Consolar VARICAL Installation Instructions And Manual Download

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Application • Use

• Large storage volumes for hot water through fresh water

heat exchanger

• Heat generators that need larger buffer volumes

-Solar heat

-Biomass boilers

-Heat pumps

-Combined heat and power units

-District heating

-Power to heat

• Especially suitable for heating system refurbishment

-Multi family homes

-Hotels

-Sun houses

Special benefits

•  Can fit through narrow cellar doors and corridors
•  Reduced space requirement compared to multiple stores
•  Pressurised store: Buffer water can be saved and used

directly – no reductions through heat exchangers

• Heat loss reduced by a half compared with storage

cascade with same thermal insulation

• Thermal insulation with optional vacuum inserts for

extremely low heat loss.

• Very good stratification layering
• Use as a hydraulic seperator with minimum mixing at

high flow rates

TECHNICAL DOCUMENTATION,
INSTALLATION INSTRUCTIONS AND MANUAL

VARICAL

The universal modular buffer store

TDMA200EN_VARICAL_2018_02_08_2018_06_11_obcfps

Summary of Contents for VARICAL

Page 1: ...d corridors Reduced space requirement compared to multiple stores Pressurised store Buffer water can be saved and used directly no reductions through heat exchangers Heat loss reduced by a half compared with storage cascade with same thermal insulation Thermal insulation with optional vacuum inserts for extremely low heat loss Very good stratification layering Use as a hydraulic seperator with min...

Page 2: ...thermal insulation 7 4 2 Dimensions weight and pressure loss 8 4 3 Minimum room sizes for module installation 9 5 Hydraulic plans 10 5 1 General 10 5 2 Integration of heat generator 12 5 3 Hot water 12 5 4 Solar system 13 5 5 Biomass boiler 14 5 6 Automatic boilers 15 5 7 Heat pump remote DHW preparation 16 5 8 CHP 17 5 9 Biomass boilers and combined thermal store 18 5 10 Large solar system 19 6 A...

Page 3: ...r or third parties or damage of the product and other material assets deriving from the use Operate the store only in technically perfect condition In case of safety related dysfunction the product must be stopped immediately and be fixed by a specialist 1 4 With applicable documents Follow the planning and operating instructions of all system components such as fresh water station 1 5 Installatio...

Page 4: ... store and the heating circuit on the other side of the same tube Then only the water the heating circuit is not using flows into the buffer through the slots in the tube This behav iour is especially important for heat pumps where any drop in temperature should be avoided 2 2 Insulation system Minimized heat loss is achieved by an innovative insulation system optimised in detail LEEPS insulation ...

Page 5: ...TW of the University of Stuttgart with 20000 cycles from 0 to 6 bar at 20 C and with 15000 cycles at 90 60 C 3 Planning aids 3 1 Transport The store modules must be transported upright The indi vidual modules are delivered on a pallet and can be easily transported with a forklift truck 3 2 Notes on buffer water Water quality The water quality of the store should at least conform to the guideline V...

Page 6: ... HFC and fiber insulat ing materials Materials used and their weightings in a store with three modules 4000 l Steel 709 6 kg 91 1 EPS 22 5 kg 2 9 EPS EPE copolymer 2 9 kg 0 4 PET fleece 18 1 kg 2 3 PS 12 kg 1 5 PA 4 7 kg 0 6 Stainless steel 4 7 kg 0 6 EPDM 4 kg 0 5 3 9 Installation location Prior to installation of the store the static load bearing capacity of the ground must be checked The weight...

Page 7: ...plastic laminated under vacuum Front insulation material PET fleece Insulation thickness coat cm 13 LEEPS 3 air cushion Front insulation thickness cm 25 Base EPS insulation thickness cm 5 Thermal conductivity LEEPS sqm W mK 0 032 Thermal conductivity PET fleece W mK 0 035 Reaction to fire class Sheath insulation B1 front insulation B2 No Modules Unit 2 3 4 5 6 7 8 Heat loss standard 3 W 189 248 30...

Page 8: ...589 11130 12688 Content l 2760 4110 5460 6810 8160 9510 10860 Weight incl pressure profile pipes and insulation Dimension mm Volume fraction Description 2130 Height with insulation 1980 100 Height without insulation 1781 95 Connection 1 2 male thread 1386 73 Connection 2 2 male thread 1046 50 Connection 3 2 male thread 706 27 Connection 4 2 male thread 311 5 Connection 5 2 male thread 728 Wide rai...

