Viessmann Vitocell 200 Cylinder User guide

Design, Installation,
User & Servicing
Instructions
An unvented hot water storage
appliance complying with the
requirements of Building Regulations
Approved Document G3 and
manufactured in accordance with
BS EN 12897, the specification for
unvented water storage vessels.
In the interest of continuously
improving the Vitocell 200 Cylinder
range, Viessmann reserve the right to
modify the product without notice, and
in these circumstances this booklet,
which is accurate at the time of printing,
should be disregarded.

Page 2
Section Page
DESIGN
Description 3
Technical Data 6
System Details 8
INSTALLATION
Installation 10
Commissioning 20
USER INSTRUCTIONS 21
SERVICING
Servicing and Maintenance 22
Fault Finding 23
Spare Parts List 26
ADDENDIX
Addendix A 27
Addendix B 28
ISSUE 4.11: 04-10
These instructions should be read in conjunction with the installation/servicing
instructions issued by the manufacturer of the heat source being used.
Any installation must be in accordance with the relevant requirements of the Gas
Safety Regulations, Building Regulations, I.E.E. Wiring Regulations and the Water Fitting
Regulations (England and Wales) or Water Byelaws (Scotland). It should be read in
accordance with the relevant recommendations of the following:
BS 6798; BS 5549; BS 5546;
BS 5440:1; BS 5440:2; CP 331:3
BS 6700: BS 5258 and BS 7593: 1992
Viessmann Vitocell 200 Cylinder is covered by Section G3 of the Building Regulations
(England and Wales) Technical Standard P3 (Scotland) and Building Regulation P5 (Northern
Ireland. Compliance can be achieved via a Competent Person Self Certification Scheme or
notificaton of installation to the Local Authority Building Control Department.
It must be installed by a competent person as defined by the relevant regulations.
Manufacturers notes must NOT be taken as over-riding statutory obligations.
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge unless
they have been given supervision or instruction concerning use of the appliance by
a person responsible for their safety. Children should be supervised at all times to
ensure they do not play with the appliance.
This information is provided to assist generally in the selection of equipment.
Responsibility for selection and specification of our equipment must however remain that
of our customer and any experts or consultants concerned with the installation(s).
Please note: that we do not therefore accept any responsibility for matters of design
selection or specification, for the effectiveness of an installation or system containing
one of our products unless specifically requested to do so in writing.
All goods are sold subject to our conditions of sale which are set out at the rear of this
specification. In the interest of continuously improving the Viessmann Vitocell 200
Cylinder range, Viessmann Limited reserve the right to modify the product without
notice, and in these circumstances this booklet, which is accurate at the time of printing,
should be disregarded. An updated set of instructions will be produced and supplied
with new appliances and will be made available for other appliances on request.
A KIWA PRODUCT APPROVED TO COMPLY WITH ALL RELEVANT PARTS OF THE BUILDING
REGULATIONS AND WATER SUPPLY (WATER FITTINGS) REGULATIONS.
VIESSMANN VITOCELL 200 CYLINDER IS PRODUCED UNDER AN ISO 9001:2000 QUALITY
MANAGEMENT SYSTEM APPROVED BY BSI.
As part of the industry wide “benchmark” initiative all Viessmann Vitocell 200 Cylinder
appliances now include a Benchmark Installation, Commissioning and Service Record
Log Book. Please read carefully and complete all sections relevant to the appliance
installation. Carrying out the work required and completing the Log Book will satisfy the
requirements of the Building Regulations for commissioning as set out in the Domestic
Heating Compliance Guide. The details of the Log Book will be required in the event of
any warranty work being required. There is also a section to be completed after each
regular service visit. The completed Log Book and these instructions should be left
with the cylinder.
CONTENTS

Page 3
DESCRIPTION
DESIGN
Supplied By: Viessmann Ltd
Maximum inlet pressure to
Pressure reducing valve 12 bar
Operating pressure (PRV setting) 3 bar
Expansion vessel charge pressure 3 bar
Expansion relief valve setting 4.75 bar
Opening pressure of P & T Relief Valve 6 bar
Opening temperature of P & T Relief Valve 95°C
Energy cut-out thermostat setting 80°C
Max. working pressure - Primary heat exchanger (Indirect models) 6 bar
Max. working pressure - Solar heat exchanger (Solar models) 10 bar
Immersion heater rating 3kW, 240V AC
All cylinders are manufactured in accordance with the requirements of BS EN 12897
The tundish must be positioned so that it is visible to the occupant and is away from
electrical devices.
Components supplied with Stainless Lite:
• Cold water inlet PRV combination valve/expansion relief
• Pressure and temperature relief valve
• Control thermostat
• Energy cut-out thermostat
• Energy cut-out motorised valve (indirects only)
• Tundish
• 3kW Immersion heater
• Expansion vessel/mounting bracket/flexible hose
• Technical/user product literature
(Note: Please refer to tables 1 and 2 on pages 6-9 to confirm the quantity of immersion
heaters supplied with the unit)
In any situation where the volume of heated pipework (eg. secondary circulation pipes
or manifold pipework for multiple units) exceeds 10 litres, then an additional expansion
vessel must be fitted to accommodate the extra expansion volume.
Handling Before Installation
Viessmann Vitocell 200 Cylinder must be handled with care and stored the correct
way up in a dry place. Any manual handling/lifting operations will need to comply
with the requirements of the Manual Handling Operations Regulations issued by the
H.S.E. The appliance can be moved using a sack truck on the rear face although care
should be taken and the route should be even. In apartment buildings containing a
number of storeys we would recommend that the appliances are moved vertically
in a mechanical lift. If it is proposed to use a crane, expert advice should be obtained
regarding the need for slings, lifting beams etc.
A specific manual handling assessment is shown in Appendix B at the rear of this
manual.
Maintenance
Modifications should not be made to this
product. Replacement parts, including immersion
heaters, should be purchased from Viessmann
Limited, or agents approved by them. Unvented
hot water storage vessels need regular routine
checks, and these are detailed below. It is for this
reason that this manual must always be left with
the Viessmann Vitocell 200 Cylinder.
It is essential that these checks be carried out
at the time of boiler maintenance by a qualified
installer:
1. Manually open the relief valves in turn, and
check that water is discharged from the
valves and runs freely through the tundish
and out at the discharge point. Ensure that
the valves re-seat satisfactorily. (Note - the
water may be very hot).
2. It is important to check that the discharge
pipework is carrying the water away
adequately. Check for blockages etc. if it is
not.
3. Turn the mains water off and remove and
clean the strainer element in the Pressure
Reducing Valve.
4. Check the charge pressure in the expansion
vessel and repressurise if required
5. Re-fill the system and ensure that all relief
valves have re-seated.
6. The Benchmark log book supplied should be
updated at each service.
7. Check the water pressure downstream of the
combination valve is 3 bar in static condition.
8. Check and if necessary, descale the heat
exchanger in hard water areas ie. above
200ppm (mg/l).
Note:
The cylinder is factory fitted with a temperature
& pressure relief valve that must not be used for
any other purpose or removed.
The cylinder is factory fitted with immersion
heaters with thermal cut outs. Immersions
without thermal cut outs must not be fitted.

