Viessmann VITOCELL 100-VH Manual

Installation, Operation
and Service Instructions
VITOCELL
r
100-VH/-BH
5603 408 v1.2 10/2012
Solar Water Heater Tanks
NCVA and NCVB Series
Read and save these instructions
for future reference.
IMPORTANT
CAUTION
The heat transfer medium must be
nontoxic water with Toxicity Class 1
as listed in “Clinical Toxicology
of Commercial Products,”
5th edition.
The heat transfer medium must
be limited to a maximum pressure
of 30 PSIG by an approved safety
or pressure relief valve.
Please file in Service Binder
Product may not be exactly as shown
Read and understand this manual
and the safety messages before
installing, operating and servicing
this water heater.
Failure to follow these instructions
and safety messages could result
in loss of life or serious injury.
This manual must remain with
water heater.

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Vitocell 100-VH/-BH Installation/Operation/Service
Explanation of Symbols
Introduction
Take note of all symbols and notations intended to draw attention to potential hazards or important product
information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below.
WARNING
Indicates an imminently hazardous situation which,
if not avoided, could result in loss of life, serious injury
or substantial product / property damage.
CAUTION
Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product/
property damage.
IMPORTANT
Indicates special advice.
Increasing the thermostat setting
(if applicable) above the preset
temperature may cause severe burns
and consume excessive energy.
Hotter water increases the risk of
scald injury.
WARNING
WARNING
Electric shock hazard indicates an
imminently hazardous situation which,
if not avoided, may result in loss of life,
serious injury or substantial product /
property damage.

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5603 408 v1.2
Vitocell 100-VH/-BH Installation/Operation/Service Table of Contents
Explanation of Symbols...............................................2
Safety.......................................................................4
Important Regulatory and Installation Requirements........5
General information..................................................5
Water treatment / filtration........................................5
Temperature control.................................................5
Anode rods.............................................................6
Temperature and pressure relief valve (T&P Valve)......6
Backflow preventer (closed loop system)....................6
Product information..................................................6
Installing the Tank.....................................................7
Locating the water heater / storage tank....................7
Insulation mounting..................................................8
Connections..............................................................9
Water connections...................................................9
Temperature and pressure relief valve (T&P)...............9
Other Connections....................................................10
Hydraulic connection..............................................10
Electric Heating Element............................................11
Heating element installation....................................11
Heating element wiring..........................................11
Installing the heating element..................................12
Heating element temperature settings......................13
Heating element replacement..................................13
General Operation.....................................................14
To fill the water heater / storage unit.......................14
To drain the water heater / storage unit....................14
Maintenance............................................................15
Anode rod............................................................15
Tank Connections.....................................................16
Repair and Service Parts............................................17
Parts list...............................................................18
Introduction
General Information
Installation
Operation
Service
Page

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5603 408 v1.2
Vitocell 100-VH/-BH Installation/Operation/Service
Safety
The warranty on this water heater/storage unit is in effect only when the water heater/ storage unit is installed and
operated in accordance with local codes and these instructions. The manufacturer of this water heater/storage unit
will not be liable for any damage resulting from failure to comply with these instructions. Read these instructions
thoroughly before starting.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause serious injury or property
damage. Refer to this manual. For assistance or
additional information, consult a qualified installer
or service agency.
CAUTION
The recommended temperature for normal residential
use is 120° F (49° C). The dial on the thermostat
does not always reflect the out coming water
temperature, which could occasionally exceed 120° F
(49° C). The variation in out coming temperature
could be based on factors including but not limited
to usage patterns and type of installation. Test your
water at the tap nearest to the water heater.
IMPORTANT
General Information
WARNING
Hotter water increases the risk of scald injury.
Before adjusting the water temperature setting,
read this instruction manual. Temperatures at which
injury occurs vary with the person’s age and the
length of exposure. The slower reaction time of
children, elderly, and physically or mentally challenged
persons increases the scalding hazard to them. It is
recommended that lower water temperatures be used
where these exposure hazards exist. Such households
may require a temperature setting less than 120° F
(49° C) to prevent accidental contact with hot water.
WARNING
Water heater blankets are not recommended and will
void the warranty.
