Viessmann Vitosol-T Operating instructions

Service instructions
for contractors
VIESMANN
Vitosol-T
For applicability, see the last page
VITOSOL-T
5458 009 GB 3/2010 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
5458 009 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 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.)
5458 009 GB

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Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 6
Scope of inspection........................................................................................... 14
Parts lists
Parts list Vitosol 200-T, type SP2......................................................................... 15
Parts list Vitosol 300-T, type SP3A...................................................................... 17
Specification
Vitosol 200-T, type SP2........................................................................................ 19
Vitosol 300-T, type SP3A..................................................................................... 19
Certificates
Declaration of conformity...................................................................................... 20
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. Checking pressure conditions and pre-charge
pressure............................................................................. 6
••• 2. Checking the function of the safety equipment............. 7
••• 3. Check electrical connections.......................................... 7
•4. Flushing, testing for leaks and filling the solar thermal
system............................................................................... 8
••• 5. Determining the flow rate and adjusting if required...... 11
• • 6. Starting the system.......................................................... 12
••• 7. Checking the switching function of the solar control
unit..................................................................................... 12
• • 8. Checking heat transfer medium and replacing if
required............................................................................. 12
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Checking pressure conditions and pre-charge pressure
Cover the collectors.
Note
The glass cover of Viessmann flat-plate
collectors is coated with a protective
foil.
For vacuum tube collectors, use the tar-
paulins available as accessories.
Before the solar thermal system is
flushed or filled, check the pre-charge
pressure of the expansion vessel. This is
no longer possible once the solar ther-
mal system is operational.
Note
A manual pressure gauge can be found
in the solar service case available as an
accessory.
Enter values into the following table.
These can be retained for later inspec-
tion and maintenance work on the solar
thermal system.
P
5
1
3
2
4
Commissioning, inspection, maintenance
Further details regarding the individual steps
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Documentation of pressure
1System pressure of the solar thermal system 1 bar
2Supplement per metre static ceiling + 0.1 bar/m
3System operating pressure (pressure gauge)
................ bar
Pressure reserve for venting + 0.1 bar
Filling pressure
................ bar
4Supplement per metre of height difference between pres-
sure gauge — expansion vessel 5
+ 0.1 bar/m
Deduction for hydraulic seal – 0.3 bar
Pre-charge pressure, expansion vessel 5
................ bar
Note
Note the pre-charge pressure level on
the expansion vessel. In doing so, spe-
cifically use the term "pre-charge pres-
sure" to prevent misunderstandings.
Example:
At 10 m static ceiling, the result is:
■ System operating pressure = 2 bar
■ Fill pressure = 2.1 bar
■ Pre-charge pressure = 1.7 bar
Checking the function of the safety equipment
Check the safety valve:
■ Response pressure
■ Correct installation, with blow-off line
Check electrical connections
Check the tightness of the electrical
plug-in connectors and cable grommets;
check cables for damage.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Flushing, testing for leaks and filling the solar thermal system
■
!Please note
Filling and commissioning the
solar thermal system without
first safeguarding heat transfer
results in thermal loads.
If commissioning is carried out
prior to this, cover the collec-
tors and keep covered until
heat transfer has been regula-
ted.
Note
The glass cover of Viessmann flat-
plate collectors is coated with a pro-
tective foil.
For vacuum tube collectors, use the
tarpaulins available as accessories.
■ Flushing the solar thermal system
– Soldered copper pipes
Flush particularly thoroughly as any
residual scale may damage the
operation of the solar thermal sys-
tem.
– Flush solar thermal system with heat
transfer medium. Otherwise there is
a risk that residual water from flush-
ing may become mixed with the heat
transfer medium and thus alter its
properties.
Note
To flush and fill the solar thermal
system, use the filling container or
filling station available as acces-
sories. These contain high speed
pumps with high pump rates and fil-
ters.
■Never drain the system with a suction
pump.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Solar-Divicon (accessory)
0
20
40
60
80
100
120 0
20
40
60
80
100
120
2
4
6
8
10
12
L/Min
BA
D
C
AThermometer/non-return valve,
flow
BThermometer/non-return valve,
return
CSafety assembly, with 6 bar safety
valve
DFlow indicator
Fill valve (accessory)
E
F
EShut-off tap
FDrain & fill taps
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5458 009 GB

