Viessmann Vitosol 100 User manual

Start-up, Service and Operating
Instructions
for use by heating contractor
Vitosol 100
Flat Plate Solar Collector
Vitosol 300
Vacuum Tube Solar Collector
For installation on sloped roofs and for
free-standing installation.
For heating domestic hot water, low-temperature heating
systems and swimming pool water via a heat exchanger.
VITOSOL
Vitosol 100
Model SV1, SH1
Read and save these instructions
for future reference.
IMPORTANT
Vitosol 300
Model SP3
5285 771 v1.1 12/2006
Please file in Service Binder

Safety, Installation and Warranty Requirements
2
Safety, Installation and Warranty Requirements
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the
instructions listed below and details printed in this manual can cause product/property damage,severe personal injury,and/or
loss of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual
subsections).
HLicensed professional mechanical
contractor
The installation, adjustment, service,
and maintenance of this equipment
must be performed by a licensed
professional heating contractor.
"Please see section
entitled “Important
Regulatory and
Installation
Requirements”.
HProduct documentation
Read all applicable documentation
before commencing installation. Store
documentation in a readily accessible
location for reference in the future by
service personnel.
"For a listing of
applicable literature,
please see section
entitled “Important
Regulatory and Safety
Requirements”.
HAdvice to owner
Once the installation work is
complete, the heating contractor must
familiarize the system
operator/ultimate owner with all
equipment, as well as safety
precautions/requirements, shut-down
procedure, and the need for
professional service annually.
HWarranty
Information contained in
this and related product
documentation must be
read and followed. Failure
to do so renders warranty
null and void.
HGrounding/lightning protection of the
solar system
In the lower part of the building,
install an electrical conductor on the
solar circuit’s piping system in
compliance with local regulations.
Connection of the solar system to a
new or existing lightning protection or
the provision of local grounding should
only be carried out by a licensed
professional, who must take into
account the prevailing conditions on
site.
HApplicability
Vitosol solar collectors are designed
for use in closed loop heating systems
for domestic hot water heating, space
heating and pool heating via a heat
exchanger. The use of Viessmann
heat transfer medium “Tyfocor-HTL”
is strongly recommended.
Other heat transfer fluids may be
suitable if they have the same
temperature range (-35°C to 170°C)
and are non-toxic.
Pool water or potable water cannot be
pumped directly through the Vitosol
collectors. Damage to collectors caused
by corrosion or scaling will void
warranty.
5285 771 v1.1
Observe maximum load and distance
from edge before installing the
substructure to the roof. If necessary,
consult with a structural engineer to
determine if the structure is suitable
for installing solar collectors. The
collectors must be securely mounted
so that the mountings can withstand
intense wind conditions and local
snow loads.
CAUTION
Gloves and eye protection must be
worn when handling solar panels.
CAUTION
Solar panel connection pipes and
solar heating fluid can become hot
enough to cause severe burns.
Extreme caution must be taken if
panels have been in a stagnant
condition (no flow of fluid).
CAUTION
Avoid scratching or sudden shocks to
glass cover of the solar panel.
CAUTION
Never step on collectors or solder in
close proximity to the glass surface
of the solar panel.
CAUTION
IMPORTANT

Contents
3
Page
Safety Important Regulatory and Safety Requirements 4..................................
General Information About these Instructions 6.............................................................................
Start-up, Inspection and
Maintenance
Quick Start-up Guide 7.....................................................................................
Procedure Overview 7.......................................................................................
Procedure 8..........................................................................................................
Flush, leak test and fill solar heating system 8.........................................
Clean collectors 9...............................................................................................
Check diaphragm expansion tank and set system pressures 10............
Vent solar heating system 12...........................................................................
Setting Values for the Flow Regulating Valve 13.......................................
Maintenance and Cleaning 13...........................................................................
Additional Information Parts List, Vitosol 100 14.................................................................................
Parts List, Vitosol 300 15..................................................................................
Technical Data 16.................................................................................................
Maintenance Record 17......................................................................................
5285 771 v1.1

