Viessmann VITOCELL 100-U User manual

VIESMANN
Installation 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
5592 936 GB 8/2007 Dispose after installation.

Please follow these safety instructions closely to prevent accidents and
material losses.
Safety instructions explained
!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 appliances must only
be carried out by a qualified gas fit-
ter.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
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.
Workingonthesystem
&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 mains isola-
tor.
&Safeguard the system against
unauthorised reconnection.
&When using gas as fuel, also close
the main gas shut‐off valve and
safeguard against unauthorised
reopening.
Safety instructions
2
5592 936 GB

Installation information
Product information .................................................................................... 4
&Vitocell 100-U and 100-W, type CVU ........................................................ 4
&Connections ............................................................................................ 4
&Installation notes ..................................................................................... 5
Installation sequence
Installing the Solar-Set................................................................................ 6
&Immersion heater..................................................................................... 6
&Solar-Set fixings ...................................................................................... 7
&Fitting the Solar-Set ................................................................................. 8
Hydraulic connection (on the solar side)...................................................... 8
&Lower heating water connections (solar) .................................................. 9
&Upper heating water connections (solar) .................................................. 10
Fitting the safety assembly.......................................................................... 11
Fitting the thermometer sensor and the cylinder temperature sensor ........... 12
&Fitting the thermometer sensor................................................................. 12
&Fitting the Vitosolic 100 cylinder temperature sensor at the front............... 13
&Installing the cylinder temperature sensor of the boiler control unit at the
back ........................................................................................................... 14
Connect control unit.................................................................................... 15
Closing and removing the Solar-Set ............................................................ 16
Checking the anode connection and fitting the lid ........................................ 17
Connections on the heating water and solar sides ....................................... 18
&System design with solar collectors, immersion heater EHE and boiler ..... 18
Connecting the domestic hot water side ...................................................... 20
Connecting the earth bonding ..................................................................... 22
Commissioning........................................................................................... 22
Index
3
5592 936 GB

Vitocell 100-U and 100-W, type CVU
Enamelled DHW cylinder with internal
indirect coils for DHW heating in con-
junction with solar heating systems,
freestanding and wall mounted boilers
and/or EHE immersion heater for
dual-mode operation.
&DHW cylinder, fully equipped with
Solar-Set, comprising:
–Solar-Divicon
–Vitosolic 100
–Pre-assembled pipework
&Content: 300 litres
&Suitable for systems conforming to
DIN 1988, DIN EN 12828, DIN 4753
&DIN registration number: Applied for
&Vitocell 100-W: in white, otherwise
identical
Connections
AConnection for thermometer sen-
sor
BMagnesium anode with earth
cable
CHeating water return, solar (lower
indirect coil)
DHot water to the pipework
EHeating water flow, solar (lower
indirect coil)
FSensor well for cylinder tempera-
ture control
GHeating water flow, boiler (upper
indirect coil)
HDHW circulation
KHeating water return, boiler
(upper indirect coil)
LCold water/drain
MHeating water return, solar (lower
indirect coil)/sensor well for cylin-
der temperature sensor, solar
NSensor well for lower thermometer
OHeating water flow, solar (lower
indirect coil)
PFemale connection for immersion
heater
Product information
4
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Installation notes
!Please note
The thermal insulation must
notbeabletocomeintocon-
tact with naked flames.
Exercise caution when welding
and soldering.
!Please note
To prevent material losses,
install the DHW cylinder in a
room free from the risk of frost
and draughts.
Drain the DHW cylinder when
not in use and there is a risk of
frost.
&Allow an adequate distance to the
wall to enable the thermostat (if
installed) to be operated.
&Level the DHW cylinder with its
adjustable feet.
Note
Never extend the adjustable feet
beyond a total length of 35 mm.
Installing the DHW cylinder with an EHE immersion heater
Installation instructions,
immersion heater EHE
Maintain the minimum clearance.
!Please note
The unheated length of any
threaded immersion heater
installedonsitemustbeat
least 100 mm.
The threaded immersion hea-
ter must be suitable for installa-
tion in enamel-coated DHW
cylinders.
Product information (cont.)
5
5592 936 GB

