Installation instructions for heating engineers Vitosol 200 Type D10, D20 and D30 Direct flow vacuum tube collector VITOSOL 200 4/2004
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 system/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. 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. Safety instruction Denotes information which must be observed to prevent accidents and material losses. Observe maximum load and distance from roof edge for the substructure installed on the roof to DIN 1 055. 2
Index Page Vertical installation on top of roof Component summary........................................................................................................... 4 Installation with roof ties..................................................................................................... 6 Installation without roof ties (roofs with higher snow loads)............................. 12 Installation without roof ties (e.g. on sheet steel roofs)........................................ 16 Fitting the mounting rails.................................................................................................... 18 Fitting the connection housing.......................................................................................... 19 Horizontal installation on top of roof Component summary........................................................................................................... 20 Installation with roof ties..................................................................................................... 22 Installation without roof ties (roofs with higher snow loads)............................. 27 Installation without roof ties (e.g. on sheet steel roofs)........................................ 30 Fitting the horizontal mounting rails.............................................................................. 31 Fitting the connection housing.......................................................................................... 32 Fitting the vertical mounting rails.................................................................................... 34 Installation on flat roofs Component summary........................................................................................................... 36 Installation.................................................................................................................................. 38 Installation on walls Component summary........................................................................................................... 40 Installation.................................................................................................................................. 42 Water connections Connecting the connection housing............................................................................... 44 Fitting the connection set.................................................................................................... 46 Fitting the vacuum tubes and collector temperature sensor............................... 48 Installation................................................................................................................................. 50 3
Vertical installation on top of roof Component summary 1 2 3 4 5 6 7 8 9 qp qq qw qe qr qt qz qi qo we wr wt wz wu wi wo ep eq ew ee er et 4
Vertical installation on top of roofs (cont.) Roof tile integration 1 Batten 38 58 2 430 mm Batten 30 100 2 430 mm 2 Zinc plated countersunk chipboard screw (Spax s) 6 80 mm 3 Zinc plated countersunk chipboard screw (Spax s) 5 30 mm 5 Roof tie with clamping bolt qq Mounting plate + 2 clamping bolts Roof tile integration (higher snow loads) qp Solar panel support with clamping bolt qq Mounting plate + 2 clamping bolts Slate integration 4 Zinc plated countersunk chipboard screw (Spax s) 6 30 mm 7 Roof tie with clamping bolt qq Mounting plate + 2 clamping bolts Plain tile integration 3 Zinc plated countersunk chipboard screw (Spax s) 5 30 mm 6 Roof tie with clamping bolt qq Mounting plate + 2 clamping bolts Corrugated roofing sheet integration (profile 5, 6 and 8) 8 Roof tie with clamping bolt for corrugated roofing sheet profile 5 and 6 9 Roof tie with clamping bolt for corrugated roofing sheet profile 8 qq Mounting plate + 2 clamping bolts For all types of roof cover qi Mounting rail with tube holders qo Mounting rail with tube support we Connection housing wr Vacuum tube wt Retaining rubber Accessories for one panel array to 6 m 2 absorber area wz Connecting pipe wu Profile clip wi Thermal insulation from 6 m 2 absorber area (adjacent collector arrays connected in series) wu Profile clip wi Thermal insulation wo Z connecting pipe ep Plug eq Plug with air vent valve Connection set, comprising wu Profile clip ep Plug ew Connecting pipe (short) ee Connecting pipe (long) er Locking ring fitting (elbow 90º), 22 mm et Support sleeve Fixing without roof ties e.g. on sheet steel roofs qw Fixing plate with 2 clamping bolts qe Fixing bracket qr Locking bolt qt Washer qz Hexagon nut 5
Vertical installation on top of roofs (cont.) Install the panel array level or slightly inclined (approx. 10 mm) towards the connection side to ensure complete venting. Installation with roof ties Summary A B C D E F G C D A Mounting rail B Roof tie C Additional batten, 38 58 mm (only for roof tile integration) D Additional batten, 30 100 mm (only for roof tile integration) E Vacuum tube F Connection housing G Mounting plate 6 Dim. X according to the width of the tile head at the back.