Page 4
DESIGN
DESCRIPTION
Introduction
Viessmann Vitocell 200 Cylinder is a range
of unvented hot water storage cylinders,
manufactured in the latest high quality duplex
stainless steel. They are designed to provide
mains pressure hot water and are supplied as a
package which complies with Section G3 of the
Building Regulations. The appliance is extremely
well insulated using high density HCFC free foam
insulation with an ozone depleting potential (ODP)
of zero and a global warming potential (GWP) of
1. It is fitted with all necessary safety devices and
supplied with all the necessary control devices to
make installation on site as easy as possible.
Viessmann Vitocell 200 Cylinder is available
in two basic variants:
1. Viessmann Vitocell 200-V Cylinder - For
use with gas or oil boilers (Figure 1). Vitocell
200 Cylinders must not be used with solid
fuel boilers or steam as the energy source.
2. Viessmann Vitocell 200-B Solar Cylinder
- For providing hot water by solar gains
and gas or oil boilers (Figure 2). Unvented
cylinders must not be used with solid fuel
boilers or steam as the energy source.
Viessmann Vitocell 200-V Cylinder
Viessmann Vitocell 200-V Cylinder is an unvented
hot water storage cylinder and is provided with
a high efficiency internal primary coil which is
designed for use with a gas or oil boiler and
is suitable for both open vented and sealed
pumped primary systems.
When used with a sealed heating system the
boiler must incorporate its own energy cut-out
overheat thermostat.
Viessmann Vitocell 200-V Cylinder models are
listed in Table 1 on Page 6 & 7.
Pipework is not supplied by manufacturer,
but to be supplied and fitted by installer.
Viessmann Vitocell 200-V Cylinder
Figure 1

Page 5
DESIGN
DESCRIPTION
Pipework is not supplied by manufacturer,
but to be supplied and fitted by installer.
Viessmann Vitocell 200-B Solar Cylinder
Viessmann Vitocell 200-B Solar Cylinder is an
unvented hot water storage cylinder and is
provided with a high efficiency internal primary
coil which is designed for use with a gas or oil
boiler and is suitable for both open vented and
sealed pumped primary systems.
When used with a sealed heating system the
boiler must incorporate its own energy cut-out
overheat thermostat.
A high efficiency second solar coil is positioned
below the primary coil to ensure maximum
benefit of solar gain energy.
Viessmann Vitocell 200-B Solar Cylinder models
are listed in Table 1 on Page 6 & 7.
Note:
The cold supply elbow c/w drain tapping
must be fitted as shown in figs 1, 2, 3 and 4.
A flexible hose can then be connected to the
drain tapping and, providing the hose runs
below the lowest level of the cylinder, then
all the water contents can be drained out by
syphonic action.
Viessmann Vitocell 200-B Solar Cylinder
Figure 2

