Viessmann VITOSOL 100-F Operating instructions

Service instructions
for contractors
VIESMANN
Vitosol-F
For applicability, see the last page
VITOSOL-F
5692 887 GB 2/2014 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ National installation regulations
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental protection
■ Codes of practice of the relevant trade
associations
■ All current safety regulations as
defined by DIN, EN, DVGW, VDE and
all locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI, SWKI and
SVGW
Working on the system
■ Isolate the system from the power sup-
ply (e.g. by removing the separate fuse
or by means of a mains isolator) and
check that it is no longer 'live'.
■ Safeguard the system against recon-
nection.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Prior to commencing any work,
touch earthed objects, such as
heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Defective components must be
replaced with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
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Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5692 887 GB

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Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 6
Scope of inspection........................................................................................... 14
Parts lists
Vitosol 100-F........................................................................................................ 15
Vitosol 200-F, type 5DIA...................................................................................... 17
Specification
Vitosol 100-F........................................................................................................ 18
Vitosol 200-F, type 5DIA...................................................................................... 18
Certificates
Declaration of conformity...................................................................................... 19
Index
Index
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Checking pressure conditions and adjusting the pre-
charge pressure of the expansion vessel if necessary 6
••• 2. Checking the function of the safety equipment............. 8
••• 3. Checking electrical connections..................................... 8
•4. Filling and flushing the solar thermal system and
checking for leaks............................................................ 8
••• 5. Determining the flow rate and adjusting if required...... 11
• • 6. Commissioning the system............................................. 12
••• 7. Checking the switching function of the solar control
unit..................................................................................... 12
• • 8. Checking and replacing the heat transfer medium if
required............................................................................. 13
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Checking pressure conditions and adjusting the pre-charge
pressure of the expansion vessel if necessary
This process may not be carried out
while the solar thermal system is in oper-
ation.
1. Cover the collectors with tarpaulins.
2. Determine the charge pressure:
■ Solar thermal system pressure
1 bar + 0.1 bar/m = system pres-
sure
■ System pressure + 0.1 bar pres-
sure reserve for ventilation
3. Determine the pre-charge pressure
of the expansion vessel:
Value for system pressure minus
0.3 bar for hydraulic seal.
4. Check pre-charge pressure and
adjust if required.
A pressure gauge can be found in
the solar service case available as
an accessory.
5. Enter the values in the following table
(for subsequent inspection and main-
tenance work).
Example:
At 10 m static head, the result is:
■ System pressure = 2 bar
■ Charge pressure = 2.1 bar
■ Pre-charge pressure = 1.7 bar
Commissioning, inspection, maintenance
Further details regarding the individual steps
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P
2
4
1
3
5
5
1System pressure of the solar thermal system 1.0 bar
2Supplement, static head 0.1 bar/m ................ bar
3System pressure (pressure gauge) ................ bar
Pressure reserve for ventilation + 0.1 bar
Charge pressure ................ bar
Pre-charge pressure of expansion vessel 5
Note
Record the "pre-charge pressure" level on the expansion
vessel.
................ bar
4Supplement 0.1 bar/m ................ bar
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the function of the safety equipment
Check the safety valve:
■ Response pressure
■ Correct installation, with discharge
pipe
Checking electrical connections
Check the tightness of the electrical
plug-in connectors and cable grom-
mets; check cables for damage.
Filling and flushing the solar thermal system and checking for
leaks
!Please note
Filling and commissioning the
solar thermal system without first
safeguarding the heat transfer
results in thermal stress.
Cover the collectors and keep
them covered until the heat trans-
fer has been regulated.
■ Accessories for flushing and filling the
solar thermal system:
–Flushing and filling facility (filling
trolley and charging station)
These contain a high speed pump
with a high pump rate, a filter and a
container for heat transfer medium.
–Filling valve set, consisting of shut-
off valve, drain valve and fill valve.
■ Flush the solar thermal system with
heat transfer medium. Otherwise there
is a risk that residual water from flush-
ing may become mixed with the heat
transfer medium. This would alter the
properties of the heat transfer
medium.
■ Flush brazed copper pipes very thor-
oughly. Any residual scale may com-
promise the operation of the solar ther-
mal system.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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The following description relates to a system with a Solar-Divicon.
P
K
N
M
G
B
C
A
H
L
L
M
EF
D
C
B
ASolar-Divicon
BShut-off valves
CNon-return valves
DSolar circuit pump
EAir separator
FShut-off valve (adjusting screw
above flow indicator H)
GDrain valve
HFlow indicator
KFill valve
LStagnation heat sink
MExpansion vessel
NFlushing and filling facility
01. Open shut-off valves B: Turn the
ball valves (thermometers) clock-
wise through 45°.