Vertical installation on top of roofs (cont.) Combination A mm B mm C mm D mm E mm D20/D20 800 1 000 1 514 800 1 000 2 953 75 D20/D30 800 1 000 1 864 1 400 1 600 3 663 75 D30/D 30 1 400 1 600 2 223 1 400 1 600 4 372 74 Centre mounting rails when fitting one collector only. 7
Vertical installation on top of roofs (cont.) Fitting roof ties for roof tile integration 2. 2 6 5 5. 3 2 1 30 x 100 1 38 x 58 3. 4. 1. Push up two rows of roof tiles in accordance with the dimensions shown in the illustration on page 6. 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 page 6. 3. Hook the roof ties into the battens in accordance with the dimensions shown in the illustration on page 7. 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. 6. Remove the roof tie clamping bolt. 8
Vertical installation on top of roofs (cont.) 8. qq 7. 7. Set the mounting plate onto the roof ties of the top row and align; insert dowel pin. 8. Fit clamping bolts to the roof ties; do not tighten the screws yet. Continue with mounting rail installation on page 18. 5 Fitting roof ties for slate integration 6. 7. 5. qq 4 3. 2. 1. Mark the position of the roof ties in accordance with the dimensions shown in the illustration on page 7. 2. Remove slates from the roof tie location. 7 3. Secure the roof ties to the roof face. Utilise commercial lead flashing to prevent the ingress of moisture. 4. Cover the roof. 5. Remove the roof tie clamping bolt. 6. Set the mounting plate onto the roof ties of the top row and align; insert dowel pin. 7. Fit clamping bolts to the roof ties; do not tighten the screws yet. Continue with mounting rail installation on page 18. 9
Vertical installation on top of roofs (cont.) Fitting roof ties in the case of plain roof tile integration 6 5. 4. 3 2. 1. Mark the position of the roof ties in accordance with the dimensions shown in the illustration on page 7. 2. Remove tiles from the roof tie location. 3. 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. Remove the roof tie clamping bolt. 0 7. qq 6. Set the mounting plate onto the roof ties of the top row and align; insert dowel pin. 7. Fit clamping bolts to the roof ties; do not tighten the screws yet. 6 6. 8. Cover the roof; match tiles with an angle cutter. Trim tiles approx. 35 mm. Continue with mounting rail installation on page 18. 10
Vertical installation on top of roofs (cont.) Fitting roof ties in the case of corrugated roofing sheet integration 5. qq 1. Mark the position of the roof ties in accordance with the dimensions shown in the illustration on page 7. 6. 4. 8,9 2. 3. 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 8 mm (on site provision) to the battens. 4. Push on the top part of the roof ties. 5. Set the mounting plate onto the roof ties of the top row and align; insert dowel pin. 6. Fit clamping bolts to the roof ties; do not tighten the screws yet. Continue with mounting rail installation on page 18. 11
Vertical installation on top of roofs (cont.) Installation without roof ties (roofs with higher snow loads) Summary A EB C D E F G A Plastic tile (on site), made by Klöber B Mounting rail C Solar panel support D Vacuum tube E Additional battens (on site) F Connection housing G Mounting plate Dim. X according to the width of the tile head at the back. 12
Vertical installation on top of roofs (cont.) Combination A mm B mm C mm D mm E mm F mm G mm H mm D20/D20 900 600 900 262.5 75 2 953 D20/D30 900 600 1 800 900 262.5 75 3 663 D30/D30 1 800 900 300 1 800 900 113.0 74 4 372 Centre mounting rails when fitting one collector only. 13
Vertical installation on top of roofs (cont.) Fitting solar panel supports 9. qq 11. 8. 1. 8. qp 10. 3x25 7. qp 3x25 7. 6 4. 6 4. 14
Vertical installation on top of roofs (cont.) 1. Secure the solar panel supports to the plastic tile (screws supplied with the tile). Note In the top row, fit the solar panel supports turned 180 º against the lower row. 2. Mark the position of the plastic tile in accordance with the dimensions shown in the illustration on page 13. 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 of the next lower row of tiles. 5. Hook in plastic tile. 8. Fill the drilled holes with silicone, and secure the tile with stainless steel plumbers screws to the additional batten. 9. Remove the clamping bolts from the top row of solar panel supports. 10. Position and align the mounting plate on the solar panel elements. 11. Fit clamping bolts to the solar panel supports; do not tighten the screws yet. 12. Cover the remaining roof area with tiles. Continue with mounting rail installation on page 18. Note For roofs with small batten cross section missing counter battens boarding bend the claws on the plastic tile sideways. 6. Cover the areas alongside with tiles. 7. Lightly secure the plastic tile. 15