Page 6
DESIGN
TECHNICAL DATA
Table 1
Model
Weight - Empty
Weight - Full
Capacity (Total Volume)
Pressure Regulator 3 bar inlet
group c/w balance cold supply,
expansion vessel connection and
expansion valve set at 4.75 bar
Expansion Vessel size.
Pre-charged to 3 bar
Overall Height
Overall Diameter
Pressure & Temperature
Relief Valve 6bar 95°C
22mm Secondary
Return Tapping
On Peak Immersion
Heater - High Level
Cold Feed 22mm
Compression Connection
Off Peak Immersion
Heater - Low Level
Volume of On Peak Water
Heated
Dual Control & Overheat Stat
Extra Stat Pocket
For Boiler Use If Required
22mm Primary Return
Compression Connection
22mm Primary Flow Compression
Connection
22mm Solar Return
Compression Connection
22mm Solar Flow
Compression Connection
Dual Control & Overheat Stat
Solar Pocket Solar Pocket
kW Rating of Primary Coil
Surface Area of
Primary Heater Coil
Pressure Loss Across
Primary Heater Coil
Surface Area of
Solar Heater Coil
Pressure Loss Across Solar Heater
Coil
Heat Up Time from 15°C to 60°C
(applies to Primary Heat Source only)
Recovery Time after 70% Draw Off
(applies to Primary Heat Source only)
Standing Losses kWhr/24hr
Dedicated Solar Volume
kg kg Litres bar Litres A=mm mm B=mm C=mm D=mm E=mm F=mm Litres G=mm
H=mm I=mm J=mm K=mm L=mm M=mm N=mm P=mm kW m2bar m2bar min min kWh Litres
Vitocell 200-V
90 19 109 90 3 12 732 550 490 n/a 352 367 n/a 40 367
367 223 312 n/a n/a n/a n/a n/a 16.5 0.59 0.165 n/a n/a 21 16 0.80 n/a
120 22 142 120 3 12 920 550 678 n/a 352 367 n/a 67 367
367 223 312 n/a n/a n/a n/a n/a 18 0.59 0.165 n/a n/a 27 19 1.00 n/a
150 26 176 150 3 18 1107 550 865 n/a 392 442 n/a 92 407
407 223 392 n/a n/a n/a n/a n/a 18.5 0.68 0.191 n/a n/a 28 19 1.20 n/a
180 28 208 180 3 18 1295 550 1053 n/a 432 442 n/a 116 447
447 223 392 n/a n/a n/a n/a n/a 19 0.78 0.216 n/a n/a 33 21 1.40 n/a
210 33 243 210 3 24 1483 550 1241 1127 432 442 n/a 145 482
482 223 392 n/a n/a n/a n/a n/a 20.5 0.78 0.216 n/a n/a 41 26 1.60 n/a
250 38 288 250 3 24 1733 550 1491 1377 927 522 512 109 577
577 223 472 n/a n/a n/a n/a n/a 21.5 0.97 0.241 n/a n/a 44 30 1.75 n/a
300 44 344 300 3 35 2020 550 1777 1577 1242 522 512 130 677
677 223 522 n/a n/a n/a n/a n/a 25 0.97 0.241 n/a n/a 48 32 1.93 n/a
Vitocell 200-B Solar
210 35 245 210 3 24 1483 550 1241 1127 822 437 n/a 95 837
n/a 522 782 223 352 419 1000 203 18.5 0.68 0.191 0.680 0.191 35 16 1.60 70
250 40 290 250 3 24 1733 550 1491 1377 947 522 n/a 115 962
n/a 607 907 223 472 539 1180 262 19 0.78 0.216 0.970 0.241 38 19 1.75 84
300 46 346 300 3 35 2020 550 1777 1577 1042 522 n/a 140 1092
n/a 702 1002 223 472 539 1367 262 20.5 0.78 0.216 0.970 0.241 41 20 1.93 100
A
C
Vitocell 200-V
D
H
F
E
I
J
B
G
F
Vitocell 200-B Solar
N
G
P
I
E
K
J
A
B
M
L
C

Page 7
DESIGN
TECHNICAL DATA
Table 1
Model
Weight - Empty
Weight - Full
Capacity (Total Volume)
Pressure Regulator 3 bar inlet
group c/w balance cold supply,
expansion vessel connection and
expansion valve set at 4.75 bar
Expansion Vessel size.
Pre-charged to 3 bar
Overall Height
Overall Diameter
Pressure & Temperature
Relief Valve 6bar 95°C
22mm Secondary
Return Tapping
On Peak Immersion
Heater - High Level
Cold Feed 22mm
Compression Connection
Off Peak Immersion
Heater - Low Level
Volume of On Peak Water
Heated
Dual Control & Overheat Stat
Extra Stat Pocket
For Boiler Use If Required
22mm Primary Return
Compression Connection
22mm Primary Flow Compression
Connection
22mm Solar Return
Compression Connection
22mm Solar Flow
Compression Connection
Dual Control & Overheat Stat
Solar Pocket Solar Pocket
kW Rating of Primary Coil
Surface Area of
Primary Heater Coil
Pressure Loss Across
Primary Heater Coil
Surface Area of
Solar Heater Coil
Pressure Loss Across Solar Heater
Coil
Heat Up Time from 15°C to 60°C
(applies to Primary Heat Source only)
Recovery Time after 70% Draw Off
(applies to Primary Heat Source only)
Standing Losses kWhr/24hr
Dedicated Solar Volume
kg kg Litres bar Litres A=mm mm B=mm C=mm D=mm E=mm F=mm Litres G=mm
H=mm I=mm J=mm K=mm L=mm M=mm N=mm P=mm kW m2bar m2bar min min kWh Litres
Vitocell 200-V
90 19 109 90 3 12 732 550 490 n/a 352 367 n/a 40 367
367 223 312 n/a n/a n/a n/a n/a 16.5 0.59 0.165 n/a n/a 21 16 0.80 n/a
120 22 142 120 3 12 920 550 678 n/a 352 367 n/a 67 367
367 223 312 n/a n/a n/a n/a n/a 18 0.59 0.165 n/a n/a 27 19 1.00 n/a
150 26 176 150 3 18 1107 550 865 n/a 392 442 n/a 92 407
407 223 392 n/a n/a n/a n/a n/a 18.5 0.68 0.191 n/a n/a 28 19 1.20 n/a
180 28 208 180 3 18 1295 550 1053 n/a 432 442 n/a 116 447
447 223 392 n/a n/a n/a n/a n/a 19 0.78 0.216 n/a n/a 33 21 1.40 n/a
210 33 243 210 3 24 1483 550 1241 1127 432 442 n/a 145 482
482 223 392 n/a n/a n/a n/a n/a 20.5 0.78 0.216 n/a n/a 41 26 1.60 n/a
250 38 288 250 3 24 1733 550 1491 1377 927 522 512 109 577
577 223 472 n/a n/a n/a n/a n/a 21.5 0.97 0.241 n/a n/a 44 30 1.75 n/a
300 44 344 300 3 35 2020 550 1777 1577 1242 522 512 130 677
677 223 522 n/a n/a n/a n/a n/a 25 0.97 0.241 n/a n/a 48 32 1.93 n/a
Vitocell 200-B Solar
210 35 245 210 3 24 1483 550 1241 1127 822 437 n/a 95 837
n/a 522 782 223 352 419 1000 203 18.5 0.68 0.191 0.680 0.191 35 16 1.60 70
250 40 290 250 3 24 1733 550 1491 1377 947 522 n/a 115 962
n/a 607 907 223 472 539 1180 262 19 0.78 0.216 0.970 0.241 38 19 1.75 84
300 46 346 300 3 35 2020 550 1777 1577 1042 522 n/a 140 1092
n/a 702 1002 223 472 539 1367 262 20.5 0.78 0.216 0.970 0.241 41 20 1.93 100
4
0
,0
0
º
4
5
,
00º
3
5
,00º
2
5,
0
0
º
1
5
,
0
0
º
NOTES
1. Not all models - see table 1.
2. Recovery times based on Primary
Coil/I.H. duty (ie. assumes the boiler
output is adequate).
3. All connections are supplied with
compression fittings for direct
connection to copper pipework.

