Viessmann VITOCELL 100-B Operating instructions

Service instructions
for contractors
VIESMANN
Vitocell 100-B
Type CVBA
Dual mode DHW cylinder with Solar-Divicon
Vitocell 100-W
Type CVBA
Dual mode DHW cylinder with Solar-Divicon
For applicability, see the last page
VITOCELL 100-B
VITOCELL 100-W
5773 800 GB 9/2013 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■ Work on gas installations must only be
carried out by a registered gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental protection
■ The Code of Practice of relevant trade
associations
■ All current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW-TR Gas,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI,
SWKI, VKF and EKAS guideline
1942: LPG, part 2
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Do not smoke. Prevent naked
flames and sparks. Do not
switch lights or electrical appli-
ances on or off.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Evacuate any people from the
danger zone.
■ Notify your gas or electricity
supplier and your local heating
contractor from outside the
building.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
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If you smell flue gas
Danger
Flue gas can lead to life threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the installation site.
■ Close all doors in the living
space.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems,
or an insufficient supply of com-
bustion air can cause life threat-
ening poisoning from carbon
monoxide in the flue gas.
Ensure the flue system is in
proper working order. Apertures
for supplying combustion air
must be non-closable.
Extractors
Operating appliances that extract air to
the outside (cooker hoods, extractors, air
conditioning units, etc.) can create neg-
ative pressure. If the boiler is operated at
the same time, this can lead to reverse
flow of the flue gas.
Danger
The simultaneous operation of
the boiler and appliances that
extract air to the outside can
result in life threatening poison-
ing due to reverse flow of the flue
gas.
Fit an interlock circuit or take suit-
able steps to ensure a sufficient
supply of combustion air.
Working on the system
■ Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■ Isolate the system from the power sup-
ply (e.g. by removing the separate fuse
or by means of a mains isolator) and
check that it is no longer 'live'.
■ Safeguard the system against recon-
nection.
Danger
Hot surfaces can cause burns.
■ Before maintenance or service
work, switch OFF the appli-
ance and let it cool down.
■ Never touch hot surfaces on
the boiler, burner, flue system
or pipework.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Safety instructions
Safety instructions (cont.)
5773 800 GB

4
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of the sys-
tem.
Faulty components must be
replaced with original Viessmann
spare parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate the
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5773 800 GB

5
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 7
Further details regarding the individual steps....................................................... 8
Parts lists
Ordering parts...................................................................................................... 15
With solar control module, type SM1.................................................................... 15
Ordering parts...................................................................................................... 17
With solar control module, type SM1.................................................................... 17
Ordering parts...................................................................................................... 19
With Vitosolic 100, type SD1................................................................................ 19
Ordering parts...................................................................................................... 21
With Vitosolic 100, type SD1................................................................................ 21
Commissioning/service reports........................................................................ 23
Specification....................................................................................................... 24
Certificates
Declaration of conformity...................................................................................... 26
Index
Index
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6
The appliance is only intended to be
installed and operated in sealed unven-
ted systems that comply with EN 12828 /
DIN 1988, or solar thermal systems that
comply with EN 12977, with due atten-
tion paid to the associated installation,
service and operating instructions. DHW
cylinders are only designed to store and
heat water of potable water quality. Heat-
ing water buffer cylinders are only
designed to hold fill water of potable
water quality. Only operate solar collec-
tors with the heat transfer medium
approved by the manufacturer.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than heating the building or
DHW shall be deemed inappropriate.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability.
Incorrect usage also occurs if the com-
ponents in the system are modified from
their intended use (e.g. through direct
DHW heating in the collector).
Adhere to statutory regulations, espe-
cially concerning the hygiene of potable
water.
Intended use
5773 800 GB

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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Operating principles....................................................... 8
•2. Filling the DHW cylinder................................................ 8
• • 3. Inspection and maintenance......................................... 9
• • 4. Shutting down the system
• • 5. Checking the function of safety valves
• • 6. Testing the anode earth current with an anode tester 9
• • 7. Cleaning the inside of the DHW cylinder...................... 9
• • 8. Checking and replacing the magnesium anode (if
required).......................................................................... 12
• • 9. Restarting the DHW cylinder......................................... 13
• • 10. Checking connections on the water side for tightness
•11. Replacing the Vitosolic 100/solar control module....... 13
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5773 800 GB

8
Operating principles
Ball valve positions
Ball valve in the solar heating water flow
and in the solar heating water return
inside the Solar-Divicon:
■ In line with the pipe run:
– Open
■ Perpendicular to the pipe run:
– Closed
■ At 45° angle to the pipe run:
– Check valve open
– The 45° angle (towards the right or
left) is only required for filling and
draining the system.
Vitosol service instructions
Venting the solar heating water flow
(HVs)
Vent at the air vent valve on the air
trap.
Setting the flow rate on the solar side
In the case of a 3-stage solar circuit
pump: Adjust via the flow meter at the
solar heating water return.
In the case of a high efficiency solar cir-
cuit pump: Fully open the ball valve of the
flow meter. The flow rate is regulated
electronically.
Flushing and filling
Use the fill valve on the solar heating
water return.
Note
Optional connection of a manual solar fill
pump (solar thermal accessories) 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 pressur-
ised, retighten the flange cover with a
torque of 25 Nm.
2. Check the fittings on the heating
water and DHW sides for tightness
and retighten if required.
3. Check the function of the safety
valves according to the manufactur-
er's instructions.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5773 800 GB

