VIESMANN
Safety instructions
Please follow these safety instructions closely to prevent accidents and material losses.
Installation, commissioning, inspection, maintenance and repairs must only be carried out by a competent person (heat- ing engineer/installation contractor).
Before working on the equipment/heat- ing system, isolate the power supply (e.g. by removing a separate mains fuse or by means of a main isolator) and safe- guard against unauthorised reconnec- tion.
Repairing components that fulfil a safety function can compromise the safe oper- ation of your heating system. For replacements, use only original spare parts supplied or approved by Viessmann.
Application
For retrofitting solar thermal systems in existing heating systems.
Comprising the following components: Solar-Divicon SR with Vitosolic 100,
type SD1 solar control unit Connection set for connection to the
retrofit cylinder
240
B Non-return valve in the flow and return pipes
C Pre-assembled and sealed valves and the safety assembly with pres- sure gauge
D Circulation pump E Fill and flushing unit F Flow indicator
System examples
There are 2 methods of control: Version A:
Transfer with sensor S3 in DHW cylin- der 2 (existing) Differential temperature control
Version B: Transfer with sensor S3 in DHW cylin- der 1 (retrofit) Control via thermostat function
If it is possible to position the tempera- ture sensor for the DHW circulation diversion in the existing cylinder, we rec- ommend version A.
Application (cont.)
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Main components
Viessmann solar collectors Mono mode DHW cylinder (existing) Solar retrofit system with the following
components: – Solar-Divicon SR – Vitosolic 100, type SD1 – DHW cylinder Vitocell 100-W, type
CUG Wall mounted oil/gas boiler or oil/gas
boiler (existing)
4
1
2
M
2
11
q U
B A
S2 S1
e Z
R 1
R 2
KM BUS
23 0
V / 5
0 H
z S3
A/B For a description of these ver- sions, see page 2
System examples (cont.)
Required equipment
ID: 4605031_0906_01 Pos. Designation 1 Oil/gas boiler or wall mounted oil/gas boiler with 2 Boiler and heating circuit control unit 3 Cylinder temperature sensor 4 Circulation pump for cylinder heating
(integrated for wall mounted oil/gas boiler) qI DHW cylinder 2, mono mode (existing) qP DHW cylinder 1, mono mode (solar retrofit system) qQ Cylinder temperature sensor S2 qW High limit safety cut-out (accessory) qE DHW circulation pump (on site)
(internal/external extension may be required for connecting a wall mounted oil/gas boiler)
qR Thermostatic mixing valve (accessory) eP Solar collectors eQ Collector temperature sensor S1 eW Solar-Divicon SR (solar retrofit system)
with eE Solar circuit pump R1
and eZ Vitosolic 100, type SD1 eU Junction box (on site) eI ON/OFF switch (on site) DHW circulation diversion qT Circulation pump R2 (transfer) (accessory) qU Temperature sensor S3
Installation information
Always install the Solar-Divicon so as to prevent steam from entering the expansion vessel in the event of stag- nation.
The Solar-Divicon is unsuitable for direct contact with swimming pool water.
Every time the system is drained, flush the system with heat transfer medium.
Install a thermal insulation loop if the expansion vessel is installed as high as or higher than the Solar-Divicon.
System examples (cont.)
6
Use only gunmetal, brass fittings, cop- per pipes or Viessmann stainless steel solar circuit pipes for the installation.
Use hemp only in conjunction with pressure and temperature-resistant sealants (e.g. Viskotex solar paste from Locher, CH-9450 Altstätten).
Check the sealing faces for cleanli- ness and damage before assembly.
Installation of the locking ring fittings
All pipes must be cut at right angles and deburred.
Initially turn the union nut by hand, then tighten with an open-ended span- ner by a further ¾ turn.
Never fit annealed copper pipes onto the locking ring fittings.
Installing the DHW cylinder
Vitocell-W installation instruc- tions
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B
8
Installation with copper pipes Insert the support sleeves into the solar circuit pipe and secure with valve connections.
Installation with stainless steel solar circuit pipe Trim and deburr in the valley of the corrugation; do not damage the peak of the corrugation.
Fit the union nut, half washer (in the fifth valley) and guide ring (in the sec- ond valley) and O-rings (in the first and third valley).
Fitting the Solar-Divicon SR
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The expansion vessel can be connected either to the flow or the return. Connec- tion to the return is standard. When con- necting to the flow, a smaller expansion vessel may possibly be selected. Observe the sizing according to the tech- nical guide or the Viessmann calculation program.
Installation with copper pipes Insert the support sleeves into the solar circuit pipe and secure with valve connections.
