Viessmann Vitosol Thermal Solar Collectors System Design Guidelines

VITOSOL

System Design Guidelines

Vitosol 200-F

Viessmann solar collectors – the right solution for every application Using solar energy to heat domestic hot water and to provide a backup for space heating

5167 156 v3.1

05/2008

Vitosol 300-T Model SP3

Vitosol 200-F

Flat plate solar collector for installation on pitched and flat roofs, and for freestanding installation

Vitosol 300-T

Vacuum tube solar collector, based on the heat pipe principle, for installation on sloped and flat roofs and for freestanding installation

Safety, Installation and Warranty Requirements

Safety, Installation and Warranty Requirements 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). H Licensed professional heating

contractor The installation, adjustment, service, and maintenance of this equipment must be performed by a licensed professional heating contractor. Please see section entitled “Important Regulatory and Installation Requirements”.

"

H Grounding/lightning protection of the

solar system 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.

CAUTION Avoid scratching or sudden shocks to glass cover of the solar panel.

CAUTION Never step on collectors or solder in close proximity to the glass surface of the solar panel. H Applicability

H Product documentation

Read all applicable documentation before commencing installation. Store documentation near boiler in a readily accessible location for reference in the future by service personnel. For a listing of applicable literature, please see section entitled “Important Regulatory and Safety Requirements”.

"

H Advice 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. H Warranty

Observe maximum load and distance from edge before installing the substructure to the roof. If necessary, consult with a structural engineer to determine if the structure is suitable for installing solar collectors. The collectors must be securely mounted so that the mountings can withstand intense wind conditions and local snow loads.

CAUTION

IMPORTANT Pool water or potable water cannot be pumped directly through the Vitosol collectors. Damage to collectors caused by corrosion, freezing or scaling will void warranty.

Gloves and eye protection must be worn when handling solar panels.

CAUTION Solar panel connection pipes and solar heating fluid can become hot enough to cause severe burns. Extreme caution must be taken if panels have been in a stagnant condition (no flow of fluid).

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Information contained in this and related product documentation must be read and followed. Failure to do so renders warranty null and void.

CAUTION

Vitosol solar collectors 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.

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Contents

Contents Safety General Information Basic Principles of Solar Technology

Page Safety Instructions Important Regulatory and Installation Requirements About these Instructions Product Information Important Regulatory and Installation Requirements Subsidies, Permits and Insurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Solar Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 HExploiting solar energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 H Solar radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 H Global radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 H Exploiting solar energy with collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 H Influence of alignment, inclination and shade on energy yield . . . . . . . . . 10 H Inclination and orientation of collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 H Angle of inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Overall System Optimisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Specification

Construction and Function of Collectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 H Vitosol 200-F – flat panel collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 H Vitosol 300-T – vacuum tube collector based on the heat pipe principle 14 Collector Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Solar coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Collector Installation and Mounting Details . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 H Installation options for different collector types . . . . . . . . . . . . . . . . . . . . . 18 H Vitosol 200-F flat panel collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 H Support weight requirements - Vitosol 300-T . . . . . . . . . . . . . . . . . . . . . . . . 24 General Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Notes on Planning and Operation

Calculating the Required Absorber Surface Area . . . . . . . . . . . . . . . . . . . . . . 27 H Calculating the absorber surface area and DHW cylinder capacity . . . . . 27 H Calculating the absorber surface area for space heating . . . . . . . . . . . . . . 28

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Sizing Pipe Diameters and Circulation Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 31 H Sizing pipe diameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 H Installation examples for Vitosol 200-F, models SV2 and SH2 . . . . . . . . 35 H Collector pressure drop information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 H Sizing pipe circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 H Technical information on the Solar-Divicon . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 H Liquid capacity of solar heating system components . . . . . . . . . . . . . . . . . 37 H Diaphragm expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 H Technical data for the expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 H Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 H High limit safety cut-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 H Thermostatic mixing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3

Contents

Contents (continued)

Page General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 H How to implement the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 System Design 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 H Dual-mode DHW heating with Vitocell-B 100 or Vitocell-B 300 DHW tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 System Design 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 H Dual-mode DHW heating and space heating backup with heating water storage tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 System Design 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 H Dual-mode DHW heating with two DHW tanks . . . . . . . . . . . . . . . . . . . . . . 50 System Design 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 H Dual-mode DHW and swimming pool water heating . . . . . . . . . . . . . . . . . 53 System Design Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 H System with bypass circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 H Bypass circuit with solar cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 H System with energy-saving mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Appendix

Calculation Example Based on the Viessmann ”ESOP” Program . . . . . . . . 58 H Solar heating systm with dual-coil DHW tank . . . . . . . . . . . . . . . . . . . . . . . 58 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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System Designs

4

Safety

Important Regulatory and Installation Requirements Codes The installation of solar heating systems might be governed by individual local rules and regulations for this type of product, which must be observed. The installation of this unit shall be in accordance with local codes. Always use latest editions of codes. Mechanical room Ensure the mechanical room complies with the requirements of the system design guideline and/or technical data manual. The solar storage tank must be installed in a mechanical room which is never subject to freezing temperatures. If not in use and danger of freezing exists in the mechanical room, ensure water in tank is drained.

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 solar heating systems. There are no user serviceable parts on this equipment.

Please carefully read this manual prior to attempting installation. Any warranty is null and void if these instructions are not followed. This product must be installed observing not only the necessary product literature (see list), but also all local, provincial/state plumbing and building codes, as they apply to this product and all periphery equipment. For information regarding other Viessmann System Technology componentry, please reference documentation of the respective product. We offer frequent installation and service seminars to familiarize our partners with our products. Please inquire.

The completeness and functionality of field supplied electrical controls and components must be verified by the heating contractor. These include pumps, valves, air vents, thermostats, temperature and pressure relief controls, etc.

Ensure main power supply to equipment, the heating system, and all external controls has been deactivated. Take precautions in both instances to avoid accidental activation of power during service work. 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.

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Technical literature Literature applicable to all aspects of the Vitosol: - Technical Data Manual - Installation Instructions - Start-up/Service Instructions - Operating Instructions and User’s Information Manual - System Design Guidelines

5

General Information

About these Instructions Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below.

WARNING Indicates an imminently hazardous situation which, if not avoided, could result in substantial product/property damage, serious injury or loss of life.

CAUTION Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or product/property damage.

IMPORTANT

Warnings draw your attention to the presence of potential hazards or important product information.

Cautions draw your attention to the presence of potential hazards or important product information.

Helpful hints for installation, operation or maintenance which pertain to the product.

This symbol indicates that additional, pertinent information is to be found in the adjacent column.

This symbol indicates that other instructions must be referenced.

Product Information Vitosol 200-F, Models SV2, SH2 Flat panel solar collector with 25 ft.2 / 2.3 m2 collector area. Max. stagnation temperature 430°F / 221°C Max. operating pressure 87 psig / 6 bar

Max. stagnation temperature 302°F / 150°C Max. operating pressure 87 psig / 6 bar

6

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Vitosol 300-T, SP3 Series Vacuum tube solar collector with 22 and 32 ft.2 / 2 and 3 m2 collector area.

Basic Principles of Solar Technology

Subsidies, Permits and Insurance Solar heating systems for DHW or swimming pool heating are subsidised by many regional and local authorities. Request information about subsidies from your local authority. Further information is available from our sales offices.

Your local planning office will be able to advise you about whether solar heating systems need planning permission.

The sun has provided the earth with light and heat for billions of years. Without it, our existence on earth would be impossible. We have been using the sun’s heat since time immemorial. In summer, it heats our buildings directly, while in winter we make use of solar energy stored in the form of wood, coal, oil and gas, to provide heat for our buildings and domestic hot water. To protect fuel reserves, the heating industry has committed itself to finding more responsible ways of handling these precious resources, which have accumulated naturally over millions of years. One rational way of achieving this aim is to make direct use of solar energy by means of collectors.

Thanks to the use of highly sophisticated collectors and a perfectly matched overall system, the economic use of solar energy is no longer a futuristic vision, but a proven everyday reality. Considering that fuel prices will continue to rise in the years ahead, investing in a solar heating system can be viewed as a ”genuine” investment in the future.

Viessmann solar collectors are tested for impact resistance, incl. hail impact, in accordance with DIN EN 12975-2. Nevertheless, we would recommend you include the collectors in your building insurance, to protect you from losses arising from any extraordinary natural phenomenon. Our warranty excludes such losses.

Solar Energy

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Exploiting solar energy

7

Basic Principles of Solar Technology

Solar Energy

(continued)

Solar radiation Solar radiation represents a flow of energy irradiated uniformly in all directions by the sun. Of that energy, an output of 429 Btu/h/ft.2 or 1.36 kW/m2, the so-called solar constant, hits the outer earth’s atmosphere.

S

RT

Diffused celestial radiation Direct solar radiation Wind, rain, snow, convection Convection losses Conduction losses

Heat radiation of the absorber Heat radiation of the glass cover Useful collector output Reflection RT Return S Supply

Global radiation

direct radiation diffused radiation

5000 4000 3000 2000 1000 0 Jan.

Feb.

March

April

May

June

July

Aug.

Sept.

Oct.

Nov.

Dec.

After penetrating the earth’s atmosphere, the solar radiation is reduced by reflection, dispersion and absorption by dust particles and gaseous molecules. That portion of this radiation which passes unimpeded through the atmosphere to strike the earth’s surface is known as direct radiation. The portion of the solar radiation which is reflected and/or absorbed by dust particles and gas molecules and irradiated back strikes the earth’s surface indirectly is known as diffused radiation. The total radiation striking the earth’s surface is the global radiation Eg, i.e., global radiation = direct radiation + diffused radiation. In the latitudes of North America, the typical global radiation under optimum conditions (clear, cloudless sky at midday) amounts to a max. of 317 Btu/h/ft.2 or 1 000 W/m2. With solar collectors, as much as 75 % of this global radiation can be utilised, depending on the type of collector.

8

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Solar irradiation in Wh/(m2 x d)

6000

Basic Principles of Solar Technology

Solar Energy

(continued)

Exploiting solar energy using solar collectors The useful energy which a collector can absorb depends on several factors. The main factor is the total solar energy available.

The amount of global energy varies from location to location (see maps below).

The type of collector, as well as its inclination and orientation, are also very important (see page 10). If the solar installation is to be operated economically, careful dimensioning of the system components is also essential.

Annual global radiation in Canada

2.5 - 3

Btu/ft2/day 787-945

kwh/m2/day

3 - 3.3 kwh/m2/day

945-1040

kwh/m2/day

1040-1134

3.6 - 3.9 kwh/m2/day 3.9 - 4.2 kwh/m2/day

1134-1228 1228-1323

4.2 - 4.4 kwh/m2/day

1323-1386

4.4 - 4.7 kwh/m2/day

1386-1481

3.3 - 3.6

> 4.7 kwh/m2/day

>1481

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Annual global radiation in the United States

3 - 4 kwh/m2/day

Btu/ft2/day 945-1260

4 - 5 kwh/m2/day

1260-1575

5 - 6 kwh/m2/day

1575-1890

6 - 7 kwh/m2/day

1890-2205

Note: Average mean daily global radiation on a south-facing surface tilted at an angle equal to the latitude of the location.