This manual has been prepared to acquaint you
with the installation, operation and maintenance of
your water heater and to provide important safety
information.
When using electrical appliances, basic safety
precautions to reduce the risk of fire, electric shock
or injury to persons should be followed, including:
1. READ ALL INSTRUCTIONS BEFORE USING THIS
WATER HEATER.
2. This water heater must be grounded, when electric
elements are used. Connect only to properly
grounded outlet.
3. Install or locate this water heater only in accordance
with the provided installation instructions.
4. Use this water heater only for its intended use
as described in this manual.
5. Do not use an extension cord set with this water
heater. If no receptacle is available adjacent to the
water heater, contact a qualified electrician to have
one properly installed.
6. As with any appliance, close supervision is
necessary when used by children.
7. Do not operate this water heater if it has been
damaged or dropped.
8. This water heater should be serviced only by
qualified service personnel. Contact nearest
authorized service facility for examination, repair
or adjustment.
CAUTION
The heat transfer medium must be either potable water
or contain only substances which are recognized as safe
by the U.S. Food and Drug Administration and the heat
transfer medium must not be corrosive to ordinary steel.
The pressure of the heat transfer medium must be
maintained less than the normal minimum operating
pressure of the potable water system.
In solar applications:

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5603 408 v1.2
Vitocell 100-VH/-BH Installation/Operation/Service
Important Regulatory and Installation Requirements
General information
This water heater/storage unit must be installed in
accordance with local codes. In the absence of local
codes, install this water heater/storage unit in accordance
with the N.E.C. Reference Book (latest edition).
The warranty for this water heater/storage unit is in effect
only when the water heater/storage unit is installed,
adjusted, and operated in accordance with these
Installation and Operating Instructions. The manufacturer
will not be held liable for damage resulting from alteration
and/or failure to comply with these instructions.
This water heater/storage unit may be used independently
when equipped with a heating element or as a storage
unit when used in conjunction with an existing water
heater or boiler.
This water heater/storage unit has been designed and
certified for the purpose of heating potable water. The
installation and use of this water heater/storage unit for
any purpose other than the heating of potable water may
cause damage to the water heater/storage unit and create
a hazardous condition and nullify the warranty.
Do not use this appliance if any part has been submerged
in water. The plumbing professional responsible for the
installation of this water heater/storage unit should be
contacted to inspect the appliance and to replace and part
of the control system, including thermostat (if equipped),
which has been submerged in water.
For water heaters equipped with a heating element; make
sure that the rating plate on the water heater is referenced
for certainty that the correct voltage is being supplied to
the water heater.
A consumable anode is used to extend tank life. The
removal of this anode, for any reason, will nullify the
warranty. In areas where water is unusually active,
and/or may occur at the hot water faucet due to a
reaction between the consumable anode and impurities
in the water. If this should happen, an alternative anode
may be purchased from the supplier that installed this
water heater/storage unit. This alternative anode will
minimize the odor while protecting the tank. Additionally,
the water heater/storage unit should be flushed with
appropriate dissolvers to eliminate any bacteria.
Before proceeding, please inspect the water heater/
storage unit and it’s components for possible damage.
DO NOT install any damaged components. If damage
is evident, please contact the supplier where the water
heater/storage unit was purchased or the manufacturer
listed on the rating plate for replacement parts.
Water treatment / filtration
In areas where poor water conditions are suspected
(i.e. lime, iron and other minerals), it is essential that the
water be tested and appropriate action taken to prevent
damage to the indirect heater and ensure the quality
of the water.
Temperature control
The proper temperature setting for domestic hot water
use is 120° F (49° C). If hotter water is required a
tempering device or anti-scald device must be installed
at the domestic hot water outlet of the heater or at the
point of use. Table 1 details the approximate relationship
of water temperature and the time with regard to scald
injury. It is important for the user to understand the
necessity of tempering or anti-scald devices when using
hotter water in domestic water heating systems.
A tempering valve or anti-scald valve shall be installed
and used according to the manufacture’s directions to
prevent scalding. Many state and local codes now require
installation of these devices. The tempering valve or anti-
scald valve will ensure potable water temperatures at the
desired set point with a higher degree of accuracy.
