Solar Divicon - CAPCO Energy Supply
Contents
1. The overflow pipe from the safety relief valve must be connected to an open container to collect glycol water in the event of the pressure relief valve releasing Mounting screws 4 Installation of the Solar Divicon 8 Fill and flush the Solar Divicon check the system for leaks and commission the system see 7 Initial Start up 9 Attach the front insulation of the Solar Divicon after commissioning the system Then insert the thermometers red thermometer in the supply left blue thermometer in the return right 10 Slide connecting wire of circulation pump downwards through wiring channel of insulation panel and connect to Vitosolic or GL 30 control unit in accordance with the control Installation Instructions 11 Slide insulating cover over piping and wiring and snap into place 12 Push the thermal insulation of the pipe work into the recesses of the thermal insulation of the Solar Divicon Installation of compression fittings 1 All pipe ends must be square and deburred 2 Copper piping in the vicinity of the compression fittings may not be soldered while connected to Solar Divicon 3 Put union nut 2 on copper pipe 1 Then slide support sleeve 3 into copper pipe 1 4 Slide olive 4 as far as it will go on the copper pipe Copper pipe and its components 2 3 and 4 must be inserted as far as possible into the ball valve 6 Tighten union nut manually then tighten it with open end wrench by a2. 0 1x__ m of installed height static pressure head must exist Purge all air from system by briefly opening ball valve 4 in the middle of the filling and flushing unit Close flush valve 5 when filling pump is running and increase system pressure to approximately 70 psig 5 bar Close fill valve 3 and switch off filling pump Open ball valve 4 in the middle of the filling and flushing unit Deaerate system until solar fluid exits without bubbles Again increase system pressure to 70 psig 5 bar and check system for leaks Set operating pressure to between 35 and 40 psig 2 5 2 8 bar Switch on circulation pump and select highest speed Allow it to circulate for at least 15 minutes Set system flow rate by selecting the required speed of circulation pump See Vitosol Service manual for required flowrates for Vitosol 100 and 300 collectors Remove hoses of filling and flushing station and screw caps on fill and flush valves Again check system for leaks Set valves to operating position Slide insulating cover over piping and snap into place Turn thermometers 45 to open flow check valves during initial flush and fill hot water heating boiler Solar control DHW storage tank Solar Divicon etc Technical literature Please file this manual in your Viessmann Service Binder 8 Parts List Solar Divicon Model No Order No DN20 7134 799 DN25 7134 800 015 008 023 Ordering Replacement Parts 002
3. Order replacement components from your Viessmann distributor Parts 001 Insulation case 002 Wall mount bracket 003 Cover plate Viessmann 004 Spring clip 005 System fill manifold 006 Hose nib 007 Gasket set 008 Safety tee 009 Ball valve with integrated flow check valve return 010 Ball valve with integrated flow check valve supply 011 Half union 1 012 Flow meter 013 Auto air vent with air separator 014 Circulation pump 120 1 60 015 Flare fittings set of 2 016 Brass coupling BSP x NPT 017 Adaptor for pressure gage 018 Handle for ball valve 019 Thermometer blue 2 020 Thermometer red 2 021 Handle cover for ball valve 012 _ 022 Pressure gage 86psi 6bar 015 Ty 001 023 Pressure relief valve 87psi Other Parts not illustrated 100 Installation and Service Instructions 101 Parts List 1 Applies only to DN25 model 2 DN20 models are shipped with F thermometers Contact Viessmann for C thermometers DN25 models are shipped with dual scale F C thermometers Product may not be exactly as illustrated Viessmann Manufacturing Company U S Inc Viessmann Manufacturing Company Inc 45 Access Road 750 McMurray Road Warwick Rhode Island 02886 USA Waterloo ON N2V2G5 CANADA 5349 544 v1 0 Technical information subject to change without notice Tel 401 732 0667 Fax 401 732 0590 Tel 519 885 6300 Fax 519 885 5342
4. ARS 16 U 15 STAR S 21 U 25 Rated voltage V AC 115 AC 115 Maximum flow rate GPM 16 16 7 Maximum head ft 20 7 21 1 Flow meter setting range USG min 0 5 to 5 1 to 10 Itr min 1 to 20 5 to 40 Safety relief valve psig 87 87 bar 6 6 Max operating temperature oF 248 248 2 120 120 Max operating pressure psig 87 87 bar 6 6 Connections Compression fittings Solar circuit inches 2 Sa Solar expansion tank inches Safety relief valve inches A Brass flow check valves Located in each supply and return lines Open manually by turning thermometer handles Material construction Flat gaskets Klingerit Max 392 F 200 C O rings VITON EPDM Max 356 F 180 C Flow check valves Brass Max 356 F 180 C Insulation EPP Max 248 F 120 C 356 F 180 C for short period 5349 544 v1 0 04 2007 2 Technical Data 3 Notes on Installation Dimensions Pump 20 9 10 O 2V OQ SOOO 234mm 9 1 5 3 Notes on Installation The distance between the Solar Divicon and the collectors must be sufficient because of the possible high temperatures near the collectors If necessary install an intermediate tank to ensure fittings do not overheat IMPORTANT Always install Solar Divicon lower than collector panels to avoid penetration of steam into the expansion tank If the expansion tank is installed as high or higher than the Solar Divic
5. Please file in Service Binder Installation Start Up and WI EMANN Service Instructions Solar Divicon Part No 7134 799 7134 800 1 Safety and Installation Requirements Please ensure that these instructions are read and understood before commencing installation Failure to comply with the instructions listed below can cause product property damage severe personal injury and or loss of life Working on the equipment Ensure main power supply to It is not permitted to carry out repairs The installation adjustment service equipment the heating system and all on parts that fulfil a safety function and maintenance of this product must external controls has been deactivated For replacements use only original be done by a licensed professional Close main oil or gas supply valve spare parts from Viessmann or those heating contractor who is qualified and Take precautions in both instances to which are approved by Viessmann experienced in the installation service avoid accidental activation of power and maintenance of solar systems during service work There are no user serviceable parts on lt gt Ensure that the installation the pump station or control literature of other components is referenced Check system pressure frequently Excessive system pressure may result in damage to the equipment 2 Technical data personal injuries or loss of life Solar Divicon Model DN 20 Model DN 25 Circulation pump Model Wilo ST