Safety
4
Important Regulatory and Safety Requirements
Instructing the system user
The installer of the system is
responsible to ensure the system
operator/ultimate owner is made
familiar with the functioning of the
system, its activation, and its
shut-down.
Initial start-up
Initial start-up must be performed by a
qualified heating contractor. Completion
of the Maintenance Record by the
heating contractor is also required.
The following topics must be covered:
Proper system operation sequence.
Explain the equipment.
Demonstrate an emergency
shut-down, what to do and what not.
Explain that there is no substitute for
proper maintenance to help ensure
safe operation.
The Maintenance Record is located on
page 17 of this manual.
Repair work
Repairing components which fulfil a
safety function can compromise the
safe operation of your heating system.
Replace faulty components only with
original Viessmann replacement parts.
Working on the equipment
The installation, adjustment, service,
and maintenance of this equipment
must be done by a licensed professional
heating contractor who is qualified and
experienced in the installation, service,
and maintenance of hot water heating
systems. There are no user serviceable
partsonthisequipment.
Please carefully read this manual prior
to attempting start-up, maintenance
or service. Any warranty is null and
void if these instructions are not
followed.
For information regarding other
Viessmann System Technology
componentry, please reference
documentation of the respective
product.
Viessmann offers frequent installation
and service seminars to familiarize our
partners with our products. Please
inquire.
Ancillary components, spare and wear
parts
Replacement and wear parts which
have not been tested together with the
solar system can compromise its
function. Installing non-authorized
components and non-approved
modifications/conversion can
compromise safety and may infringe our
warranty conditions.
For replacement, use only original
Viessmann replacement parts or those
which are approved by Viessmann.
Ensure main power supply to
equipment, the heating system, and all
external controls has been deactivated.
Take precautions in all instances to
avoid accidental activation of power
during service work.
Technical literature
Literature applicable to all aspects of
the Vitosol 100 or Vitosol 300:
- Technical Data Manual
- Installation Instructions
- Service Instructions
- Operating Instructions
and User’s Information Manual
- System Design Guidelines
The completeness and functionality of
field supplied electrical controls and
components must be verified by the
heating contractor. These include low
water cut-offs, flow switches (if used),
staging controls, pumps, motorized
valves, air vents, thermostats, etc.
Leave all literature at the installation
site and advise the system
operator/ultimate owner where the
literature can be found. Contact
Viessmann for additional copies.
5285 771 v1.1
IMPORTANT
IMPORTANT

General Information
5
About these Instructions
Take note of all symbols and notations intended to draw attention to potential hazards or important product
information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below
Warnings draw your attention to the
presence of potential hazards or
important product information.
Cautions draw your attention to the
presence of potential hazards or
important product information.
Helpful hints for installation, operation
or maintenance which pertain to the
product.
This symbol indicates that additional,
pertinent information is to be found in
column three.
This symbol indicates that other
instructions must be referenced.
5285 771 v1.1
Indicates an imminently hazardous
situation which, if not avoided, could
result in substantial product/property
damage, serious personal injury or
loss of life.
WARNING
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or
product/property damage.
CAUTION
IMPORTANT

Start-up, Inspection and Maintenance
6
Quick Start-up Guide
1. Thoroughly flush system to remove
debris and flux residue (see page 8).
2. Fill system with solar fluid using
charge pump or hand fill pump.
3. Fill system to minimum cold fill
pressure (see page 11).
Typical values:
1-story home = 33 psig / 2.2 bar
2-story home = 37 psig / 2.5 bar
4. Purge all air by running solar loop
pump at maximum speed. After
system is completely vented, shut
off air vent valve in top of system
(see page 12).
5. Check and adjust nitrogen cushion
pressure in the diaphragm expansion
tank (see page 9).
6. Setsystemflowrate(seepage13).
7. Provide overflow container (minimum
size should equal collector fluid
volume).
8. Set control settings: Differentials,
maximum tank temperature.
5285 771 v1.1
4.
6.
7.5.
2.
1.
3.
2.
Do not add water to Tyfocor heat
transfer fluid!
CAUTION

