Viessmann Vitosol 200-T Operating instructions

Service instructions
for contractors
VIESMANN
Vitosol 200-T, 300-T
For applicability, see the last page
VITOSOL 200-T, 300-T
5692 736 GB 11/2008 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and
material losses.
Safety instructions explained
!Please note
This symbol warns against the
risk of material losses and
environmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on electrical equipment must
only be carried out by a qualified
electrician.
■ The system must be commissioned by
the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the
prevention of accidents,
■ all legal instructions regarding
environmental protection,
■ the Code of Practice of relevant trade
associations.
■ all current safety regulations as
defined by DIN, EN, DVGW, VDE and
all locally applicable standards
Working on the system
■ Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate fuse
or by means of a main isolator.
■ Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electrostatic
discharges.
Touch earthed objects, such as
heating or water pipes, to
discharge static loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your heating
system.
Replace faulty components only
with original Viessmann spare
parts.
Safety instructions
Safety instructions
5692 736 GB

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Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the heating system can
compromise its function.
Installing non-authorised
components and non-approved
modifications or conversions can
compromise safety and may
invalidate our warranty.
For replacements, use only
original spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5692 736 GB

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Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 6
Parts lists
Parts list Vitosol 200-T, type SD2......................................................................... 11
Parts list Vitosol 200-T, type SD2A...................................................................... 13
Parts list Vitosol 300-T......................................................................................... 15
Specification
Vitosol................................................................................................................... 17
Solar-Divicon (accessory).................................................................................... 18
Heat transfer medium (accessory)....................................................................... 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. Cleaning, testing for leaks and filling the solar thermal
system............................................................................. 6
••• 2. Checking the function of the safety equipment
••• 3. Checking the expansion vessel and the system
pressure........................................................................... 7
••• 4. Checking the electrical connections............................ 7
• • 5. Starting the heating system........................................... 7
• • 6. Ventilating the solar thermal system............................ 8
••• 7. Checking the switching function of the solar control
unit................................................................................... 10
••• 8. Checking the flow rate
•9. Shutting down the system............................................. 10
• • 10. Checking gaskets and seals
• • 11. Checking the frost protection temperature and the pH
value of the heat transfer medium................................ 10
• • 12. Checking the thermal insulation of the pipes.............. 10
• • 13. Checking circulation pumps
•14. Cleaning collectors
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Cleaning, testing for leaks and filling the solar thermal system
■Never drain the system with a vacuum
pump.
■ Check the system for leaks:
The collector in its cold state must be
subject to a positive pressure of at
least 1.0 bar. At a static head of 10 m,
this would result in a system pressure
of 2.0 bar.
1. Cover collectors where necessary.
Open any installed shut-off gates or
valves by hand. Open the non-return
valves when using a Solar-Divicon:
Flow/return: Turn the thermometer
clockwise through 45°.
2. Close the shut-off valve of the fill
valve and open the drain valve.
3. Flush the system via the return
connections. Fill and flush the system
with heat transfer medium via the fill
valve.
Flush using a high-speed pump over
an open container and continue until
no air remains in the collector system.
Correct commissioning can only be
guaranteed with a system that is
completely free of air. Now close the
drain valves on the fill valve, open the
shut-off valve and check the system
for leaks. Observe the permissible
operating pressure.
Pressure must not drop for at least
half an hour.
Notes
■ A heat transfer medium containing
glycol can be damaged if it is exposed
to temperatures above 170 °C for a
prolonged period (stagnation).
Temperatures in excess of 200 °C
result in a slow thermal breakdown of
the 1.2-propylene glycol that can be
recognised by the darkening of the
heat transfer medium.
Furthermore, it can result in the solar
circuit suffering from sludge and hard
deposits, particularly in conjunction
with other contaminants (cinder,
swarf) and air.
■ Ensure that the system is properly
cleaned, filled and ventilated after
installation.
■ After filling the system with the heat
transfer medium, ensure that the
system is properly vented and that
heat is transferred inside the system,
i.e. that longer periods of stagnation
are prevented.
■ Blow-off and drain lines must
terminate in an open container, that is
capable of collecting the total capacity
of the collector.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 736 GB