WARNING
Incorrect operation of this appliance may create a hazard
to life and property and will nullify the warranty.
IMPORTANT
WARNING
Do not store or use gasoline or other flammable,
combustible, or corrosive vapors and liquids in the
vicinity of this or any other appliance.
General Information
Hot water in excess of 120° F (49° C)
can cause scalding!
WARNING

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5603 408 v1.2
Vitocell 100-VH/-BH Installation/Operation/Service
Important Regulatory and Installation Requirements (continued)
Anode rods
The anode rod is used as a consumable element within
the volume of the storage tank. The purpose of the
magnesium anode rod is to protect the inside of the tank
against corrosion. The anode rod should be inspected
twice in the first year and at least yearly once a time
interval for inspection has been developed. Water
conditions can influence the consumption rate of the
anode rod. Please see the maintenance section of this
manual for instructions on how to change the anode rod
in your water heater.
Backflow preventer (closed loop system)
Some local municipal codes and ordinances require the
use of these devices on potable (domestic) water lines.
Where backflow preventers are required, it will be
necessary to install a thermal expansion tank (designed
for used with potable water) in order to prevent pressure
build up in the indirect heater and associated piping,
which could cause the T&P valve to discharge. Follow
the expansion tank manufacturer’s recommendations
when selecting a tank for your hot water system.
Product information
79 USG (300 L) and 119 USG (450 L) capacity
Enameled indirect-fired domestic hot water storage tank
with one or two heat exchanger coils.
General Information
The following chart details the relationship between water
temperature and time for scalding injury to occur.
CAUTION
Hydrogen gas is produced in a hot water system served
by the heater that has not been used for a long period
of time (2 weeks or more). Hydrogen gas is extremely
flammable. To reduce the risk of injury under these
conditions, it is recommended that the hot water faucet
be opened for several minutes at the kitchen sink before
using any electrical appliance connected to the hot water
system. When hydrogen is present, there will probably
be an unusual sound such as air escaping through the
pipe as the water begins to flow. There should be no
smoking or open flame near the faucet at the time it is
open.
CAUTION
To reduce the risk of excessive pressures and
temperatures in this water heater, install temperature
and pressure protective equipment required by local
codes and no less than a combination temperature and
pressure relief valve certified by a nationally recognized
testing laboratory that maintains periodic inspection of
production of listed equipment or materials, as meeting
the requirements for Relief Valves and Automatic Gas
Shutoff Devices for Hot Water Supply Systems, ANSI
Z21.22. This valve must be marked with a maximum
set pressure not to exceed the marked maximum
working pressure of the water heater. Install the valve
in an opening provided and marked for this purpose in
the water heater, and orient it or provide tubing so that
any discharge from the valve exits only within 6 in.
above, or at any distance below, the structural floor,
and does not contact any live electrical part. The
discharge opening must not be blocked or reduced
in size under any circumstances.
Temperature and pressure relief valve (T&P Valve)
Approx. Water
Temperature
Time to produce 2nd and 3rd
Degree burns on adult skin
120° F (49.0° C) more than 5 minutes
125° F (51.5° C) 1.5 to 2 minutes
130° F (54.5° C) about 30 seconds
135° F (57.0° C) about 10 seconds
140° F (60.0° C) less than 5 seconds
145° F (63.0° C) less than 3 seconds
150° F (63.5° C) about 1.5 seconds
155° F (68.5° C) about 1 second

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5603 408 v1.2
Vitocell 100-VH/-BH Installation/Operation/Service
Installing the Tank
Locating the water heater / storage tank
If you have a choice of where to install the water heater
consider the following:
1. Put the water heater indoors as close as possible to
where the most hot water is needed, to prevent heat
loss through water pipes.
2. It is handy to have a floor drain, tub or sink nearby,
which will make it easier to drain water from the water
heater.
3. The solar water heater or the pipes and the connections
may, in time, leak. Put the water heater/storage tank
in a place where a water leak will not damage anything.
4. You must not put the water heater in an area where
it might freeze. Do not extend the T&P valve discharge
line to the outdoors or into an area where it may freeze.