Start-up, Inspection and Maintenance
7
Procedure Overview
Start-up steps
Inspection steps
Maintenance steps Page
S1. Flush, leak test and fill solar heating system 8.................................................................................................................
M2. Shut down solar heating system 9........................................................................................................................................
M3. Clean collectors 9.......................................................................................................................................................................
I M 4. Check gaskets and sealed unions 9......................................................................................................................................
I M 5. Check thermal pipework insulation 10................................................................................................................................
S I M 6. Check for proper operation of all safety equipment 10...................................................................................................
S I M 7. Check proper expansion tank and system pressures 10.................................................................................................
S M 8. Vent solar heating system 12.................................................................................................................................................
S I M 9. Check electrical connections 12.............................................................................................................................................
I M 10. Check frost protection temperature of heat transfer medium 12...............................................................................
S M 11. Start-up heating system 12..................................................................................................................................................
S I M 12. Check switching functions of solar control unit 12........................................................................................................
I M 13. Check for proper operation of circulation pumps 13.....................................................................................................
S I M 14. Check flow rate 13..................................................................................................................................................................
5285 771 v1.1

Start-up, Inspection and Maintenance
8
Procedure
1. Flush, leak test and fill solar heating system
Service
Start-up
All work on the solar circuit or the components of the solar heating system may only be carried out if the sky is very
cloudy, early in the morning, in the evening or with covered collectors.
We recommend the system is only flushed with the specified heat transfer medium to prevent a mixing with residual
water inside the system. Mixing would alter the level of frost protection.
HHeat transfer media containing glycol
can be damaged if they are subjected
to temperatures above 170°F / 77°C
for a prolonged period of time
(stagnation).
This can lead to the system suffering
from sludge and hard deposits,
particularly in conjunction with other
contaminants.
HEnsure that the system is correctly
flushed, filled and vented after
installation. After filling the system
with heat transfer medium, ensure the
system is correctly vented and that
heat is transferred inside the system,
i.e. that longer periods of stagnation
are avoided.
HThe blow-off and drain pipes should
terminate in an open container
capable of holding the maximum
possible collector fluid volume.
1. Cover up collectors, if necessary.
2. Manually open any installed isolation
valves.
3. Open the flow check valves on Solar
Divicon on the supply and return lines
by:
HTurning the thermometers counter
clockwise 45°.
4. Close the shut-off valve on the
system fill manifold Iandopenthe
drain valve .
5. The system is flushed via the return
line to the collector.
Fill and flush the system with heat
transfer medium via the filling valve
.
Flush using a quick-running pump
until you can be sure that all air has
been purged from the solar panel
system. Proper start-up can only be
guaranteed with a system that is
completely free of air.
6. Close the drain valve on the
system fill manifold. Continue to
charge system until desired cold fill
pressure is achieved, then close .
Open the shut-off valve and
check the system for leaks.
Observe the permissible operating
pressure. The pressure should not
drop over the space of at least one
hour.
5285 771 v1.1
Never mix Tyfocor HTL with alternative
heat transfer media or with water.
CAUTION
Never flush with water when it is
freezing, if no heat transfer medium is
used.
CAUTION
Never drain the system with a vacuum
pump.
CAUTION
IMPORTANT

Start-up, Inspection and Maintenance
SR
T T
T
T
I
h
9
Procedure (continued)
S Supply
RReturn
Collector (Vitosol 100 or 300)
Solar Divicon
Overflow container
Expansion tank
Manual solar filling pump
Filling
Shut-off valve
Drain
ISystem fill manifold ( , , )
DHW tank
Air separator
Solar control unit
Fast air vent valve, c/w shutoff
Flow meter
hstatic head (used to calculate
system pressure)
2. Shut down solar heating system
Service
Maintenance
The collectors must be covered before
any work on the components of the
solar heating system begins, in order to
prevent equipment damage.
Isolate the main power supply of the
system (e.g. by unplugging the control
system or by means of a main power
disconnect switch) and safeguard
against unauthorized and/or accidental
reactivation.
3. Clean collectors
Service
Maintenance
In areas experiencing frequent rain,
collector cleaning is not usually
required. In areas with very dry
climates, urban areas or dusty areas,
check and clean collectors periodically.
Use a soap and water solution and flush
thoroughly with water.
4. Check gaskets and sealed unions
Inspection and Maintenance
Replace all worn/faulty parts.
5285 771 v1.1
IMPORTANT