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P
A
B
C
D
APressure gauge
BDrain & fill taps
CContainer for heat transfer medium
DShut-off valve
1. Open shut-off taps or valves. With the
Solar-Divicon, open the non-return
valves by turning the thermometers
clockwise through 45° (see diagram
on page 9).
2. Close shut-off tap E; open drain &
fill taps F on the fill valve (see dia-
gram on page 9).
Connect hoses from the flushing and
filling facility. Fill the container with
heat transfer medium.
Note
Flush the system via the return con-
nection (flow direction to the collec-
tor).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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3. Use a high speed pump to flush the
system. Observe the fluid level in the
container and top up with heat trans-
fer medium if necessary to prevent
any air entering the solar circuit. Let
the fill pump run until no more air bub-
bles rise to the top of the container.
4. Close the drain tap on the fill valve
and let the fill pump run until the
required system pressure is reached
(including 0.1 bar pressure reserve
for residual ventilation during opera-
tion).
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 extracted via the air sep-
arator.
5. Close the fill tap on the fill valve; open
the fill pump.
Pressure must not drop for at least 30
minutes.
6. Vent the circulation pumps. Select
manual mode.
Repeat the ventilation process until
the float in the flow indicator of the
Solar-Divicon (see diagram on
page 9) holds a constant position
when the pump is running.
Note
Air can be recognised in the flow indi-
cator (float moves).
Determining the flow rate and adjusting if required
Read off the value at the bottom edge of
the float in the flow indicator of the Solar-
Divicon (see diagram on page 9).
In conjunction with multi-stage circula-
tion pumps, set required flow rate via
output stage (see the following table for
approximate set values).
Flow rates to be set
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.)
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Specific flow rate 25 l/(h·m2)
Collector area in
m2
Flow rate in
l/min
2 0.8
3 1.3
4 1.7
5 2.1
6 2.5
7 2.9
8 3.3
9 3.8
10 4.2
Starting the system
Close the air vent valve. Observe operating instructions of
installed components.
Checking the switching function of the solar control unit
Solar control unit installation and
service instructions
Checking heat transfer medium and replacing 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 pro-
tection 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.
With the solar service case (acces-
sory), the pH value and frost protection
temperature can be checked.
In some cases the manufacturer of the
heat transfer medium can 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
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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1. Check the pH value of the heat trans-
fer medium using the pH strip in the
solar service case (accessory).
The colour of the pH strip indicates
the approximate value. If the value is
below 7.5, replace the heat transfer
medium.
Notes on replacing the heat trans-
fer medium
The heat transfer medium can only
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
a Viessmann antifreeze tester or the
manual refractometer in the solar
service case.
Solar service case operating
instructions
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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The solar thermal system should be
inspected once a year to ensure opera-
tional reliability.
In addition to this, a visual check of all
essential components (e.g. collectors
and pipework) is recommended every
three to five 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 heat transfer medium.
■ Start circulation pump manually if nec-
essary (listen for noises).
■ Compare flow rate with set value.
■ Check thermostatic mixing valve is
moving easily (if installed).
■ Check plausibility of the solar param-
eters subject to the solar radiation (e.g.
flow and return temperatures at the
thermometers; collector and cylinder
temperatures at the solar control unit).
The safety valve does not have to be
checked if there are no visible signs of
use (e.g. deposits, drips).
Scope of inspection
Scope of inspection
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When ordering spare parts:
Quote the part and serial no. (see type
plate) and the position 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 holder
003 Retaining clip
004 Retaining rubber
005 O-ring
006 U-pipe
007 U-pipe with air vent valve
008 Clamping bracket, complete
009 Connection pipe (short)
011 Connection pipe (long)
012 Elbow fitting with support ferrule
013 Connection pipe
014 Support sleeve
015 Thermal insulation cap, complete
016 Mounting bracket
017 Fixing pin
019 Locking bracket
020 Spacer
021 Mounting bracket
Parts not shown
010 Special grease
018 Tube retainer
022 Installation instructions (installation
with roof hooks or mounting
bracket)
023 Installation instructions (installation
with rafter anchor)
024 Dismantling instructions
025 Service instructions
026 Operating instructions
Parts lists
Parts list Vitosol 200-T, type SP2
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50%
001 002 003 004
008005
011 012009
015 017016
013
006 007
014
019
020 021
Parts lists
Parts list Vitosol 200-T, type SP2 (cont.)
5458 009 GB

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When ordering spare parts:
Quote the part and serial no. (see type
plate) and the position 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 holder
003 Retaining clip
004 Retaining rubber
005 O-ring
006 U-pipe
007 Clamping bracket, complete
008 Connection pipe (short)
010 Connection pipe (long)
011 Elbow fitting with support ferrule
012 Connection pipe
013 Support sleeve
014 Thermal insulation cap, complete
015 Mounting bracket
016 Fixing pin
Parts not shown
009 Special grease
017 Installation instructions (installation
with roof hooks or mounting
bracket)
018 Dismantling instructions
019 Service instructions
020 Operating instructions
030 Installation instructions (installation
with rafter anchor)
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 m22.00 3.02
Aperture area m22.15 3.23
Optical efficiency η0% 76.6 76.6
Heat loss factor k1W/(m2·K) 1.42 1.42
Heat loss factor k2W/(m2·K2)0.005 0.005
Thermal capacity c kJ/(m2·K) 8.4 8.4
Max. idle temperature °C 270 270
Permiss. operating pressure bar 6 6
Content, heat transfer medium litres 1.2 1.7
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) 8.4 8.4
Max. idle temperature °C 273 273
Permiss. operating pressure bar 6 6
Content, heat transfer medium litres 1.2 1.7
Specification
Vitosol 200-T, type SP2
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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 an 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 device must be equipped in accordance with current national regula-
tions prior to 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 March 2010 Viessmann Werke GmbH&Co KG
pp. Manfred Sommer
Certificates
Declaration of conformity
5458 009 GB