Installation, Start-up and
Service Instructions
For use by the heating contractor
Solar-Divicon, DN25B
997692210VIEUS0x-mub-en – V01 05/2014
Please file in Service Binder
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Solar-Divicon DN25B Installation, Start-up, Service
Table of Contents
1 For your safety .................................................................................................................................................. 3
1.1 About this manual ............................................................................................................................................... 3
1.2 Designated use ................................................................................................................................................... 3
1.3 Qualification of the installer ................................................................................................................................. 3
1.4 Hand-over of the system [specialist] ................................................................................................................... 4
1.5 General safety instructions .................................................................................................................................. 4
1.6 General instructions regarding solar fluid ............................................................................................................ 5
2 Description of the product .................................................................................................................................. 6
3 Assembly and installation [specialist] ................................................................................................................. 7
4 Commissioning [specialist] .............................................................................................................................. 10
4.1 Flushing and filling the solar circuit [specialist] .................................................................................................. 11
4.2 Preparation for flushing [specialist] ................................................................................................................... 13
4.3 Flushing and filling [specialist] ........................................................................................................................... 13
4.4 Setting the solar loop flowrate [specialist] ......................................................................................................... 15
5 Cleaning .......................................................................................................................................................... 16
6 Maintenance and decommissioning [specialist] ............................................................................................... 16
6.1 Partial draining of the solar installation [specialist] ............................................................................................ 17
6.2 Complete draining of the solar installation [specialist] ....................................................................................... 17
6.3 Replacing the pump [specialist] ........................................................................................................................ 18
6.4 Replacing the gaskets in the solar station [specialist] ....................................................................................... 18
6.5 Dismounting [specialist] .................................................................................................................................... 19
7 Application range of the check valves [specialist] ............................................................................................. 20
8 Spare parts [specialist] .................................................................................................................................... 21
9 Technical data and pressure drop characteristic .............................................................................................. 22
9.1 Pressure drop characteristic ............................................................................................................................. 2 3
10 Commissioning log .......................................................................................................................................... 24
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Solar-Divicon DN25B Installation, Start-up, Service
1 For your safety
Carefully read this manual before installation and
commissioning. Non-observance of the instructions
in this manual may lead to serious material damage
and serious injuries that may result in death.
Keep this manual in close proximity of the system for
later use.
1.1 About this manual
This manual describes the function, installation,
commissioning and operation of the solar stations
Solar-Divicon DN25B.
The chapters called [specialist] are only addressed
to installation contractors.
For other components of the solar installation, such
as collectors, storage tanks, expansion tanks, and
controllers, please refer to the instructions of the
corresponding product.
1.3 Qualification of the installer
Indicates that there is risk of
death, serious injuries or
considerable material
damage if suitable safety
precautions are not taken.
Indicates that there is a risk
of light injuries if suitable
safety precautions are not
taken.
Indicates that there is a risk
of material damage if suitable
safety precautions are not
taken.
1.2 Designated use
The solar station is a pre-assembled fitting assembly
checked for tightness and used for recirculating the solar
fluid in a closed loop solar circuit. The solar station must
only be used in solar thermal systems as pumping station
in the solar circuit, taking into consideration the technical
limit values indicated in this manual. The station may only
be assembled indoors. The station must be assembled
and operated as described in this manual!
Unintended use of the solar station will invalidate any
liability claims.
Only use accessories from Viessmann.
The wrapping materials are made of recyclable materials
that can be recycled by standard recycling operations.
Installation and commissioning of this equipment
should be done by qualified installers [specialist] in
accordance with local, state, provincial, and federal
codes which may be applicable.
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The following must also be observed during
installation and commissioning:
Relevant regional and national regulations (for
example Occupational Safety and Health Act)
Relevant accident prevention regulations (for
example of the Employer's Liability Insurance
Association)
Instructions and safety instructions mentioned in
this manual
Solar-Divicon DN25B Installation, Start-up, Service
1.4 Hand-over of the system [specialist]
After installation and commissioning, the installer is
responsible for familiarizing the end user with the functions
of the system and the basic safety measures.
After commissioning, fill in the log on the last page of
this manual.
Hand the manual over to the end user and instruct
them to to keep the manual in close proximity to the
system.
Instruct the end user to have the solar station
serviced and repaired by a specialist only.
The controller settings must not be changed by the
customer.
Explain to the end user the function of the system and
of the safety devices. Point out to the end user that
the shell must remain mounted during operation and
that the ball valves in the temperature gauges and
flowmeter must always be open.
General safety instructions
1.5
Before installing and commissioning the product, you must read and observe the following safety instructions:
Danger of scalding due to escaping
vapor!
Flush and fill the system only if the
collector temperatures are below
150 °F (70 °C).
Connect a discharge line to the
safety assembly. Observe the
instructions regarding the pressure
relief valve.
The pressures calculated by the
installation planner for the
expansion tank and the operating
pressure of the installation must be
set prior to filling system
.
Personal injury and material
damage caused by excess
pressure!
Closing both ball valves will disconnect
the safety assembly from the heat
exchanger. Heating the storage tank
can result in the formation of high
pressures, which may lead to material
damage and personal injury!