Start-up, Inspection and Maintenance
10
Procedure (continued)
5. Check the thermal pipework insulation
Service
Inspection and Maintenance
Check the thermal insulation of the
pipework for damage and fit. No bare
metal or fiberglass insulation should be
exposed. Adjust if necessary.
Replace all worn/faulty parts.
The thermal insulation*1 of external
pipework must be resistant to
temperature, water and UV radiation. It
must be protected against destruction
by vermin and birds (e.g. metal casing).
*1 e.g. HT/Armaflex made by Armacell
6. Check for proper operation of all safety equipment
Service
Start-up, Inspection and Maintenance
7. Check diaphragm expansion tank and set system pressures
Service
Start-up, Inspection and Maintenance
Legend
Process medium
Nitrogen filling
Nitrogen buffer
Safety water seal,
min. 0.8 USG / 3 ltr.
Safety water seal under max.
pressure
1. Drain the system until the pressure
gage indicates 0, or isolate the
expansion tank from the system and
reduce the pressure at the expansion
tank connection.
2. If the air cushion charge pressure of
the diaphragm expansion tank is
lower than the set system fluid
pressure value, top up with sufficient
nitrogen to raise the charge pressure
to match the set fluid pressure.
Set air cushion charge pressure of
the expansion tank using this
formula:
22 psig+0.45xstatic head in ft
(1.5bar+0.1xstatic head in m)
Static head (collector top edge to the
expansion tank) = ft / m
=22psig+0.45x ft=psig
=(1.5bar+0.1x m=bar)
Continued on following page.
5285 771 v1.1
IMPORTANT
Delivered condition
(45psig/3barinlet
pressure)
Solar heating system
filled without
heat effect
Under max. pressure
at the highest
process medium
temperature

Start-up, Inspection and Maintenance
11
Procedure (continued)
7. Check diaphragm expansion tank and set system pressures (continued)
ServiceStart-up, Inspection and Maintenance
3. Top up system with heat transfer
fluid, until the system pressure
exceeds the set air cushion charge
pressure of the diaphragm expansion
tank by 4.5 to 7.5 psig / 0.3 to 0.5
bar (to create safety water seal in
the expansion tank).
Total system capacity = liquid
content of the pipework + collector
content + content inside the indirect
coils in the DHW tank plus safety
water seal for the expansion tank.
Safety water seal:
=approx. 0.005 x liquid
content of system (min. 3 ltrs)
=approx. 0.005 x / ltr=
The safety water seal must be at least
0.8 USG / 3 ltrs.
When cold, the collector fluid pressure
must be at least 22 psig / 1.5 bar. This
results in a system pressure of:
22 psig + 0.45 x static head(ft) + (4.5
to 7.5 psig) or
1.5 bar + 0.1 x static head (m) + (0.3
to 0.5 bar).
Typical fluid pressures:
1-story home, static head = 10 ft / 3 m
Cold fill pressure = 33 psig / 2.2 bar
2-story home, static head = 20 ft / 6 m
Cold fill pressure = 37 psig / 2.5 bar
5285 771 v1.1
IMPORTANT
Never mix Tyfocor HTL with water or
alternate heat transfer fluid.
CAUTION

Start-up, Inspection and Maintenance
12
Procedure (continued)
8. Vent solar heating system
Service
Start-up and Maintenance
1. Open the flow check valves on Solar
Divicon turning the thermometer
45°. Open the air vent valve at the
top of the system and the air
separator.
2. Adjust the circulation pump to its
highest speed setting, and vent by
starting and stopping several times (a
vented pump will operate almost
silently).
3. Repeat the venting step until the
float in the flow meter of Solar
Divicon holds a steady position when
the pump is running (highest speed
setting).
Note:
Air bubbles will be visible in the flow
meter (float moves).
4. Adjust the flow rate via the speed
selector switch of the circulation
pump (for Solar Divicon model
PS 10). See page 13 for suggested
flow settings for different collector
arrays.
Read the value at the bottom edge of
the float.
5. Repeat the venting steps after the
system has been operating a few
days.
Note:
Top up with heat transfer medium
and repeat the venting process with
the system in its cold state, if the
system pressure has dropped.
6. Close the air vent valve at the top of
the collectors after system venting is
complete.
9. Check electrical connections
ServiceStart-up, Inspection and Maintenance
Check the tightness of electrical
connections and cable grommets.
Check the cables for possible damage.
10. Check frost protection temperature of heat transfer medium
Service
Inspection and Maintenance
Check the frost limit of Tyfocor HTL
heat transfer medium with a Viessmann
frost protection tester, or approved
alternate.
11. Start-up heating system
Service
Start-up and Maintenance
Please refer to the operating
instructions of all installed
components.
12. Check switching functions of solar control unit
ServiceStart-up, Inspection and Maintenance
Please refer to the installation
instructions of the solar control
unit.
5285 771 v1.1