Vertical installation on top of roofs (cont.) Installation without roof ties (e.g. on sheet steel roofs) Summary A B C D E A Mounting bracket B Mounting rail C Vacuum tube D Connection housing E Fixing plate 16
Vertical installation on top of roofs (cont.) Fitting mounting rails 2. qo qw 1. qr qe qt qz qi 1. *1 When fitting several collectors side by side, maintain a clearance between the mounting rails in accordance with the illustration on page 7 and 13. Collector type D20 D30 A mm 800 1 000 1 400 1 600 1. Secure the fixing plates and brackets to the substrate in accordance with the dimensions shown in the illustration. 2. Secure the mounting rails with the locking bolt to the fixing bracket. Locking bolt must be turned 90º. Continue with fitting the connection housing on page 19. 17
Vertical installation on top of roofs (cont.) Fitting mounting rails qo qq qi 1. 2. *1 When fitting several collectors side by side, maintain a clearance between the mounting rails in accordance with the illustration on page 7 and 13. 1. Position the mounting rails with tube supports on the mounting plate; click the clamping bolts into position, but do not tighten them yet. 2. Position the mounting rails with tube supports on the lower row of roof ties or the solar panel supports; click the clamping bolts into position, but do not tighten them yet. 18
Vertical installation on top of roofs (cont.) Fitting the connection housing we qq,qw Position the connection housing on the mounting plate or the fixing plates; click the clamping bolts into position, but do not tighten them yet. Please note The tube holders on the mounting rail must be in line with those in the connection housing. Where necessary, align with a piece of string. Where several collectors are installed side by side, continue with fitting the connection housing on page 44. Otherwise, continue with fitting the connection set on page 46. 19
Horizontal installation on top of roof Component summary 1 2 3 4 5 6 7 8 9 qp qq qw qe qr qt qz qu qi qo wp wq ww we wr wt wz wu wi wo ep eq ew ee er et 20
Horizontal installation on top of roofs (cont.) Roof tile integration 1 Batten 38 58 2 430 mm Batten 30 100 2 430 mm 2 Zinc plated countersunk chipboard screw (Spax s) 6 80 mm 3 Zinc plated countersunk chipboard screw (Spax s) 5 30 mm 5 Roof tie with bracket Roman tile cover (higher snow loads) qp Solar panel support with bracket Plain tile integration 3 Zinc plated countersunk chipboard screw (Spax s) 5 30 mm 6 Roof tie with bracket Slate integration 4 Zinc plated countersunk chipboard screw (Spax s) 6 30 mm 7 Roof tie with bracket Corrugated roofing sheet integration (profile 5, 6 and 8) 8 Roof tie with bracket for corrugated roofing sheet profile 5 and 6 9 Roof tie with bracket for corrugated roofing sheet profile 8 Fixing without roof ties e.g. on sheet steel roofs Items qq to we For all types of roof cover qq Fixing plate qw Fixing plate with 2 clamping bolts qe Fixing bracket qr Locking bolt qt Washer qz Hexagon nut qu Mounting rail 2 050 mm qi Mounting rail with tube holders qo Mounting rail with tube support wp Retaining plate (U shaped) wq Retaining plate ww Spacer we Connection housing wr Vacuum tube wt Retaining rubber Accessories for one panel array to 6 m 2 absorber area wz Connecting pipe wu Profile clip wi Thermal insulation from 6 m 2 absorber area (adjacent collector arrays connected in series) wu Profile clip wi Thermal insulation wo Z connecting pipe ep Plug eq Plug with air vent valve Connection set, comprising wu Profile clip ep Plug or eq Plug with air vent valve (only for water connection from below) ew Connecting pipe (short) ee Connecting pipe (long) er Locking ring fitting (elbow 90º), 22 mm et Support sleeve 21