6. full turn Make sure that the copper pipe does not slide out of the compression fitting when tightening the union nut Uninstall the Solar Divicon In order to detach the Solar Divicon from the wall mount bracket remove the safety clips by means of a screwdriver Chel velit a 5 Notes on the Expansion Tank 6 Notes on the Circulation Pump 5 Notes on the Expansion Tank The heating system must be equipped with a membrane pressure expansion tank Should the expansion tank be installed at the same level or higher than the Solar Divicon a heat insulating loop is required The membrane and gaskets of the expansion tank must be suitable for the heat transfer medium and for the high temperature in a solar system Adjust inlet pressure of the expansion tank to system for information regarding the calculation of the inlet pressure setpoint value see Service Instructions for Viessmann solar panels Refer to Vitosol Service Instructions for setting the system and expansion tank pressures 6 Notes on the circulation pump Connect solar control unit to power supply after flushing and filling the system see Service and Installation Instructions for Viessmann solar panels Circulation pump settings The flow rate through the collectors and the pump speed required depends on the number and type of collectors Refer to Vitosol Service Instructions or Vitosol System Design Guidelines for suggested flow rates S
7. hut off valve Solar control unit 3 speed pump Fast air vent c w shut off valve Overflow container Flow check valves HWR Heating water return to collectors HWS Heating water supply to storage For additional information on installation examples and installation illustrations of solar heating systems see Vitosol System Design Guidelines 4 Installation of the Solar Divicon Installation Steps 1 2 Unpack accessories and the Solar Divicon Determine the position of the Solar Divicon Consider the space for the expansion tank Remove the thermometers from the Solar Divicon by pulling forward Pull off the front insulation of the Solar Divicon Hold the Solar Divicon in position on the wall and mark the position of the wall holder Drill 5 16 or 8mm holes for the wall bracket and insert the supplied plugs into the holes Secure the back panel of the Solar Divicon to the wall using the supplied screws Place assemble and connect the expansion tank A field supplied isolation valve is recommended between the expansion tank and the Solar Divicon Connect piping of the solar circuit to top and bottom connections using the supplied compression fittings and hex nuts Firmly tighten all union nuts and screw connections The pressure gage does not need to be sealed with any sealants before inserting it into the valve Hand tighten the pressure gage and loosen it until you can read the indication properly IMPORTANT
8. on a thermal insulation loop is required During initial system fill turn temperature dial gages 45 This will bypass the integrated flow check valves After filling and purging is complete return the valve to the original position Temperature dial gages can be turned 90 to shut off flow completely Only use bronze metal brass and or copper fittings for the installation Do not use galvanized pipes or fittings and graphitized gaskets Do not use any plastic pipes Components IMPORTANT The Solar Divicon is not suited for direct contact with swimming pool water Flow meter Insulation cover 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 Flush and fill manifold Air separator located under insulation that are in contact with the heat transfer medium Composition propylene glycol water mix 50 must be resistant to it Prior to installation Ensure that seals are clean and undamaged Solar Divicon must be grounded to protect against lightning The expansion tank must be checked regularly 3 Notes on Installation OZZrF ACT7 7 TOTMMVOWODSD Solar Divicon Safety relief valve 87psig 6bar Solar panels Solar expansion tank Connection to solar DHW storage tank Pressure gage Flush and fill manifold Flowmeter Air Separator Integrated thermometer s
9. tar S 16 U Water flow m h 0 0 5 1 15 2 225 3 25 20 v 3 10 E 5 0 0 5 10 15 Water flow US gpm Star S 21 U Water flow m h 0 0 5 1 T5 2 2 5 3 25 7 20 5 15 4E 3 3 2 5 1 0 0 0 5 10 15 Water flow US gpm 6 7 Initial Start up and commissioning Connect pressure hose to fill valve 3 of filling and flushing unit on the Solar Divicon and open valve Connect flush hose to flush valve 5 and open valve Close ball valve 4 in the middle of the filling and flushing unit so that handle is in horizontal position Open both flow check valves 1 and 2 by turning the thermometers 45 Pour sufficient solar fluid into container of a filling and flushing station and fill solar system using charging pump or hand pump Flush solar system for at least 15 minutes to remove all debris Flushing or pressure testing with water only is not recommended As it is generally not possible to drain the system completely there is a risk of frost damage Informing the system operator The installer of the solar system is required to properly acquaint the system operator to functions of the heating system For initial start up please reference the corresponding Installation or Operating Instructions of all componentry solar panels WARNING Prior to start up ensure the system is completely sealed Under cold fill conditions an overpressure of at least 22 psig 0 45 psig x _ ft 1 5 bar
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