Viessmann Vitosol 200-T Operating instructions

Service instructions
for contractors
VIESMANN
Vitosol 200-T
Type SP2A
Vitosol 300-T
Type SP3B
Vacuum tube collectors based on the heat pipe principle
For applicability, see the last page
VITOSOL 200-T
VITOSOL 300-T
5772 274 GB 2/2013 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
5772 274 GB

3
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.)
5772 274 GB

4
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 6
Scope of inspection........................................................................................... 15
Parts lists
Parts list Vitosol 200-T......................................................................................... 16
Parts list Vitosol 300-T......................................................................................... 18
Specification....................................................................................................... 20
Certificates
Declaration of conformity...................................................................................... 21
Index
Index
5772 274 GB

5
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 and adjusting the flow rate if required...... 12
• • 6. Commissioning the system............................................. 13
••• 7. Checking the switching function of the solar control
unit..................................................................................... 13
• • 8. Checking and replacing the heat transfer medium if
required............................................................................. 13
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5772 274 GB

6
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
5772 274 GB

7
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.)
5772 274 GB

8
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 heat transfer
results in thermal stress.
Cover the collectors and keep
covered until heat transfer has
been regulated.
■ Accessories for flushing and filling the
solar thermal system:
–Flushing and filling facility (filling
trolley and filling station)
These contain a high speed pump
with a high pump rate, a filter and a
container for heat transfer medium.
–Filling valve, consisting of shut-off
valve, drain valve and fill valve.
■ Flush solar thermal system with heat
transfer medium. Otherwise there is a
risk that residual water from flushing
may become mixed with the heat
transfer medium. This would alter the
properties of the heat transfer
medium.
■ Flush soldered copper pipes 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.)
5772 274 GB

9
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: Use a
screwdriver to turn the slot on the
adjusting screw to position "S".
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5772 274 GB

10
03. Connect hoses from 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. Let the
fill pump of flushing and filling
facility N run until no more air bub-
bles rise to the top of the container
(at least 20 to 30 min).
Note
Briefly open shut-off valve F
towards the end of the flushing proc-
ess: Use a screwdriver to 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. Let the fill
pump of flushing and filling
facility N run 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.
Pressure must not drop for at least
30 minutes.
10. Open shut-off valve F: Use a
screwdriver to 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.)
5772 274 GB

11
11. Vent the circulation pump. Select
manual mode.
Open the air vent valve on air sep-
arator E.
Let the circulation pump run until
the float in the flow indicator
holds a constant position when the
pump is running.
2
4
6
8
10
12
l/min
Note
If there is air in the system, the float
will cycle.
12. Close shut-off valves B: Move the
ball valves (thermometers) into the
vertical position.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5772 274 GB

12
Determining and adjusting the flow rate if required
Check the value at the bottom edge of
the flow indicator float.
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 the 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.)
5772 274 GB

13
Flow rates to be set
Specific flow rate 25 l/(h.m2)
Collector area in
m2
Flow rate in
l/min
1.26 0.5
1.51 0.6
3.03 1.3
4.54 1.9
6.06 2.5
7.56 3.1
9.07 3.8
10.58 4.4
12.10 5.0
13.61 5.7
Commissioning the system
Note
For Solar-Divicon, do this at air separa-
tor H.
Observe operating instructions of
installed components.
Checking the switching function of the solar control unit
Solar control unit installation and
service instructions
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:
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5772 274 GB

14
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.)
5772 274 GB

15
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
5772 274 GB

16
Ordering parts
The following information is required:
■ Serial no. (see type plate)
■ Position of the part (from this parts list)
Standard parts are available from your
local supplier.
0001 Vacuum tubes
0002 Tube cap
0003 Tube retainer
0004 Clamping rings (12 pce)
0005 Spring clip
0006 O-rings (4 pce)
0007 Collector fastening
0008 Connection pipe (short)
0009 Connection pipe (long)
0010 Special valve grease
0011 Clamping bracket
0012 Elbow fitting with support sleeve
0013 Connection pipe with thermal
insulation
0014 Bend
0015 Bend with air vent valve
0016 Support sleeve
0017 Mounting bracket for sheet steel
roofs
0018 Locking bracket
0019 Mounting bracket for horizontal
installation
0020 Dismantling instructions
0021 Installation instructions
0022 Service instructions
0023 Operating instructions
0024 Thermal insulation cap
0025 Fixing pins for side cover
0026 Side seal
0027 Pipe gasket
0028 Cap
0029 Spring clip for connection pipes
Parts lists
Parts list Vitosol 200-T
5772 274 GB

17
0028
0027
0026
0025
0024
0023
0022
0021
0020
0019
0018
0017
0016
0015
0014
0013
0012
0011
0010
0009
0008
0007
0006
0005
0004
0003
0002
0001
0029
Parts lists
Parts list Vitosol 200-T (cont.)
5772 274 GB

18
Ordering parts
The following information is required:
■ Serial no. (see type plate)
■ Position of the part (from this parts list)
Standard parts are available from your
local supplier.
0001 Vacuum tubes
0002 Tube cap
0003 Tube retainer
0004 Clamping rings (12 pce)
0005 Spring clip
0006 O-rings (4 pce)
0007 Collector fastening
0008 Connection pipe (short)
0009 Connection pipe (long)
0010 Special valve grease
0011 Clamping bracket
0012 Elbow fitting with support sleeve
0013 Connection pipe with thermal
insulation
0014 Bend
0015 Support sleeve
0016 Mounting bracket for sheet steel
roofs
0017 Dismantling instructions
0018 Installation instructions
0019 Service instructions
0020 Operating instructions
0021 Thermal insulation cap
0022 Fixing pins for side cover
0023 Side seal
0024 Pipe gasket
0025 Cap
0026 Spring clip for connection pipes
Parts lists
Parts list Vitosol 300-T
5772 274 GB

19
0001 0002 0003 0004 0005 0006
0007 0008 0009 0010 0011 0012
0013 0014 0015 0016 0017 0018 0019
0020 0021 0022 0023 0024 0025 0026
Parts lists
Parts list Vitosol 300-T (cont.)
5772 274 GB

20
Vitosol 200-T, type SP2A
1.26 m21.51 m23.03 m2
Absorber area m21.26 1.51 3.03
Aperture area m21.33 1.60 3.19
Optical efficiency η0
(relative to the aperture area)
% 78.5 78.5 78.5
Heat loss factor k1W/(m2·K) 1.42 1.42 1.42
Heat loss factor k2W/
(m2·K2)
0.005 0.005 0.005
Thermal capacity c kJ/(m2·K) 8.4 8.4 8.4
Max. stagnation temperature °C 292 292 292
Permiss. operating pressure bar 6 6 6
Content, heat transfer medium litre 0.75 0.87 1.55
Vitosol 300-T, type SP3B
1.51 m23.03 m2
Absorber area m21.51 3.03
Aperture area m21.60 3.19
Optical efficiency η0
(relative to the aperture area)
% 80.2 80.2
Heat loss factor k1W/(m2·K) 1.37 1.37
Heat loss factor k2W/(m2·K2)0.0068 0.0068
Thermal capacity c kJ/(m2·K) 8.4 8.4
Max. stagnation temperature °C 160 160
Permiss. operating pressure bar 6 6
Content, heat transfer medium litre 0.87 1.55
Specification
Specification
5772 274 GB