9

Basic Principles of Solar Technology

Solar Energy

(continued)

Influence of alignment, inclination and shade on energy yield

Optimum alignment and inclination North

West

East

South

Example: 30°; 45° south-west

Annual irradiation in %

Angle of inclination

The solar generator provides the highest annual solar yield for a DHW system when facing south with an inclination of approx. 30 to 35 degrees to the horizontal plane. However, the installation of a solar heating system is still viable even when the installation deviates quite significantly from the above (south-westerly to south-easterly alignment, 25 to 55 degrees inclination). The graph illustrates the loss of yield resulting from an installation of the collector array which is less than perfect. The graph also indicates that a shallower inclination is more favourable, if the collector surface cannot be pointed south. A solar heating system with a 30º inclination and an alignment of 45º south-westerly still achieves 95% of its optimum yield. Even with an east-westerly alignment, you can still expect 85% with a roof inclination between 25º and 40º. A more steeply sloped installation would be more favourable in winter, but the system achieves two thirds of its yield during the summer months. On the other hand, an angle of inclination less than 20 degrees should be avoided, otherwise the solar generator will become too contaminated, or snowcovered. Installing the collector array on different roofs requires complex hydraulic interconnections between the individual collectors. Every array is equipped with a separate collector temperature sensor and a separate pump line. The increase in energy yield is therefore offset by the higher installation costs, resulting in a significantly reduced cost:benefit ratio.

Position and size the collector array so that the influence of neighbouring structures, trees, power lines, etc., which throw shadows over the array, is minimised. Also consider how neighbouring properties will be likely to develop over a period of 20 years, as regards additional buildings, plants and saplings. 10

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Shade reduces energy yield

Basic Principles of Solar Technology

Solar Energy

(continued)

Inclination and orientation of collectors To achieve optimum energy absorption, the collectors must be oriented towards the sun. The angle of inclination and the azimuth angle are the dimensions used to determine the orientation of the collectors. Angle of inclination Angle of inclination α

IMPORTANT The angle of inclination for Vitosol 300-T collectors must be at least 25º in order to guarantee circulation of the evaporator liquid in the heat pipe

The angle of inclination a is the angle between the horizontal and the collector plane. For pitched roof installations, the angle of inclination is determined by the slope of the roof. The largest amount of energy can be captured by the collector’s absorber when the collector plane is aligned at right angles to the irradiation of the sun. Because the angle of irradiation depends on the time of day and the time of year, the collector plane should be aligned according to the position of the sun during the phase of maximum energy supply. In practice, angles of inclination of between 30 and 45º have proven to be ideal. For most installations in North America, for example, an angle of inclination of between 25 and 70º is advantageous, depending on the period of use. Lower angles of inclination are better for applications where more energy is required in the summer months (i.e. pool heating). Higher angles of inclination are better for applications where more energy is required in the winter months. Capturing the maximum amount of energy throughout the year can be achieved using an angle of inclination equal to the latitude of the building site. This is ideal for domestic hot water heating applications. Azimuth angle

Example:

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Deviation from south: 15º east

Collector plane Azimuth angle

The azimuth angle describes the deviation of the collector plane from south; the collector plane aligned to the south is the azimuth angle = 0º. Because solar irradiation is at its most intensive at midday, the collector plane should be oriented as closely as possible to the south. However, deviations from south up to 45º south-east or south-west have minimal impact on annual energy production. 11

Basic Principles of Solar Technology

Overall System Optimization A high-quality solar collector cannot by itself guarantee the optimum operation of a solar installation. This depends more on the complete system solution as a whole. Viessmann supplies all the components required for a solar heating system:

H a control unit that is tailored to the

individual solar heating system, H a DHW tank incorporating a solar heat exchanger low inside the tank, H a preassembled pump station with all necessary hydraulic components, H design details aimed at achieving fast-responding control and therefore maximum yields from the solar heating system.

Correctly designed solar heating systems with well matched system components can cover 50 to 80 % of the annual energy demand for DHW heating in detached and semi-detached houses. We will be pleased to assist you with the design of solar heating systems. The elements of a solar heating system are shown in the diagram.

T

T

T

DHW

S

R

I

DCW

*1

12

Brass elbow c/w sensor well Dual-mode DHW tank I Tank temperature sensor Air separator Solar control unit Flexible connection pipe

Collector temperature sensor Fast air-vent, c/w shutoff valve *1 R Return to collector S Supply from collector

Install at least one air-vent valve (quick-acting air-vent valve or a manual vent valve, see page 43) at the highest point of the system.

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Solar collector Solar-Divicon (pumping station) Overflow container Expansion vessel Solar manual filling pump System fill manifold valve

Specification

Construction and Function of Collectors Vitosol 200-F flat panel collector Vitosol 200-F flat plate solar collector is available as: H Vertical version Model SV2 and horizontal version Model SH2, each offering 2.3 m2 / 25 ft2 absorber surface. The main component of Vitosol 100 is the Sol-Titanium coated copper absorber. It ensures high absorption of solar radiation and low emission of thermal radiation. A copper pipe through which the heat transfer medium flows is fitted to the absorber. The heat transfer medium channels the absorber heat through the copper pipe. The meander-shaped direct flow absorber of models SV2 and SH2 provides an extremely even flow through each individual collector in the collector arrays. The absorber is surrounded by a highly insulated collector housing which minimises collector heat losses. The high quality thermal insulation provides temperature stability and is free from gas emissions. The cover comprises a solar glass panel. The glass has a very low iron content, thereby reducing reflection losses. Continuous profiled seal (vulcanised) Solar glass cover, 3.2 mm thick Meander-shaped copper pipe Copper absorber Melamine resin foam

Mineral fiber Aluminum frame sections Aluminum-zinc bottom panel Connection pipe

The collector housing comprises a powder-coated aluminium frame (recycled aluminium), within which the solar glass panel is permanently sealed. Model SV2 and SH2 Up to twelve collectors can be joined to form a single collector array. For this purpose, the standard delivery includes flexible connection pipes, sealed with O-rings. A general connection kit with clamping ring connections enables the collector array to be readily attached to the pipes of the solar circuit. The collector temperature sensor is installed in the solar circuit flow via a sensor well set.

Technical Data Vitosol 200-F, SV2/SH2 Gross Area

Absorber Area

Aperture Area

Dimensions

m2

ft2

m2

ft2

m2

ft2

mm

in

kg

lb

SV2

2.51

27.0

2.32

25

2.33

25.1

1056x 2380x90

41¾x 93¾x3½

52

115

SH2

2.51

27.0

2.32

25

2.33

25.1

2380x90x 1056

93¾x41¾x x3½

52

115

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Model

Weight

13

Specification

Construction and Function of Collectors

(continued)

Vitosol 300-T vacuum tube collector

Vitosol 300-T vacuum tube collectors are available in two types: 20 tube version, 30 tube version The tube shape gives the collector great stability and high impact resistence. Re-evacuation of the tubes is not necessary as the tubes have a permanent airtight seal. The vacuum in the glass tubes ensures optimum heat insulation. Convection losses between the glass tube and the absorber are almost completely eliminated. This enables the utilisation of even low radiation levels (diffused radiation). The performance of the collector does not drop off as significantly in cold weather as a flat plate collector. On average, approximately 30% to 50% higher annual solar energy gain than flat plate collectors can be expected. Built into each vacuum tube is a Sol-Titanium coated copper absorber. It is a highly selective surface that ensures high absorption of solar radiation and low emission of thermal radiation.

Condenser Double pipe heat exchanger

Technical Data Vitosol 300-T, 2m2/3m2 Model Gross Area

Absorber Area

Aperture Area

Dimensions

Weight

mm

m2

ft2

m2

ft2

m2

in

kg

lb

2m2

2.83

30.5

2.05

22

2.11 22.7 1419x 1996x 122

55¾x 78½x 4¾

45

99

3m2

4.24

45.6

3.07

33

3.17 34.1 2126x 1996x 122

83¾x 78½x 4¾

68

150

14

ft2

Please note: The angle of inclination must be at least 25º to guarantee circulation of the evaporator liquid inside the heat exchanger.

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Evacuated glass tube Heat pipe Absorber

A heat pipe filled with an evaporator liquid is arranged on the absorber. The heat pipe is connected to the condenser via a flexible coupling. The condenser is mounted in a double pipe heat exchanger. This involves a so-called ”dry connection”, i.e. pipes can be rotated or replaced even when the installation is filled and under pressure. Heat is transferred from the absorber to the heat pipe. This lets the liquid evaporate. The vapour then rises to the condenser. The heat is transferred to the passing heat transfer medium by the double-pipe heat exchanger containing the condenser which causes the vapour to condense. The condensate flows back into the heat pipe and the process is repeated.

Specification

Construction and Function of Collectors

(continued)

Vitosol 300-T (continued) Absorber surface areas of up to 6 m2 can be joined to form a single collector array. For this purpose, the standard delivery includes flexible connection pipes, sealed with O-rings. A connection kit with clamping ring connections enables the collector array to be readily connected to the pipes of the solar circuit. The collector temperature sensor is installed in a sensor mounting on the flow pipe in the connection housing of the collectors.

102mm / 4” Legend

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Groove for retaining clip

15

Specification

Collector Efficiency Some of the solar radiation striking the glass of the collectors is ”lost” due to reflection and absorption. The optical efficiency ηo takes these losses into account. When the collectors heat up, they transfer heat to the environment as the result of conduction, radiation and convection. These thermal losses are allowed for by the heat loss factors k1 and k2 .

The heat loss factors and optical efficiency combine to form the collector efficiency curve which can be calculated on the basis of the following formula:

η = η o − k 1 ⋅ ∆T − k2 ⋅ ∆T Eg Eg

2

Eg= radiation intensity (W/m2) ∆ T = Temperature difference between ambient air and collector fluid ºC

If the difference between the collector and ambient temperature is zero, the collector loses no heat to the environment, and the efficiency η is at its maximum level; this is known as the optical efficiency ηo. The thermal capacity is a measure of the thermal inertia of the collector, and shows the response behaviour of the collector when heating and cooling. A low thermal capacity is of advantage with wide ranging temparature and weather conditions typical in northerly climates. The table below lists comparative values for the optical efficiency and the heat loss factors as tested in European certification labs. Vitosol 200-F and 300-T are both tested and certified in North America to SRCC OG-100.

Collector type

Vitosol 200-F Vitosol 300-T *1

Opt. efficiency level *1 in i % ηo 79.3 82.5

Heat loss factors k1 in W/(m2 · K) 3.95 1.19

k2 in W/(m2 · K2) 0.0122 0.009

Spec. thermal capacity p y kJ/( 2 · K) kJ/(m 6.4 5.4

ηo based on absorber area

H

0.9 0.8 0.7 0.6 0.5 0.4 0.3

Efficiency

0.2

0

0 10 20 30 40 50 60 70 80 90 100 Temperature difference in degrees C between ambient air and collector fluid

Vitosol 300-T Vitosol 200-F

16

5167 156 v3.1

0.1

Specification

Solar Coverage The solar coverage value indicates what percentage of the energy required annually for domestic hot water applications can be covered by the solar heating system. The absorber surface area should be sized so that the ”production” of surplus heat is just about avoided during the summer months. The higher the solar cover rate, the lower the efficiency, since a high cover rate has the effect of raising the temperature level of the solar circuit. This results in increased heat losses and lower seasonal efficiency.