Make sure that you are able to reach the drain valve
and all access panels when water heater is in place.
This will make it easy to service the water heater.
The location where this water heater/storage unit is to
be installed is of utmost importance. Before installing this
water heater/storage unit, consult the installation section
of these instructions. After reading these Installation and
Operating instructions, select a location for the water
heater/storage unit where the floor is level and is easily
accessible to a power supply and water connections.
It is recommended that the water heater/storage unit
be located near the centre of greatest hot water usage
to prevent heat loss through the pipes.
DO NOT locate the water heater/storage unit where
water lines could be subjected to freezing temperatures.
Locate the water heater/storage unit so that access
panels and drain valves are accessible.
Water heater/storage unit corrosion and component failure
can be caused by the heating and breakdown of airborne
chemical vapors. Examples of some typical compounds
that are potentially corrosive are: spray can propellants,
cleaning solvents, refrigerator and air conditioning
refrigerants, swimming pool chemicals, calcium and
sodium chloride (salts), waxes and process chemicals.
These materials are corrosive at very low concentration
levels with little or no odor to reveal their presence.
Note: Damage to the water heater/storage unit caused
by exposure to corrosive vapors is not covered
by the warranty. Do not operate the water
heater/storage unit if exposure has or will occur.
Do not store any potentially corrosive compounds
in the vicinity of the water heater /storage unit.
This water heater/storage unit must be located in an area
where leakage of the tank or water line connections and
the combination temperature and pressure relief valve will
not result in damage to the area adjacent to the water
heater/ storage unit or to lower floors of the structure.
When such locations cannot be avoided, a suitable drain
pan must be installed under the water heater/storage unit.
The drain pan must have a minimum length and width of
at least 4 in. (10.2 cm) greater than the diameter of the
water heater. The drain pan, as described above, can be
purchased from your plumbing professional. The drain
pan must be piped to an adequate drain. The piping must
be pitched for proper drainage.
Note: For California installation this water heater must
be braced, anchored, or strapped to avoid falling
or moving during an earthquake. See instructions
for correct installation procedures. Instructions
may be obtained from California Office of the State
Architect, 400 P Street, Sacramento, CA 95814.
Installation
WARNING
Water heater/storage units are heat producing appliances.
To avoid damage or injury, there shall be no materials
stored against the water heater/storage unit and proper
care shall be taken to avoid unnecessary contact
(especially by children) with the water heater/storage unit.
UNDER NO CIRCUMSTANCES SHALL FLAMMABLE
MATERIALS, SUCH AS GASOLINE OR PAINT THINNER
BE USED OR STORED IN THE VICINITY OF THIS WATER
HEATER/STORAGE UNIT OR ANY LOCATION FROM
WHICH FUMES COULD REACH THE WATER HEATER/
STORAGE UNIT.
This water heater MUST be installed indoors out of the
wind and weather.
This water heater/storage unit shall NOT be installed in
any location where gasoline or flammable vapors are likely
to be present, unless the installation is such to eliminate
the probable ignition of gasoline or flammable vapors.
To comply with NSF requirements this water heater is to be:
■ Sealed to the floor with sealant, in a smooth and easily
cleanable way, or
■ Installed with an optional leg kit that includes legs
and/or extensions that provide a minimum clearance
of 6 in. beneath the water heater.

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5603 408 v1.2
Vitocell 100-VH/-BH Installation/Operation/Service
Installing the Tank (continued)
The solar indirect water heater must be installed indoors.
Locate the water heater as close as practical to the
solar heating system and leave sufficient clearances for
servicing the heater. The entire solar heating system
should be located as close as possible to points of hot
water use for the fastest delivery of hot water.
If possible, please use the following installation clearances
for service access.
Insulation mounting
(Applies only to units with removable soft foam insulation)
Installation
Storage
Capacity
USG (L) 79 (300) 119 (450)
Rear in. (mm) 18 (460) 18 (460)
Sides in. (mm) 12 (300) 12 (300)
Top in. (mm) 48 (1200) 48 (1200)
Front in. (mm) 24 (600) 24 (600)
CAUTION
DO NOT store or use gasoline or other flammable,
combustible or corrosive vapors and/or liquids in the
vicinity of the water heater or any other appliance.