Page 8
DESIGN
SYSTEM DETAILS
Viessmann Vitocell 200-V Cylinder
Basic Appliance
1. Hot water draw off (22mm) compression
2. Temperature & pressure relief valve 95°/6 bar
3. Hot water secondary return 22mm
(not fitted to smaller sizes, see table 1)
4. Immersion heater 1¾” BSP 3kW
5. 22mm cold supply compression
6. Immersion heater 1¾” BSP 3kW
7. Dual control/overheat stat pocket (22mm)
8. Boiler control sensor pocket (spare)
9. Primary return (22mm)
10. Primary flow (22mm))
Component kit supplied separately
A. Combination inlet group incorporating
pressure reducing valve, strainer, check
valve, balance cold take off point, expansion
relief valve and expansion vessel connection
points.
B. Potable expansion vessels c/w flexible hose
and wall bracket
C. Tundish
D. Dual control thermostat and combined
overheat thermostat
E. Two port (22mm) zone valve for
primary circuit
F. Wiring junction box for primary system
1
2
3
4
7
5
6
9
8
10
Typical arrangement of component kit shown fitted to the appliance for clarity
Pipework to be supplied and fitted by installer.

Page 9
DESIGN
SYSTEM DETAILS
7
9
3
11
6
12
12
1
2
8
4
5
10
Viessmann Vitocell 200-B Solar Cylinder
Basic Appliance
1. Hot water draw off (22mm) compression
2. Temperature & pressure relief valve 95°/6 bar
3. Hot water secondary return 22mm
(not fitted to smaller sizes, see table 1)
4. Immersion heater 1¾” BSP 3kW
5. 22mm cold supply
6. Dual control/Overheat stat pocket
7. Primary return (22mm)
8. Primary flow (22mm)
9. Dual control/Overheat stat pocket
10. Solar coil return to panel collector (22mm)
compression
11. Solar coil flow from panel (22mm) compression
12. Solar thermostat pocket
Component kit supplied separately
A. Combination inlet group incorporating
pressure reducing valve, strainer, check valve,
balance cold take off point, expansion relief
valve and expansion vessel connection points.
B. Potable expansion vessels c/w flexible hose
and wall bracket
C. Tundish
D. Dual control thermostat and combined
overheat thermostat (x2)
E. Two port (22mm) zone valve for
primary circuit
F. Wiring junction box for primary system
Typical arrangement of component kit shown fitted to the appliance for clarity
Pipework to be supplied and fitted by installer.

Page 10
INSTALLATION
INSTALLATION
General Design Considerations
The cupboard footprint needs to be at least
650mm square for units up to 300 litres and
730mm for 400 litre.
The base chosen for the cylinder should be
level and capable of supporting the weight of
the unit when full of water as shown in General
Data. The discharge pipework for the safety
valves must have a minimum fall of 1 : 200 from
the unit to a safe discharge point. All exposed
pipework should be insulated and the unit
should NOT be fixed in a location where the
contents could freeze.
The pipe connecting the boiler flow to the
appliance must not be less than 22mm
copper or equivalent.
Mains Water Supply
Existing properties with a 15mm supply will be
satisfactory provided the local mains pressure
is good, but should be confined to single
bathroom properties. For new properties where
simultaneous demand is required to more than
one bathroom or a bathroom and one or more
en-suites, the communication and service pipe
into the dwelling should be a minimum of
22mm (usually in the form of a 25mm MDPE
supply). The minimum recommended static
pressure to operate a Viessmann Vitocell 200
Cylinder domestic system is 3 bar. There should
be a flow of at least 30 litres per minute or above
available into the property. Normally Viessmann
Vitocell 200 Cylinder provides well in excess of
40 litres/min in most conditions. Flow rates
for ALL mains pressure systems are subject
to district pressures and system dynamic loss.
Particularly on larger properties with more
than one bathroom, the pipe sizes should be
calculated in accordance with BS6700.
Model Selection
Where selecting a solar model, it is important to
check the dedicated solar volume (shown in tables 1
& 2) is suitable for the total floor area of the dwelling
to ensure compliance with Building Regulations. The
maximum floor area of the dwelling permitted for
the models is shown opposite.
The suggested model sizes are based on
typical hot water usage. For high specification
dwellings an increase of one model size should
be considered.
If two Viessmann Vitocell 200 Cylinders are coupled together the secondary inlet and
outlet pipes must be balanced. The units must be fitted on the same level.
Note: No valves must be fitted between the expansion vessel and the storage
cylinder(s).
I.V.
Combination Valve
I.V.
Model Selection Guide
Max hot water demand
Max number
of bed spaces
(Bedrooms)
Litres
1 shower room Bedsit (0) 90
1 bathroom 2 (2) 120
1 bathroom 4 (3) 120
1 bathroom + separate shower room 6 (4) 150
1 bathroom + 2 separate shower rooms or 2
bathrooms 7 (5) 180
2 bathrooms + separate shower room 7 (5) 210
2 bathrooms + 2 separate shower rooms 7 (5) 250
3 bathrooms + 2 separate showers rooms 9 (6) 300
Solar Model Selection Guide
Max hot water demand Max floor
area (m2)Bedrooms Litres
1 bathroom + 1 shower room 66 1-3 210
1 bathroom + 2 shower rooms 84 2-4 250
2 bathrooms + 1 shower room 113 3-4 300

