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 777 GB 12/2008 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
designed for qualified personnel.
■ 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
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental 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 sup-
ply 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 unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electrostatic dis-
charges.
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 heating
system.
Replace faulty components only
with original Viessmann spare
parts.
Safety instructions
Safety instructions
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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 com-
promise its function. Installing
non-authorised components and
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 777 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 SD2A...................................................................... 11
Parts list Vitosol 300-T, type SP3A...................................................................... 13
Specification
Vitosol 200-T, type SD2A..................................................................................... 15
Vitosol 300-T, type SP3A..................................................................................... 15
Solar-Divicon (accessory).................................................................................... 15
Heat transfer medium (accessory)....................................................................... 16
Certificates
Declaration of conformity...................................................................................... 17
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 con-
nections. 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 gly-
col can be damaged if it is exposed to
temperatures above 170 °C for a pro-
longed 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 sys-
tem is properly vented and that heat is
transferred inside the system, i.e. that
longer periods of stagnation are pre-
vented.
■ Blow-off and drain lines must termi-
nate in an open container, that is capa-
ble of collecting the total capacity of
the collector.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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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 pres-
sure 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 = con-
tent 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 instal-
led components.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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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 venti-
lated pump runs almost silently)
through a relay test (manual opera-
tion).
Repeat the ventilation process until
the float in the flow meter of the
Solar-Divicon holds a constant posi-
tion when the pump is running (high-
est 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 fol-
lowing tables for approximate set val-
ues).
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 tables do not take the pipe pressure drop into account.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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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 any damaged 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.)
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When ordering spare parts:
Quote the part and serial no. (see type
plate) and the item no. of the required
part (as per this parts list).
Obtain standard parts from your local
supplier.
Parts
001 Vacuum tube, complete
002 Connecting pipe
003 Connecting pipe (short)
004 O-ring
005 Retaining rubber
006 Tube supports
007 Clamping bracket, complete
008 Locking profile, complete
012 Spacer
013 Connecting pipe (long)
014 Profile clip
015 Elbow fitting with support ferrule
016 Thermal insulation cap, complete
017 Support sleeve
018 Mounting bracket, complete
020 U-pipe
025 U-pipe with air vent valve
026 Tube clip
027 O-ring
028 Side cover, l.h.
029 Side cover, r.h.
Parts not shown
009 Special grease
021 Installation instructions
022 Dismantling instructions
023 Service instructions
024 Operating instructions
Parts lists
Parts list Vitosol 200-T, type SD2A
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001 002 003 004
005 006 008
013 015
007
012 014
017 020018
016
025
027026 028 029
Parts lists
Parts list Vitosol 200-T, type SD2A (cont.)
5692 777 GB

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When ordering spare parts:
Quote the part and serial no. (see type
plate) and the item no. of the required
part (as per this parts list).
Obtain standard parts from your local
supplier.
Parts
001 Heat pipe vacuum tube, complete
002 Tube supports
003 Retaining clip
004 Retaining rubber
005 O-ring
006 U-pipe
007 Clamping bracket, complete
008 Connecting pipe (short)
010 Connecting pipe (long)
011 Elbow fitting with support ferrule
012 Connecting pipe
013 Support sleeve
014 Thermal insulation cap, complete
015 Mounting bracket
016 Fixing pin
Parts not shown
009 Special grease
017 Installation instructions
018 Dismantling instructions
019 Service instructions
020 Operating instructions
Parts lists
Parts list Vitosol 300-T, type SP3A
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001 002 003
004 006 007005
010 011008
014 016013 015
012
Parts lists
Parts list Vitosol 300-T, type SP3A (cont.)
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2 m23 m2
Absorber area m22.01 3.02
Aperture area m22.14 3.23
Optical efficiency η0% 78.9 79.1
Heat loss factor k1W/(m2·K) 1.36 1.10
Heat loss factor k2W/(m2·K2)0.0075 0.0076
Thermal capacity c kJ/(m2·K) 10.0 10.1
Max. idle temperature °C 295 295
Permiss. operating pressure bar 6 6
Content, heat transfer medium litres 3.8 5.8
Vitosol 300-T, type SP3A
2 m23 m2
Absorber area m22.00 3.02
Aperture area m22.15 3.23
Optical efficiency η0% 80.9 80.4
Heat loss factor k1W/(m2·K) 1.37 1.33
Heat loss factor k2W/(m2·K2)0.0068 0.0067
Thermal capacity c kJ/(m2·K) 8.5 8.4
Max. idle temperature °C 273 273
Permiss. operating pressure bar 6 6
Content, heat transfer medium litres 1.2 1.8
Solar-Divicon (accessory)
Safety valve 6 bar,
120 °C
Max. operating tempera-
ture
120 °C
Permiss. operating pres-
sure
6 bar
Specification
Vitosol 200-T, type SD2A
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The heat transfer medium provided is a
liquid based on 1.2-propylene glycol with
frost protection down to −28°C.
Monitor the operating condition of the
medium as part of the annual service of
the solar thermal system by the heating
contractor.
The solar service case (accessory) ena-
bles, amongst other things, the checking
of the pH value and the frost protection
temperature.
In some cases the manufacturer of the
heat transfer medium may carry out a
laboratory test of the medium, subject to
arrangement.
TYFOROP CHEMIE GmbH
Anton-Rée-Weg 7
D - 20537 Hamburg
e-mail: [email protected]
Internet: www.tyfo.de
Specification
Heat transfer medium (accessory)
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We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, declare as sole respon-
sible body, that the products
Vitosol 200-T and 300-T
conform to the following standards:
DIN 1055
EN 12975 to Solar-KEYMARK
In accordance with the following directives, these products are designated _:
2006/95/EC
89/336/EEC
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 assembly
according to article 3 (2), subject to the installation of at least one pair
The pressure device was tested without fitted equipment (safety assembly).
The pressure vessel must be equipped in accordance with current national require-
ments before installation and commissioning.
The product characteristics determined as system values for the Vitosol prod-
uct as part of EC type testing according to the Efficiency Directive (see speci-
fication table) can be used for the energy assessment of heating and ventilation
equipment to DIN V 4701-10.
Allendorf, 1. December 2008 Viessmann Werke GmbH&Co KG
pp. Manfred Sommer
Certificates
Declaration of conformity
5692 777 GB

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Applicability
Applies to the following collectors:
Vitosol 200-T, type SD2A, 2 m2Part no. SK00 857
Vitosol 200-T, type SD2A, 3 m2Part no. SK00 858
Vitosol 300-T, type SP3A, 2 m2Part no. SK01 430
Vitosol 300-T, type SP3A, 3 m2Part no. SK01 431
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 777 GB Subject to technical modifications.
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