 Solar Control Unit SCU 123
Other Parts (not illustrated)
400 Installation and Service
Instructions
401 Parts List
Product may not be exactly as illustrated.

5724 267 v1.0
19
Service
Parts
Solar-Divicon-HX
300 Split ring compression,
fitting, ¾”
302 Ball valve, supply,
¾” x ¾”
304 Thermometer, 32-320°F
(red)
306 Heat exchanger
308 Gasket, 24 x 17 x 2 mm
310 Flange elbow G,
¾” x ¾”
312 Plug, 3/8”
314 Stainless steel tube
316 Vent plug, 3/8”
318 Air separator
320 Stainless steel tube
322 Flange elbow,
90° x F ½”
324 Flow meter
326 Cap, ¾”
328 Gasket, 30 x 21 x 2 mm
330 Solar Circulation pump
332 Half union, G 1”
334 Thermometer, 32-320°F
(blue)
336 Ball valve, return
¾” x ¾”
338 Pressure relief valve,
SV 6 bar / 87psig
340 Lock nut, ¾”
342 Stainless steel tube,
d = 18 x 1 cm
344 Tee, 2 x ¾” x ¾”
346 Double nipple,
¾” with O-ring
348 Stainless steel tube,
d = 18 x 1 cm
350 Flange fitting ¾” x ¾”
352 Half union, G 1¼”
354 DHW Circulation pump
Wilo S21BU
356 Gasket, 38 x 27 x 2 mm
358 Adaptor, 1¼” x 1”
360 Stainless steel tube,
d = 22 x 1.2 mm
362 Flange nipple, ¾” x ¾”
364 Temperature sensor
366 Piston valve DN20,
2 x ¾”
368 Stainless steel tube,
d = 22 x 1.2 cm
370 Temperature Sensor,
PT1000
372 Clip, d = 8 mm
374 Flange elbow G ¾” x 1”
Product may not be exactly as
illustrated.

5724 267 v1.0
Technical Data
Characteristics
20
Start-up and Maintenance
Start-up and Maintenance
Primary (solar) loop pump charts
Fig. 18 Pump curve chart and friction chart - DN 25
Fig. 17 Pump curve chart and friction chart - DN 20
pressure (fthead)
pressure (mwc)
flow rate (gal/min)
flow rate (L/h)
pressure (fthead)
pressure (mwc)
flow rate (gal/min)
flow rate (L/h)