Page 11
INSTALLATION
INSTALLATION
General Restrictions
a. The highest hot or cold water draw off point should not exceed 10 metres above the
Pressure Reducing Valve.
b. An ascending spray type bidet or any other appliance with a Class 1 back-syphonage
risk requiring a type A air gap should not be used.
c. Viessmann Vitocell 200 Cylinder should not be used where steam is the primary
heating medium, or in a situation where maintenance is likely to be neglected.
d. Unvented cylinders are not suitable for use with solid fuel boilers.
e. If the supply to the mixer fittings (other than a dual outlet type) is not taken
from the balanced supply the system will become over pressurized and cause the
pressure relief valve to discharge. Over time this could also cause the premature
failure of the appliance itself which will not be covered by the warranty,
f. In larger properties with a number of bathrooms/en-suites and long pipe runs
we would recommend that the balanced cold supply is provided with its own
pressure reducing valve and is not taken from the balanced cold connection on the
combination valve. In this case it will also be necessary to fit a small expansion vessel
on the balanced cold water system to accommodate the pressure rise caused by the
increase in temperature of the balanced cold water.
g. Check the performance requirements of the terminal fittings with regard to flow/
pressure are suitable.
Shower Fittings
Aerated taps are recommended to prevent splashing. Any type of shower mixing valve
can be used as long as both the hot and cold supplies are mains fed. However, all
mains pressure systems are subject to dynamic changes particularly when other hot
and cold taps/showers are opened and closed, which will cause changes in the water
temperature at mixed water outlets such as showers. For this reason and because
these are now no more expensive than a manual shower we strongly recommend
the use of thermostatic showers with this appliance. These must be used in 3 storey
properties where the impact on pressure/temperature of opening another tap in the
system is greater than normal. The shower head provided must also be suitable for
mains pressure supplies.
Pipe Layout
In all mains pressure installations it is important
to remember that the incoming cold supply
must be shared between all terminal fittings. It
is important that a 22mm supply is brought to
the appliance and a 22mm take-off is continued
at least to the bath. If there are two baths, 28mm
pipework should be considered. One metre of
smaller diameter pipework, or flow restrictors,
should be provided on the final connection to
all outlets so as to balance the water available.
In any event the distribution pipework should
generally be in accordance with EN806:1.
Plastic Pipework
This appliance is suitable for use with
plastic pipework as long as the material
is recommended for the purpose by the
manufacturer and is installed fully in accordance
with their recommendations.
Secondary Hot Water Circulation
Some models are fitted with a secondary return
tapping as standard (see table 1 for details).
If fitted, an extra expansion vessel may be
necessary. A non-return valve MUST be FITTED
near the return connection. No valve or terminal
fitting should be installed between the non
return valve and the cylinder. (See schematic
arrangement on page 13.)
INCOMING COLD SUPPLY
M
DC
DC
DC
TO
EXTERNAL
TAP
SINK
WATER SOFTENER (IF NECESSARY)
WM or DWM
WHB W.C.
DC
DC
SH
DHW
WHB
WC BATH
SCV SCV
P&T
ERV/NRV
PRV
DCV
Note:
Cold supplies to single taps must be
taken from the mains cold water
system.
Cold supplies to mixer taps must be
taken from the balanced cold water
connection on the combination
valve.

Page 12
INSTALLATION
INSTALLATION
Typical Discharge Pipe Arrangement
15 mm
discharge
pipe
Expansion
relief
valve
Dotted line showing
alternative route with
single tundish being used
500 mm max.
P & T
Relief
Valve
300 mm
min.
22 mm metal pipe with continuous
fall up to 9m equivalent length (D2).
NOTES:
The discharge will consist of scalding
water and steam. Asphalt, roofing felt
and non-metallic rainwater goods may
be damaged by such discharges.
It is not acceptable to discharge straight
into a soil pipe.
Discharge below
fixed grating
Fixed
Grating
Trapped gully
Locations to be avoided when siting a discharge
pipe at high level:
1. The discharge pipe should not be located
above a pedestrian area, or above a window,
door, ventilator etc.
2. Subsequent freezing of the discharge
should not create a hazard to persons
about the building.
3. The adjacent structure should be impervious
to water at 80ºC. x= dia. of discharge
pipe
Pressure & Temperature/expansion Relief
Valve Pipework
The relief valve should be installed to discharge
in accordance with G3 of the Approved
Document of the Building Regulations and
should be piped to where it is visible, but will
not cause danger to persons or damage to
materials.
The following information is taken from
Approved Document G3 of the Building
Regulations and is provided to assist with
the design and installation of the discharge
pipework. However, the information is not
exhaustive and reference should always be
made to Approved Document G3 of the Building
Regulations. The final decision regarding any
arrangements rests with Building Control and
it is recommended that their advice is sought
if you have any concerns regarding this aspect
of the installation.
The two safety valves will only discharge
water under fault conditions. When operating
normally water will not be discharged.
The tundish should be vertical, located in the
same space as the unvented hot water storage
system and be fitted as close as possible and
within 500mm of the safety device e.g. the
temperature relief valve.
The discharge pipe (D2) from the tundish should
terminate in a safe place where there is no risk
to persons in the vicinity of the discharge, be
of metal and:
a) Be at least one pipe size larger than the
nominal outlet size of the safety device unless
its total equivalent hydraulic resistance
exceeds that of a straight pipe 9m long
i.e. discharge pipes between 9m and 18m
equivalent resistance length should be at
least two sizes larger than the nominal outlet
size of the safety device, between 18 and
27m at least 3 sizes larger, and so on. Bends
must be taken into account in calculating
the flow resistance. Refer to the table and
the worked example.
An alternative approach for sizing
discharge pipes would be to follow BS6700
Specification for design installation, testing
and maintenance of services supplying water
for domestic use within buildings and their
curtilages.
b) Have a vertical section of pipe at least
300mm long, below the tundish before any
elbows or bends in the pipe work.
c) Be installed with a continuous fall.
WORKED EXAMPLE
The example below is for G1/2 temperature relief valve with a discharge pipe (D2)
having 4 elbows and length of 7m from the tundish to the point of discharge.
From the table below:
Maximum resistance allowed for a straight length of 22mm copper discharge pipe
(D2) from a G1/2 temperature relief valve is: 9m subtract the resistance for 4 x 22mm
elbows at 0.8m each = 3.2m.
Therefore the maximum permitted length equates to: 5.8m.
5.8m is less than the actual length of 7m therefore calculate the next largest size.
Maximum resistance allowed for a straight length of 28mm pipe (D2) from a G1/2
temperature relief valve equates to: 14m.
As the actual length is 7m, a 28mm (D2) copper pipe will be satisfactory.
Sizing of copper discharge pipe ‘D2’ for a temperature relief valve
with a G1/2 outlet size (as supplied)
Size of discharge
pipework
Maximum length of
straight pipe
(no bends or elbows)
Deduct the figure below
from the maximum
length for each bend or
elbow in the discharge
pipe
22mm Up to 9m 0.8m
28mm Up to 18m 1m
35mm Up to 27m 1.4m