02. Close shut-off valve F: Using a
screwdriver, turn the slot on the
adjusting screw to position "S".
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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03. Connect hoses of flushing and filling
facility N to drain valve G and fill
valve K.
04. Fill the container of flushing and fill-
ing facility N with heat transfer
medium.
05. Open drain valve G and fill
valve K.
06. Start the fill pump of flushing and fill-
ing facility N.
07. Observe the fluid level in the con-
tainer and top up with heat transfer
medium if necessary to prevent any
air entering the solar circuit. Leave
the fill pump of flushing and filling
facility N running until no more air
bubbles rise to the top of the con-
tainer (at least 20 to 30 min).
Note
Briefly open shut-off valve F
towards the end of the flushing proc-
ess: Using a screwdriver, turn the
slot on the adjusting screw above
the flow indicator to the vertical posi-
tion. Any air that remains in the
return is eliminated.
08. Close drain valve G. Leave the fill
pump of flushing and filling
facility N running until the required
charge pressure is reached.
Notes on residual ventilation
Even after thorough ventilation,
some dissolved air will still remain in
the heat transfer medium. This will
be released as the temperature
rises, and will be discharged via air
separator E.
09. Close fill valve K; stop the fill pump
of flushing and filling facility N.
The pressure must not drop for at
least 30 minutes.
10. Open shut-off valve F: Using a
screwdriver, turn the slot on the
adjusting screw above the flow indi-
cator to the vertical position.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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11. Vent the circulation pump. Select
manual mode.
Open the air vent valve on air sep-
arator E.
Leave the circulation pump running
until the float in the flow indica-
tor holds a constant position while
the pump is running.
Note
If there is air in the system, the float
will oscillate.
12. Close shut-off valve B: Set the ball
valves (thermometers) to vertical
position.
Determining the flow rate and adjusting if required
Check the flow rate at the top edge of the
float.
20
5
15
25
10
35
30
l/min
In conjunction with multi stage circulation
pumps, set the required flow rate via the
output stage (see the following table for
approximate set values).
Note
With a Solar-Divicon, make the adjust-
ment via shut-off valve F (adjusting
screw above the flow indicator).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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High-flow operation, specific flow
rate 40 l/(h·m2)
Number of
collectors
Flow rate in l/min
2 3
3 4.5
4 6
5 7.5
6 9.5
7 10.5
8 12.5
9 14
10 15.5
11 17
12 18.5
13 20
14 21.5
15 23.5
Low-flow operation, specific flow rate
15 l/(h·m2)
Number of
collectors
Flow rate in l/min
6 3.5
7 4
8 4.5
9 5
10 5.5
11 6.5
12 7
13 7.5
14 8
15 8.5
16 9
18 10.5
20 11.5
Vitosol 200-F, type 5DIA
Set throughput to 5 to 6 l/min.
Commissioning the system
Close the air vent valve.
Note
With a Solar-Divicon, do this at
air separator E.
Observe operating instructions of
installed components.
Checking the switching function of the solar control unit
Solar control unit installation and
service instructions
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking and replacing the heat transfer medium if required
■ The heat transfer medium provided is
a liquid based on 1,2-propylene glycol
with a pH value of 9.0 to 10.5 and frost
protection down to -28 °C.
■ Have the condition of the medium
checked as part of the annual service
of the solar thermal system by the
heating contractor.
■ The pH value and frost protection tem-
perature can be checked with the
solar service case (accessories).
Solar service case operating
instructions
In some cases the manufacturer of the
heat transfer medium can carry out a
laboratory test of the medium, subject
to arrangement.
■ Manufacturer:
TYFOROP CHEMIE GmbH
Anton-Rée-Weg 7
D - 20537 Hamburg
Email: [email protected]
Internet: www.tyfo.de
1. Check the pH value of the heat trans-
fer medium using the pH strip in the
solar service case.
The colour of the pH strip indicates
the approximate value. If the value is
below 7.5, replace the heat transfer
medium.
Information on replacing the heat
transfer medium
The heat transfer medium can be
mixed with Tyfocor G-LS.
Never mix with water or third party
media.
2. Check the frost protection tempera-
ture of the heat transfer medium with
an antifreeze tester or the manual
refractometer in the solar service
case.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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The solar thermal system should be
inspected once a year to ensure opera-
tional reliability.
In addition to this, a visual inspection of
all essential components (e.g. collectors
and pipework) is recommended every 3
to 5 years.
■ Vent the solar thermal system.
■ Compare system operating pressure
with the set value. If the values are dif-
ferent, check the expansion vessel.
■ Check the heat transfer medium.