IF YOU SMELL GAS:
DO NOT try to light any appliance.
DO NOT touch any electric switch; do not use any
telephone in your building.
Immediately call your gas supplier from a telephone in
another building. Follow your gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire
department.
DO NOT OPERATE THE APPLIANCE UNTIL THE
LEAKAGE IS CORRECTED!
CAUTION
Do not drop water heater or lay heater down on its side.
Move the water heater into position by sliding or using
an appropriately sized hand truck.
IMPORTANT
For the position of the flange perforation Ø 7 in. (180 mm),
please refer to the enclosed drawing.
Please do not use tools or band clamps!
Please don’t try to close the insulation by force!
To mount put the insulation loosely around the storage
tank. Adjust the insulation by tapping with the palm of
the hand from the backside in direction to the zipper till
the insulation can be closed easily.
Note: The closing direction of the zipper is always FROM
THE TOP TO THE BOTTOM!
IMPORTANT
Synthetic materials are subject to temperature variation!
Do not put the insulation on the tank if temperature is
below 68° F (20° C). Cold stored insulations have to be
warmed up to room temperature!
(DO NOT USE any heat source to speed up this process).
After setting up the storage tank and before connecting
the drinking water-, circulation- and heating lines, the
insulation has to be put on.

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5603 408 v1.2
Vitocell 100-VH/-BH Installation/Operation/Service
Connections
Water connections
Note: Before proceeding with the installation, close the
main water supply valve. After shutting the main
water supply valve, open a faucet to relieve the
water line pressure to prevent any water from
leaking out of the pipes while making the water
connections to the water heater/storage unit.
After the pressure has been relieved, close the
faucet. Make the proper plumbing connections
between the water heater/storage unit and the
plumbing system in the house. Install a shutoff
valve in the cold water supply line.
Temperature and pressure relive valve (T&P)
For protection against excessive temperatures and
pressure, install temperature and pressure protective
equipment required by local codes, but not less than
a combination temperature and pressure relief valve
certified by a nationally recognized testing laboratory
that maintains periodic inspection of production of listed
equipment or materials, as meeting the Requirements for
Relief Valves and Automatic Gas Shutoff Devices for Hot
Water Supply Systems, ANSI Z21.22, and the Standard
CAN1-4.4 Temperature, Pressure, Temperature and
Pressure Relief Valves and Vacuum Relief Valves.
The combination temperature and pressure relief valve
shall be marked with a maximum set pressure, not to
exceed the maximum working pressure of the water
heater/ storage unit. The combination temperature and
pressure relief valve shall also have an hourly rated
temperature steam BTU discharge capacity not less than
the hourly input rating of the water heater/storage unit.
Install the combination temperature and pressure relief
valve into the opening provided and marked for this
purpose on the water heater/storage unit.
Note: Some models may already be equipped or supplied
with a combination temperature and pressure relief
valve. Verify that the combination temperature and
pressure relief valve complies with local codes.
If the combination temperature and pressure relief
valve does not comply with local codes, replace
it with one that does. Follow the installation
instructions above on this page.
Install a discharge line so that water discharged from the
combination temperature and pressure relief valve will exit
within 6 in. above or any distance below the structural
floor and cannot contact any live electrical part.
The discharge line is to be installed to allow for complete
drainage of both the temperature and pressure relief valve
and the discharge line. The discharge opening must not
be subjected to blockage or freezing.
DO NOT thread, plug or cap the discharge line. It is
recommended that a minimum of 4 in. (10.2 cm) be
provided on the side of the water heater/storage unit
for servicing and maintenance of the combination
temperature and pressure relief valve.
DO NOT place a valve between the combination
temperature and pressure relief valve and the tank.
CAUTION
If sweat fittings are to be used, DO NOT apply heat to
the nipples of the water heater/storage unit. Sweat the
tubing to the adapter before fitting the adapter to the
water connections. It is imperative that heat is not
applied to the nipples containing a plastic liner.