Page 13
INSTALLATION
INSTALLATION
d) It is preferable for the discharge to be visible at both the tundish and the final point
of discharge but where this is not possible or practically difficult there should be
clear visibility at one or other of these locations. Examples of acceptable discharge
arrangements are:
1. Ideally below the fixed grating and above the water seal in a trapped gulley.
2. Downward discharges at a low level; i.e. up to 100mm above external surfaces
such as car parks, hard standings, grassed areas etc are acceptable providing
that where children play or otherwise come into contact with discharges, a
wire cage or similar guard is positioned to prevent contact whilst maintaining
visibility.
3. Discharges at a high level; e.g. into metal hopper and metal down pipe with the
end of the discharge pipe clearly visible (tundish visible or not) or onto a roof
capable of withstanding high temperature discharges of water and 3m from
any plastic guttering systems that would collect such discharges.
4. Where a single pipe serves a number of discharges, such as in blocks of flats,
the number served should be limited to not more than 6 systems so that any
installation can be traced reasonably easily. The single common discharge pipe
should be at least one pipe size larger than the largest individual discharge pipe
to be connected. If unvented hot water storage systems are installed where
discharges form safety devices may not be apparent i.e. in dwellings occupied by
blind, infirm or disabled people, consideration should be given to the installation
of an electronically operated device to warn when discharge takes place.
Safety
The safety devices supplied or fitted on an Viessmann Vitocell 200 Cylinder are selected
for their suitability for the temperatures and pressures involved. They must not be
changed, removed or by-passed and it is essential that only genuine replacement parts
supplied or approved by Viessmann Limited are used. This includes the immersion
heaters, which must incorporate an energy cut-out. All parts are available to approved
installers from Viessmann Limited.
Combination Inlet Group
Combines elements 1, 2 and 3 below.
1. Pressure Reducing Valve - This must be fixed
near the cylinder. The cold water supply to
any mixer taps/showers must be taken from
the cold water tapping of this valve to ensure
balanced hot and cold pressures. This valve
is factory set to ensure the correct operating
pressure for the Viessmann Vitocell 200
Cylinder.
2. Non Return Valve - This is integral with the
pressure reducing valve to prevent backflow
of hot water towards cold water draw off
points.
3. Cold Water Expansion Relief Valve - This safety
device is preset at the factory and will relieve
excess cold water pressure resulting from a
fault condition.
P&T Relief Valve
Tundish
Hot Outlet
To Drain
PRV
ERV NRV
Stop
Tap
Kitchen
Cold
Tap Combination
Valve
Balanced
Cold
Outlets
Immersion Heater
Expansion
Vessel
Boiler
Return
Boiler
Flow
2 Port Valve
Secondary
Return Circuit
Schematic Diagram
Non Return
Valve
Pump

Page 14
INSTALLATION
INSTALLATION
Safety
Cut-out
Thermostat
Immersion Heater Wiring
E
L
N
Temperature/Pressure Relief Valve
This safety device is also pre-set at the factory and relieves before the temperature
reaches 100°C. It is also a Pressure Relief Valve, and is pre-set to 6 bar.
Immersion Heaters
These are 3kW 240V AC heaters and incorporate a thermostat and a manually reset
energy cut-out which operates at 80°C. They have incalloy elements to prolong their
life expectancy in aggressive water conditions.
Please refer to table 1 to clarify how many off peak and on peak immersions are
included with the unit you require.
Where it is intended that units are fitted to offpeak circuits, then suitable controllers
such as the Horstmann off peak electric time controller will be required. External
wiring to the immersion heaters must be in accordance with the relevant IEE Wiring
Regulations and the circuit must be protected by a suitable fuse and a double pole
isolating switch.
The correct method of terminating the wiring to the immersion heater is shown
opposite.
Line Strainer
This is integral within the combination inlet group to reduce the likelihood of
contaminants fouling the valve seat. Following installation this line strainer must be
cleaned and replaced. This needs to be carried out on a regular basis. as part of the
annual maintenance/service check.
Tundish
This is to allow the discharge from any Relief Valve to be seen. It must be fitted away
from any electrical devices. See page 12 for discharge pipework details.
Safety
The immersion heaters must be earthed and they must be isolated from the mains
before the cover is removed on every occasion. Replacement immersion heaters
should be obtained from Viessmann Limited.
Control/Overheat Dual Thermostats
Care must be taken to ensure that the solar probes are fully inserted into the pockets
provided.

