Viessmann Vitosol 100 Bedienungsanleitung

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

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

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

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

General Information

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

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

7.5.

Do not add water to Tyfocor heat

transfer fluid!

CAUTION

Start-up, Inspection and Maintenance

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

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

T T

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

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

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