Viessmann VITOCELL 100-B Operating instructions

Service instructions
for contractors
VIESMANN
Vitocell 100-B
Vitocell 100-W
Type CVB
Dual mode DHW cylinder
300 to 500 l
For applicability, see the last page
VITOCELL 100-B
VITOCELL 100-W
5605 803 GB 6/2014 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 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:
■ National installation regulations
■ 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, VDE and
all locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI and SWKI
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).
Safety instructions
Safety instructions
5605 803 GB

3
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
■ 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.
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.
Safety instructions
Safety instructions (cont.)
5605 803 GB

4
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.)
5605 803 GB

5
Intended use....................................................................................................... 6
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 7
Further details regarding the individual steps....................................................... 8
Parts lists
Parts lists, 300 l.................................................................................................... 12
Parts lists 400 l and 500 l..................................................................................... 16
Commissioning/service reports........................................................................ 24
Product characteristics..................................................................................... 25
Accessories
Accessory specification........................................................................................ 26
Certificates
Declaration of conformity...................................................................................... 27
Index
Index
5605 803 GB

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
Intended use
5605 803 GB

7
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the DHW cylinder.................................................. 8
• • 2. Inspection and maintenance........................................... 8
• • 3. Shutting down the system
• • 4. Checking the function of safety valves
• • 5. Testing the anode earth current with an anode tester.. 9
• • 6. Cleaning the inside of DHW cylinders............................ 10
• • 7. Checking and replacing the magnesium anode............ 11
• • 8. Returning the DHW cylinder to use................................ 11
• • 9. Checking connections on the water side for tightness
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5605 803 GB

8
Filling the DHW cylinder
1. Fill the DHW cylinder from the DHW
side.
Note
Once 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 side and at the
immersion heater (if installed) for
tightness. Retighten fittings if
required.
3. Check the function of the safety
valves according to the manufactur-
er's instructions.
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
We additionally recommend that the
magnesium anode function is checked
annually. This function check can be
made without interrupting operation, by
measuring the earth current with an
anode tester (see page 9).
Commissioning, inspection, maintenance
Further details regarding the individual steps
5605 803 GB

9
Testing the anode earth current with an anode tester
B
A
DC
1. Remove cover A and flange insula-
tion or thermal insulation mat B.
2. Remove the thermometer sensor (if
fitted).
3. Pull earth cable C off tab D.
4. Connect tester in series between
earth cable C and tab D.
■ Current > 0.3 mA detectable: Mag-
nesium anode OK
■ Current < 0.3 mA or no current
detectable: inspect the magnesium
anode visually (see page 11).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5605 803 GB

10
Cleaning the inside of DHW cylinders
C
C
1x 7x
8x
A B
1. Drain the DHW cylinder from the
DHW side.
2. Remove cover A, thermal insulation
mat B and flange cover C.
Note
The cylinder can be cleaned via the
upper or the lower flanged aperture.
3. Disconnect the DHW cylinder from
the pipework to prevent cleaning
agent and contaminants from enter-
ing the pipework.
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.
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.)
5605 803 GB

11
Checking and replacing the magnesium anode
Check the magnesium anode.
If the diameter of the magnesium anode
is ≤ 10-15 mm, we recommend replacing
it.
Note
A chain anode is available as an acces-
sory for tight spaces.
Returning the DHW cylinder to use
8x
2x
EB F
B
A
A
E
G
1x
7x
DC
1. Reconnect the DHW cylinder to the
pipework.
2. Insert new gaskets A underneath
flange covers B.
3. Mount the upper flange cover with
earth cable C and the lower flange
cover. Tighten the screws with a max-
imum torque of 25 Nm.
4. Push earth cable C onto tab D.
5. Fill the DHW cylinder from the DHW
side. Retighten the flange cover with
a maximum torque of 25 Nm.
6. Fit the thermometer sensor (if instal-
led).
7. Fit flange insulation or thermal insu-
lation mats E, cover F and cover
G.
Note
DHW cylinder 300 l: Route the ther-
mometer lead through the groove in
the flange insulation.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5605 803 GB

12
Overview of the assemblies
B
C
A
AType plate
BCylinder assembly incl. thermal
insulation
CAccessory flange assembly
Cylinder assembly incl. thermal insulation
Pos. Component Serial no.
7498989 7498998
Part no.
0001 Adjustable foot 7818798 7818798
0002 Sensor retainer 7819654 7819654
Parts lists
Parts lists, 300 l
5605 803 GB

