Viessmann VITOCELL 100-U Operating instructions

VIESMANN
Service instructions
for contractors
Vitocell 100-U
Type CVU
Dual-mode DHW cylinder with Solar-Set
Vitocell 100-W
Type CVU
Dual-mode DHW cylinder with Solar-Set
VITOCELL 100-U
VITOCELL 100-W
5692 747 GB 8/2007 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 747 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 747 GB

Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance................................... 5
Further details regarding the individual steps .............................................. 6
Parts list .................................................................................................... 12
Commissioning/service reports............................................................... 14
Specification............................................................................................. 15
Accessories
Accessory specification .............................................................................. 17
Certificates
Declaration of conformity ............................................................................ 18
Index
4
Index
5692 747 GB

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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••• 1. Control principles................................................................. 6
•2. Filling the DHW cylinder..................................................... 6
•• 3. Inspection and maintenance ............................................ 7
•• 4. Shutting down the system
•• 5. Checking the function of all safety valves
•• 6. Testing the anode earth current with an anode
tester.......................................................................................... 7
•• 7. Cleaning the inside of the DHW cylinder...................... 8
•• 8. Checking and replacing the magnesium anode (if
required)................................................................................... 9
•• 9. Returning the DHW cylinder into use ............................ 10
•• 10. Checking connections on the water side for leaks
Steps - commissioning, inspection and maintenance
5
Commissioning, inspection, maintenance
5692 747 GB

Control principles
Setting of ball valves
One ball valve each in the heating
water flow (solar) and in the heating
water return (solar) within the Solar-
Set:
&Laterally to the pipe run:
–open
&Acrossthepiperun:
–closed
&Diagonally 45 ° to the pipe run
–Check valve open
–The diagonal position 45 ° (clock-
wise or anti-clockwise) is only
required for filling and draining the
system.
Vitosol service instructions
Venting the heating water flow (solar) (HVs)
Ventingviatheairventvalveonthe
vent pot.
Adjusting the flow rate
Adjustment via flow meter on the
heating water return (solar).
Flushing &filling
Implementation via a flush & fill valve
on the heating water return (solar).
Note
Optional connection of a manual solar
fill pump (accessories for solar heat-
ing systems) to raise the pressure
after venting.
Filling the DHW cylinder
1. Fill the DHW cylinder from the
DHW side.
Note
When the DHW cylinder is pres-
surised, re-torque the flange lid
withatorqueof25Nm.
2. Check the fittings on the heating
water and DHW side for leaks and
tighten, if required.
3. Check the function of the safety
valves according to manufacturer's
instructions.
Further details regarding the individual steps
6
Commissioning, inspection, maintenance
5692 747 GB

Inspection and maintenance
DIN 1988 requires a visual inspection
and (if required) cleaning no later than
two years after the cylinder has been
taken into use and thereafter accord-
ing to requirements.
Note
We additionally recommend that the
function of the magnesium anode is
checked annually. This function check
can be made without interrupting the
operation, by measuring the earth cur-
rent with an anode tester (see
page 7).
Testing the anode earth current with an anode tester
Further details regarding the individual steps (cont.)
7
Commissioning, inspection, maintenance
5692 747 GB

1. Remove lid Aand flange insula-
tion B.
2. Remove upper thermometer
sensor C.
3. Pull earth cable Eoff tab D.
4. Connect the tester in series
between earth cable Eand con-
nection tap D.
&The anode is OK if the indicated
current is > 0.3 mA.
&Visually inspect the anode, if the
current measures < 0.3 mA or if
there is no current at all (see
page 9).
Cleaning the inside of the DHW cylinder
1. Drain the DHW cylinder from the
DHW side.
2. Remove flange lid A.
Note
Thesystemcanonlybecleaned
via the upper flange aperture.
3. Disconnect the DHW cylinder from
the pipe system to prevent cleaning
agent and contamination from
entering the pipework.
4. Remove loose deposits with a high
pressure cleaner.
!Please note
Pointed objects or those
with sharp edges will
damage the internal cylinder
wall.
Only use plastic tools to
clean the inside.
Further details regarding the individual steps (cont.)
8
Commissioning, inspection, maintenance
5692 747 GB

5. Werecommendtoemployacon-
tractor to remove stubborn depos-
its. Use a chemical cleaning agent
to remove hard deposits that can-
notberemovedwithahighpres-
sure cleaner.*1.
!Please note
Cleaning agents containing
hydrochloric acid attack the
material of the DHW cylin-
der.
Never use such cleaning
agents.
Danger
Cleaning agent residues can
lead to poisoning.
Always observe the details
provided by the manufac-
turer of the cleaning agent.
6. Fully drain any cleaning agent.
7. Thoroughly flush the DHW cylin-
der after cleaning.
Checking and replacing the magnesium anode (if required)
Check the magnesium anode.
We recommend you replace the mag-
nesium anode if it has been reduced
down to 710-15 mm.
Note
A chain anode is available (upon
request) where space is restricted.
Further details regarding the individual steps (cont.)
9
Commissioning, inspection, maintenance
5692 747 GB
*1Manufacturer: Grünbeck Wasseraufbereiter GmbH, Industriestraße 1, D-89420 Höch-
städt

