Viessmann VITOSOL-F Operating instructions

Service instructions
for contractors
VIESMANN
Vitosol-F/-FM
For applicability, see the last page
VITOSOL-F/-FM
5687 433 GB 8/2016 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 intended for author-
ised contractors.
■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 to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for the protection of the envi-
ronment
■Codes of Practice of the relevant trade associations
■All relevant safety regulations as defined by DIN, EN,
DVGW, VDE and locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI, SWKI and SVGW
Working on the system
■Isolate the system from the power supply (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 reconnection.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing 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 func-
tion can compromise the safe operation of your
system.
Replace faulty components with genuine
Viessmann spare parts.
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions
Safety instructions
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1. Information Symbols ................................................................................................. 4
Intended use .......................................................................................... 4
Product information ................................................................................ 5
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 6
3. Parts lists Ordering parts ........................................................................................ 13
Parts list ................................................................................................. 14
4. Scope of inspection ................................................................................................................ 18
5. Specification Vitosol 100-F .......................................................................................... 19
Vitosol 100-FM ....................................................................................... 19
Vitosol 200-F/-FM .................................................................................. 19
Vitosol 300-F .......................................................................................... 19
6. Final decommissioning Final decommissioning and disposal ..................................................... 21
7. Certificates Declaration of conformity ....................................................................... 22
Index
Index
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Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The collectors provide central heating backup and
solar backup for DHW heating. They are only intended
to be installed and operated in sealed systems that
comply with EN 12976 and EN 12977, with due atten-
tion paid to the associated installation, service and
operating instructions. Only operate the collectors with
heat transfer medium approved by the manufacturer.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than heating a building or DHW shall be deemed inap-
propriate.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Incorrect usage of the collectors or the installation sys-
tem or incorrect operation is prohibited (e.g. the collec-
tors being opened by the system user, failure to
observe the installation instructions). Failure to
observe these instructions can change functions,
endanger life and limb of the user or third parties and
will result in an exclusion of liability.
Incorrect usage also applies if components in the sys-
tem are modified from their intended use (e.g. through
direct DHW heating in the collector).
Adhere to statutory regulations, especially concerning
the hygiene of potable water.
Information
Symbols
5687 433 GB
Information

5
Vitosol-F/-FM are high performance flat-plate collec-
tors.
Universal application, for flat and pitched roofs, or free-
standing.
For heating DHW, heating water and swimming pool
water via a heat exchanger.
Information
Product information
5687 433 GB
Information

6
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Checking pressure conditions, adjusting the expansion vessel pre-charge pressure
if necessary........................................................................................................................... 7
••• 2. Checking the function of the safety equipment................................................................ 8
••• 3. Checking the electrical connections.................................................................................. 8
•4. Filling, flushing and checking the solar thermal system for leaks.................................. 8
••• 5. Determining the flow rate and adjusting it if required...................................................... 10
• • 6. Performing a test flush........................................................................................................ 11
• • 7. Commissioning the system................................................................................................. 11
••• 8. Checking the switching function of the solar control unit............................................... 11
• • 9. Checking and replacing the heat transfer medium if required........................................ 12
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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This process cannot be carried out while the solar
thermal system is in operation.
1. Cover the collectors with tarpaulins.
2. Determine the charge pressure:
■Solar thermal system pressure = system pres-
sure
■System pressure + 0.1 bar pressure reserve for
venting
3. Determine the pre-charge pressure of the expan-
sion vessel:
Value for system pressure minus 0.3 bar for
hydraulic seal
4. Check the pre-charge pressure and adjust if
required.
The solar service case (accessories) contains a
pressure gauge.
5. Enter the values in the table below (for subsequent
inspection and maintenance work).
P
2
4
1
3
5
5
Fig. 1
Commissioning, inspection, maintenance
Checking pressure conditions, adjusting the expansion vessel pre-charge
pressure if necessary
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The following values result at 10 m static head (example)
Vitosol-FM Vitosol-F
1Solar thermal system pressure 3.0 bar 1.0 bar
2Supplement, static head 0.1 bar/m 1.0 bar 1.0 bar
3System pressure (pressure gauge) 4.0 bar 2.0 bar
Pressure reserve for venting + 0.1 bar + 0.1 bar
Charge pressure 4.1 bar 2.1 bar
System pressure (pressure gauge) af-
ter venting
4.0 bar 2.0 bar
Deduction for hydraulic seal − 0.3 bar − 0.3 bar
4Supplement per m of height difference
between pressure gauge and expan-
sion vessel
0.1 bar x 1 m = 0.1 bar 0.1 bar x 1 m = 0.1 bar
5Pre-charge pressure, expansion
vessel
Note
Record the "pre-charge pressure" on
the expansion vessel.
3.8 bar 1.8 bar
Checking the function of the safety equipment
Check the safety valve:
■Response pressure
■Correct installation, with discharge pipe
Checking the electrical connections
Check the tightness of the electrical plug-in connectors
and cable grommets; check cables for damage.
Filling, flushing and checking the solar thermal system for leaks
!Please note
Filling and commissioning the solar thermal sys-
tem without first safeguarding the heat transfer
results in thermal stress.
Cover the collectors and keep them covered
until the heat transfer 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.
–Fill 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 flushing may become mixed with the heat trans-
fer medium. This would alter the properties of the
heat transfer medium.
■Flush brazed copper pipes very thoroughly. Any
residual scale may compromise the operation of the
solar thermal system.
Commissioning, inspection, maintenance
Checking pressure conditions, adjusting the… (cont.)
5687 433 GB