Absorber surface in m2

Vitosol 200-F

0

13

26

40

53

66

79

ltrs/day 106 USG/day

92

The diagrams show the coverage values that can be achieved with the various collector types, based on H the meteorological records for a typical location at 49° latitude, H south-facing roofs, H a roof pitch of 45º and H a DHW temperature of 113°F / 45ºC in the standby tank. This data represents approximate guide values.

DHW consumption Vitosol 300-T

Absorber surface in m2

USG/day

0

13

26

40

53

66

79

Note: Solar fractions will be higher for locations in southern parts of the USA due to higher levels of radiation.

ltrs/day 106 USG/day

92

DHW consumption

Influence of various parameters on solar coverage Reference system 100 litres/day

76

300 litres/day

52

400 litres/day

45

Collector inclination 30°

61 61

Collector inclination 60° 45

Westerly orientation South-west orientation

56

*1

Vacuum tubes Hannover

77 55

Freiburg

69 0

20

5167 156 v3.1

Solar cover rate in %

*1

Reference system:

62

40

60

H 4-person household with hot water

consumption of 53 USG/day / 200 litres/day H 2 Vitosol 200-F collectors, model SV2 and SH2 H 45º roof inclination H South-facing roof orientation H Dual-mode DHW cylinder, 300 litres H Meteorological records for a typical location at 49° latitude The bars indicate the expected coverage values for deviations from the reference system. 80

For comparable absorber surface area.

17

Specification

Collector Installation and Mounting Installation options for different collector types

Viessmann offers universal mounting systems to simplify installation. The mounting systems are suitable for virtually all forms of roofs, as well as installation on flat roofs or ground mounted free-standing installations.

Fitting

Collector type

Pitched roofs

A Vitosol 200-F, model SV2 Vitosol 300-T B Vitosol 200-F, model SH2

Flat roofs

C Vitosol 200-F, model SV2, SH2 Vitosol 300-T

Freestanding installation

D Vitosol 200-F, model SV2, SH2 Vitosol 300-T

Sloped roofs - rooftop installation Required roof area

A

mm

A

in

B

mm

B

Vitosol 200-F, type SV2

2380

93 3/4 1056 + 16*1

41 5/8 + 5/8*1

Vitosol 200-F, type SH2

1056

41 5/8 2380 + 16*1

93 3/4 + 5/8*1

Vitosol 300-T, type SP3, 2m2

2031

80

1418 + 102*1

55 3/4 + 4*1

Vitosol 300-T, type SP3, 3m2

2031

80

2127 + 102*1

83 3/4 + 4*1

*1

18

Add this value for every additional collector.

in

5167 156 v3.1

Collector Type

Specification

Collector Installation and Mounting

(continued)

Vitosol 200-F flat panel collector Flat collectors are ideally suited for domestic hot water and swimming pool heating applications.

Model SH2 has been specially designed for installation on flat roofs and for freestanding installation.

Both vertical and horizontal types are suitable for installation on pitched roofs. The selection of method of installation is influenced by the structural characteristics of the building.

Viessmann offers a universal fastening system to simplify installation. The fastening system is suitable for virtually all forms of roof and roofing.

Installation kits are available for installing collectors on flat roofs. An engineering evaluation is required to establish additional superimposed loads from wind or snow, as described in the local building code. Retain the services of a professional structural engineer to calculate additional live loads due to the installation of solar collectors on the roof.

Sloped Roofs Installation Details

a

b 40 10

c

5167 156 v3.1

Collector Lag bolt Mounting rail Roof bracket

Collector

Dimension

Model SV2

inches mm inches mm

Model SH2

a

b 93¾ 2 380 41¾ 1 138

c 74¾ - 82½ 1 900 - 2 100 19½ - 35½ 500 - 900

3½ 89 3½ 89

19

Specification

Collector Installation and Mounting

(continued)

Flat roof installation H Collectors secured against lifting

A collector system must be secured by additional weights against slippage and lifting (see table on the following page). Slippage is the movement of the collectors on the roof surface due to wind, because of insufficient friction between the roof surface and the collector system.

require less ballast weight, but additional attachment to the roof or building structure with wires, cables or other sufficient means. Min. 6 ft/ 2m

The collectors should be installed with an angle of inclination of 35º to 45º if the load capacity of the roof allows this. Maintain a minimum distance of 2m/6ft from the roof edge in all installations. Outside of this area you may experience significant increases in wind turbulance. The system will also be hard to access if modifications are required. If the roof size dictates a modification of the array distribution, ensure that arrays of the same size are created.

H Collectors secured against slippage

require more ballast weight, but no additional attachment to the roof or substructure.

Roof edge Min. 6 ft/ 2m Collector array

Determining the collector row distance “z” When installing several collector rows in sequence, exact dimensions (dimension “z”) must be maintained to prevent unwanted shade. Determine angle of the sun β.

This should be chosen so that the midday sun on Dec. 12 can fall onto the collector without creating shade. In North America, this angle is dependent upon latitude and is between 13º (Edmonton) and 41º (Miami).

Example Boston is located approx. 42.5º latitude. Angle of the sun β= 90º-23.5º-latitude (23.5º should be accepted as the constant) 90º-23.5º-42.5º = 24º l · sin (180 º - ( α+ β )) z = sin β Vitosol 200-F, type SV2

l

l

α

β

z =

z z l

α β

= Collector row distance = Collector height (see page 13 and 14)

= Collector angle of inclination = Angle of the sun

Collector row distance ”z” (all dimensions in mm) Vitosol 200-F Collector type

β = 24º (Boston)

2385mm sin (180 º - 69 º) 0 sin 24º

z = 5474mm

Vitosol 300-T

Type SV2 Angle of inclination α

Type SH2 Angle of inclination α

Angle of inclination α

Angle of sun β

35º

45º

35º

45º

35º

45º

55º

15.0º

7059

7880

3140

3550

5991

6772

7349

17.5º

6292

7035

2799

3130

5340

5970

6419

20.0º

5712

6320

2541

2812

4848

5363

5716

22.5º

5256

5758

2338

2561

4461

4886

5164

25.0º

4887

5303

2174

2359

4148

4500

4716

27.5º

4582

4926

2038

2191

3888

4180

4346

20

5167 156 v3.1

α

l = 2380mm α= 45º

Specification

Collector Installation and Mounting

(continued)

Vitosol 200-F flat panel collector (continued) Please refer to Vitosol 200-F Installation instructions for additional information on collector mounting on 5285 710.

IMPORTANT An evaluation by a professional structural engineer is required to calculate additional live loads due to the installation of solar collectors on a roof.

Vitosol 200-F, type SV2 and SH2 Collector angle of inclination - 25º or 45º Ballast to be applied and maximum load on the substructures of flat roofs to DIN 1055 Collector angle of inclination

25º

Installation height above ground m

45º

Ballast against slippage*1 Ballast against lifting*1 Ballast against slippage

Ballast against lifting

up to 8

up to 8

8 to 20

20 to 100

up to 8

8 to 20

20 to 100

up to 8

8 to 20

20 to 100

8 to 20

20 to 100

Ballast to be applied Type SV2

kg

315

554

793

144

304

465

508

842

1213

128

224

346

Type SH2

kg

323

561

800

155

315

476

492

845

1198

132

254

375

*1 See description on page 20. Collector supports The collector supports are pre-assembled. They consist of foot support A, bearing supports and adjustment pieces. The upper adjustment pieces contain holes for adjusting the angle of inclination. Connection cross ties are required for 1 to 6 collectors connected in a series.

Type SV2 Foot support hole dimensions 80

80

50

75

11

75

897

1795

1620

50

722

11

Type SH2 Foot support hole dimensions

100

5167 156 v3.1

A Foot support

100

A

21

Specification

Collector Installation and Mounting

(continued)

Vitosol 200-F A

Installation on substructures

A Connection cross ties

X Y

Z *1 X

*1 For calculating dimension “z”, see page 20 Installation with ballast

A

A Connection cross ties

X Y

Z *1

X

Collector type

x

SV2

590

23 1/4

481

19

SH2

1920

75 5/8

481

19

22

mm x

in y

mm y

in

5167 156 v3.1

*1 For calculating dimension “z”, see page 20

Specification

Collector Installation and Mounting

(continued)

Vitosol 300-T sloped roof installation details

230mm / 9” 340mm / 13.4”

1650mm / 65”

Deviations from south can be compensated by axial rotation of the vacuum tubes.

1600mm / 63”

Collector Roof bracket Roof joist Collector installation rail with tube mountings Roof sheathing complete with shingles Lag bolt

1419mm/55 3/4” 102mm / 4”

3m2 version

2126mm/83 3/4”

5167 156 v3.1

2m2 version

23

Specification

Collector Installation and Mounting

(continued)

Flat roof support weight requirements - Vitosol 300-T Collector angle of inclination of 25º Weight of supports

Installation height above ground

ft. m

Weight of supports lbs per support A kg per support A lbs per support B kg per support B

Secured against slippage*1 up to 26 26 to 66 up to 8 8 to 20 2m2 3m2 2m2 3m2 Version Version Version Version 168 256 284 430 76 116 129 195 225 102

342 155

392 178

593 269

Secured against lifting*1 up to 26 26 to 66 up to 8 8 to 20 2m2 3m2 2m2 3m2 Version Version Version Version 57 90 112 176 26 41 51 80 141 64

220 100

276 125

421 191

*1 See description on page 20. Support A Support B

B

A

Model

2m2 Version

3m2 Version

inches mm Dimension Y inches mm Surface area (X x Y) ft.2 m2 Weight of lbs collector kg

76¼ 1940 56¾ 1440 30 2.80 99 45

76¼ 1940 84½ 2149 44½ 4.15 150 68

5167 156 v3.1

Dimension X

24

Specification

Collector Installation and Mounting

(continued)

Flat roof support weight requirements - Vitosol 300-T (continued) Collector angle of inclination of 45º Weight of supports Secured against slippage ft. up to 26 26 to 66 8 to 20 m up to 8 2m2 3m2 2m2 3m2 Version Version Version Version 344 390 586 lbs per support A H 20 225 156 177 266 kg per support A 102 564 633 948 lbs per support B 377 256 287 430 kg per support B 171

Installation height above ground Weight of supports

Secured against lifting up to 26 26 to 66 up to 8 8 to 20 2m2 3m2 2m2 3m2 Version Version Version Version --------161 73

245 111

302 137

454 206

Support A Support B

B

A

Model

2m2 Version

3m2 Version

inches mm Dimension Y inches mm Surface area (X x Y) ft.2 m2 Weight of lbs collectors kg

60¼ 1530 56¾ 1440 24 2.20 99 45

60¼ 1530 84½ 2149 35 3.27 150 68

5167 156 v3.1

Dimension X

25

Specification

General Installation Instructions H Vitosol solar collectors are hailproof.