Horizontal installation on top of roofs (cont.) Installation with roof ties Summary A B CD E C D A Mounting rail B Roof tie C Additional batten, 38 58 mm (only for roof tile integration) D Additional batten, 30 100 mm (only for roof tile integration) E Connection housing Dim. X according to the width of the tile head at the back. Dimension A, see table on page 23. 22
Horizontal installation on top of roofs (cont.) Combination A mm B mm C mm D20 930 1 290 D30 1 650 2 000 D20/D20 930 1 290 1 470 1 700 2 490 2 800 D20/D30 930 1 290 1 470 1 700 3 110 3 500 D30/D20 1 650 2 000 2 180 2 420 3 110 3 500 D30/D30 1 650 2 000 2 180 2 420 3 740 4 220 23
Horizontal installation on top of roofs (cont.) Fitting roof ties for roof tile integration 2. 2 5 5. 3 2 1 30 x 100 1 38 x 58 3. 4. 1. Push up the roof tiles in accordance with the dimensions shown in the illustration on page 22 and 23. 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 page 22. 3. Hook the roof ties into the battens in accordance with the dimensions shown in the illustration on page 23. 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 fitting horizontal mounting rails on page 31. 24
Horizontal installation on top of roofs (cont.) Fitting roof ties in the case of plain roof tile integration 6 4. 3 2. 1. Mark the position of the roof ties in accordance with the dimensions shown in the illustration on page 23. 2. Remove tiles from the roof tie location. 3. 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; match tiles with an angle cutter. Trim tiles approx. 35 mm. Continue with fitting horizontal mounting rails on page 31. 25
Horizontal installation on top of roofs (cont.) Fitting roof ties for slate integration 7 3. 4 2. 1. Mark the position of the roof ties in accordance with the dimensions shown in the illustration on page 23. 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 fitting horizontal mounting rails on page 31. Fitting roof ties in the case of corrugated roofing sheet integration 4. 8,9 3. 1. Mark the position of the roof ties in accordance with the dimensions shown in the illustration on page 23. 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. 2. 3. Secure the roof ties with hexagon woodscrews 8 mm (on site provision) to the battens. 4. Secure the top of the roof ties and mounting brackets. Continue with fitting horizontal mounting rails on page 31. 26
Horizontal installation on top of roofs (cont.) Installation without roof ties (roofs with higher snow loads) Summary A BC D E E A Plastic tile (on site), made by Klöber B Mounting rail C Solar panel support D Connection housing E Additional battens (on site) Dim. X according to the width of the tile head at the back. 27
Horizontal installation on top of roofs (cont.) Combination A mm B mm C mm D mm E mm D20 930 1 290 D30 920 1 040 1 650 2 000 D20/D20 930 1 290 1 470 1 700 2 490 2 800 D20/D30 930 1 290 1 470 1 700 2 496 2 760 3 110 3 500 D30/D20 920 1 040 1 650 2 000 2 180 2 420 3 110 3 500 D30/D30 920 1 040 1 650 2 000 2 180 2 420 3 110 3 500 3 740 4 220 28
Horizontal installation on top of roofs (cont.) Fitting solar panel supports 1. 8. qp 1. 3x25 8. 7. qp 3x25 4. 7. 6 6 4. 1. Secure the solar panel 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 page 28. 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 of the next lower row of tiles. 5. Hook in plastic tile. Note For roofs with small batten cross section missing counter battens boarding bend the claws on the plastic tile sideways. 6. Cover the areas alongside with tiles. 7. Lightly secure the plastic tile. 8. Fill the drilled holes with silicone, and secure the tile with stainless steel plumbers screws to the additional batten. 9. Cover the remaining roof area with tiles. Continue with fitting horizontal mounting rails on page 31. 29
Horizontal installation on top of roofs (cont.) Installation without roof ties (e.g. on sheet steel roofs) Summary A B C Collector type D20 D30 A mm 930 1 290 1 650 2 000 A Mounting bracket B Mounting rail C Connection housing 30
Horizontal installation on top of roofs (cont.) Fitting horizontal mounting rails qz qt qe qr qu 1. Secure the fixing brackets to the substrate in accordance with the dimensions shown in the illustrations. 2. Secure the mounting rails to the fixing bracket. Locking bolt must be turned 90º. Continue with fitting the connection housing on page 32. 1. 2. Fitting horizontal mounting rails 0 qu Secure the mounting rails with brackets to the roof ties or solar panel supports; maintain dimension 170 mm on the side of the connection housing. 56,, 7, 8, 9, qp 31
