Viessmann VITOSOL-F Operating instructions

VIESMANN
Service instructions
for contractors
Vitosol-F
For applicability, see the last page
VITOSOL-F
5692 741 GB 6/2008 Please keep safe.

Please follow these safety instructions closely to prevent accidents and
material losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!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 gas equipment must only
be carried out by a qualified gas fit-
ter.
&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,
&theCodeofPracticeofrelevant
trade associations,
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances ON or OFF.
&Close the gas shut-off valve.
&Open windows and doors.
&Remove all people from the
danger zone.
&Notify your gas or electricity
supplier from outside the
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Closealldoorsleadingtothe
living space.
Safety instructions
2
Safety instructions
5692 741 GB

Workingonthesystem
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
&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 electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which
fulfil a safety function can com-
promise the safe operation of
your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 741 GB

Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance................................... 5
Further details regarding the individual steps .............................................. 6
Parts lists
Parts list Vitosol 200-F, 300-F ..................................................................... 12
Specification
Vitosol 200-F, 300-F.................................................................................... 14
Solar-Divicon (accessory)........................................................................... 14
Heat transfer medium (accessory)............................................................... 14
Certificates
Declaration of conformity ............................................................................ 15
Index
4
Index
5692 741 GB

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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•1. Cleaning, testing for leaks and filling the solar
heating system....................................................................... 6
•2. Shutting down the system ................................................. 7
•3. Cleaning collectors
•• 4. Checking gaskets and seals
•• 5. Checking the thermal insulation of the pipes ............ 7
••• 6. Checking the function of the safety equipment
••• 7. Checking the expansion vessel and the system
pressure ................................................................................... 8
••8. Ventilating the solar heating system ............................. 9
••• 9. Checking the electrical connections............................. 10
•• 10. Checking the frost protection temperature and the
pH value of the heat transfer medium ........................... 10
••11. Starting the heating system .............................................. 10
••• 12. Checking the switching function of the solar
control unit .............................................................................. 11
•• 13. Check circulation pumps
••• 14. Checking the flow rate
Steps - commissioning, inspection and maintenance
5
Commissioning, inspection, maintenance
5692 741 GB

Cleaning, testing for leaks and filling the solar heating sys-
tem
&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. Do not remove the cover foil from
the solar glass for filling the sys-
tem.
Open any installed shut-off gates
or valves by hand. Open the non-
return valves when using a Solar-
Divicon:
Flow/return: 45° - thermometer
turned clockwise.
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 sys-
tem with heat transfer medium via
the fill valve.
Flushusingahigh-speedpump
over an open container and con-
tinue until no air remains in the col-
lector system. Correct
commissioning can only be guaran-
teed with a system that is comple-
tely free of air. Now close the drain
valves on the fill valve, open the
shut-off valve and check the sys-
tem for leaks. Observe the permis-
sible operating pressure.
Pressure must not drop for at least
half an hour.
Further details regarding the individual steps
6
Commissioning, inspection, maintenance
5692 741 GB

Information
&Heat transfer media containing gly-
col can be damaged, if they are sub-
jected for long periods to
temperatures above 170 °C (stag-
nation).
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 sys-
tem, i.e. that longer periods of stag-
nation are prevented.
&Blow-off and drain lines must termi-
nate in an open container, that is
capable of collecting the total capa-
city of the collector.
Shutting down the system
!Please note
To prevent equipment damage, cover the collectors before any work on
the components of the solar heating system begins.
Mixing the heat transfer medium with water reduces the frost and corro-
sion 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 iso-
lator) and safeguard against
unauthorised reconnection.
Checking the thermal insulation of the pipes
Check the thermal insulation of the
pipework for damage and tight fit.
Replace all faulty parts.
Further details regarding the individual steps (cont.)
7
Commissioning, inspection, maintenance
5692 741 GB

Note
The thermal insulation of external
pipes must be resistant to tempera-
ture and UV rays. The insulation must
be protected against attack from small
animals and birds (e.g. metal sheath),
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 com-
plete 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.
Further details regarding the individual steps (cont.)
8
Commissioning, inspection, maintenance
5692 741 GB

Ventilating the solar heating 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 opera-
tional 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
Vitosol 200-F, type 5DI
Throughput 3 to 4 l/min
Vitosol 200-F, 300-F
Thedetailsinthefollowingtabledonottakethepipepressuredropinto
account.
Further details regarding the individual steps (cont.)
9
Commissioning, inspection, maintenance
5692 741 GB