Nevertheless we recommend to include bad weather and hail damage coverage into your home owners insurance package. Our warranty does not cover such damages.

H Please observe local building code

guidelines for maximum load restrictions on the substructure and for necessary distance to roof edge.

H Make sure to remove snow off

collectors if more than 20” / 50 cm have accumulated.

H Mount collectors carefully, so that

even during storm and bad weather mounting clamps can absorb any tension.

H An access door or skylight should be

provided in the roof in the vicinity of the collectors to facilitate inspection and maintenance work.

H When there is a relatively large

distance between the collector panel and the roof ridge, a snow board must be installed above the collector panel in regions where heavy snowfalls can be expected.

H Filling the solar heating systems with

Viessmann “Tyfocor-HTL” heat transfer medium is highly recommended. Other heat transfer fluids may be suitable if they have the same temperature range (-35ºC / -31ºF to 170ºC / 338ºF) and are non-toxic.

H Use high temperature insulation

materials. In pump idle mode and with strong solar irradiation, collectors could reach an idle temperature of over 200ºC / 392ºF. Protect pipe insulation and sensor cables against attack by birds and animals.

H Grounding and lightning protection of

5167 156 v3.1

the solar heating system An electrically conductive connection of the pipework system of the solar circuit should be implemented in the lower part of the building in accordance with local regulations. Connection of the collector system to a new or existing lightning protection system or the provision of local grounding should only be carried out by a licensed professional, taking local conditions into account.

26

Notes on Planning and Operation

Calculating the Required Absorber Surface Area Calculating the absorber surface area and DHW tank capacity Absorber surface area Estimates based on meteorological conditions such as annual global radiation, cloud cover etc. are sufficiently accurate for practical purposes. In order to obtain a comprehensive summary of the solar coverage for domestic hot water heating, it is recommended that this estimate should form the basis of a calculation carried out using a solar computer simulation. Viessmann can provide design support and computer simulations upon request. Contact your local Viessmann sales representative. The cover rate determined by this program should be 50 to 60 % for relatively small systems (detached house), and at least 40 % for larger systems (apartment block). Guide values for estimating the required absorber surface area can be drawn from the table on page 30. The absorber surface area calculated on the basis of this table has proved to be accurate in practice.

The basis for designing a solar DHW heating system is the DHW daily demand. It can be estimated based on the following table: DHW Demand Vp litres/(d · person) For DHW temps temps. 45ºC 60ºC Residential properties*1 High demands Average demands Low demands

50 - 80 30- 50 15 - 30

35-56 21-35 11-21

DHW tank capacity (solar storage) The following values can be used as a basis for calculating the cylinder storage capacity: The total available solar DHW tank capacity (dual-coil tank or preheating tank) should be sized on the basis of 1.5 to 2 times the daily requirements. For fluctuating DHW demand use larger storage (daily demand x2). For relatively constant demand use value 1.5. The minimum solar storage tank volume should be based on 50 liter/m2/ 1.25gal/ft2 collector absorber area.

Typical Solar Storage and Collector Selection Daily DHW Demand @ 50ºC/120ºF

Solar Tank Capacity

Vitosol 200-F Flat Plate Collectors SH2/SV2

Vitosol 300-T Tube Collectors

2

120L 32 gal.

200L 53 gal.

1

1x2m2

3-4

180-240L 48-63 gal.

300L 79 gal.

2

1x3m2

5-6

300-360L 79-95 gal.

450L 120 gal.

3

1x2m2 + 1x3m2

5167 156 v3.1

# People in household

27

Notes on Planning and Operation

Calculating the Required Absorber Surface Area System for space heating backup - DHW cylinder and collector 100

A

75

E

25

B D C

A B C D E

Nov.

Dec.

Oct.

Aug.

Sep.

Jul.

Jun.

May

Mar. Apr.

Feb.

0 Jan.

Energy requirement or gain (%)

50

Space heating requirement for one house (typical construction) Space heating requirement for one low energy house Hot water requirement Solar energy yield at 5 m2 absorber surface (2 flat collectors) Solar energy yield at 15 m2 absorber surface (6 flat collectors)

For buildings with a higher energy demand the coverage drops lower. Use the Viessmann ESOP calculation program when making sizing calculations. Max. connectable collector area when using Vitocell tanks must follow the chart on page 31.

5167 156 v3.1

Concentrating exclusively on the central heating demand can lead to problematic oversizing of the system. For low energy houses (heat demand less than 50 kWh/(m2p.a.), solar coverage of 20 to 25% refers to the total energy demand, incl. provision for DHW heating.

The period when the greatest amount of solar energy is available does not coincide with the time when the most heat is required. While the heat consumption for DHW heating is relatively constant throughout the year, only very little solar energy is available at the times when the heat demand for central heating is at its highest (see diagram). A relatively large absorber area is required to provide central heating backup. In summer, this can result in stagnation in the solar circuit. Systems for heating backup require additional storage tanks and controls. The basis for sizing a solar heating system for central heating backup is the space heating demand of the building during spring, autumn and in winter, as well as the heating demand in summer (i.e. the demand for DHW heating). Heat demand in summer, e.g to avoid condensation in cellars, to use underfloor heating in bathrooms, increases the demand. For efficient operation of a solar central heating backup, the collector area should be 2 to 2.5 times larger than the DHW heat demand in summer requires. To avoid excessive summer time temperature stagnation avoid using collector areas greater than 3 times what would be used for DHW requirements only.

28

Notes on Planning and Operation

Calculating the Required Absorber Surface Area

(continued)

Swimming pool water heating system - heat exchanger and collector

A solar heating system in no way alters this typical temperature pattern. The solar application leads to a definite increase in the base temperature. Subject to the ratio between the pool surface and the collector area, a different temperature can be reached. The adjacent diagram shows with which ratio of aperture or absorber area to the pool surface what average temperature increase can be reached. This ratio is independent of the collector type used due to the comparably low collector temperatures and the operating period (summer). For this reason, unglazed collectors are most often used for outdoor pools.

Average pool temperature in 0C

Open-air swimming pools are mainly used between May and September [in northern USA]. The energy demand required depends mainly on the leakage rate, evaporation, loss (water must be replenished cold) and the transmission heat loss. Through using a cover, the evaporation and consequently the energy demand of the pool is reduced to a minimum. The largest energy input comes direct from the sun, which shines onto the pool surface. Therefore the pool has a ”natural” base temperature which can be shown in the adjacent diagram as an average pool temperature over the operating time.

Note Revising and maintaining the pool temperature at a higher base level using a conventional heating system does not alter this ratio. However, the pool will be heated up much more quickly. 25 20 15 10 5 0

Average temperature increases in degrees C/day

Open-air swimming pools

Jan Feb MarApr May Jun Jul Aug Sep Oct Nov Dec

Location Boston 40m2 Upper surface 1.5m deep protected position covered at night

8 7 6 5 4 3 2 1 0

0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 Ratio-absorber area to the pool surface (open-air swimmimg pool)

5167 156 v3.1

Indoor swimming pools Indoor swimming pools generally have a higher target temperature than open-air pools and are used throughout the year. If, over the course of the year, a constant pool temperature is required, indoor swimming pools must be heated in dual-mode. To avoid sizing errors, the energy demand of the pool must be measured. For this, suspend heating the water for 48 hours and determine the temperature at the beginning and end of the test period. The daily energy demand can therefore be calculated from the temperature difference and the capacity of the pool. For new builds, the heat demand of the swimming pool must be calculated.

On a summer day (clear skies), a collector system used to heat a swimming pool in northern USA produces energy of approx. 4.5kWh/m2 absorber area. Calculation example for Vitosol 200-F Pool surface: 36 m2 Average pool depth: 1.5m Pool capacity: 54m3 Temperature loss on 2 days: 2ºC Daily energy demand: 54m3⋅1K⋅1.16

kWh K m3

Collector area:

62.6 kWh

=13.9m2 4.5 kWh/m2

This corresponds to 6 collectors. For a first approximation (cost estimate), an average temperature loss of 1C/day can be used. With an average pool depth of 1.5m an energy demand of 1.74kWh/day is required to maintain the base temperature. It is therefore sensible to use approx. 0.4m2 absorber area per m2 of pool surface.

= 62.6kWh

29

Notes on Planning and Operation

Calculating the Required Absorber Surface Area

(continued)

Guide values for sizing solar heating systems (continued) H Absorber surface area (data based on meteorological records for a site at 49° latitude)

Application

Required absorber surface area A for coverage of

DHW heating Detached & semi-detached houses Multi-occupancy dwellings

60 % Vitosol 200-F

ft.2/person m2/person ft.2/person m2/person

40 up to 50 % Vitosol 200-F

Vitosol 300-T

13 - 16 1.2 - 1.5 8.6 - 11.8 0.8 - 1.1

8.6 - 10.8 0.8 - 1.0 6.5 - 8.6 0.6 - 0.8

10.8 - 13 1.0 - 1.2 6.5 - 8.6 0.6 - 0.8

Vitosol 300-T 6.5 0.6 4.3 0.4

-

8.6 0.8 6.5 0.6

Information regarding the DHW cylinder When sizing the solar heating system, observe the max. aperture area which may be connected to the different DHW cylinders. At a design output of 600W/m2 and a temperature difference between DHW temperature (at the height of the solar

DHW Tank

Capacity

heat exchanger, lower indirect coil) and solar circuit return (lower than 10ºC), the max. number of collectors mentioned in the table (values apply to all Viessmann collectors) should not be exceeded.

If a higher system temperature range is acceptable, then the number of collectors can be no more than doubled.

Max. connectable number of collectors Vitosol 200-F

Vitosol 300-T 2m2

Vitosol 300-T 3m2

300 L/79 gal.

4

5

3

Vitocell-B 100/300

450 L/120 gal.

7

7

5

Vitocell-V 100/300

200 L/53 gal. 300 L/79 gal. 450 L/120 gal.

3 4 7

4 5 7

3 3 5

5167 156 v3.1

Vitocell-B 100/300

30

Notes on Planning and Operation

Sizing Pipe Diameters and Circulation Pump Solar heating system operating modes

Volume flow in the collector array Generally, very low flow rates are required for Vitosol collectors. This results in small pipe and pump requirements. There are different operating modes, which depend on the total area of collectors installed, and piping requirements. At the same irradiation level, and consequently the same collector output, a higher flow rate means a lower temperature spread in the collector circuit; a lower flow rate means a higher temperature spread. With a high temperature spread, the average collector temperature increases, i.e the operating efficiency of the collector drops accordingly. Therefore, with lower flow rates the use of electrical energy (pump size) reduces and a smaller size connection pipe is possible. To safeguard a safe flow rate and a turbulent flow, Vitosol flat-plate collectors require a flow rate of at least 15 liters/(h.m2). Vitosol tube collectors require at least 25 liters/(h.m2). Generally, when setting the collector volume flow, the necessary volume flow of the connected heat exchanger should also be taken into account. 1. High-flow mode For solar heating systems up to 270º ft.2 / 25 m2 absorber surface area, we recommend the high flow operation. This reduces the temperature spread between supply and return. The higher flow rate requires a slightly larger pipework size, and larger pump sizes.