7
Checking the expansion vessel and the system pressure
1. Drain the system. For this, close the
cap valve on the expansion vessel (if
installed) and reduce the pressure.
2. If the pre-charge pressure of the
expansion vessel is lower than the
set value, top up with nitrogen until
the pre-charge pressure equals the
set value.
Static head (top edge of collector to
expansion vessel): ........... m
Set pre-charge pressure of the
expansion vessel:
0.7 bar + 0.1 x static head in m
0.7 bar + 0.1 x ......... m = ........ bar
3. Top-up heat transfer medium until the
system pressure is 0.3 to 0.5 bar
higher than the set pre-charge
pressure of the expansion vessel
(create a safety water seal in the
expansion vessel).
The safety water seal should be
0.005 x liquid content of the complete
system, but no less than 3 litres.
Liquid content of the system =
content of pipes + content of
collectors + content of the indirect coil
of the DHW cylinder and safety water
seal for the expansion vessel.
Checking the electrical connections
Check the tightness of the electrical
plug-in connectors and cable grommets;
check cables for damage.
Starting the heating system
Observe operating instructions of
installed components.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 736 GB

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Ventilating the solar thermal system
1. Open the air vent valve.
Vent the circulation pumps. For this,
adjust the circulation pumps to their
maximum speed, switching the pump
ON and OFF several times (a
ventilated pump runs almost silently)
through a relay test (manual
operation).
Repeat the ventilation process until
the float in the flow meter of the
Solar-Divicon holds a constant
position when the pump is running
(highest pump rate).
Note
Air can be recognised in the flow rate
indicator (float moves).
2. Set required flow rate above output
rate of the circulation pump (see
following tables for approximate set
values).
Read the value on the underside of
the float.
3. Repeat the ventilation process after
the system has been operational for
several days.
Note
If the system pressure drops, top-up
the heat transfer medium in the cold
state and ventilate again.
4. Always shut off the air vent valve after
ventilation.
Adjustable flow rates
The details in the following table do not take the pipe pressure drop into account.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 736 GB

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Low-flow operation, 25 l/(h·m2),
Vitosol 300-T
Collector area in
m2
Throughput in
l/min
2 0.8
3 1.2
4 1.6
5 2.0
6 2.5
7 3.0
8 3.3
9 3.8
10 4.0
11 4.5
12 5.0
13 5.5
14 5.8
15 6.2
16 6.6
17 7.0
18 7.5
19 8.0
20 8.3
24 10.0
30 12.5
36 15.0
40 16.7
High-flow operation, 60 l/(h·m2),
Vitosol 200-T, 300-T
Collector area in
m2
Throughput in
l/min
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
24 24
30 30
High-flow operation, 40 l/(h·m2),
Vitosol 200-T
Collector area in
m2
Throughput in
l/min
11 7.3
12 8.0
13 8.6
14 9.3
15 10.0
16 10.6
17 11.3
18 12.0
19 12.6
20 13.3
24 16.0
30 20.0
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the switching function of the solar control unit
Solar control unit installation and
service instructions
Shutting down the system
!Please note
To prevent equipment damage, cover the collectors before any work on the
components of the solar thermal system begins.
Mixing the heat transfer medium with water reduces the frost and corrosion
protection. Only flush the system with the specified heat transfer medium.
Never mix "Tyfocor LS" with other heat transfer media.
Electrically isolate the system (e.g. at a
separate MCB/fuse or the main isolator)
and safeguard against unauthorised
reconnection.
Checking the frost protection temperature and the pH value of
the heat transfer medium
Check the frost protection temperature
of the "Tyfocor LS" heat transfer medium
with a Viessmann antifreeze tester or the
manual refractometer in the solar service
case (accessory).
Check the pH value using the pH strip in
the solar service case (accessory).
Checking the thermal insulation of the pipes
Check the thermal insulation of the pipes
for positioning and damage and adjust if
required.
Replace all faulty parts.
Note
The thermal insulation of external pipes
must be resistant to temperature and UV
rays. The insulation must be protected
against attack from small animals and
birds (e.g. metal sheath).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 736 GB