Horizontal installation on top of roofs (cont.) Fitting the connection housing we A qq 1. Position the fixing plate as a drilling template onto the bottom of the connection housing (50 mm from the outside edge), and drill holes A with a 8.5 mm bit. 50 A Note Locking bolts must be turned 90 º. 2. Secure the fixing plate flush with the lower mounting rail. 3. Secure the fixing plate flush with the upper mounting rail. 4. Click the connection housing into the clamping bolts. 5. Secure the connection housing with locking bolts to the fixing plates. Do not tighten the screws yet. 32
Horizontal installation on top of roofs (cont.) 4. 3. we qw qz qt qr qu qr 5. 2. qq qz qt qu 33
Horizontal installation on top of roofs (cont.) Fitting vertical mounting rails qo qe 3x 1. 2. qo qq qw qu qi qi 4. qr wq wp 6. 3. 5. qt qz qu 34
Horizontal installation on top of roofs (cont.) Please note Locking bolts must be turned 90 º. 1. Secure the fixing brackets to the mounting rails in accordance with the dimensions shown. 2. Secure the mounting rails to the fixing bracket. 3. Secure the retaining plate (U shaped) to the lower mounting rail. 4. Slide the mounting rail with the tube holders into the retaining plate. Please note The tube holders on the mounting rail must be in line with those in the connection housing. Where necessary, align with a piece of string. 5. Push the locking bolt through the slot in the plate into the mounting rail with the tube holders, and secure the retaining plate. 6. Secure the retaining plate to the mounting rail. If a second collector is fitted above the first: Secure spacers to the top and bottom of the fitted mounting rails. Continue as described above. Tighten all clamping bolts. ww Continue with connecting the connection housing on page 44. 35
Installation on flat roofs Component summary 1 2 3 4 5 6 7 qi qo we wr wt wz wu wi wo ep eq ew ee er et 36
Installation on flat roofs (cont.) 1 Fixing plate with 2 clamping bolts 2 Mounting bracket 3 Rawl plug S 10 4 Washer 5 Hexagon screw 8 70 mm 6 Locking bolt 7 Hexagon nut qi Mounting rail with tube holders qo Mounting rail with tube support we Connection housing wr Vacuum tube wt Retaining rubber Accessories for one panel array to 6 m 2 absorber area wz Connecting pipe wu Profile clip wi Thermal insulation from 6 m 2 absorber area (adjacent collector arrays connected in series) wu Profile clip wi Thermal insulation wo Z connecting pipe ep Plug eq Plug with air vent valve Connection set, comprising wu Profile clip ep Plug ew Connecting pipe (short) ee Connecting pipe (long) er Locking ring fitting (elbow 90º), 22 mm et Support sleeve 37
Installation on flat roofs (cont.) Installation Secured against slippage Installation height above ground m up to 8 8 to 20 20 to 100 Weight of supports per support A *1 per support B *1 kg kg Type D20 22 26 Type D30 33 39 Type D20 44 46 Type D30 65 69 Type D20 66 67 Secured against lifting Installation height above ground m up to 8 8 to 20 20 to 100 Weight of supports Type D20 Type D30 per support A *1 kg 15 22 per support B *1 kg 18 27 *1 For supports, see drawing on page 39. Type D20 31 32 Type D30 46 49 Type D20 48 48 Type D30 98 101 Type D30 72 73 When fitting several collectors side by side, maintain a clearance between the mounting rails in accordance with the illustration on page 7. 1. Position supports on a solid foundation on protective mats; ensure that the collector array can be oriented towards south (longitudinal tube axis aligned east west). 2. Secure the fixing brackets to supports B in accordance with the dimensions shown (screws provided on site). 3. Secure the fixing brackets to supports A in accordance with the dimensions shown (screws provided on site). 4. Secure the mounting rails to the fixing bracket. Locking bolt must be turned 90º. 38 5. Position the connection housing on the fixing plates; click the clamping bolts into position and tighten them. Please note The tube holders on the mounting rail must be in line with those in the connection housing. Where necessary, align with a piece of string. Where several collectors are installed, continue with connecting the connection housing on page 44. Otherwise, continue with fitting the connection set on page 46.