Immersion heater
If an EHE immersion heater is
installed (accessory), we would
recommend to do this prior to fitting
the base support for the Solar-Sets,
but to leave the electrical connection
until later.
Installation instructions,
immersion heater EHE
!Please note
To prevent equipment damage,
cables must not come into con-
tact with hot parts.
Ensure sufficient thermal insu-
lation between the cables and
hot pipework.
&Route the supply cable of the EHE
immersion heater on the right side
of the base support and secure with
the cable ties supplied.
&Remove the cover from the facia of
the Solar-Set, enabling the facia to
be pulled over the fitted EHE immer-
sion heater.
If no EHE immersion heater is
installed: Seal in the plug (R 1½")
supplied into the free female connec-
tion above the sensor well (Psee
page 4). The cover remains fitted to
the solar-Set facia.
Installing the Solar-Set
6
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Solar-Set fixings
Insert the screws supplied approx.
half way into the cylinder.
Installing the Solar-Set (cont.)
7
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Fitting the Solar-Set
&Lead the base support for the Solar-
Set with corresponding openings
through both screws and hook in.
&Insert the third screw at the top of
the cylinder through a suitable slot.
&Tighten all 3 screws.
&Remove the cardboard transport
packing for securing the pump and
pipes from within the Solar-Set.
Hydraulic connection (on the solar side)
Note
To join and fit the heating water con-
nections (solar), release the fixing
clamps from the pipework, if required.
Installing the Solar-Set (cont.)
8
5592 936 GB

Lower heating water connections (solar)
AHeating water return of the solar
heating system
BHeating water flow of the solar
heating system
Secure both pipelines (heating water
return, solar Aand heating water
flow, solar B) with the flat packing-
ings and union nuts supplied. Tighten
the fixing clamps.
Hydraulic connection (on the solar side) (cont.)
9
5592 936 GB

Upper heating water connections (solar)
AHeating water return of the solar
heating system
BHeating water flow of the solar
heating system
&Lead the upper 2 connection pipes
(heating water return/flow, solar)
through the appropriate 4 openings
in the base support of the Solar-Set
and the DHW cylinder.
&Secure the thermally insulated
upper connection pipes (heating
water return/flow, solar) with the flat
packings and union nuts supplied.
Note
Apply the thermal insulation of the
pipes after the installation over the
entire pipe length up to the edge of
the DHW cylinder.
Hydraulic connection (on the solar side) (cont.)
10
5592 936 GB

AHeating water return of the solar
heating system
BOptional connection of the dia-
phragm expansion vessel (DEV)
&Fit the safety assembly at the back
of the DHW cylinder at the top to the
heating water return, solar A.
&Safeguard the correct orientation of
the clamping ring.
&Counterhold the connecting pipe on
the DHW cylinder when tightening
the union nut.
Fitting the safety assembly
11
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Fitting the thermometer sensor
!Please note
To prevent equipment damage,
cables must not come into con-
tact with hot parts.
Ensure sufficient thermal insu-
lation between the cables and
hot pipework.
Fitting the thermometer sensor and the cylinder temperature sensor
12
5592 936 GB

&Never wrap insulating tape around
the sensor.
&Insert the thermometer sensor with
the long lead into the clamping
bracket on the flange lid until it bot-
toms out.
Note
Never store excess lengths in the
Solar-Set but underneath the cylin-
der lid.
&Secure the thermometer sensor with
the short lead on the outside of the
contact spring of the sensor retainer
(not in the groove) so that it is flush
with the front of thespring(see
page 4).
&Insert the sensor retainer together
with the sensor into the sensor well
until it bottoms out.
Fitting the Vitosolic 100 cylinder temperature sensor at the
front
AHeating water return, solar (lower
indirect coil)/sensor well for cylin-
der temperature sensor, solar
&Seal in the sensor well (standard
delivery) into the threaded elbow of
the heating water return, solar A.
&Insert the cylinder temperature sen-
sor until it bottoms out inside the
sensor well.
Note
The lead of the cylinder temperature
sensor is already connected at the
control unit.
Fitting the thermometer sensor and the cylinder . . . (cont.)
13
5592 936 GB

Installing the cylinder temperature sensor of the boiler con-
trol unit at the back
Note
The cylinder temperature sensor is
supplied with the Viessmann boiler
control unit or is available as an
accessory.
ASensor well for cylinder tempera-
ture control
Fitting the thermometer sensor and the cylinder . . . (cont.)
14
5592 936 GB