H A smaller pump capacity is required

resulting in lower electrical consumption.

In the low-flow operating mode, the pipes can be sized on the basis of a flowrate of H Vitosol 200-F: approx. 15 liters/h per m2 absorber surface area (approx. 0.07 gpm/m2 absorber surface area). H Vitosol 300-T: approx. 25 litrers/h per

m2 absorbed surface area (approx. 0.11gpm/m2 absorber surface area).

With both collector models, a uniform flow rate through all collectors is guaranteed if the Viessmann piping layout drawings are followed. To reduce the amount of installation work required for the piping, it is advisable to connect two rows of collectors with all piping connections on one side of the array. Pipe installation information To minimise the pressure drop through the piping of the solar heating systems, the flow velocity in the copper pipe should not exceed 3.5ft/s. We recommend flow velocities between 1.3 and 2.3ft/s. At these flow velocities, pressure drops of between 1 and 2.5 mbar/m pipe length occur.

IMPORTANT Do not use galvanized pipes, galvanized fittings or graphitised gaskets. Hemp should be used only in conjunction with pressure and temperature-resistant sealant.

IMPORTANT The components used must be resistant to the heat transfer medium (for composition, see the datasheet for the specific collector).

IMPORTANT The thermal insulation of external piping must be resistant to temperature, UV radiation and to attack by birds or animals. Insulate internal ”hot” pipework according to current practice (fire protection, touch protection), e.g. using high-temperature resistant insulation, as offered by Armacell.

For the installation of the collectors, we recommend the use of commercial copper pipe and red bronze fittings or stainless steel pipe. The cross-sections should be sized as for a conventional heating system on the basis of flow rate and velocity (see the tables below).

5167 156 v3.1

In the high-flow operating mode, the pipes can be sized on the basis of a flowrate of H Vitosol 200-F: approx. 40 liters/h per m2 absorber surface area (approx. 0.18 gpm/m2 absorber surface area). H Vitosol 300-T: 60 liters/h per m2 absorber surface area (0.27 gpm/m2 absorber surface area). 2. Low-flow mode For large solar installations (larger than 270 ft.2 / 25 m2 absorber surface area), low flow mode operation can be used.. Advantages of the low-flow mode: H A high temperature level is reached quickly in the collector circuit. H The low flow rate in the collector circuit means that much smaller pipe sizes are required. 31

Notes on Planning and Operation

Sizing Pipe Diameters and Circulation Pump

(continued)

Sizing pipe diameters (continued) Vitosol 200-F (high-flow operating mode), 40 liters/(h.m2) or 0.18gpm/m2 Number of collectors Model SV2 and SH2 Volume flow gpm liters/min Flow velocity ft./s m/s Pressure drop in the ft. of pipework head/ft. mbar/m

2

3

4

0.8 3.1

1.2 4.6

1.6 6.2

5 2.1 7.8 1.3 to 2.3 0.4 to 0.7

6

8

10

12

2.5 9.3

3.3 12.4

4.1 15.5

4.9 18.6

0.11 to 0.27 1.0 to 2.5

Vitosol 300-T (high-flow operating mode), 60 liters/(h.m2) or 0.3gpm/m2 Absorber surface area

m2

Volume flow

gpm liters/min ft./s m/s ft. of head/ft. mbar/m

Flow velocity Pressure drop in the pipework

2

3

4

5

0.53 2

0.8 3

1.1 4

1.3 5

6

8

10

12

15

2.1 8

2.6 10

3.2 12

4.0 15

6

8

10

12

0.8 0.92 2.9 3.5 0.7 to 1.3 0.2 to 0.4

1.25 4.7

1.53 5.8

1.85 7.0

1.6 6 1.3 to 2.3 0.4 to 0.7 0.11 to 0.27 1.0 to 2.5

Vitosol 200-F (low-flow operating mode), 15 liters/(h.m2) or 0.07gpm/m2 Number of collectors Model SV2 and SH2 gpm Volume flow liters/min Flow velocity ft./s m/s

2

3

4

0.3 1.2

0.5 1.8

0.6 2.3

5

Pressure drop in the ft. of pipework head/ft. mbar/m

0.11 to 0.27 1.0 to 2.5

Vitosol 300-T (low-flow operating mode), 25 liters/(h.m2) or 0.11gpm/m2 Absorber surface area

m2

Volume flow

gpm liters/min ft./s m/s ft. of head/ft. mbar/m

Flow velocity

3

4

5

0.21 0.8

0.3 1.2

0.45 1.7

0.6 2.1

6 0.7 2.5 0.7 to 1.3 0.2 to 0.4

8

10

12

15

0.9 3.3

1.1 4.2

1.3 5.0

1.64 6.2

0.11 to 0.27 1.0 to 2.5 5167 156 v3.1

Pressure drop in the pipework

2

32

Notes on Planning and Operation

Sizing Pipe Diameters and Circulation Pump

(continued)

Installation examples (hydraulic connection) Vitosol 200-F, type SV2/SH2 High -flow operation Installation of collectors, connection on alternate sides, max. 12 collectors. Ø 28x1 C

Installation of collectors, single-sided connection, max. 10 collectors. C

A

Ø 28x1

A max. 12

max. 10

B

B

Ø 28x1

Ø 28x1

Supply (hot) Return Air vent valve (shut-off type)

Low-flow operation Installation of collectors, connection on alternate sides, max. 10 collectors. Ø 18x1 C

Installation of collectors, single-sided connection, max. 8 collectors. C

max. 10 B

A

Ø 18x1

A max. 8

B

Ø 18x1

Ø 18x1

Supply (hot) Return Air vent valve (shut-off type)

Vitosol 300-T, type SP3 Installation on pitched roofs (max. 6 per array) Connection from the left (preferred option) C A B

Connection from the right C A B

Ø 18x1

Ø 18x1

5167 156 v3.1

Supply (hot) Return Air vent valve (shut-off type)

33

Notes on Planning and Operation

Sizing Pipe Diameters and Circulation Pump

(continued)

Collector pressure drop information (relative to water, approx. 30% higher for Tyfocor HTL @ 40ºC)

” w.c. mbar 800 2000

1000

200 160

500 400

120

300

80

200

40

20

100

50 40

12

30 0.5

80

200

40

100

32

80

24 20 16

60 50 40

12

30

8

20

4

10

3.2

8

2.4 2

6 5

1.6

4

1.2

3

0.8

2

Pressure drop

Pressure drop

400

1 0.3

2 3 4 5 l/min 0.5 0.8 1.11.3 gpm Waterflow

mbar

Vitosol 300-T vacuum tube collector “ w.c.

Vitosol 200-F, flat plate collector model SV2 and SH2

1 1 0.3

2

3

4

5

6

0.5 0.8 1.1 1.3 1.6

10

ltr/h

2.6

GPM

Waterflow

1 1 2 1 2

34

2m2 3m2 model 2m2 model 2m2 and 1 x model 3m2 model 3m2

For calculation of total pressure drop

H Collectors connected in series:

Total pressure drop = sum of the individual resistance values H Collectors connected in parallel: Total pressure drop = individual pressure drop (assuming all individual resistance values are equal). 5167 156 v3.1

Calculating pressure drop The total pressure drop of the solar heating system consists of: H collector resistance values, H pipe resistance values, H individual resistance values of the fittings and H individual resistance values of the fittings and H resistance values of the heat exchanger in the DHW tank.

x x x x x

Notes on Planning and Operation

Sizing Pipe Diameters and Circulation Pump

(continued)

Sizing the circulation pump If the flowrate and pressure drop of the entire system are known, the pump is selected on the basis of the pump characteristics. Variable-speed pumps which can be matched to the system by switching are the most suitable. To simplify the installation and selection of the pumps and safety equipment, Viessmann supplies the Solar-Divicon. The Solar-Divicon comprises H pre-assembled and sealed valves and safety assembly, H flow regulating valve with meter to control the solar heating system during commissioning and operation, H flow check valves, H system pump (2 sizes available), H pressure gage, H 2 thermometers, H 2 isolation valves, H pressure relief valve, 87 psig / 6 bar.

Two models of Solar-Divicon are available: Model DN 20 H up to 12 Vitosol 200-F collectors H up to 20 m2 absorber surface area with Vitosol 300-T, Model DN 25 H up to 18 Vitosol 200-F collectors H up to 30 m2 absorber surface area with Vitosol 300-T. Final determination of which Solar-Divicon model to use must be based on system layout and pipe sizes used.

IMPORTANT The Solar-Divicon and the solar pump line are not suitable for direct contact with swimming pool water or potable water.

IMPORTANT Always install Solar-Divicon at a lower height than the collectors to prevent steam from entering the expansion vessel in the event of stagnation.

IMPORTANT For systems which are installed in the roof space or involve short pipe lengths, a preliminary vessel should be provided if necessary.

1 2 3 4 5 6 7 8 9

Pressure relief valve, 87 psig/6 bar Expansion tank connection Pressure gage, 0-6 bar/0-87 psig Temperature gage c/w integrated shut-off valves and flow check valves Pump Flow meter Insulation door Flush and fill manifold Air separator (locked under insulation)

VL Flow RL Return Shut-off valve Thermometer Non-return valve Solar circuit circulation pump Flow rate indicator

A B C

5167 156 v3.1

D A E VL

RL

The solar circuit pump line is constructed as the pump line of the Solar-Divicon. 35

Notes on Planning and Operation

Sizing Pipe Diameters and Circulation Pump

(continued)

Technical information on the Solar-Divicon

Solar-Divicon

Model

Circulation pump (Model: Wilo) Rated voltage

V

Maximum delivery

GPM

Maximum head

ft.

Flow meter (setting range)

USG/min

DN 20

DN 25

STAR S 16 U 15

STAR S 21 U 25

AC 115

AC 115

16

16.7

20.7

21.1

0.5 to 5

1 to 10

1 to 20

5 to 40

87 6 248 120

87 6 248 120

Flow meter (setting range)

ltrs/min

Pressure relief valve

psig, bar

Maximum operating temperature

°F, °C

Maximum operating pressure

psig, bar

87 6

87 6

inches mm inches mm inches mm

1/2

3/ 4

Connections (Compression fittings Ø): Solar circuit Solar expansion tank Safety relief valve

22 3/ 4 22 3/ 4 22

22

3/ 4

22

3/ 4

22

Characteristics

Pump model DN 25

5167 156 v3.1

Pump model DN 20

36

Notes on Planning and Operation

Safety Equipment Liquid capacity of solar heating system components USG liters USG liters USG liters USG liters

0.48 1.83 0.65 2.48 0.32 1.20 0.47 1.80

Solar-Divicon (pumping station for the collector circuit)

USG liters

0.08 0.30

Vitocell-B 100

USG liters

79 300

120 450

Heating water capacity of bottom coil

USG liters

2.6 10

3.3 12.5

Vitocell-B 300

USG liters

79 300

79 300

Heating water capacity of bottom coil

USG liters

2.9 11

3.9 15

Vitocell-V 300, Tank capacity (with indirect coil/s) Heating water capacity of coil

USG liters USG liters

Vitosol 200-F,

model SV2

Vitosol 200-F,

model SH2

Vitosol 300-T,

model 2m2 model 3m2

Tank capacity

Dimension USG/ft. pipe

53 200 3.2 11.9

79 300 2.9 11

120 450 4 15

3/ ” 8

½”

¾”

1”

1¼”

1½”

0.0083

0.013

0.027

0.045

0.068

0.095

5167 156 v3.1

Copper pipe, type M Water content

Tank capacity

37

Notes on Planning and Operation

Safety Equipment h Static height T

A

h DHW

B C

D G

Information regarding stagnation System idle periods, e.g. due to defects or incorrect operation, can never be ruled out. For this reason solar heating systems must be protected according to the current technical standards against the potential difficulties which may arise from idle periods, i.e. systems cannot be damaged or cause damage if idle periods occur. Collectors and connection pipes are designed for the maximum expected temperatures in case of stagnation. Temperatures over 170ºC / 338ºF have a detrimental effect on the process medium. When designing the collector array it should be ensured that the system can “breathe” properly (e.g. do not route solar pipes above the collector array).