13
Pos. Component Serial no.
7498989 7498998
Part no.
0003 Vitocell 100 type plate 5603690 5603699
0004 Gasket 7819647 7819647
0005 Anode flange with gasket 7823194 7823194
0006 Clamping bracket 7818061 7818061
0007 Magnesium anode d = 40 x 520/490 7823192 7823192
0008 Thermometer cover 7820231 7823198
0009 Thermometer 30 -120 °C 7819509 7819509
0010 Vitocell 100 logo 7818348 7818348
0011 Flange insulation 7823572 7823572
0012 Top panel 7817804 7822689
0013 Sensor well for thermometer 7819676 7819676
0014 Elbow 7810494 7810494
0015 Blank flange with gasket 7817821 7817821
0016 HoriCell thermal insulation mat 7811311 7811311
0017 Cover 7819515 7823057
0018 Plug 7819664 7819664
0019 Cover 7819414 7823056
0020 Locating ferrule 7818522 7818522
0021 Vitocell 100-B/-W CVB installation instructions 5603864 5603864
0022 Vitocell 100-B/-W CVB service instructions 5603709 5603709
0023 Touch-up spray paint, 150 ml can 7819545 7822681
0024 Touch-up paint stick 7819546 7822682
0025 Vitocell 100 logo 7839781 7839784
0026 Viessmann logo 7839162 7839162
Parts lists
Parts lists, 300 l (cont.)
5605 803 GB

14
0004
0004
0007
0006
0004
0013
0008
0024
0023
0022
0021
0014
0002
0002
0003
0020
0001
0015
0016
0017
0018
0019
0009
0007
0004
0005
0006
0011
0012
0010
0026
0025
Parts lists
Parts lists, 300 l (cont.)
5605 803 GB

15
Accessory flange assembly 300 l
Pos. Component Part no.
0001 Gasket 7819647
0002 Flange 7248053
0003 Fascia 7265251
0004 Accessory flanges installation instructions 5603937
000100020003
0004
Parts lists
Parts lists, 300 l (cont.)
5605 803 GB

16
Overview of the assemblies
CB
D
A
AType plate
BCylinder assembly
CThermal insulation assembly
DAccessory flange assembly
Parts lists
Parts lists 400 l and 500 l
5605 803 GB

17
Cylinder assembly 400 and 500 l
Pos. Component Serial no.
7497190 7497192
Part no.
0001 Adjustable foot 7818798 7818798
0002 Sensor retainer 7819654 7819654
0003 Vitocell 100-B type plate 5601460 5601461
0004 Gasket 7819647 7819647
0005 Anode flange with gasket 7823539 7823195
0006 Clamping bracket 7818061 7818061
0007 Magnesium anode d=40 7823537 7823193
0008 Sensor well R ½ x 220 with retainer 7822257 7822257
0009 Elbow 7810494 7810494
0010 Blank flange with gasket 7817821 7817821
0011 Plug 7819664 7819664
0012 Vitocell 100-B/-W CVB installation instructions 5603864 5603864
0013 Vitocell 100-B/-W CVB service instructions 5603709 5603709
Parts lists
Parts lists 400 l and 500 l (cont.)
5605 803 GB

18
0013
0012
0008
0004
0007
0006
0004
0004
0007
0009
0002
0002
0003
0001
0004
0010
0011
0005
0006
Parts lists
Parts lists 400 l and 500 l (cont.)
5605 803 GB

19
Thermal insulation assembly 400 and 500 l
Thermal insulation assembly 400 l
Pos. Component Serial
no.
7497190
Part no.
0001 Clip fastening (6 pce) 7835643
0002 Thermal insulation jacket, right section 7836139
0003 Thermal insulation jacket, left section 7836140
0004 Thermal insulation mat, top 7836158
0005 Thermal insulation mat, bottom 7836165
0006 Cover 7836095
0007 Cover strip 7836075
0008 Thermometer cover (grey) 7820231
0009 Thermometer 30 -120 °C 7819509
0010 Viessmann logo 7819230
0011 Cover strip 7836084
0012 Pipe collar (3 pce) 7835767
0013 Flange cover 7836191
0014 Thermal insulation jacket, right section 7836198
0015 Thermal insulation jacket, left section 7836197
0016 Cover 7836098
0017 Thermometer cover 7823198
0018 Flange cover 7836192
0019 Cover with logo 7840352
Parts lists
Parts lists 400 l and 500 l (cont.)
5605 803 GB

20
0015
0017
0018
0013
0014
0016
0001
0001
0012
0003
0009
0008
0007
0006
0004
0005
0011
0002
0010
0019
0019
Parts lists
Parts lists 400 l and 500 l (cont.)
5605 803 GB