Page 15
INSTALLATION
INSTALLATION
Heating/primary Systems
The boiler and primary/heating systems should be
sized and installed in accordance with BS 5449.
Safety
Viessmann Vitocell 200 Cylinder is fitted with a
Combined Temperature/Pressure Relief Valve to
cope with any increase in system temperature
and pressure above the design limitations,
when used with boilers up to 45kW output,
which is the maximum allowed by section G3
of the Building Regulations. The primary water
temperatures should be controlled as outlined
below.
Primary Circuit
It is essential that the circuit between the boiler and
the Viessmann Vitocell 200 Cylinder is pumped.
The motorised zone valve supplied should be
fitted adjacent to the unit and controlled by the
cylinder thermostat supplied. The thermostat and
motorised valve must be wired so that they both
switch off should an overheat situation develop.
It is important to follow the wiring diagram in the
Wiring Section of these instructions.
Sealed Primary Circuit
Any boiler used must be fitted with an over
temperature cut-out. Unvented primary circuits
may be filled or replenished by means of a
temporary connection between the circuit and
a supply pipe provided a ‘Listed’ double check
valve or some other no less effective backflow
prevention device is permanently connected
at the inlet to the circuit and the temporary
connection is removed after use. Alternatively,
a CA device can be used, which will allow the
system to be permanently connected to the
cold mains supply. The primary system can
then be topped up, when required, in the same
way as an open vented system fitted with an
F&E Cistern.
4-Pipe System
If the Vitocell 200 is installed with a Viessmann
Vitodens condensing system boiler then it is
recommended to install the system to a 4-pipe
system as shown in the diagram opposite.
The Viessmann Vitodens system boilers are
operating on sealed primary circuit and are
factory fitted with an integral diverter valve,
PRV and expansion vessel and suitable energy
cut-out device to comply with G3 requirements.
If any Vitodens system boiler is installed with a
Vitocell 200, an additional DHW cylinder sensor
kit (7179 114) is required.
Schematic Open Vented Primary System
Boiler
Pump
150mm max.
Warming/Overflow
Pipe
F & E Cistern
Minimum
distance as
required by
boiler
manufacturers
instructions
Motorised Valve
Motorised Valve
(Energy cut-out)
Schematic Sealed Primary System
Boiler
Motorised Valve
Motorised Valve
(Energy cut-out)
Expansion
Vessel
Gauge
Safety Valve
Pump
Viessmann 4-pipe System
Boiler
Note
Energy cutout devices fitted
in the Viessmann boiler

Page 16
Schematic Solar System With Viessmann Boiler As Solar Controller
Solar Pumping Station
Solar Panel
Expansion
Vessel
Solar
Controller
Note
Energy cutout devices fitted
in the Viessmann boiler
INSTALLATION
INSTALLATION
A typical arrangement of a solar system
incorporating a Viessmann Vitocell 200-B Solar
Cylinder appliance is shown opposite.
All components in a solar primary system must
be marked or identifiable in such a way that
their design pressure and temperature can be
readily determined.
A safety device (pressure relief valve) to control
the risk of over-pressure in system components
should be fitted. A termination from a safety
pressure device should minimise the risk of
damage to persons or materials. Suitable
locations are a high temperature receptacle, in
internal gully or else issue externally at ground
level. High level termination from walls or on
roofs could cause injury to people or animals
below if the valve were to release scalding
water and steam.
The pipe leading to the safety device and the
collector should be of rigid and non-deformable
construction, without any possibility of
restriction or disclosure by any other fitted
component.
A more detailed diagram of our recommended
arrangement for a typical solar system is shown
on page 18.
The Viessmann solar controller ‘Solar Divicion’
complies with notes a, b and c listed below and
therefore a motorised valve is not required in
the solar circuit.
The solar pocket provided accommodates an
8mm diameter sensor which, with the sensor
located in the solar collector (or in the flow
pipe immediately adjacent to the collector),
will provide the information required by the
Vitosolic 100 controller.
Note:
The motorised valve can be omitted provided
that:
a) the solar collector is wholly above the
cylinder
b) the manual RESET high limit thermostat
acts directly onto the pump
c) check valves are present on both flow and
return to prevent gravity circulation
Solar systems designed and installed according
to Viessmann instructions will conform with
the above.

Page 17
INSTALLATION
INSTALLATION
Mixed HW out
Mains CW in
Figure 1: Cold port of the blending valve connected to mains supply
NOT ALLOWED
Mixed HW out
Mains CW in
Figure 3: Cold port of the blending valve connected to mains supply
to the vessel after the inlet control group
Mixed HW out
Mains CW in
Non-Return Valve (must be fitted)
Figure 2: Cold port of the blending valve connected to balanced cold
supply - NON-RETURN VALVE MUST BE FITTED
Fitting Blending Valves To The Unvented
Viessmann Vitocell Appliances
When fitting a blending valve to the unvented
appliances, it is important that the installation
does not contravene the G3, WRC and Health
and Safety directives or the manufacturers
recommendations. If this is the case, then
the warranty should be null & void. The key
requirements to comply with these regulations
are: -
1. Any fitting or material in contact with
potable water (e.g. a blending valve) must
be approved by WRC or an equivalent body.
2. Connections or wiring arrangements must
not bypass any safety devices.
3. Any expansion due to heating must not be
allowed to expand back into the cold mains.
4. The settings of any safety devices must not
be tampered with or adjusted.
The diagrams opposite shows how the
blending valve can be piped onsite.
Figure 1 shows the cold water port of the
blending valve connected to the mains cold
water supply before the inlet control group.
This arrangement is completely unacceptable
and illegal because: -
• the water is allowed to expand in to mains
cold water supply.
• the vessel will be charged to the incoming
mains supply which may be considerably
higher than the working pressure of the
vessel.
If this arrangement is used then the warranty
will not be valid.
Figure 2 shows the cold water port of the
blending valve connected to the balanced
cold water outlet. This arrangement will only
be acceptable if an approved non-return valve
is fitted, otherwise: -
• during the heating cycle, the water will
expand back into the mains supply, as the
regulating valve must not be relied upon
to act as a check valve under all operating
conditions.
• depending upon the characteristics of the
blending valve, hot water may also flow from
the balanced cold water taps.
Figure 3 shows the cold port of the blending
valve connected to the cold water supply to the
vessel after the inlet control group. This should
be the preferred method. It is recommended
that the installer should ensure that there is no
gravity circulation in the pipework connected to
the cold port. If necessary, this can be achieved
by fitting a non-return valve or using a thermal
trap.

