Viessmann VITOSOL-F Operating instructions
Service instructions
for contractors
VIESMANN
Vitosol-F
For applicability, see the last page
VITOSOL-F
5692 808 GB 3/2009 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
5692 808 GB
3
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 808 GB
4
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.............................................................................. 11
Specification
Vitosol 200-F........................................................................................................ 13
Vitosol 300-F........................................................................................................ 13
Solar-Divicon (accessory).................................................................................... 13
Heat transfer medium (accessory)....................................................................... 13
Certificates
Declaration of conformity...................................................................................... 15
Index
Index
5692 808 GB
5
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Flushing, 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 system........................................................ 7
• • 6. Venting the solar thermal system................................. 8
••• 7. Checking the switching function of the solar control
unit................................................................................... 9
••• 8. Checking the flow rate
•9. Shutting down the system............................................. 9
• • 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
5692 808 GB
6
Flushing, 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. Leave collectors covered or cover if
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 30
minutes.
Notes
■ A heat transfer medium containing gly-
col can deteriorate if it is exposed to
temperatures above 170 °C for pro-
longed periods (stagnation).
Temperatures in excess of 200 °C
result in a slow thermal breakdown of
the 1,2-propylene glycol that can be
recognised by a 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 correctly
flushed, filled and ventilated after
installation.
■ After filling the system with the heat
transfer medium, ensure that the sys-
tem is fully vented and that heat is
transferred inside the system.
■ Blow-off and drain lines must termi-
nate in an open container, that is capa-
ble of collecting the full collector con-
tent.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 808 GB
7
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 system
Observe operating instructions of instal-
led components.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 808 GB
8
Venting 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 the required flow rate via the
pump rate of the circulation pump
(see following tables for approximate
set values).
Check the value underneath the
float.
3. Repeat the venting process after the
system has been operational for sev-
eral days.
Note
If the system pressure drops, top-up
the heat transfer medium in the cold
state and vent again.
4. Always shut off the air vent valve after
venting.
Adjustable flow rates
Vitosol 200-F, type 5DI
Throughput 3 to 4 l/min
Vitosol 200-F, 300-F
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.)
5692 808 GB
9
High-flow operation, 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, 15 l/(h·m2)
Number of
collectors
Flow rate in l/min
6 3.5
7 4
8 4.5
9 5
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 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 com-
mencing any work on the compo-
nents of the solar thermal sys-
tem.
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 808 GB
10
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).
Solar service case operating
instructions
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.)
5692 808 GB
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