If this water heater/storage unit is installed in a closed
water supply system, such as the one having a back-flow
preventer in the cold water supply, provisions shall be
made to control thermal expansion. DO NOT operate this
water heater/storage unit in a closed system without
provisions for controlling thermal expansion. Your water
supplier or local plumbing inspector should be contacted
on how to control this situation.
After installation of the water lines, open the main water
supply valve and fill the water heater/storage unit. While
the water heater/storage unit is filling, open several hot
water faucets to allow air to escape from the water
system. When a steady stream of water flows through
the faucets, close them and check all water connections
for possible leaks.
Never operate the water heater/storage unit without first
being certain it is filled with water.
Installation

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5603 408 v1.2
Vitocell 100-VH/-BH Installation/Operation/Service
Other Connections
Note: For installation see the hydraulic connection diagram.
DO NOT install a check valve or any other device that
would prevent the reverse flow of water unless required
by local codes. A closed system will result and frequent
operation of the relief valve will occur.
After the installation of all water lines is complete, open
the main water supply valve and fill the water heater/
storage unit. Open several hot water faucets to allow air
to escape from the system while the water heater/storage
unit is filling. When water passes through all the faucets,
close the faucets and check for possible leaks in the
system.
This water heater/storage unit can deliver scalding
temperature water at any faucet in the system. Be careful
whenever using hot water to avoid scalding injury.
Certain appliances such as dishwashers and automatic
clothes washers may require increased temperature water.
By setting the thermostat on this water heater/storage
unit to obtain increased temperature water required by
these appliances, you may create the potential for scald
injury. To protect against injury, you should install an
ASSE approved mixing valve in the water system.
■ The tank including the parts mounted at the installed
premises shall be subjected to the tightness test (not
the pressure test) of the overall system. In rare cases,
screw connections can become loose as a result of
transport, shocks, handling mistakes, etc. and shall,
therefore, be included in the check performed during
commissioning.
■ The fastening torque of the flanges shall be between
15 lb/ft (20 Nm) and 22 lb/ft (30 Nm). As the seal may
have set, the fastening torques shall be tested before
filling the system. Following each start-up (after the
first heating), the fastening torques shall be checked
and the flanges retightened, if necessary. Seals are
wear parts and intended for single use only; in the
case of revision or back fitting, but after 2 years at
the latest, the seals shall be replaced.
■ With combination storage systems the potable water
side shall always be filled and commissioned first.
The working pressures given on the type plate shall
not be exceeded. Water hammers in the potable
water network shall be avoided by suitable measures
(expansion vessel, delayed closing fittings, etc.).
In the case of special steel corrugated tubes, a
precharged expansion tank is required.
■ All heat exchangers within the tank shall be operated
using water only (no steam). For heating medium
temperatures exceeding 203° F (95° C) the following
applies: The insulation shall be suitable for temperatures
above 203° F (95° C) (points of contact with the heat
exchanger connections). Appropriate connecting and
sealing materials shall be used.
■ A suitable water filter shall be installed in the cold
water feed line and commissioned accordingly, taking
into account the current state of the art.
■ Clean the outside of the tank using water only (moist
cloth).
■ We retain the right for changes of the technical data
and comments due to further development.
WARNING
Hydrogen gas can be produced in a hot water system
served by this water heater/storage unit that has not
been used for a long period of time (generally two weeks
or more). Hydrogen gas is extremely flammable.
To reduce the risk of injury under these conditions, it
is recommended that the hot water faucet be opened
for several minutes at the kitchen sink before using any
electrical appliance connected to the hot water system.
If hydrogen is present, there will probably be an unusual
sound such as air escaping through the pipe as the water
begins to flow. There should be no smoking or open
flame near the faucet at the time it is open.
CAUTION
Under certain conditions, water in this water heater/
storage unit may become excessively hot. It is
recommended that an ASSE approved mixing valve
may be installed in the outlet line to reduce the risk
of scald injury by preventing point of discharge water
temperatures in excess of 140° F (60° C).
Installation
This valve will reduce point of discharge temperature
by mixing cold and hot water in branch supply lines.
Such valves are available from the local plumbing supplier.
Please consult with a plumbing professional.
Hydraulic connection