VL RL E

T F

KW

Collector Safety valve Solar-Divicon Pre-cooling vessel (see below) Diaphragm expansion vessel Dual-mode DHW cylinder High limit safety cut-out (see page 41)

Information regarding the heat transfer medium Heat transfer media containing glycol can be damaged, if they are subjected for long periods of temperatures above 170ºC / 338ºF. This can lead to the system suffering from sludge and hard deposits, particularly in conjunction with other contaminants (flux and oxidized deposits). Therefore, after completing the installation, thoroughly flush out the system. After filling the system with process medium, ensure that heat is transferred inside the system, i.e. that

longer periods of stagnation are prevented. System must be air-tight as glycol deterioration is always worse in presence of O2 molecules. Check the glycol every 2 years. Information regarding pre-cooling vessels Pre-cooling vessels or stratification cylinders in solar heating systems protect the diaphragm expansion vessel from over heating if stagnation occurs. The installation of such vessels is recommended if the content of the pipework between the collector array Content litres

and the expansion vessel is lower than 50% of the capacity of the correctly sized expansion vessel. The reference value is the total volume which evaporates in idle conditions. Sizing: Capacity of the correctly sized expansion vessel less the content of the return line between the collector array and the expansion vessel. Determining the capacity of the pre-cooling vessel: 1.5 x collector content x number of collectors.

Number of collectors Vitosol SV2 Vitosol SH2 Vitosol 300-T 2m2 Vitosol 300-T 3m2

12 38

4

3

6

4

5167 156 v3.1

RL Return VL Flow

The solar heating system must be protected in respect to temperature, pressure and discharge of liquid in accordance with local regulations. The collector circuit must be protected in such a way that at the highest possible collector temperature (= idle temperature) no heat transfer medium can escape from the safety valve. This is achieved through the appropriate sizing of the expansion vessel and matching of the system pressure. For total pipework lengths shorter than 10m/32ft, we recommend the installation of a pre-cooling vessel and diaphragm expansion vessel into the hot supply pipe and only the pressure relief valve into the return pipe.

Notes on Planning and Operation

Safety Equipment

(continued)

Diaphragm expansion tank

A

B Delivered condition (3 bar/45 psig pressure)

A

A

D

E

C

C

Solar heating system filled without heat effect

Process medium Nitrogen filling

Under max. pressure at the highest process medium temperature

Nitrogen buffer Safety water seal, min. 3l/0.8gal

Specification - Viessmann expansion tank A B Øa Øa

Construction and operation A diaphragm expansion tank is a sealed expansion vessel whose gas space (nitrogen filling) is separated from the liquid space (heat transfer medium) by a diaphragm and whose inlet pressure is subject to the system height. To safely prevent steam being created during the operating stage, collectors must indicate a pressure of at least 15 psig / 1 bar in their cold state. The expansion tank inlet pressure is then higher by an amount of 0.45 psig x static height (h) in ft. or 0.1 bar x static height (h) in m. In hot conditions, the system pressure rises by approx. 15 to 30 psig/1 to 2 bar. Maximum idle temperature of collectors: Vitosol 200-F, Models SV2, SH2 Flat panel solar collector with 25 ft.2 / 2.3 m2 collector area. Max. shutdown temperature 430°F / 221°C Max. operating pressure 87 psig /6 bar

b

Vitosol 300-T, SP3 Series Vacuum tube solar collector with 22 and 32 ft.2 / 2 and 3 m2 collector area. Max. shutdown temperature 302°F / 150 °C Max. operating pressure 87 psig /6 bar

b

To ensure that no heat transfer medium can escape from the pressure relief valve, the expansion tank must be sufficiently large to accommodate the liquid content of the collector when steam forms (stagnation).

IMPORTANT Expansion tank

Content litres

A

18 25 40 50 80

5167 156 v3.1

B

Operating pressure bar 10 10 10 10 10

Øa mm

b mm

Connection Weight R kg

280 280 354 409 480

370 490 520 505 566

¾” ¾” ¾” 1” 1 1”

7.5 9.1 9.9 12.3 18.4

The cold fill inlet pressure (gas space) must be adjusted on site as follows: 15 psig + 0.45 psig x static height in ft 1 bar + 0.1 bar x static height in m The system operating pressure must be 4.5 to 7.5 psig/0.3 to 0.5 bar higher than the inlet pressure of the diaphragm expansion tank. The waterseal should be 0.005x the total liquid content of the system but not less than 3 liters.

39

Notes on Planning and Operation

Safety Equipment

(continued)

Technical data for the expansion tank (continued)

(V v + V 2 + z ⋅ V k) ⋅ (p e + 1) VN = pe − p st

Whereby VN = nominal capacity of the diaphragm expansion tank in liters Vv = safety water seal (here heat transfer medium) in litres Vv = 0.005 · VA in litres (min. 3 litres) VA = liquid capacity of the entire system (see page 42). pst = nitrogen inlet pressure of expansion vessel in bar pst =1 bar + 0.1 · h h =static head of the system in m (see drawing on page NO TAG) z = number of collectors Vk = collector capacity in litres (see page 37). V2 = volume increase when the system heats up V2 =

VA · β

=expansion quotient ( β= 0.13 for Viessmann heat transfer medium from –20 to 120ºC) pe = permissible end pressure in bar pe =psi – 0.1 · psi psi =safety valve blow off pressure b

WARNING Do not use expansion tanks that are not designed for solar heating systems. Temperatures during stagnation periods can reach extremely high levels, which could result in serious injuries from hot system fluid discharging from pressure relief valve.

WARNING Do not undersize expansion tank.

40

Calculation example Solar heating system with: 2 Vitosol 200-F, type SV2 @ 1.83 litres Liquid capacity: VA = 25 litres Static head: h = 5 m Permissible final pressure: pe = 5.4 bar (ü) (Safety valve blow off pressure: 6 bar) VN =

(V v + V 2 + z ⋅ V k) ⋅ (p e + 1) p e − p st

Vv =VA · 0.005 Vv =0.125 litres, selected 3 litres (see previoys page). V2 =VA · b V2 =3.25 litres pst =1.5 bar + 0.1 bar/m · 5 m pst =2.0 bar VN =

(3 + 3.25 + 2 ⋅ 1.83) ⋅ (5.4 + 1) 5.4 − 1.5

VN =16.3 litres Due to the possibility of steam collecting in the solar circuit pipe, we recommend multiplying the calculated value VN by a safety factor of 1.5. Select a 25 liter expansion vessel.

Selection table for expansion tanks, subject to collector model (in conjunction with a 6 bar safety valve) These details provide only guide values; a final calculation must be carried out. Vitosol 200-F, model SV2 Number of System Static collectors capacity head VA h (m) liters 2 20 5 10 3 25 5 10 4 32 5 10 5 35 5 10 Vitosol 200-F, model SH2 Number of System Static collectors capacity head VA h m liters 2 20 5 10 3 30 5 10 4 35 5 10 5 40 5 10 Vitosol 300-T Absorber System surface capacity area VA m2 liters 3 16 4

18

5

23

6

25

9

35

Static head h (m) 5 10 5 10 5 10 5 10 5 10

Expansion tank capacity liters 25 25 40 40 40 50

Expansion tank capacity liters 25 40 40 40 50 50 80

Expansion tank capacity liters 18 18 18 25 25 40

5167 156 v3.1

The nominal capacity of the expansion vessel is calculated according to the equation

Notes on Planning and Operation

Safety Equipment

(continued)

Pressure relief valve The operating pressure of the pressure relief valve is the maximum system pressure +10 %. The pressure relief valve must comply with all local codes. The pressure relief valve must be matched to the output of the collector or the collector assembly and be able to handle their maximum output of 900w/m2.

IMPORTANT When use is made of water containing antifreeze or synthetic heat transfer media which are miscible with water (e.g. Viessmann heat transfer medium) and whose boiling point is higher than that of water, the blow off and discharge pipes must be run to an open container capable of accommodating the total capacity of the collectors. Use only pressure relief valves designed for a maximum of 87 psig / 6 bar and 248ºF / 120ºC bearing the markings ”S” (solar) as part of the product identification.

IMPORTANT Solar-Divicon is equipped with a pressure relief valve for max. 87 psig / 6 bar and 248ºF / 120ºC. High limit safety cut-out The Vitosolic 200 solar control unit is equipped with an electronic limit thermostat which is preset in the factory to 167ºF / 75ºC and can be adjusted. For systems with a sufficiently large DHW capacity, this protection is adequate, as the maximum operating temperature does not exceed 23ºF / 11ºC.

Example: Vitosol 200-F flat collector x 4=, approx. 7 m2 absorber surface area DHW cylinder with 300 litres capacity 300 = 40 litres/m2, 7.5

e.g. no high limit safety cut-out required.

5167 156 v3.1

An additional mechanical high limit safety cut-out is required, if the DHW tank capacity is less than 40 liters/m2 collector surface area.

41

Notes on Planning and Operation

Safety Equipment

(continued)

Thermostatic mixing valve Solar storage tank Thermostatic anti-scald mixing valve

DHW

A thermostatic mixing valve is required for all solar systems to prevent domestic hot water temperatures higher than 140 ºF / 60 ºC (local codes may require different temperature settings). Install an anti-scald mixing valve designed for potable domestic hot water systems.

DCW

WARNING

5167 156 v3.1

The domestic hot water temperature must be limited to 140 °F / 60 °C by installing a mixing device, e.g. a thermostatic anti-scald mixing valve.

42

Notes on Planning and Operation

Accessories

22

Solar manual filling pump

R ½”

38

.

22

R1”

approx. 166

Quick-acting air-vent valve (with tee)

Threaded elbow

160 (220) 65

15 220

290 40

For installation at the highest point of the system. With shut-off valve and locking ring connection.

Flexible connection pipe

22

For the installation of the DHW tank temperature sensor into the tank return. Comes as standard equipment with Vitocell-B 100 tanks and is an accessory with Vitocell-B 300 tanks.

For replenishing and raising the pressure.