High-flow operation, 40 l/(h·m
2
)
Number of col-
lectors
Flow rate in l/min
23
34.5
46
57.5
69.5
710.5
812.5
914
10 15.5
11 17
12 18.5
13 20
14 21.5
15 23.5
Low-flow operation, 15 l/(h·m
2
)
Number of col-
lectors
Flow rate in l/min
63.5
74
84.5
95
10 5.5
11 6.5
12 7
13 7.5
14 8
15 8.5
16 9
18 10.5
20 11.5
Checking the electrical connections
Check the tightness of the electrical
plug-in connectors and cable grom-
mets; check cables for damage.
Checking the frost protection temperature and the pH value
of the heat transfer medium
Check the frost protection tempera-
ture 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 with a pH strip in
the solar service case (accessory)
(see page 14).
Solar service case operating
instructions
Starting the heating system
Observe operating instructions of
installed components.
Further details regarding the individual steps (cont.)
10
Commissioning, inspection, maintenance
5692 741 GB

Checking the switching function of the solar control unit
Solar control unit installation
and service instructions
Further details regarding the individual steps (cont.)
11
Commissioning, inspection, maintenance
5692 741 GB

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 Connecting pipe
002 Connecting pipe (short)
003 Connecting pipe (long)
004 Plug
005 Locking ring fitting with support
sleeves
006 Elbow fitting with support sleeves
007 Clamping bracket, complete
008 Connecting part
009 Mounting plate
010 Spacer plug
011 Retaining plate
012 O-ring
013 Retaining screws
014 Profile clip
015 Diagonal sealing strip
016 Support sleeve
017 Resilient buffer
018 Mounting bracket
Parts not shown
020 Special grease
021 Dismantling instructions
022 Operating instructions
023 Service instructions
025 Installation instructions for slop-
ing roofs (pitched roofs), rooftop
installation
026 Installation instructions for slop-
ing roofs (pitched roofs), roof
integration
027 Installation instructions for flat
roofs or freestanding installation
Parts list Vitosol 200-F, 300-F
12
Parts lists
5692 741 GB

Parts list Vitosol 200-F, 300-F (cont.)
13
Parts lists
5692 741 GB

Type SV/SH 5DI
Absorber area m
2
2.32 4.76
Aperture area m
2
2.33 4.96
Thermal capacity c kJ/(m
2
·K) 5.35 6.4
Max. idle temperature °C 202 185
Permissible operating pressure bar 6 6
Content, heat transfer medium litres 1.83/2.48 4.2
Solar-Divicon (accessory)
Safety valve 6 bar, 120 °C
Max. operating
temperature
120 °C
Permissible oper-
ating pressure
6bar
Heat transfer medium (accessory)
The supplied heat transfer medium 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 heating system by the
heating contractor.
The heat transfer medium is still OK if
the pH value lies between 10.0 and
8.5. Replace with fresh heat transfer
medium from values below 7.5.
Thesolarservicecase(accessory)
enables, amongst others, the check-
ing of the pH value and the frost pro-
tection 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
Vitosol 200-F, 300-F
14
Specification
5692 741 GB

We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, declare as sole
responsible body, that the products
Vitosol 200-F and 300-F
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
requirements before installation and commissioning.
The product characteristics determined as system values for the product
Vitosol product as part of EC type testing according to the Efficiency
Directive (see specification table) can be used for the energy assessment of
heating and ventilation equipment to DIN V 4701-10.
Allendorf, 01.06.08 Viessmann Werke GmbH&Co KG
pp. Manfred Sommer
Declaration of conformity
15
Certificates
5692 741 GB

Applicability
Applies to the following col-
lectors:
Vitosol 200-F, type 5DI Part no. 3004 363
Vitosol 200-F, type SV2 Part no. 7248 237
Vitosol 200-F, type SH2 Part no. 7248 238
Vitosol 300-F, type SV3 Part no. 7248 611
Vitosol 300-F, type SH3 Part no. 7248 612
16
Printed on environmentally friendly, chlorine-free bleached paper
5692 741 GB Subject to technical modifications.
Viessmann Werke GmbH&Co KG
D-35107 Allendorf
Telephone: [phone]
Fax: [phone]
www.viessmann.com
Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Telephone: [phone]
Fax: [phone]
E-mail: [e-mail]