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The following description is in conjunction with Solar-Divicon (see separate installation and service instructions)
P
K
N
M
G
B
C
A
H
L
L
M
EF
D
C
O
Fig. 2
ASolar-Divicon
BShut-off valve (flow)
CNon-return valves
DSolar circuit pump
EAir separator
FShut-off valve (adjusting screw above flow indica-
tor H)
GDrain valve
HFlow indicator
KFill valve
LStagnation heat sink
MExpansion vessel
NFlushing and filling facility
OShut-off valve (return)
01. Open shut-off valve (flow) B: Turn the ball valve
(thermometer) clockwise through 45°.
02. Close shut-off valve (return) O: Turn the ball
valve (thermometer) clockwise through 90°.
03. Close shut-off valve F: Using a screwdriver, turn
the slot on the adjusting screw to position "S".
Fig. 3
04. Connect hoses of flushing and filling facility N to
drain valve G and fill valve K.
05. Fill the container of flushing and filling facility N
with heat transfer medium.
06. Open drain valve G and fill valve K.
07. Start the fill pump of flushing and filling facility N.
08. Observe the fluid level in the container 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 container
(at least 20 to 30 min).
Note
Briefly open shut-off valve F towards the end of
the flushing process: Using a screwdriver, turn the
slot on the adjusting screw above the flow indica-
tor to the vertical position. Any air that remains in
the return is eliminated.
Commissioning, inspection, maintenance
Filling, flushing and checking the solar… (cont.)
5687 433 GB

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09. Close drain valve G. Leave the fill pump of flush-
ing 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.
10. Close fill valve K; stop the fill pump of flushing
and filling facility N.
The pressure must not drop for at least 30
minutes.
11. Open shut-off valve F: Using a screwdriver, turn
the slot on the adjusting screw above the flow indi-
cator to the vertical position.
12. Turn shut-off valves B and O to their operating
positions (0°).
13. Set the circulation pump to manual mode.
Open the air vent valve on air separator E.
Leave the circulation pump running until the float
in the flow indicator holds a constant position
while the pump is running.
Note
If there is air in the system, the float will oscillate.
Determining the flow rate and adjusting it if required
Check the flow rate at the top edge of the float.
If no flow rate is indicated, the non-return valve in the
return does not open automatically; the flow path is
blocked.
Open shut-off valve (return) O (see diagram on
page 9): turn ball valve (thermometer) 45° clockwise.
This opens a bypass around the non-return valve. If a
flow rate is now indicated, the flow path is blocked.
Perform a test flush to cause the non-return valve to
open (see page 11).
20
5
15
25
10
35
30
l/min
Fig. 4
In conjunction with multi stage circulation pumps, set
the required flow rate via the output stage (see the fol-
lowing tables for approximate set values).
Note
With a Solar-Divicon, make the adjustment via shut-off
valve F (adjusting screw above the flow rate indica-
tor).
Fig. 5
Commissioning, inspection, maintenance
Filling, flushing and checking the solar… (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 25 l/(h·m2)
Number of collectors Flow rate in l/min
6 5.5
7 6.5
8 7.5
9 8.5
10 9.5
11 10.5
12 11.5
13 12.5
14 13.5
15 14
16 15
18 17
20 19
Performing a test flush
For components, see diagram on page 9
1. Connect the pressure hose (return hose) of flush-
ing and filling facility N to drain valve G.
2. Connect the fill hose of flushing and filling
facility N to fill valve K.
3. Close shut-off valve (flow) B: Turn the ball valve
(thermometer) clockwise through 90°.
4. Open shut-off valve (return) O: Turn the ball valve
(thermometer) to the 0° vertical position.
5. Open drain valve G and fill valve K.
6. Start the fill pump of flushing and filling facility N.
A pressure greater than 1 bar will open the non-
return valve.
Commissioning the system
Close the air vent valve.
Note
With a Solar-Divicon, do this at air separator E.
Observe operating instructions of installed com-
ponents.
Checking the switching function of the solar control unit
Solar control unit installation and service instruc-
tions
Commissioning, inspection, maintenance
Determining the flow rate and adjusting it if… (cont.)
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■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, Tyfocor LS
–−12 °C, Mediterráneo
–−47 °C, Arctic
■Monitor the operating condition of the medium as
part of the annual service of the solar thermal system
by the heating contractor.
■The pH value and frost protection temperature can
be checked with the solar service case (accesso-
ries).
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 transfer medium
using the pH strip in the solar service case.
The colour of the pH strip indicates the approxi-
mate 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 Tyfo-
cor G-LS.
Never mix with water or third party media.
2. Check the frost protection temperature of the heat
transfer medium with an antifreeze tester or the
manual refractometer in the solar service case.
Commissioning, inspection, maintenance
Checking and replacing the heat transfer medium if required
5687 433 GB