1000

approx. 225

22

22

Air separator Stainless steel corrugated pipe with thermal insulation and compression fitting connection. Comes with thermal insulation. Set of 2 per package.

111

5167 156 v3.1

For installation in the supply pipe of the solar circuit, preferably upstream of the inlet to the DHW tank. With automatic air-vent valve, shut-off valve and locking ring connection. This is not required if a Solar Divicon model DN 20 or DN 25 is used.

43

System Designs

General Information For our climatic zone: dual systems In our climatic zone, solar radiation is insufficient to cover the entire requirements for domestic hot water or swimming pool heating as well as space heating by means of solar energy. Therefore, a solar heating system for DHW or swimming pool water heating and/or central heating should always be combined with another heat generator. In dual systems, for example, an oil or gas-fired boiler supplies the additional heat required. How to implement the installation

WARNING With temperatures over 140°F / 60°C, the DHW temperature must be limited to 140°F / 60°C by installing a mixing device, e.g. a thermostatic mixing valve (DHW tank accessory).

Over the following pages, we have described methods of operation and used design suggestions to illustrate various installation ideas involving different equipment specifications. A summary is provided which lists essential control equipment. The temperatures stated are guide values; other values may be set to meet particular requirements. The circulation pumps referred to in these examples (standard delivery with Solar-Divicon) are AC pumps. DHW tank backup by the boiler is suppressed by the Vitosolic, when the anticipated heat requirement for DHW heating is expected to be covered by the solar heating system. This may require the use of the optional expansion boards. When connection between the Vitosolic and the boiler control (Vitodens programming unit, Vitotronic 300 or Dekamatik) is made via the KM-BUS, the setpoint temperature for boiler backup of DHW is reduced, stopping the boiler from coming on. Abbreviations used in the examples: Domestic cold water Domestic hot water Return Supply

5167 156 v3.1

DCW DHW R S

44

System Designs

System Design 1 Dual-mode DHW heating with Vitocell-B100 or Vitocell-B 300 DHW tanks - with Vitosolic 200 or GL 30 control DHW heating without solar energy

DHW heating with solar energy

The top part of the DHW tank is heated by the boiler. The DHW tank temperature sensor of the boiler control unit switches tank heating circulation pump .

When a temperature difference higher is than the value set in control unit measured between collector temperature sensor and tank temperature sensor , solar circuit circulation pump is switched ON and the DHW tank is heated up. The temperature in the DHW tank is limited by the electronic limit or by thermostat in control unit high limit safety cut-out (if required).

When the preset temperature is exceeded, these devices switch OFF . The solar circuit circulation pump electronic temperature limit is set at the factory.

Installation diagram 2

A

1

B

DHW C

4 D 28 E

F

S

5 5

R

6

21

7

3

5167 156 v3.1

G

Solar collector Solar-Divicon Taps *1

DCW

H

DHW circulation DHW circulation output of the boiler control unit or timer installed on site

Heating circuit Oil/gas-fired boiler DHW cylinder

High limit safety cut-out, see page 41.

45

System Designs

System Design 1

(continued)

Dual-mode DHW heating with Vitocell-B100 or Vitocell-B 300 DHW tanks - with Vitosolic 200 or GL 30 control (continued) Control equipment required Number Part no.

2

Description Control of DHW cylinder loading by solar energy Vitosolic 200 or GL 30 control Collector temperature sensor

3

DHW tank temperature sensor*1

1

4

Solar circuit circulation pump (standard equipment of Solar-Divicon, see page 35)

1

5

1

6

High limit safety cut-out (see page 41)*2 Control of DHW tank loading by the boiler DHW tank temperature sensor

7

Circulation pump for DHW tank loading

1

Item 1

*1Installation requires a threaded *2Accessory with Vitodens.

1 1

1

7134 552 7134 450 Included in standard equipment for item 1 Included in standard equipment for item 1 7133 454 or 7133 455 Supplied on site Included in standard equipment of boiler control unit *2 DHW tank accessory

elbow (standard delivery for Vitocell-B 100, accessory for Vitocell-B 300 ).

WARNING

5167 156 v3.1

The domestic hot water temperature must be limited to 140 °F / 60 °C by installing a mixing device, e.g. a thermostatic anti-scald mixing valve.

46

System Designs

System Design 2 Dual-mode DHW heating and space heating backup with heating water storage tank - with Vitosolic 200 DHW heating without solar energy

Space heating without solar energy

Space heating with solar energy

The upper indirect coil of the DHW tank is heated by a boiler. The DHW tank temperature sensor of the boiler control unit switches circulation pump to heat up the DHW tank.

Diverter valve remains at zero volts (setting ”AB-B”), if the differential temperature between heating water storage tank temperature sensor (discharge) and space heating return temperature sensor falls below the value set at control unit . No flow through the heating water storage tank takes place. The boiler provides heat to the heating circuit according to the heating curve set at the boiler control unit.

Heating water storage tank circuit and circulation circulation pump pump for storage tank heating are switched ON and the heating water storage tank is heated up, when a temperature difference higher than the differential temperature preset in control unit is measured between collector temperature sensor and storage tank temperature sensor . The temperature inside (re-loading) the heating water storage tank will be limited by the electronic limit thermostat in control unit . When the preset temperature is exceeded, this device switches the storage tank circuit circulation pump and OFF. Circulation pump is switched OFF for approx. 2 minutes, roughly every 15 minutes (adjustable time), to check whether the temperature at the collector temperature sensor is high enough to change over to DHW tank loading.

DHW heating with solar energy Solar circuit circulation pump is switched ON and the DHW is heated up, when a temperature difference higher than the value set in control unit is measured between collector temperature sensor and DHW temperature sensor . The temperature in the DHW is limited by the electronic limit thermostat in or by high limit safety control unit cut-out (if required). When the preset temperature is exceeded, these devices switch OFF . solar circuit circulation pump The electronic temperature limit is set at the factory.

5167 156 v3.1

Control unit switches diverter valve to position ”AB-A” and the space heating return water will be channelled into the boiler via the storage tank, if the temperature differential between storage tank temperature sensor (discharge) and space heating return temperature sensor exceeds that set at control unit . If the temperature of the pre-heated return water is insufficient, the boiler re-heats the water to the necessary flow temperature level.

47

System Designs

System Design 2

(continued)

Installation diagram 2

Refer to Viessmann sample layout drawing #5 for alternate layout. (contact Viessmann sales rep. for details)

A

B

C

1

4 qE

DHW D

S

R

5 5

6 qP 21

9

qT

7

AB

qR A

B

3 G

qW

Solar collector Solar-Divicon Solar pump line Taps

*1High

48

limit safety cut-out, see page 41.

H

K

DHW circulation DHW circulation output of the boiler control unit or timer installed on site

DCW

Heating water storage tank Oil/gas-fired boiler DHW tank 5167 156 v3.1

qQ

System Designs

System Design 2

(continued)

Dual-mode DHW heating and space heating backup with heating water storage tank - with Vitosolic 200 (continued) Control equipment required Number

Part no.

1 2

Description Control of DHW tank loading by solar energy Vitosolic 200 Collector temperature sensor

1 1

3

DHW tank temperature sensor*1

1

4

Solar circuit circulation pump (standard equipment of Solar-Divicon, see page 35)

1

5 8

1 1

6

High limit safety cut-out (see also page 41) Circulation pump (relayering) Control of DHW tank loading by the boiler DHW tank temperature sensor

7134 450 Included in standard equipment for item 1 Included in standard equipment for item 1 7133 454 or 7133 455 Supplied on site Supplied on site

7

Circulation pump for DHW tank loading

1

9 qP qQ

Space heating control with solar energy Return temperature sensor (heating circuit) Temperature sensor (storage tank), discharge Temperature sensor (storage tank, re-loading)

1 1 1

Item

qW qE qR qT *1A

Three-way diverter valve Solar circuit circulation pump for storage tank heating (part of the solar pump line, see page 35) Circulation pump for storage tank heating Heat exchanger

1

Included in standard equipment of the boiler control unit DHW tank accessory

1 1

7170 965 7170 965 Included in standard equipment for item 1 Supplied on site Supplied on site

1 1

Supplied on site Supplied on site

threaded elbow (standard delivery for Vitocell-B 100, accessory for Vitocell-B 300 ) is recommended for this installation.

Note: , circulation pump for storage tank and heat exchanger Heating water storage tank indirect-fired storage tank, c/w internal heat exchanger coil (e.g. Vitocell-V 100).

can all be replaced with an

WARNING

5167 156 v3.1

The domestic hot water temperature must be limited to 140 °F / 60 °C by installing a mixing device, e.g. a thermostatic anti-scald mixing valve.

49

System Designs

System Design 3 Dual-mode DHW heating with two DHW tanks - with Vitosolic 200 DHW heating without solar energy

DHW heating with solar energy

DHW tank 2 is heated by the boiler. The DHW tank thermostat with connected tank temperature sensor of the boiler control unit switches circulation to heat up the DHW tank. pump

is Solar circuit circulation pump switched ON and DHW tank 1 is heated up, when a temperature difference higher than the value set in control unit is measured between collector temperature sensor and tank temperature sensor . The temperature in DHW tank 1 is limited by the electronic limit or by thermostat in control unit high limit safety cut-out (if required). When the preset temperature is exceeded, this device switches OFF solar circuit circulation pump . The electronic temperature limit is set at the factory.

DHW circulation pump 8b (if installed) is switched ON and circulation pump 8a is switched OFF, so that the DHW circulation only affects DHW tank .

Circulation pump 8a is switched ON, when the temperature at sensor in DHW tank 1 exceeds that at sensor in DHW tank 2. The DHW circulation covers both DHW tanks. This feeds the water heated in DHW tank 1 into DHW tank 2. This way, DHW tank 2 is also heated by solar energy. DHW circulation pump 8b (if installed) for DHW tank 2 is controlled by the boiler control unit. Circulation pump 8a will be switched OFF if the temperature in DHW tank 2 rises above that in DHW tank 1.

WARNING

5167 156 v3.1

The domestic hot water temperature must be limited to 140 °F / 60 °C by installing a mixing device, e.g. a thermostatic anti-scald mixing valve.

50

System Designs

System Design 3

(continued)

Installation diagram (system with two DHW cylinders with indirect coils) 2

A

B

1

4

C

8a

D E 28 8b

F 5

S

5

R

DHW 21

DCW

2

qP 6

1

9

3

7 G

5167 156 v3.1

Solar collector Solar-Divicon Taps DHW circulation

*1High

H

DCW

K

DHW circulation output of the boiler control unit or timer installed on site Heating circuit

Oil/gas-fired boiler DHW tank 2 DHW tank 1

limit safety cut-out, see page 41.

51

System Designs

System Design 3

(continued)

Dual-mode DHW heating with two DHW tanks - with Vitosolic 200 (continued) Control equipment required Item

Description

Number

Part no.