In operation, the ball valves with
temperature gauges and the ball
valve at the flowmeter must always
be open.
Close the ball valves only when
service is required.
Material damage due to mineral oils!
Mineral oil products permanently damage the EDPM
sealing elements, resulting in a loss of their sealing
characteristics. We cannot be held liable for damage
caused by seals thus damaged, nor will we offer a
replacement under warranty.
It is imperative to prevent the EPDM sealing
elements from making contact with substances
containing mineral oils.
Use silicone- or polyalkylene-based lubricants free of
mineral oil, such as Unisilikon L250L and Syntheso
Glep 1 from the company Klüber or a silicone spray
Risk of burns!
The valves, fittings and the pump may
heat up to more than 212 °F (100 °C)
during operation.
The shell must remain closed during
operation.
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Solar-Divicon DN25B Installation, Start-up, Service
1.6 General instructions regarding solar fluid
Only use solar fluid specified in the Vitosol Collector Installation Manuals and the Vitosol Operating and Service
Instructions.
Also refer to these manuals to determine the following:
Solar fluid fill pressure
Fluid volume required to fill system
pH testing
Maintenance requirements.
Propylene glycol: Hazardous in case of ingestion!
Propylene glycol is hazardous in case of ingestion.
It is irritant in case of eye or skin contact.
Wear chemical resistant protective gloves and safety
glasses with side-shields when handling propylene
glycol mixtures.
Observe the instructions of the antifreeze
manufacturer.
It often happens that solar thermal systems cannot be completely drained after flushing. Thus, there is a risk of frost
damage when flushing with water. Therefore, the solar thermal system should only be flushed and filled with the solar
fluid used later on.
All components in the solar station are resistant to a percentage of propylene glycol of up to 50%.
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Solar-Divicon DN25B Installation, Start-up, Service
2 Description of the product
The solar station is mounted on a wall support and held
by clip springs. The station contains important valves,
fittings and safety equipment for operating a solar thermal
system:
1.1 Return to the collector field
1.2
1.3 Pressure relief valve, 87 psi (6 bar)
1.4 Fill valve
1.5 Connection for the expansion tank
1.6 Pressure gauge 87 psi (6 bar)
2 Solar pump
3.1 Ball valve in flowmeter
3.2 Drain valve
3.3 Flowmeter
3.4 Return from the storage tank
4.1 Supply to the storage tank
4.2 Airstop equipped with manual bleeder
Ball valve with temperature gauge in the return
equipped with replaceable spindle (blue)
5.2
5.1 Supply from the collector field
Assembly example
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Ball valve with temperature gauge in the supply
equipped with replaceable spindle (red)
Solar-Divicon DN25B Installation, Start-up, Service
3 Assembly and installation [specialist]
The solar station may only be installed indoors with a power supply of 120 V / 60 Hz. The installation site must be dry,
stable and frost-free.
Material damage due to high temperatures!
Since the solar fluid may be very hot near the
collector, the fitting assembly must be installed at a
sufficient distance from the collector field.
It may be necessary to install an upstream tank, in
order to protect the expansion tank
Solar-Divicon DN25B Installation Steps:
1. Remove the station from the packaging.
2. Pull off the front shell.
3. Hold the solar station to the mounting location and
level the unit. Mark the mounting hole locations
(next to the temperature gauges) onto the mounting
surface.
4. Drill the holes into the mounting surface, and fasten
the solar station to the wall by means of the
enclosed screws and, if required, the enclosed wall
anchors.
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Solar-Divicon DN25B Installation, Start-up, Service
Assembly of the cutting-ring compression fitting:
Push the union nut ② and the cutting ring ③ onto the 1” copper
pipe ①. The pipe must protrude at least ⅛" (3 mm) from the cutting
ring in order to ensure the force transmission and the sealing.
5. Connect the solar station to the system by means
of copper or stainless steel pipes
⑤ Supply from collector field
① Return to the collector field
④ Supply to the storage tank
③ Return from the storage tank
All pipe connections are designed as cutting-ring
compression fitting 1" copper pipe. Pipe size can be
reduced to ¾” copper if required.
Insert the support sleeve ④ into the copper pipe.
Insert the copper pipe with the plugged-on individual parts (②, ③
and ④) all the way into the housing of the cutting-ring fitting ⑤.
First tighten the union nut ② manually.
Tighten the union nut ② by rotating it by one full turn.
Secure the housing of the cutting-ring fitting ⑤ against distortion in
order to avoid damaging the sealing ring.
6. Connect a discharge line to the connection (1.3) at
the pressure relief valve. Conduct the discharge
line into a heat-resistant container. Secure the
discharge line such that in the event of escaping
vapor people in the vicinity are not put at risk.
7. Connect the connecting line for the expansion
tank below the pressure gauge (1.5).
8. Adapt the initial pressure of the expansion tank to
the system and connect the expansion tank.
Observe the manufacturer's separate instructions
of the expansion tank! Also observe the layout of
the installation planner.
9. Check all pipe connections and retighten if
necessary.
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