Returning the DHW cylinder into use
1. Reconnect the DHW cylinder to the
pipework.
2. Insert new gasket Aunderneath
flange lid B.
3. Remove the flange lid with earth
cable Cand tighten the screws
with a maximum torque of 25 Nm.
4. Push earth lead Conto tab D.
5. Fill the DHW cylinder from the
DHW side and then retighten the
flangelidwithatorqueof 25Nm.
6. Remove upper thermometer
sensor E.
Further details regarding the individual steps (cont.)
10
Commissioning, inspection, maintenance
5692 747 GB

7. Fit flange insulation Fand lid G.
Note
Guide the thermometer lead
through the groove in the flange
insulation.
Further details regarding the individual steps (cont.)
11
Commissioning, inspection, maintenance
5692 747 GB

When ordering spare parts:
Quote the type 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 Anode flange with gasket
002 Sensor fixture
003 Clamping bracket
005 Adjustable foot
006 Thermometer
007 Gasket
008 Flange insulation
009 Top panel
010 Plug
013 Vitocell 100 logo
014 Sensor well for thermometer
015 Centring ferrule (4 pce.)
101 Solar flow connecting pipe*1
102 Pipe piece, solar flow with gas-
kets
103 Ball valve, flow with gaskets
104 Venting pot with air vent valve
and gaskets
105 Cylinder connection pipe, flow
with gaskets
106 Gasket set G 1" (5 gaskets)
107 Gasket set G ¾" (2 gaskets)
108 Cylinder connection piece with
gaskets
109 Elbow, return with gaskets
110 Flus/fill facilities with gaskets
111 Flow meter with gaskets
112 Circulation pump motor
113 Gasket set, pump (2 gaskets)
114 Ball valve, return with gaskets
115 Pipe piece, solar return with gas-
kets
116 Connecting pipe, solar return*1
117 Safety assembly, solar
201 Solar station frame
202 Lid
203 Cover
204 Base carrier
205 Fixing elements
Parts not shown
011 Spray paint
012 Touch-up paint stick
020 Installation instructions
021 Service instructions
Wearing part
004 Magnesium anode or, alterna-
tively, chain anode upon request
Vitosolic parts:
Installation and service instruc-
tions, Vitosolic
AType plate
BVitosolic 100
Parts list
12
Parts list
5692 747 GB
*1Also order pos. 107

Parts list (cont.)
13
Parts list
5692 747 GB

Commissioning Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Commissioning/service reports
14
Commissioning/service reports
5692 747 GB

Product parameters
Cylinder capacity l 300
Standby heat loss*1
qBS with 45 K temperature differential
kWh/24 h 1.00
Vaux (volume standby section) l 127
Vsol (volume solar section) l 173
Specification (incl. Solar-Set)
Grundfos circulation pump 25–60
Rated voltage V~ 230
Power consumption at
&output stage I W 40
&output stage II W 65
&output stage III W 80
Flow indicator l/min 2 to 15
Safety valve (solar) bar 6
Max. operating temperature °C 120
Max. operating pressure bar 6
Pump curve
APressure drop curve BResidual head
Specification
15
Specification
5692 747 GB
*1Standard characteristics

The pressure drop curve relates to all
Solar-Set components together:
&Air vent valve
&Ball valves (HVs and HRs)
&Flow meter
&Pipework
Pump curve (cont.)
16
Specification
5692 747 GB

Electric immersion heater EHE
Only for use with soft to medium-hard water up to 2.51 mmol/l (hardness level
2).
Rated output at standard opera-
tion/quick heat-up
kW 2 4 6
Type of current and rated voltage 3/N/ 400 V/50 Hz
Rated current A8.7
Heat-up time for heating from 10
to 60 °C when an electric immersion
heater has been fitted
h 3.8 1.9 1.3
Capacity l 300
Capacity that can be heated
with the electric immersion heater
EHE
l130
Total width b
with the electric immersion heater
EHE
mm 919
Accessory specification
17
Accessories
5692 747 GB

We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, confirm as sole
responsible body that the products Vitocell 100-U (type CVU) and
Vitocell 100-W (type CVU) comply with the following standards:
DIN 4753
AD 2000 regulations
This product is designated _-0036 in accordance with the following Directives:
89/336/EEC
97/23/EC
2006/95/EC
Details according to the Pressure Equipment Directive (97/23/EC):
&Heated pressure vessel (not at risk from overheating)
&Class I and II according to appendix II, diagram 2
&ModulesBandC1accordingtoappendixIII
&Materials to AD regulations in accordance with assessment and appendix I,
4.2, b)
&Corrosion supplement to appendix I, 2.2 and AD 2000 regulations
Allendorf, 30 August 2007 Viessmann Werke GmbH&Co KG
pp. Manfred Sommer
Declaration of conformity
18
Certificates
5692 747 GB

19
5692 747 GB

20
Printed on environmentally friendly, chlorine-free bleached paper
5692 747 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]