Start-up, Inspection and Maintenance
13
Procedure (continued)
13. Check for proper operation of circulation pumps
Service
Inspection and Maintenance
14. Check flow rate
ServiceStart-up, Inspection and Maintenance
Setting Values for the Flow Meter
Vitosol 100, Model SV1 and SH1 Vitosol 300, Model SP3
Number
of solar
panels
Solar-
Divicon
Model
Flow rate
in ltrs/min
Flow rate
in GPM
Collector
surface
area
in m2
Solar-
Divicon
Model
Flow rate
in ltrs/min
Flow rate
in GPM
2
3
4
5
6
7
PS 10
3to4
4.5 to 6
6to8
7.5 to 10
9to12
10.5 to 14
0.8 to 1.1
1.2 to 1.6
1.6 to 2.1
2.0 to 2.6
2.4 to 3.2
2.8 to 3.7
2
3
4
5
6
7
8
9
10
PS 10
2to 2.5
3to 4
4to 5
5to 6.5
6to 8
7to 9
8 to 10.5
9to12
10 to 13
0.5 to 0.7
0.8 to 1.1
1.1 to 1.3
1.3 to 1.7
1.6 to 2.1
1.8 to 2.4
2.1 to 2.8
2.4 to 3.2
2.6 to 3.4
8
9
10
11
12
13
14
15
PS 20
12 to 16
13.5 to 18
15 to 20
16.5 to 22
18 to 24
19.5 to 26
21 to 28
22.5 to 30
3.2 to 4.2
3.6 to 4.8
4.0 to 5.3
4.4 to 5.8
4.8 to 6.3
5.2 to 6.9
5.5 to 7.4
6.0 to 8.0
11
12
13
14
15
16
17
18
19
20
PS 20
11 to 14.5
12 to 16
13 to 17
14 to 18.5
15 to 20
16 to 21
17 to 22.5
18 to 24
19 to 25
20 to 26.5
2.9 to 3.8
3.2 to 4.2
3.4 to 4.5
3.7 to 4.9
4.0 to 5.3
4.2 to 5.5
4.5 to 6.0
4.8 to 6.3
5.0 to 6.6
5.3 to 7.0
Maintenance and Cleaning
Regular inspection and service by a
qualified heating contractor is critical to
the performance of the Viessmann
Vitosol 100 and 300. Neglected
maintenance, e.g. forgoing regular
cleaning services, impacts on warranty
and will result in decreased efficiency
of the system. Regular cleaning and
maintenance ensures clean,
environmentally friendly and efficient
operation. We recommend a
maintenance contract with a qualified
heating contractor.
HKeep collectors clean
HCheck integrity of collector roof
mounting hardware
HRegularly check the pressure gage
HHave any leaks repaired immediately
by a heating contractor
HAfter approximately six months the
following functions should be tested:
-operating pressure
-smooth running of the pump(s)
-supply temperatures
-control functions
HAfter five years, the storage tank
heat exchanger should be inspected
5285 771 v1.1