Page 18
INSTALLATION
INSTALLATION
1 98765432 10
T
S1
S1
1 bar
Solar
Pumping
Station
Solar Coil
C1 2 C1
+ C
o
+ C
o
L N
230 VAC 5 amp
Mains Supply
Dual Thermostat
Viessmann
Vitocell 200-B
Solar Cylinder
TAnti Gravity
Check Valve
Pressure
Relief Valve
Anti Gravity
Check Valve
Standard 10 way
wiring junction box
(Not supplied)
No isolation valve
should be installed
between the solar
circuit and the safety
valve (pressure relief
valve)
Vitosolic 100 Type SD1
212019181716
LNR1NR2N
1514131211109654321
S1 S2 S3 PWM 145
Schematic Showing Solar Wiring Requirements

Page 19
INSTALLATION
INSTALLATION
1 98765432 10 11 12
N L 1 2 3 4
OFF ON OFF ON
HW CH
1 2 3 4
Room ThermostatCentral Heating Control
C12
C1
Dual Aqau Stat
Overheat Stat Control Stat
LNE
Mains Supply Fed Via Double Pole Isolator 230 VAC ~ 5 Amps
Danfoss WB12 Wiring Centre
HTG VALVE
HW VALVE
Typical schematic wiring diagram for an unvented installation
(not applicable for the Viessmann 4-pipe system)
The electrical installation must
comply with IEE requirements.
For electrical installation
refer to BS7671
Note: Do not attempt
the electrical work unless
you are competent to carry
out to the above standard
BlueBl BrownBr
Green Grey Green / Yellow
G Gr G/Y
WIRE COLOUR LEGEND
Black Orange Yellow White Red
B Or Y Wh R
Br Bl G/Y Br Br Bl G/Y Or
Gr
5 Amps
Br Bl G/Y Br Br B *Br Bl G/Y
Br
B
Bl Br Br Br
Br Bl B
G/Y G/Y Br *Br
* Blue core used from standard 3 core flex please ensure you use brown sleeving at both terminating ends to identify core potential.
3 core flex
4 core cable
L N
L
L_P
SL_B
E
N
N_P
E_P
Br Bl G/Y B Br Bl G/Y
Boiler Pump
ISSUE No : 3
APPROVED
DRN. DATE
23-09-09
S. Gatora
V4043A TWO PORT ZONE VALVE
AB
HTG
Br Bl G/Y OrGr
V4043A TWO PORT ZONE VALVE
AB
DHW
Br Bl G/Y Or Gr
GAS BOILER
Boiler Permanent Live
Boiler Neutral
Boiler Earth
Boiler Switch Live Demand
Boiler Controlled Pump
Provide extra core from terminal 12 to L-P connection on the boiler (shown dotted) and remove the boiler pump link if the boiler has an independant pump output.
LNE
(S-PLAN) WIRING DIAGRAM WITH TWO 2 PORT VALVES AND BOILER CONTROLLED PUMP OVERRUN OPTION
Br Bl G/Y
BBr
Or
ELECTRONICS

Page 20
INSTALLATION
COMMISSIONING
Commissioning
Connections can come loose in transit, and all should be checked before
installation.
Ensure that the immersion heater setting is 60°C and that the wiring is in accordance
with the diagram.
Check the pressure on the air side of the expansion vessel = 3 bar. This must be done
when the volume in the cylinder is cold.
Check that the drain cock is closed, and open all the cold and hot water taps and other
terminal fittings. Allow the system to fill with water, and to run until there is no air left
in the system. Close the taps and inspect the system closely for leaks.
Manually open the Relief Valves one by one and check that water is discharged and
run freely through the tundish and out at the discharge point. The pipework should
accept full bore discharge without overflowing at the tundish, and the valve should
seat satisfactorily.
Allow the cylinder to heat to normal working temperature, then thoroughly flush the
domestic hot and cold water pipework through each tap.
NOTE: If this appliance is to be installed in other than a single domestic dwelling ie.
in an apartment block or student flats etc., the hot and cold water system will need
to be disinfected in accordance with BS6700 and the Water Regulations.
Because the Viessmann appliance is stainless steel, the use of chlorine as the
disinfection agent can cause damage unless the appliance is adequately flushed
and refilled with the mains water immediately on completion of the disinfection
procedure. Damage caused through a failure to do this adequately will not be covered
by the warranty.
For the above reasons we recommend the use of a non chlorine dased disinfectant
such as Fernox LP Sterox as manufactured by Cookson Electronics when carrying out
disinfection of systems incorporating these appliances.
Remove the filter from the combination inlet group clean and replace. Refill the system
and open all hot taps until there is no air in the pipe work. ENSURE CYLINDER IS
DRAINED PRIOR TO CHECKING OR REMOVING FILTER FROM THE COMBINATION
INLET GROUP.
IMPORTANT - DRAIN DOWN PROCEDURE
1 Switch off both the boiler and the immersion heater
2 Open the nearest hot tap and run all hot water until cold
3 Close the incoming cold main at the stop tap
4 Hold open the pressure and temperature relief valve until water stops
discharging into the tundish
5 Open all the taps in the property
6 Open the drain cock and immediately hold open the pressure and
temperature relief valve again until the cylinder is empty
Allow the cylinder to heat to normal working
temperature with whatever heat source is to
be used, and check again for leaks. The Pressure
Relief Valve should not operate during the
heating cycle.
The boiler/heating systems should be filled
and commissioned in accordance with good
practice following the guidance in BS 5449/the
boiler manufacturers instructions.
NOTE: This appliance is covered by BENCHMARK
and the log book must be completed after
commissioning and after every maintenance/
service visit.