VIESMANN. Installation and service instructions. Solar-Divicon SR. Safety instructions. Application. for contractors. Part no and

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1 Installation and service instructions for contractors VIESMANN Solar-Divicon SR Part no and 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 (heating engineer/installation contractor). Before working on the equipment/heating system, isolate the power supply (e.g. by removing a separate mains fuse or by means of a main isolator) and safeguard against unauthorised reconnection. Repairing components that fulfil a safety function can compromise the safe operation 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 10/2009

2 Application (cont.) Solar-Divicon SR (excluding upper insulation shell) A B C D 480 E F 240 A Air separator with manual air vent valve B Non-return valve in the flow and return pipes C Pre-assembled and sealed valves and the safety assembly with pressure 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 cylinder 2 (existing) Differential temperature control Version B: Transfer with sensor S3 in DHW cylinder 1 (retrofit) Control via thermostat function If it is possible to position the temperature sensor for the DHW circulation diversion in the existing cylinder, we recommend version A. 2

3 System examples (cont.) Function description, electrical connections and required adjustments, Vitosolic 100, type SD1 installation and service instructions 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) 3

4 System examples (cont.) Hydraulic installation scheme ID: _0906_01 ep eq S1 S2 ez R2 R1 230 V / 50 Hz ew P qe ee qr qt B qu qw 2 A qu 1 3 qq qp qi M KM BUS S3 A/B For a description of these versions, see page 2 4

5 System examples (cont.) Required equipment ID: _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 stagnation. 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. 5

6 Installation information (cont.) Use only gunmetal, brass fittings, copper 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 cleanliness 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 spanner by a further ¾ turn. Never fit annealed copper pipes onto the locking ring fittings. Installing the DHW cylinder Vitocell-W installation instructions 6

7 Fitting the connection set

8 Fitting the Solar-Divicon SR 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 second valley) and O-rings (in the first and third valley). 8

9 Fitting the Solar-Divicon SR (cont.)

10 Making the connection with the expansion vessel The expansion vessel can be connected either to the flow or the return. Connection to the return is standard. When connecting to the flow, a smaller expansion vessel may possibly be selected. Observe the sizing according to the technical 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 second 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 (liquid 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 10

11 Making the connection with the expansion vessel (cont.) Expansion vessel in the return A

12 Making the connection with the expansion vessel (cont.) Expansion vessel in the flow A Fitting temperature sensors 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. 12

13 Fitting temperature sensors (cont.) Secure inside an existing sensor well in the upper part or with a sensor clip to the cylinder flange (thermally insulate the temperature sensor). Vitocell-W installation instructions Instructions for the existing cylinder In the retrofit cylinder in the sensor well for the temperature sensor. 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 instructions Electrical connections at the solar control unit 1. Hook the upper insulation shell together with the solar control unit into the hinges. 3. Close the upper insulation shell. 2. Route the circulation pump power cable out of the lower insulation shell through the aperture into the upper insulation shell. 13

14 Electrical connections at the solar control unit (cont.) A B 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 circulation pump power cable through the strain relief fitting into the wiring chamber of the solar control unit. 7. Make the electrical connections. Vitosolic 100, type SD1 installation and service instructions 6. Route sensor leads and power cable through the aperture in the bottom of the solar control unit cover. 14

15 Parts list, Solar-Divicon SR 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 15

16 Parts list, Solar-Divicon SR (cont.)

17 Parts list, connection set 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. 003 Sensor well with gasket 004 Strain relief fitting 005 Threaded elbow Parts 001 Gasket set 002 Pipe bends, flow/return 17

18 Parts list, connection set (cont.) Specification Circulation pump (Grundfos) Rated voltage 230 V~ 18

19 Specification (cont.) Power consumption at Output stage I 40 W Output stage II 60 W Output stage III 75 W Max. pump rate 1.4 m 3 /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 22 mm pipe) Expansion vessel 22 mm 19

20 Specification (cont.) Pump station pressure C Pressure in mbar B A Pump rate in l/h Pump rate in l/min Pump rate in m³/h 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 connected components and Vitosolic 100, type SD1 installation and service instructions 20

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24 Printed on environmentally friendly, chlorine-free bleached paper 24 Viessmann Werke GmbH&Co KG D Allendorf Telephone: Fax: Viessmann Limited Hortonwood 30, Telford Shropshire, TF1 7YP, GB Telephone: Fax: Subject to technical modifications.