Additional Information
14
Parts List for Vitosol 100
When ordering replacement parts
Please provide collector Model and Serial Number from rating plate when ordering replacement parts.
Order replacement parts from your Viessmann distributor.
Parts
001 Interconnection pipe
002 Connecting pipe (short)
003 Connecting pipe (long)
004 Plug
005 Compression fitting with support
sleeves
006 Elbow fitting with support sleeves
007 Clamping bolt, complete
008 Joining element for mounting rail
009 Mounting plate
010 Spacer plug
011 Holding plate
012 O-ring
013 Retaining screws
014 Hose clip
015 Diagonal sealing strip
016 Support sleeve
Parts not shown:
020 Special grease
021 Operating Instructions
022 Service Instructions
024 Installation Instructions
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001 002 003 004
005 006 007
008 009 010
011 014012 013
015 016

Additional Information
15
Parts List for Vitosol 300
When ordering replacement parts
Please provide boiler Model and Serial Number from rating plate when ordering replacement parts.
Order replacement parts from your Viessmann distributor.
Parts
001 Heat pipe vacuum tube, complete
002 Tube retainer
003 Retaining clip
004 Locking rubber
005 O-rings
006 U-pipe with hose clip
007 Clamping bolt, complete
008 Short connecting pipe with hose
clip
010 Long connecting pipe with hose
clip
011 Elbow fitting with support sleeves
012 Interconnection pipe
013 Support sleeve
014 Thermal insulation cap, complete
015 Mounting bracket
016 Pipe plugs
Parts not shown:
012 Terminal box for Vitosol 300,
Model SP3, 2m2
013 Terminal box for Vitosol 300,
Model SP3, 3m2
020 Service Instructions
021 Operating Instructions
022 Installation Instructions
025 Special grease
5285 771 v1.15285 771 v1.1
001 002 003
004 006 007005
010 011008
014 016013 015012

Additional Information
16
Technical Data
Vitosol 100
Model SV1 SH1
Absorber surface area ft.2/m224.8 / 2.30 24.8 / 2.30
Optical efficiency η0%81 81
Heat loss coefficient U1W/(m2·K) 3.48 3.48
Heat loss coefficient U2W/(m2·K2)0.0164 0.0164
Angle correction factor IAM (50 ºC) 1.02 1.02
Thermal capacity c kJ/(m2·K) 6.4 6.4
Max. stagnation temperature ºF / ºC 430 / 221 430 / 221
Permiss. operating pressure psig
bar
87
6
87
6
Vitosol 300
Model SP3
2m2
SP3
3m2
Absorber surface area ft.2/m
222 / 2.05 33 / 3.07
Number of tubes per collector 20 30
Optical efficiency η0%82.5 82.5
Heat loss coefficient U1W/(m2·K) 1.19 1.19
Heat loss coefficient U2W/(m2·K2)0.009 0.009
Angle correction factor IAM (50 ºC) 1.02 1.02
Thermal capacity c kJ/(m2·K) 5.4 5.4
Max. stagnation temperature ºF / ºC 302 / 150 302 / 150
Permiss. operating pressure psig
bar
87
6
87
6
Heat transfer medium
Tyfocor-HTL
The heat transfer medium supplied is a
liquid based on 1.2-propylene glycol
with a frost protection limit of -31°F /
-35°C.
The pH value should be in the range of
7.5 - 8.5. This should be tested
annually. If the pH value falls below
7.0, the heat transfer fluid should be
drained, flushed and refilled with the
new fluid.
Solar Divicon (accessory)
Safety valve 87 psig / 6 bar
248°F / , 120°C
Max. operating temp. 248°F / 120°C
Permiss. operating pressure 87 psig /
6bar
5285 771 v1.1

Additional Information
17
Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service
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Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service
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on:
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Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service
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on:
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Maintenance Record
5285 771 v1.1

18
5285 771 v1.1

19
5285 771 v1.1

Viessmann Manufacturing Company Inc.
750 McMurray Road
Waterloo, Ontario •N2V 2G5 •Canada
Tel. [phone] •Fax [phone]
www.viessmann.ca •[e-mail]
Viessmann Manufacturing Company (U.S.) Inc.
45 Access Road
Warwick, Rhode Island •02886 •USA
Tel. [phone] •Fax [phone]
www.viessmann-us.com •[e-mail]
20
5285 771 v1.1 Technical information subject to change without notice. Printed on environmentally friendly
(recycled and recyclable) paper.