Page 9: ...6 323 6 modules 529 197 7 modules 592 260 8 modules 655 323 When assessing access note the lengths of pipe Recomended value Min value for assembly B Room width ca 350 cm ca 290 cm C Recommended clearance lateral wall to store without insulation ca 100 cm ca 50 cm D Minimum longitudinal wall to store distance without insulation ca 70 cm s l E Minimum longitudinal wall to store distance with insulat...

Page 10: ...onstant pressure and possible additional shut off devices for maintenance and service work Recommendation Air separator at the top connection input Boiler flow for DHW preparation 65 C Boiler flow Solar system flow Return to boiler with solar operation Return to boiler without solar Solar system return Make connections to stop reverse flow and thermosyphon Solid fuel boiler Pump Automatic air sepa...

Page 11: ...SB Store bottom C Collector CI Circulation HF Heating flow Syphoning of the connections Syphon connections should be used The height of the Syphon drop should be at least 10 cm pipe work should be thin walled steel or stainless steel tube no CU pipe should be used Proper syphon connection pipes are offered as accessories Double connection to a single outlet If a storage connection with double conn...

Page 12: ...heat generator Notes on the integration of different heat generators Flow hot water heating depending on the system at the appropriate height connection Return without solar at the bottom Observe information from the boiler manufacturer Return protection depending on the boiler maybe necessary to prevent sooting Follow the manufacturers instructions Modulating condensing boiler Return protection s...

Page 13: ...13 5 4 Solar system System separation of collectors for frost protection function CI T D M A VA R I C A L Hydraulic plans ...

Page 14: ...SB HT LT HF HF CI C Biomass boiler with return protection fresh water station 2 mixed heating circuits HT high temperature and low temperature LT Use of the complete buffer volume for the heat generator and the solar system T D M A VA R I C A L Hydraulic plans ...

Page 15: ...eating circuits buffer only for DHW preparation via fresh water station HTG directly from the boiler solar 1 1 If smaller DHW volume is sufficient use higher solar flow and boiler return connections LT HT HF HF CI ST SBT SBB SB C T D M A VA R I C A L Hydraulic plans ...

Page 16: ...ithout solar Connect return pipe of the heat pump at the bottom Heat pump with decentralized storage of domestic hot water solar transfer station Generally the district network can be supplied with the low radiant temperature The temperature is raised only to fixed DHW reheating times 1 2 LT LT LT LT ST SBT SBB SB C T D M A VA R I C A L Hydraulic plans ...

Page 17: ... circuits Central fresh water station According to the manufacturer s specifications and type of pipe network or heating water it may be necessary to indirectly connect the CHP see the following drawing HT LT HF HF CI ST SBT SBB SB T D M A VA R I C A L Hydraulic plans ...

Page 18: ... exchanger Can be omitted in the case of sufficient mixing volume in the combined thermal store 2 Reloading can also be with a pump and 2 changeover valves Scalding protection DHW and DHW recirculation not drawn 5 9 Biomass boilers and combined thermal store HT LT HF HF ST SB C Control principle When heating requirements in combined thermal store will be loaded to P1 When solar Combisystems to hig...

Page 19: ...e and with reloading of com bined thermal store Auxiliary heating of Combisystems by condensing boiler 2 Heating circuits high temperature HT and Low tempera ture LT Use of the complete buffer volume for the biomass boiler and the solar system Scald protection DHW and DHW recirculation not drawn T D M A VA R I C A L Hydraulic plans ...

Page 20: ... and pencil Step Ladder 6 3 Floor preparation The store must be mounted on the bottom rails Set the position of the bottom rails with the store projection see illustration below and Chapter 3 planning aid Take into account the dimensions for the future plumbing and mainte nance access L length of the track rails in mm 2 modules 1380 3 modules 2010 4 modules 2640 5 modules 3270 6 modules 1890 2010 ...

Page 21: ... touches the ground next to the rail is flush Preferably apply the layer as thin as possible NOTE Alternatively compensate only area under rails with levelling compound and joint such as with silicone the gaps between the floor and the insulation after mounting the insulation The correct distance between the rails is achieved with 2 stencils 1 Transfer the positions of the drill holes for the fixi...

Page 22: ...or seals 6 5 Container Assembly After hardening of floor material an end module is placed on the rails and pushed to the end Insert the 5 sealing sleeves pre greased at the factory into the gaskets until they stop On the second module lubricate the 5 seals with the lubri cating grease 1 in the outer conical area The grease is enclosed with the shipment T D M A VA R I C A L Assembly instructions ...