■ Start circulation pumps manually if
necessary (listen for noises).
■ Compare flow rate with set value.
■ Check thermostatic mixing valve (if
installed).
■ Check plausibility of the solar param-
eters subject to the current insolation
level (e.g. flow and return tempera-
tures at the thermometers; collector
and cylinder temperatures at the solar
control unit).
Only check the safety valve if there are
visible signs of it being open (e.g. depos-
its, drips).
Scope of inspection
Scope of inspection
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Pos. Component Part no.
0001 Connection pipe 7827517
0002 Connection pipe (short) 7827514
0003 Connection pipe (long) 7827515
0004 Plug 7827516
0005 Locking ring fitting with support sleeves 7819612
0006 Elbow fitting with support sleeves 7819611
0007 Clamping bracket, complete 7825026
0008 Connecting part 7819609
0009 Mounting plate 7819608
0012 O-rings 7819604
0014 Profile clamp 7317074
0015 Diagonal strip 7816271
0016 Support sleeve 7824605
0020 Special valve grease 7819602
0021 Dismantling instructions 5581863
0022 Operating instructions 5581554
0023 Service instructions 5681887
0025 Installation instructions, above roof installation with roof hooks 5581860
0026 Installation instructions, above roof installation with rafter an-
chors
5368679
0027 Installation instructions for flat roofs or freestanding installation,
variable angle of inclination
5581924
0028 Installation instructions for flat roofs or freestanding installation,
fixed angle of inclination
5458706
0029 Sealing screws 7834844
0030 Collector holder with screws 7834845
0031 Sealing material 7834846
0032 Bit holder 7834847
0033 Air vent plug 7818288
0034 Cross union with support sleeves 7834848
0035 Repair panel 7834849
0036 Woodscrew 8 x 120 7834850
0037 Fixing clamp 7834851
0038 Support brackets for rafter hooks 7521304
0039 Woodscrew 8 x 120 7841223
0040 Rail connectors 7521305
0041 Installation instructions, above roof installation with rafter hooks 5693696
Parts lists
Vitosol 100-F
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0037
0036
0035
0034
0033
0032
0031
0030
0029
0028
0027
0026
0025
0023
0022
0021
0020
0016
0015
00140012
0009
0008
0007
0006
0005
0004
0003
0002
0001
Parts lists
Vitosol 100-F (cont.)
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0041
0040
0039
0038
Vitosol 200-F, type 5DIA
Component Part no.
Aluminium flashing 7838113
Aluminium clip 7838114
Parts lists
Vitosol 100-F (cont.)
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Type SV1A/SH1A SV1B/SH1B
Absorber area m22.32 2.32
Aperture area m22.33 2.33
Thermal capacity c kJ/(m2K) 4.7 4.5
Max. stagnation temperature °C 200 196
Permiss. operating pressure bar 6 6
Content, heat transfer medium litres 1.48/233 1.67/2.33
Vitosol 200-F, type 5DIA
Absorber area m24.76
Aperture area m24.92
Thermal capacity c kJ/(m2K) 6.40
Max. stagnation temperature °C 200
Permiss. operating pressure bar 6
Content, heat transfer medium litres 3.34
Specification
Vitosol 100-F
5692 887 GB

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We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm as sole respon-
sible body that the product Vitosol-F complies with the following standards:
DIN 1055-1: 2002-06
DIN 1055-4: 2005-03
DIN 1055-5: 2005-07
EN 12975 to Solar KEYMARK
In accordance with the following directives, this product is designated with _:
2006/95/EC
2004/108/EC
97/23/EC
Details according to the Pressure Equipment Directive (97/23/EC):
■ Heated pressure equipment
■ Class I according to appendix II, diagram 5
■ Module A according to appendix III
■ Identification of individual devices with a content of less than 2 litres as an assembly
according to article 3 (2), subject to the installation of at least one pair
The pressure vessel was tested without fitted equipment (safety equipment).
The pressure vessel must be equipped in accordance with current national regula-
tions prior to installation and commissioning.
For the energy assessment of heating and ventilation equipment to DIN V 4701-10
as required by the EnEV, when determining system values for the product Vitosol,
the product characteristics calculated as part of output testing can be used (see
specification table).
Allendorf, 01 August 2012 Viessmann Werke GmbH&Co KG
Authorised signatory Manfred Sommer
Certificates
Declaration of conformity
5692 887 GB

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Applicability
Serial No.:
7417761 7417762 7417767 7417768
7439235
Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Viessmann Werke GmbH&Co KG
D-35107 Allendorf
Telephone: [phone]
Fax: [phone]
www.viessmann.com
5692 887 GB Subject to technical modifications.