Installation with stainless steel solar circuit pipe Trim and deburr in the valley of the corrugation; do not damage the peak of the corrugation. Fit the union nut, half washer (in the fifth valley) and guide ring (in the sec- ond valley) and O-rings (in the first and third valley).
Secure the discharge pipe with safety valve A of the safety assembly on site. Place a drip pan underneath (liq- uid seal must be equal to the liquid content of the collectors).
Discharge pipe: – Up to 2 m pipe length, minimum pipe
diameter 20 mm – Up to 4 m pipe length, minimum pipe
diameter 25 mm, up to 2 pipe bends
Making the connection with the expansion vessel
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A
1.
1.
2.
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A
1.
3.
2.
3.
4.
Cylinder temperature sensor S2
The cylinder temperature sensor is already fitted into the sensor well of the threaded elbow.
Should it be necessary to remove it, see step 4 on page 7.
Temperature sensor S3 for transfer of heat
See system example on page 4.
Making the connection with the expansion vessel (cont.)
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Secure inside an existing sensor well in the upper part or with a sensor clip to the cylinder flange (thermally insu- late the temperature sensor).
Instructions for the existing cyl- inder
In the retrofit cylinder in the sensor well
for the temperature sensor.
Vitocell-W installation instruc- tions
Fitting the high limit safety cut-out
Secure the sensor of the high limit safety cut-out with the temperature sensor retainer.
DHW cylinder installation instruc- tions
Electrical connections at the solar control unit
1. Hook the upper insulation shell together with the solar control unit into the hinges.
2. Route the circulation pump power cable out of the lower insulation shell through the aperture into the upper insulation shell.
3. Close the upper insulation shell.
Fitting temperature sensors (cont.)
14
4.
5.
B
A
A Circulation pump power cable B Aperture for sensor leads and power
cable
4. Remove cover from the solar control unit.
5. Open solar control unit and route cir- culation pump power cable through the strain relief fitting into the wiring chamber of the solar control unit.
6. Route sensor leads and power cable through the aperture in the bottom of the solar control unit cover.
7. Make the electrical connections.
Vitosolic 100, type SD1 instal- lation and service instruc- tions
Electrical connections at the solar control unit (cont.)
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When ordering spare parts Quote the part and the item no. of the required part (as per this parts list). Obtain standard parts from your local supplier.
Parts 001 Locking ring fitting with support
sleeve 002 Insulation shells with hinges 003 Ball valve, flow, with red handle 005 Flow indicator with fill and flushing
unit
006 Circulation pump 007 Gasket set 008 Safety assembly 009 Ball valve, return, with blue handle 010 Pressure gauge, 10 bar 014 Set of handles, red and blue 015 Locking disc 016 Air separator 017 Cap
Parts not shown 011 Half washer pack 012 Installation and service instructions
Parts list, Solar-Divicon SR 56
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When ordering spare parts Quote the part and the item no. of the required part (as per this parts list). Obtain standard parts from your local supplier.
Parts 001 Gasket set 002 Pipe bends, flow/return
003 Sensor well with gasket 004 Strain relief fitting 005 Threaded elbow
Parts list, connection set 56
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Parts list, connection set (cont.)
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Power consumption at Output stage I Output stage II Output stage III
40 W 60 W 75 W
Max. pump rate 1.4 m3/h Max. head 5.8 m Flow indicator 2 to 12 l/min Safety valve 6 bar Max. operating temperature 120 °C Max. operating pressure 6 bar Connections 7 Solar circuit (locking ring fitting/stainless steel solar circuit
pipe) 22 mm
0 200 400 600 800 1000 Pump rate in l/h
0 3.3 6.7 10.0 13.3 16.7 20.0 Pump rate in l/min
0 0.2 0.4 0.6 0.8 1.0 1.2 Pump rate in m³/h
A
B
C
The internal pressure drop of the Solar-Divicon SR has been taken into consideration.
A Output stage I B Output stage II
C Output stage III
Commissioning and adjustment
Service instructions of the con- nected components and Vitosolic 100, type SD1 installation and service instructions
Specification (cont.)
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Viessmann Limited Hortonwood 30, Telford Shropshire, TF1 7YP, GB Telephone: +44 1952 675000 Fax: +44 1952 675040 E-mail: info-uk@viessmann.com
Viessmann Werke GmbH&Co KG D-35107 Allendorf Telephone: +49 6452 70-0 Fax: +49 6452 70-2780 www.viessmann.com
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Installation information
Installing the DHW cylinder
Fitting the connection set
Fitting the Solar-Divicon SR
Fitting temperature sensors
Fitting the high limit safety cut-out
Electrical connections at the solar control unit
Parts list, Solar-Divicon SR
Parts list, connection set