Page 23: ...module Keep straight when entering the sleeves The modules must be centered and connected with 2 x M20 screws and nuts 1 on both sides NOTE Optionally fit pipes early if space is constricted There might be not enough space in front of the store for the pipes to fit in see technical data minimum room size after installation of all store modules In this case it is possi ble to insert the 5 loading a...

Page 24: ...unloading tube is near the opposite end module a second person can push the Then slide the second end module Connect all modules twice on both sides with the M20 nuts and bolts 1 Slide the connecting rods through the two end modules NOTE For 7 modules the connecting rods are supplied in 2 parts Connect both parts of the connecting rod using the coupling nut ATTENTION The connecting rods must be sc...

Page 25: ...ound which the end sleeves lie behind the EPDM seal The barrel nuts must be at least screwed in after mounting the pressure profile by the distance X 1 mm after hand tight assembly carrying aid 2 into the tube guiding the tube out through the last seal The insertion aid is removed again and used for all tubes Align pipes with the same overhang on both sides The O ring seal and a seal end sleeve ar...

Page 26: ...operation of pressure tests NOTE Damage of the heating system due to over pressure Don not connect the store to the heating system during pressure testing Slowly fill the store with water Vent the store through the air vent and the top connection The pressure profiles are fitted to both ends of store over the 2 connections and held in place with 4 x M6 bolts Two barrel nuts with washers are screwe...

Page 27: ...sleeve damaged Is the gasket sleeve damaged 3 End seal leaks at O ring seal Is the O ring sealing surface of the stainless steel end sleeve damaged Is the O ring damaged 4 If necessary consultation with technical support and if necessary order a replacement seal 5 Fix cause of the leakage 6 Slide the modules together 7 Replace connecting rod and loading and unloading loading pipes 8 Insert the end...

Page 28: ...e sheet metal bore radially Insert the module seal Through the hole grasp the gasket inside 1 all around and manover to the center of the hole The manovering 1 ensures that the inner sealing lip 2 of the seal rests correctly on the container steel everywhere Then the seal inside and outside must have a uniform circular curve otherwise repeat the process 6 8 Connection to the heating system Equipot...

Page 29: ...en the runners and slid under the store Modules 2 3 4 5 6 7 8 Number of VIP on base plate 6 8 10 13 15 18 20 height Apply double sided tape directly above and below the square profile of the end modules Glue on convection brake fleece strips Glued surface narrow side 1 of the strip Floor insulation The floor plates are pushed under the store It must protrude T D M A VA R I C A L Assembly instructi...

Page 30: ...acket should only be carried out after completion of all work in the immediate vicinity Preparation of convection control The insulation jacket is first fitted with a foam strip convec tion brake The enclosed double sided adhesive tape 1 is stuck to the top of only one of two insulation shells After removing the protective film from the double sided tape the convection brake foam strip is also stu...

Page 31: ...h a saw Insert one half of the clamping profile into the slots of the jacket on the top at one end Mounting instructions clamp profile NOTE For the installation of the insulation a ladder is recommended Lubricate the channels of the insulation with silicone grease before inserting the clamps It maybe necessary to spread the legs of the clamping profile to get it engaged T D M A VA R I C A L Assemb...

Page 32: ...In doing so press the insulation from the outside Insert the next section of the insulation shell and push together at the top Slide the 2 pieces of insulation together Repeat steps until the insulation is fully assembled Clamp the shells with the profiles either as you go during the installation or all at the end Temperature sensor Insert all temperature sensors 1 according to the wiring diagram ...

Page 33: ...s of fleece should be placed in the slots of the outer shell on each side if not using the VIPS CONTROL The following points must be documented All insulation shells side and top sections pushed together without gaps Front insulation is installed tight to the side and floor pieces Pipe passes through front insulation without air gaps Front insulation fleece Remove outer strip from the front insula...

Page 34: ... in the midline are connected with the help of the plastic plug 2 The front halves can be drawn together using the holes next to the pipe passages In addition the insulation jacket shell should be pulled from both sides inwards until the holes are aligned The store is fully insulated T D M A VA R I C A L Assembly instructions ...

Page 35: ...n be opened at the top and vented by pulling the vent hose see section 6 7 ATTENTION Hold a container under the breather hose so that the insulation does not get wet 6 11Disassembly At the end of the service life the store can be dismantled for recycling in the reverse order of the assembly steps T D M A VA R I C A L Assembly instructions ...

Page 36: ...ch Fon 07621 42228 500 Fax 07621 42228 555 info consolar com www consolar com NOTE The information provided in the technical documentation and instructions do not claim to be exhaustive and do replace proper planning Changes and errors excepted For advice on Consolar products go to Changes and errors excepted T D M A VA R I C A L Imprint ...

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