1 2

Control of DHW tank 1 loading by solar energy Vitosolic 200 Collector temperature sensor

1 1

3

DHW tank temperature sensor*1

1

4

Solar circuit circulation pump (standard equipment of Solar-Divicon, see page 35)

1

5

High limit safety cut-out (see also page 41)

1

7134 552 Included in standard equipment for item 1 Included in standard equipment for item 1 7133 454 or 7133 455 Supplied on site

6

Control of DHW tank 2 loading by the boiler DHW tank temperature sensor

1

7

Circulation pump for DHW tank loading*3

1

8

DHW circulation changeover DHW circulation pump or circulation pump (relayering)

1

Supplied on site

9

Temperature sensor tank 1

1

qP

Temperature sensor tank 2

1

Included in standard equipment for item 1 7170 965

*1The screw-in elbow which is *2Accessory with Vitodens. *3Part of the standard delivery

Included in standard equipment of boiler control unit *2 Accessories DHW tank

available as an accessory for the DHW cylinder is recommended for installation purposes. with Vitodens (for types with DHW heating).

WARNING

5167 156 v3.1

The domestic hot water temperature must be limited to 140 °F / 60 °C by installing a mixing device, e.g. a thermostatic anti-scald mixing valve.

52

System Designs

System Design 4 Dual-mode DHW and swimming pool water heating - with Vitosolic 200 DHW heating without solar energy

DHW heating with solar energy

Swimming pool water heating

The top part of the DHW tank is heated by the boiler. The DHW tank temperature sensor of the boiler control unit switches tank heating circulation pump .

Solar circuit circulation pump for DHW is switched ON and the heating DHW tank is heated up, when a temperature difference higher than the value set in control unit is measured between collector temperature sensor and DHW tank temperature sensor .

Solar circuit circulation pump for DHW is switched OFF, and solar heating circuit circulation pump for swimming pool heating is switched ON, if the temperature at DHW tank is so high, that temperature sensor the temperature difference falls below the set differential temperature for DHW heating. The temperature at collector temperature sensor must then be higher by the temperature difference for swimming pool water heating set in control unit than the temperature at temperature sensor (swimming pool) . Swimming pool water limit thermostat switches circulation (max. limit) pump OFF when the desired set water temperature has been reached. Circulation pump is switched OFF for approx. 2 minutes roughly every 15 minutes (adjustable time), to check whether the temperature at the collector temperature sensor is high enough to change over to DHW tank loading.

Solar circuit circulation pump for DHW is switched OFF, and solar heating circuit circulation pump for swimming pool heating is switched ON (see ”Swimming pool water heating”), if the temperature at DHW tank temperature sensor is so high that the actual temperature difference falls below the set differential temperature. The temperature in the DHW tank is limited by the electronic limit thermostat in control unit or by (if high limit safety cut-out required). When the preset temperature is exceeded, these devices switch OFF solar circuit circulation pump . The electronic temperature limit is set at the factory.

When the solar energy is insufficient to heat the swimming pool water, the heating of the swimming pool water will be taken over by the oil/gas-fired boiler via temperature sensor in heat exchanger 2.

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The filter time and any boiler backup should fall outside those times when heating by solar energy can be expected.

53

System Designs

System Design 4

(continued)

Installation diagram 2

A

B

C

1

qP

4

DHW D E F 28

S

G

R

5 5

6 8

21

7

3 H

qR L

DCW

K

qT

M

qE

2

qQ

N

9

1

O

*1High

54

limit safety cut-out, see page 41.

DHW circulation output of the boiler control unit or timer installed on site Heating circuit Oil/gas-fired boiler Dual-mode DHW tank

Swimming pool Heat exchanger 2 Heat exchanger 1 Filter system with pump

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Solar collector Solar-Divicon Solar pump line Taps DHW circulation

System Designs

System Design 4

(continued)

Dual-mode DHW and swimming pool water heating - with Vitosolic 200 (continued) Control equipment required Number

Part no.

1 2

Description Control of DHW tank loading by solar energy Vitosolic 200 Collector temperature sensor

1 1

3

DHW tank temperature sensor*1

1

4

Circulation pump for the solar circuit (standard equipment of Solar-Divicon, see page 35)

1

5 8

High limit safety cut-out (see also page 41) Circulation pump

1 1

7134 552 Included in standard equipment for item 1 Included in standard equipment for item 1 7133 454 or 7133 455 Supplied on site Supplied on site

6

Control of DHW tank loading by the boiler DHW tank temperature sensor

1

7

Circulation pump for DHW tank loading

1

9

Control of swimming pool heating by solar energy Temperature sensor (swimming pool)

1

Item

qP qQ qE qR qT *1A

Solar circuit circulation pump for swimming pool heating (part of the solar pump line, see page 35) Swimming pool limit thermostat (max. limit) Control of swimming pool heating by the boiler Temperature sensor (heat exchanger 2) Limit thermostat (max. limit) Circulation pump for swimming pool water heating

Included in standard equipment of the boiler control unit DHW tank accessory

1

Included in standard equipment for item 1 Supplied on site

1

Supplied on site

1 1 1

7170 965 Supplied on site Supplied on site

threaded elbow (standard delivery for Vitocell-B 100, accessory for Vitocell-B 300) is recommended for this installation.

WARNING

5167 156 v3.1

The domestic hot water temperature must be limited to 140 °F / 60 °C by installing a mixing device, e.g. a thermostatic anti-scald mixing valve.

55

System Designs

System Design Extensions Bypass circuit To improve the start-up characteristics of the system or for systems with several collector arrays, operation with a bypass circuit is feasible. Version 1 - bypass circuit with collector temperature sensor and bypass sensor The Vitosolic 200 records the collector temperature via the collector temperature sensor. If the set temperature difference between the collector temperature sensor and the

cylinder sensor is exceeded, the bypass pump is switched ON. If the temperature difference between the bypass sensor and the cylinder

S1

R5

Note The pump of the Solar-Divicon is used as the bypass pump and the pump of the solar circuit pump line is used as the solar circuit pump.

R1

S3 VL

temperature sensor is exceeded by 2.5 K the solar circuit pump is switched ON and the bypass pump is switched OFF.

R1 R3 S1 S3

Solar circuit pump Bypass pump Collector temperature sensor Bypass sensor

RL

Version 2 - bypass circuit with solar cell (e.g. with an external heat exchanger) For this system version, the solar circuit pump takes on this additional function. The Vitosolic 200 records the solar intensity via the solar cell.

The solar circuit pump will be switched ON, if the set irradiation threshold is exceeded.

The pump will be switched OFF, if the irradiation falls below the set switching threshold (shutdown delay approx. 2 min).

CS

R1 S1 RL

5167 156 v3.1

VL

CS Solar cell R1 Solar circuit pump S1 Collector temperature sensor

56

System Designs

System Design Extensions

(continued)

System with energy-saving mode

Version 3 - bypass circuit with solar cell and collector temperature sensor The Vitosolic 200 records the solar intensity via the solar cell. If the set irradiation threshold is exceeded, the bypass pump is switched ON. The bypass pump is switched OFF

and the solar circuit pump will be switched ON, if the set temperature difference between the collector temperature sensor and cylinder temperature sensor is exceeded.

The bypass pump will also be switched OFF if the irradiation falls below the set switching threshold (shutdown delay approx. 2.5 min).

Note The pump of the Solar-Divicon is used as the bypass pump and the pump of the solar circuit pump line is used as the solar circuit pump.

CS

R5

R1

S1 RL

Solar cell Solar circuit pump Bypass pump Collector temperature sensor

5167 156 v3.1

VL

CS R1 R5 S1

57

Appendix

Calculation Example Based on the Viessmann “ESOP” Program

Solar heating system with dual-coil DHW tank 2 x Vitosol 200-F

200 litres/day 45 °C Azimuth: 0° Inclination: 45°

300 litres

11 kW

Results of simulation over a one-year period 59.8 % 36.2 % 2 214 kWh 6.12 MWh 2 975 kWh 274 m3 520 kg

5167 156 v3.1

DHW solar fraction System efficiency Heat yield of collector circuit Irradiation on reference surface Heat requirement for DHW heating Natural gas savings CO2 emissions avoided

58

Appendix

Calculation Example Based on the Viessmann “ESOP” Program

(continued)

Solar heating system with dual-coil DHW tank (continued)

Coverage 59.8%

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Period: 1.1. – 31.12.

System parameters Collector circuit details 2 collectors Total surface area, gross: 5.42 m2 Angle of inclination: 45º

Model: Vitosol 200-F Net: 4.99 m2 Azimuth: 0º

DHW cylinder with two indirect coils Capacity: 300 l

Model: Vitocell-B 100 (300 litres)

DHW consumer Type: Detached house

200 l per day at 45 ºC set temperature, 365 days

Cold water

February: 8 ºC

Total annual global radiation: 1101.08 kWh/m2

5167 156 v3.1

Weather statistics A location at 49º latitude

August: 12 ºC

59

Appendix

Glossary Absorber Device contained inside a solar collector for absorbing radiation energy and transferring this as heat to a liquid. Absorption Absorption of radiation. Condenser Device in which vapour is precipitated as liquid. Convection Transfer of heat by a flowing medium. Convection creates energy losses caused by a difference in temperature, e.g. between the glass plate of the collector and the hot absorber. Dispersion Interaction of radiation with matter by which the radiation direction is altered; total energy and wavelength remain unchanged. Efficiency The efficiency of a solar collector is the input/output ratio of the collector. Relevant variables are, for example, the ambient and absorber temperatures. Emission Radiation of beams, e.g. light or particles.

Heat loss coefficients k1 and k2 k1 is the constant component of the heat loss of a collector and is usually designated as k value (unit: W/(m2 · K)). k2 is the quadratic component of the temperature-dependent heat loss (unit: W/(m2 · K2)). Any informative statement about the heat losses of a collector requires both values to be quoted. Heat pipe Closed, capillary container which contains a small quantity of highly volatile liquid. Heat transfer medium Fluid which picks up the useful heat in the absorber of the collector and transfers it to a user (heat exchanger).

Selective surface The absorber in the solar collector has been given a highly selective coating to improve its efficiency. This specially applied coating enables the absorption to be maintained at a very high level for the incident sunlight spectrum (approx.94 %). The emission of the long-wave heat radiation is largely avoided. The high-selectivity black chromium coating is very durable. Stagnation Condition of a collector when no heat is being conducted away by the heat transfer medium. Vacuum A space devoid of air.

Photovoltaic effect Gaining electrical energy from solar energy. Radiation energy Quantity of energy transmitted by radiation. Radiation level (irradiation) Radiation power, impacting per unit surface, expressed in W/m2, or Btu/h/ft.2.

5167 156 v3.1

Evacuation Evacuating air from a container. This reduces the air pressure and creates a vacuum.

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5167 156 v3.1

Printed on environmentally friendly (recycled and recyclable) paper. Technical information subject to change without notice.

64

Viessmann Manufacturing Company Inc. 750 McMurray Road Waterloo, Ontario • N2V 2G5 • Canada Tel. (519) 885-6300 • Fax (519) 885-0887 www.viessmann.ca • [email protected]

5167 156 v3.1

Viessmann Manufacturing Company (U.S.) Inc. 45 Access Road Warwick, Rhode Island • 02886 • USA Tel. (401) 732-0667 • Fax (401) 732-0590 www.viessmann-us.com • [email protected]