Installation on flat roofs (cont.) we 5. A qo 5 4 2 3 3. qi 4. 1 5 4 6 4. 2 3 2. B 2 47 A Support A B Support B C Clamping bolt Collector type D20 D30 A mm 930 1 290 1 650 2 000 39
Installation on walls Component summary 1 2 3 4 5 6 7 8 qi qo we wr wt wz wu wi wo ep eq ew ee er et 40
Installation on walls (cont.) 1 Fixing plate with 2 clamping bolts 2 Mounting bracket 3 Rawl plug S 10 4 Washer 5 Hexagon screw 8 70 mm 6 Locking bolt 7 Hexagon nut 8 Locking profile qi Mounting rail with tube holders qo Mounting rail with tube support we Connection housing wr Vacuum tube wt Retaining rubber Accessories for one panel array to 6 m 2 absorber area wz Connecting pipe wu Profile clip wi Thermal insulation from 6 m 2 absorber area (adjacent collector arrays connected in series) wu Profile clip wi Thermal insulation wo Z connecting pipe ep Plug eq Plug with air vent valve Connection set, comprising wu Profile clip ep Plug or eq Plug with air vent valve (only for water connection from below) ew Connecting pipe (short) ee Connecting pipe (long) er Locking ring fitting (elbow 90º), 22 mm et Support sleeve 41
Installation on walls (cont.) Installation 1 4. 2. 6 47 3. 2 1. 3 3. we qo 8 qi 6 4 7 Collector type A mm 5. D10 450 645 D20 D30 800 1 000 1 400 1 600 42
Installation on walls (cont.) When fitting several collectors, maintain a clearance between the mounting rails in accordance with the illustration on page 7. 1. Secure the fixing brackets to the wall in accordance with the dimensions shown (screws provided on site). 2. Secure the fixing plates to the wall in accordance with the dimensions shown (screws provided on site). 3. Secure the mounting rails to the fixing bracket. Locking bolt must be turned 90º. 5. Secure the locking profile with the locking bolt to the mounting rails. Locking bolt must be turned 90º. Where several collectors are installed above each other, continue with connecting the connection housing on page 44. Otherwise, continue with fitting the connection set on page 46. 4. Position the connection housing on the fixing plates; click the clamping bolts into position and tighten them. Please note The tube holders on the mounting rail must be in line with those in the connection housing. Where necessary, align with a piece of string. 43
Water connections Connecting the connection housing Interconnecting pipes must be free from damage and contamination. Lubricate all plug in joints (O ring seals) on the collectors only with the special grease supplied with the connection set. Up to 6 m 2 absorber area A wu wi B wz we 3. 1. 2. 5. A Flared coupling B Groove for profile clip 1. Insert the interconnecting pipes into the flow and return connectors. 2. Push the second connection housing carefully against the first and insert the interconnecting pipes. 3. Fit the profile clips onto the flared coupling and the interconnecting pipes to secure the assembly. 4. Secure the connection housing. 5. Cut the thermal insulation longitudinally, fit it and join its cut faces with adhesive. 44
Water connections (cont.) From 6 m 2 absorber area (where collector arrays installed side by side are connected in series) A ep wu B wo eq we 1. 5. 4. 2. 3. 7. A Flared coupling B Groove for profile clip 1. Insert the interconnecting pipe into the flow connector. 2. Insert drain plugs into the return connector. 3. Push the second connection housing carefully onto the first, and insert the interconnecting pipe into the return connector. 5. Fit the profile clips onto the flared coupling and the interconnecting pipes or plug to secure the assembly. 6. Secure the connection housing. 7. Cut the thermal insulation longitudinally, fit it and join its cut faces with adhesive. 4. Insert the plug with air vent valve into the flow connector of the second connection housing. 45
Water connections (cont.) Fitting the connection set eq wu D ep we A D EW 3. 2. 4. 5. 1. C BeE er et A Flared coupling B Groove for profile clip C Return connector; to collector D Flow connector; to DHW cylinder 46