9
Inspection and maintenance
DIN 1988 requires a visual inspection
and (if necessary) cleaning no later than
two years after the cylinder has been
commissioned, and thereafter according
to requirements.
Note
In addition, we recommend an annual
visual inspection of the magnesium
anode (see page 12).
Testing the anode earth current with an anode tester
B
A
DC
1. Remove cover A and flange insula-
tion B.
2. Pull earth cable C off tab D.
3. Connect tester in series between
earth cable C and tab D.
■ The anode is OK if the current
measures > 0.3 mA.
■ If the current measures < 0.3 mA or
if there is no current at all, the
anode must be visually inspected
(see page 12).
Cleaning the inside of the DHW cylinder
Danger
Unchecked leakage of DHW or
heating water can result in scald-
ing and structural damage.
Only open the DHW and heating
water connections after the DHW
cylinder has been depressur-
ised.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5773 800 GB

10
D
7x
1x
A
B
E
1. Drain the DHW cylinder from the
DHW side.
!Please note
Material losses may result
from draining with a vacuum
pump when the air vent valve
is closed.
Open the air vent valve during
draining.
2. Remove cover A, flange insulation
B and flange cover E.
3. Disconnect the DHW cylinder from
the pipework to prevent cleaning
agents and contaminants entering
the pipe system.
4. Remove loose deposits with a high
pressure cleaner.
!Please note
Pointed or sharp cleaning
equipment will damage the
cylinder interior.
Only use plastic tools to clean
the inside.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5773 800 GB

11
5. Use a chemical cleaning agent to
remove hard deposits that cannot be
removed with a high pressure
cleaner.
!Please note
Cleaning agents containing
hydrochloric acid attack the
material of the DHW cylinder.
Never use such cleaning
agents.
Danger
Cleaning agent residues can
result in poisoning.
Always observe the informa-
tion provided by the cleaning
agent manufacturer.
6. Fully drain any cleaning agent.
7. Flush the DHW cylinder thoroughly
after cleaning.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5773 800 GB

12
Checking and replacing the magnesium anode (if required)
F
Check magnesium anode F.
If the magnesium anode has degraded
to 710−15 mm, we recommend replac-
ing it.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5773 800 GB

13
Restarting the DHW cylinder
G
A
B
E
7x
1x
DC
1. Reconnect the DHW cylinder to the
pipework.
2. Insert new gasket G under flange
cover E.
3. Mount flange cover E with earth
cable C and tighten the screws with
a maximum torque of 25 Nm.
4. Push earth cable C onto tab D.
5. Fill the DHW cylinder from the DHW
side, then retighten flange cover E
with a torque of 25 Nm.
6. Mount flange insulation B and cover
A.
Replacing the Vitosolic 100/solar control module
1. Remove thermal insulation towards
the front.
2. Remove the Vitosolic 100 towards
the front
or
remove the solar control module by
pulling it forward.
3. Open the control unit casing and dis-
connect the cables/leads.
Vitosolic 100/solar control
module installation and serv-
ice instructions
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5773 800 GB

14
4. Install the new control unit in reverse
order.
5. Adjust the Vitosolic 100 to suit the
respective pump.
Vitosolic 100/solar control
module installation and serv-
ice instructions
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5773 800 GB

15
The following information is required:
■ Serial no. (see type plate)
■ Position number of the part from this
parts list
Standard parts are available from your
local supplier.
With solar control module, type SM1
Version with standard pump
0001 Adjustable foot
0002 Outer jacket
0003 Type plate
0004 Edge profile fastener, internal
0005 Edge profile fastener, external
0006 Fixing part
0007 Insulating parts
0009 Gasket set G 1
0010 U-tube, solar flow
0011 Air vent plug
0012 Locking ring fitting
0013 Sheet metal retainer
0015 Solar circuit pump
0016 Safety assembly
0017 Flow meter
0018 Ball valve, solar return
0019 Ball valve handle, blue
0020 Gasket 21 x 30 x 2
0021 Seal ring R ½, mixer
0022 Strain relief
0023 KM BUS cable l = 4500 mm
0024 Solar return elbow
0025 Solar control module, type SM1
0026 Connection line
0027 Solar circuit pump connecting
cable
0028 Power cable l = 4500 mm
0030 Temperature sensor NTC
0031 Top panel
0032 Adaptor lead, collector tempera-
ture sensor
0033 Flange insulation
0034 Anode flange
0035 Cast rod anode
0036 Gasket
0037 Sensor retainer
0038 Plug
0039 Solar expansion vessel 18 l,
10 bar
0040 Cover G 2
0041 Connecting elements
0042 Bracket
0043 Vitocell 100 logo
0044 Viessmann logo
0045 Pressure gauge
0046 Solar control module, type SM1
installation and service instruc-
tions
0047 Vitocell 100 service instructions
0048 Vitocell 100 installation instruc-
tions
Parts lists
Ordering parts
5773 800 GB