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The following details are required when ordering parts:
■Serial no. (see type plate on the collector)
■Position number of the part
Parts lists
Ordering parts
5687 433 GB
Components

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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
Fig. 6
Parts lists
Parts list
5687 433 GB
Components

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Pos. Part
0001 Connection pipe
0002 Connection pipe (short)
0003 Connection pipe (long)
0004 Plug
0005 Locking ring fitting with support sleeves
0006 Elbow fitting with support sleeves
0007 Clamping bracket, complete
0008 Connecting part
0009 Mounting plate
0012 O-rings
0014 Profile clip
0015 Diagonal sealing strip
0016 Support sleeve
0020 Special valve grease
0021 Dismantling instructions
0022 Operating instructions
0023 Service instructions
0025 Installation instructions, above roof installation with roof hooks
0026 Installation instructions, above roof installation with rafter anchors
0027 Installation instructions for flat roofs or freestanding installation, variable angle of inclination
0028 Installation instructions for flat roofs or freestanding installation, fixed angle of inclination
0029 Sealing screws (5.5 x 25/6.3 x 45)
0030 Collector retainer with screws
0031 Sealing material
0032 Bit holder
0033 Air vent plug
0034 Cross union with support sleeves
0035 Repair panel
0036 Wood screws, 8 x 120 (5 pce)
0037 Fixing clamp
Parts lists
Parts list (cont.)
5687 433 GB
Components

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0053
0057
0056
0055
0054
0052
0051
0050
0049
0046
0047
0042
0048
0043
0040
0039
0041
0044
0038
Fig. 7
Parts lists
Parts list (cont.)
5687 433 GB
Components

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Pos. Part
0038 90° elbow and sensor well (long)
0039 Tee (short connection pipe)
0040 Elbow fitting, 2 x 22 mm
0041 90° elbow and sensor well (short)
0042 90° elbow (long connection pipe)
0043 Corner tee
0044 Corner tee and sensor well (long)
0046 Tee and sensor well (short)
0047 Tee (long connection pipe)
0048 90° elbow (short connection pipe)
0049 Corrugated pipe with thermal insulation (type SV)
0050 Corrugated pipe with thermal insulation (type SV)
0051 Corrugated pipe with thermal insulation (type SH)
0052 Corrugated pipe with thermal insulation (type SH)
0053 Installation instructions for pitched roofs, roof integration
0054 Support brackets for rafter hooks
0055 Wood screws, 8 x 120 (2 pce)
0056 Rail connectors
0057 Installation instructions, above roof installation with rafter hooks
Parts lists
Parts list (cont.)
5687 433 GB
Components

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The solar thermal system should be inspected once a
year to ensure operational reliability.
In addition to this, a visual inspection of all essential
components (e.g. collectors and pipework) is recom-
mended every 3 to 5 years.
■Vent the solar thermal system.
■Compare system operating pressure with the set
value. If the values are different, check the expan-
sion 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 parameters subject to
the current insolation level (e.g. flow and return tem-
peratures 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. deposits, drips).
Scope of inspection
Scope of inspection
5687 433 GB
Maintenance

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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/(m2·K) 4.7 4.5
Collector efficiency ηcol at a
temperature differential of 40 K
57.6 57
Max. stagnation temperature °C 200 196
Permiss. operating pressure bar 6 6
Heat transfer medium content l 1.48/2.33 1.48/2.33
Vitosol 100-FM
Type SV1F SH1F
Absorber area m22.32 2.32
Aperture area m22.33 2.33
Thermal capacity c kJ/(m2·K) 6 6
Collector efficiency ηcol at a
temperature differential of 40 K
64.7 62.9
Max. stagnation temperature °C 145 145
Permiss. operating pressure bar 6 6
Heat transfer medium content l 1.83 2.67
Vitosol 200-F/-FM
Vitosol 200-F Vitosol 200-FM
Type SV2C/SH2C SV2D SV2F/SH2F
Absorber area m22.32 2.32 2.32
Aperture area m22.33 2.33 2.33
Thermal capacity c kJ/(m2·K) 5.0 4.6 5
Collector efficiency ηcol at a
temperature differential of 40 K
62.4/63.4 62.5 63.4/61.8
Max. stagnation temperature °C 186 185 145
Permiss. operating pressure bar 6 6 6
Heat transfer medium content l 1.83/2.48 1.83 1.83/2.48
Vitosol 300-F
Type SV3C/SH3C
Absorber area m22.32
Aperture area m22.33
Thermal capacity c kJ/(m2·K) 5.0
Collector efficiency ηcol at a
temperature differential of 40 K
69.9/70.7
Max. stagnation temperature °C 206
Specification
Vitosol 100-F
5687 433 GB
Appendix

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Type SV3C/SH3C
Permiss. operating pressure bar 6
Heat transfer medium content l 2.04/2.65
Specification
Vitosol 300-F (cont.)
5687 433 GB
Appendix