Water connections (cont.) When assembling the locking ring fitting, observe the following: All pipe ends must be square and deburred. Push the union nut and the locking ring onto the pipe and lightly lubricate the threads with oil. Push the pipe into the compression fitting as far as it will go. Initially turn the union nut by hand, then tighten with an open ended spanner by a further ¾ turn. Do not use annealed copper pipes with compression fittings. 1. Insert the plug or plug with air vent valve until they bottom out. Please note Use the plug with air vent valve, if the water connections from the collector array are routed downwards. 2. Insert the connecting pipes until they bottom out. 3. Fit the profile clips onto the flared coupling, plugs and pipes to secure the assembly. 4. Thread the locking ring fittings onto the connecting pipe. 5. Insert into the support sleeves of the solar circuit pipes. Make the connection between the panel array and the solar circuit fittings. 6. Tighten all clamping bolts and screws. 47
Water connections (cont.) Fitting vacuum tubes and collector temperature sensor Safety instruction Wear gloves and safety goggles to prevent burns and injuries. wt wr A B C 7. 8. 6. 5. 2. 3. D 4. qi A Flow connection B Return connection C Adhesive tape D Template Wall Pitched roof Flat roof 48
Water connections (cont.) Safety instruction Only rotate the vacuum tubes with locking ring released. Otherwise there is a risk of breakage. 1. Open the connection housing and remove the thermal insulation mat. 2. Remove the protective cap from the vacuum tubes. 3. Click the vacuum tubes into the tube holders on the mounting rails until they bottom out inside the coupling. Ensure no part of the thermal insulation is pinched in the process. 4. For roofs with deviations from due south: Adjust the angle of inclination of the vacuum tube absorber using the template supplied by turning the tubes around their own axis (coated side of the absorber oriented towards the sun). 6. Secure the vacuum tubes with the retaining rubber. 7. Fit the collector temperature sensor in the connection housing position that is furthest west. Insert the sensor into the holder until it bottoms out. Route the sensor lead in the recess of the thermal insulation and secure with adhesive tape. 8. Secure the sensor with PG thread onto the casing. 9. Carefully position the thermal insulation mat and close the connection housing. 5. Initially tighten the locking ring fitting by hand. For this, hold the soldered hexagon nut with an open ended spanner SW 17. Then tighten the locking ring fitting by 1½ turns. 49
Installation Safety instruction Use only gunmetal and brass fittings and copper pipes for the installation. Never use galvanized pipes, galvanized fittings or graphitised gaskets. Use hemp only in conjunction with pressure and temperature resistant sealants (e.g. Viscotex Solarpaste, Locher, CH 9450 Altstätten). Never step onto solar panels. Never solder near or on the collector. O T A N B T T R M G G VL RL D C L T H K F E A Collector B Solar Divicon C Collecting container D Expansion vessel E Manual solar fill pump F Filling point G Shut off valve 50 H Drain K Fill valve assembly (F, G, H) L DHW cylinder M Air separator N Solar control unit O Air vent valve
Installation (cont.) 1. Route pipes so that they can be completely vented. Install at least one air vent valve at the highest point of the system. Install an air separator at an accessible point in the pipework (see fig. on page 50). 2. Equip the system to EN 12 975 with expansion vessel, safety valve and circulation pump. 3. The expansion vessel must be approved to DIN 4807, and must be arranged with a heat insulating loop. The diaphragms and seals of the expansion vessel and the safety valve must be suitable for the process medium. 4. When operating without Solar Divicon, use only safety valves designed for a max. of 120 ºC and 6 bar bearing the marking "S" (solar) as part of the component identification. 5. Make all unions pressure and temperature resistant (observe the max. standby temperature of the solar panel). For commissioning of the solar heating system, see service instructions. For the calculation of the inlet pressure, see the service instructions. 51
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