&Never wrap insulating tape around
the sensor.
&Secure the cylinder temperature
sensor on the outside of the contact
spring of the sensor retainer (not in
the groove) so that it is flush with
the front of the spring.
&Insert the sensor retainer together
with the sensor into sensor well A
until it bottoms out.
Connect control unit
The following leads/cables are
already connected at the
Vitosolic 100:
&Cylinder temperature sensor
&Pump connecting cable
Note
If not yet connected, push the pump
connecting cable plug into the pump.
The following leads/cables must still
be connected at the Vitosolic 100:
&Power supply
&Collector temperature sensor
&Connection at the Vitotronic boiler
control units (KM BUS)
!Please note
Neverroutepowercablesand
collector temperature sensor
leads immediately next to each
other. Otherwise false readings
could be transferred from the
collector temperature sensor.
Route both leads on separate
sides at the top underneath the
DHW cylinder lid. Lead them
with a gap between each other
through the centring ferrules in
the cylinder jacket.
Installation and service instruc-
tions Vitosolic 100
Collector installation instruc-
tions
Fitting the thermometer sensor and the cylinder . . . (cont.)
15
5592 936 GB

Fitting the Solar-Set facia:
&Hook in the Solar-Set facia with the
2 lower side tabs into the slots in the
base support.
&Push the facia in and push the 2
upper side locking bolts into the
appropriate spring catches of the
base support.
&Insert the screw supplied for addi-
tional security into the top of the
Solar-Set facia.
Note
Release the Solar-Set facia in
reverse order and remove.
Closing and removing the Solar-Set
16
5592 936 GB

AMagnesium anode
BEarth lead
CThermometer lead
DType plate
Note
Guide the thermometer leads through
the groove in the flange insulation.
Checking the anode connection and fitting the lid
17
5592 936 GB

&Connect the pipework with detach-
able fittings.
&Cap connections that are not
required.
&Adjust the control thermostat so that
the DHW temperature in the cylin-
der does not exceed 95 ºC.
Permissible temperatures
solar side 160 °C
heating water side 160 °C
Permissible operating
pressure
solar side 10 bar
heating water side 10 bar
Test pressure
solar side 16 bar
heating water side 16 bar
Note
Vitosol collectors can be used up to
6bar.
System design with solar collectors, immersion heater EHE
and boiler
&Heating of the domestic hot water
through solar collectors via the
lower indirect coils and/or through
theEHEimmersionheater
&Heat supply for reheating or heating
of the DHW through a boiler via the
upper indirect coil
Connections on the heating water and solar sides
18
5592 936 GB

KW Cold water
WW DHW
S1 Collector temperature sensor
S2 Cylinder temperature sensor
(solar side)
1Vitocell 100-U and 100-W,
type CVU, comprising:
2DHW cylinder with Solar-Set
Solar set, comprising:
3Fill valve
4Solar-Divicon
5Vitosolic 100
6Solar collector
7DHW circulation
8Heating circuit
9Oil/gas fired boiler
qP Air separator
qQ Stratification pump
qW Cylinder temperature sensor
(primary side)
Connections on the heating water and solar sides (cont.)
19
5592 936 GB

1. For heating water flow tempera-
tures in excess of 95 ºC:
Remove the cover bezels from the
heating water side pipe outlets
(bezels have l.h. threads).
2. Install the heat supply control unit.
3. Install the flow line with an incline
and fit an air vent valve at its high-
est point.
4. Only for heating water flow tem-
peratures in excess of 110 ºC:
Install a type-tested high limit
safety cut-out, if none has been
installed in the system. For this,
use a temperature limiter and a
high limit safety cut-out.
5. For solar heating systems:
Install an additional high limit
safety cut-out, if less than 40 litres
DHW volume is available per m
2
collector area (irrespective of the
collector type).
Connecting the domestic hot water side
&For the DHW connection, observe
DIN 1988 and DIN 4753.
&Connect the pipework with detach-
able fittings.
&Seal connections that are not
required, with red brass caps.
&Equip the DHW circulation line with
a DHW circulation pump and a
check valve.
&Connection of the DHW circulation
pump:
–Connection to the boiler control
unit,ifthatisequippedwitha
DHW circulation pump connec-
tion.
–Connection with a time switch, if
no DHW circulation pump connec-
tion is available on the boiler con-
trol unit.
–Connection via the time switch.
Permissible temperature: 95 °C
Permissible operating
pressure:
10 bar
Test pressure: 16 bar
Connections on the heating water and solar sides (cont.)
20
5592 936 GB