16
0033
0010
0011
0019
0018
0045
0043
0030
0032
0028
0023
0027
0024
0017
0013
0039
0046 0047 0048
0042
0026
0005
0004
0003
0002
0038
0040
0037
0001
00060021
0015
0022
0009
0012
0025
0034
0036
0035
0036
0044
0004
0005
0043
0016
0007
0007
0035
0044
0031
0041
0020
0048
Parts lists
With solar control module, type SM1 (cont.)
5773 800 GB

17
The following information is required:
■ Serial no. (see type plate)
■ Position number of the part from this
parts list
Standard parts are available from your
local supplier.
With solar control module, type SM1
Version with high efficiency pump
0001 Adjustable foot
0002 Outer jacket
0003 Type plate
0004 Edge profile fastener, internal
0005 Edge profile fastener, external
0006 Fixing part
0007 Insulating parts
0009 Gasket set G 1
0010 U-tube, solar flow
0011 Air vent plug
0012 Locking ring fitting
0013 Sheet metal retainer
0014 Plug set, 230 V
0015 Solar circuit pump
0016 Safety assembly
0017 Flow meter
0018 Ball valve, solar return
0019 Ball valve handle, blue
0020 Gasket 21 x 30 x 2
0021 Seal ring R ½, mixer
0022 Strain relief
0023 KM BUS cable l = 4500 mm
0024 Solar return elbow
0025 Solar control module, type SM1
0026 Connection line
0027 Solar circuit pump connecting
cable
0028 Power cable l = 4500 mm
0030 Temperature sensor NTC
0031 Top panel
0032 Adaptor lead, collector tempera-
ture sensor
0033 Flange insulation
0034 Anode flange
0035 Cast rod anode
0036 Gasket
0037 Sensor retainer
0038 Plug
0039 Solar expansion vessel 18 l,
10 bar
0040 Cover G 2
0041 Connecting elements
0042 Bracket
0043 Vitocell 100 logo
0044 Viessmann logo
0045 Pressure gauge
0046 Solar control module, type SM1
installation and service instruc-
tions
0047 Vitocell 100 service instructions
0048 Vitocell 100 installation instruc-
tions
0049 Plug set, LV
0050 Solar circuit pump connecting
cable
Parts lists
Ordering parts
5773 800 GB

18
0001
0018
0020
0015
00220025
0041
0035
0031
0021
0013
00160024
0017
0007
0007
0050
0014
0049
0004
0005
0043
0044
0035
0036
0036
0034
0012
0009
0006
0037
0040
0038
0002
0003
0004
0005
0026
0042
004800470046
0039
0027
0023
0028
0032
0030
0043
0044
0045
0019
0011
0010
0033
Parts lists
With solar control module, type SM1 (cont.)
5773 800 GB

19
The following information is required:
■ Serial no. (see type plate)
■ Position number of the part from this
parts list
Standard parts are available from your
local supplier.
With Vitosolic 100, type SD1
Version with standard pump
0001 Adjustable foot
0002 Outer jacket
0003 Type plate
0004 Edge profile fastener, internal
0005 Edge profile fastener, external
0006 Fixing part
0007 Insulating parts
0009 Gasket set G 1
0010 U-tube, solar flow
0011 Air vent plug
0012 Locking ring fitting
0013 Pressure gauge
0015 Solar circuit pump
0016 Safety assembly
0017 Flow meter
0018 Ball valve, solar return
0019 Ball valve handle, blue
0020 Gasket 21 x 30 x 2
0021 Seal ring R ½, mixer
0022 Strain relief
0024 Solar return elbow
0025 Vitosolic 100, type SD1
0026 Fixing part
0027 Solar circuit pump connecting
cable
0028 Power cable l = 4500 mm
0029 Temperature sensor NTC
0030 Top panel
0031 Adaptor lead, collector tempera-
ture sensor
0032 Flange insulation
0033 Anode flange
0034 Cast rod anode
0035 Gasket
0036 Sensor retainer
0037 Plug
0038 Solar expansion vessel 18 l,
10 bar
0039 Cover G 2
0040 Connecting elements
0041 Bracket
0042 Connection line
0043 Sheet metal retainer
0044 Viessmann logo
0045 Vitocell 100 logo
0046 Vitocell 100 installation instruc-
tions
0047 Vitosolic 100, type SD1 installa-
tion and service instructions
0048 Vitocell 100 service instructions
0049 Vitosolic 100, type SD1 operating
instructions
Parts lists
Ordering parts
5773 800 GB

20
0016
0003
0020
0040
0034
0044
0030
0042
0025
0007
0007
0013
0012 0004
0005
0045
0044
0035
0034
0026
0009 0007
0043
0039
0038
0002
0021
0027
0031
0015
0011
0006
0017
0010
0018
0019
0037
00240022
0028
0029
0001
0048
0049
0046
0047
0041
0036
0004
0005
0035
0033
0032
0045
Parts lists
With Vitosolic 100, type SD1 (cont.)
5773 800 GB