Viessmann Vitocell 100 User manual

THE HEAT TRANSFER
MEDIUM MUST BE WATER
OR OTHER NON-TOXIC
FLUID HAVING A TOXICITY
RATING OR CLASS OF 1,
AS LISTED IN CLINICAL
TOXICOLOGY OF
COMMERCIAL PRODUCTS,
5TH EDITION.
THE PRESSURE OF THE
HEAT TRANSFER MEDIUM
MUST BE LIMITED TO A
MAXIMUM OF
30 PSIG BY AN APPROVED
SAFETY OR RELIEF VALVE
(SEE PAGE 2).
CAUTION
Read and save these instructions
for future reference.
IMPORTANT
Vitocell 100
Installation Instructions
Vitocell 100
CHA Series
Enameled indirect-fired domestic hot water storage tank
42 and 53 USG / 160 and 200 ltr capacities
5167 514 v1.1 02/01
Please file in Service Binder

Safety, Installation and Warranty Requirements
2
Safety, Installation and Warranty Requirements
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the
instructions listed below and details printed in these instructions can cause product/property damage,severe personal injury,and/or
loss of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
HLicensed professional heating
contractor
The installation, adjustment, service,
and maintenance of this equipment
must be performed by a licensed
professional heating contractor.
"Please see section
entitled “Important
Regulatory and
Installation
Requirements”.
HProduct documentation
Read all applicable documentation
before commencing installation. Store
documentation near boiler in a readily
accessible location for reference in
the future by service personnel.
"For a listing of
applicable literature,
please see section
entitled “Important
Regulatory and
Installation Requirements”.
HAdvice to owner
Once the installation work is
complete, the heating contractor must
familiarize the system
operator/ultimate owner with all
equipment, as well as safety
precautions/requirements, shut-down
procedure, and the need for
professional service annually before
the heating season begins.
HWarranty
Information contained in
this and related product
documentation must be
read and followed. Failure
to do so renders warranty
null and void.
5167 514 v1.1
THE HEAT TRANSFER
MEDIUM MUST EITHER BE
POTABLE WATER OR
CONTAIN ONLY
SUBSTANCES WHICH ARE
RECOGNIZED AS SAFE BY
THE U.S. FOOD AND DRUG
ADMINISTRATION.
THE PRESSURE OF THE
HEAT TRANSFER MEDIUM
MUST BE MAINTAINED
LESS THAN THE NORMAL
MINIMUM OPERATING
PRESSURE OF THE
POTABLE WATER SYSTEM.
CAUTION

Index
3
Page
Safety Important Regulatory and Installation Requirements 4.....
General Information About these Instructions 5........................................................
Product Information 5.................................................................
Set-up Tank Set-up 5................................................................................
Connections Orientation and Dimensions 6..................................................
Installation of Tank Temperature Sensor
and/or Aquastat 7
..........................................................................
Verification of Anode Connection 8........................................
Boiler Water Connections 8.......................................................
Domestic Hot Water Connections 9.......................................
Appendix Pressure Drop Information 11.....................................................
Post Installation... 12....................................................................
Start-up Information 12................................................................
Service Binder 12...........................................................................
5167 514 v1.1

Safety
4
Important Regulatory and Installation Requirements
Codes
The installation of indirect-fired hot
water storage tanks might be governed
by individual local rules and regulations
for this type of product and such rules
and regulations must be observed. The
installation of this unit shall be in
accordance with local codes. Always
use latest editions of codes.
Mechanical room
Ensure the mechanical room complies
with the requirements of the system
design guideline and/or technical data
manual.
The tank must be installed in a
mechanical room which is never subject
to freezing temperatures.
If not in use and danger of freezing
exists in the mechanical room, ensure
water is drained from tank.
Please carefully read this manual prior
to attempting installation. Any
warranty will be null and void if these
instructions are not followed.
This product must be installed
observing not only the necessary
product literature (see list below), but
also all local, provincial/state
plumbing and building codes as they
apply to this product and all periphery
equipment.
For information regarding other
Viessmann System Technology
componentry, please reference
documentation of the respective
product.
We offer frequent installation and
service seminars to familiarize our
partners with our products. Please
inquire.
Working on the equipment
The installation, adjustment, service,
and maintenance of this equipment
must be done by a licensed professional
heating contractor who is qualified and
experienced in the installation, service,
and maintenance of hot water heating
systems. There are no user serviceable
parts on this equipment.
Ensure main power supply to
equipment, the heating system, and all
external controls has been deactivated.
Close main oil or gas supply valve. Take
precautions in both instances to avoid
accidental activation of power during
service work.
The completeness and functionality of
field supplied electrical controls and
components must be verified by the
heating contractor. These include
low-water cut-offs, flow switches (if
used), staging controls, pumps,
motorized valves, air vents,
thermostats, temperature controls, etc.
Technical literature
Literature applicable to all aspects of
the Vitocell:
- Technical Data Manual
- Installation Instructions
- Start-up/Service Instructions
- Operating Instructions
and User’s Information Manual
Leave all literature at the installation
site and advise the system
operator/ultimate owner where the
literature can be found. Contact
Viessmann for additional copies.
5167 514 v1.1
If the heating system itself is to be
filled with Glycol or any other
antifreeze, the system fill must be of
non-toxic or food grade antifreeze. In
any circumstance, a non-toxic fluid
must be used. Ensure a copy of the
Material Safety Data Sheet (MSDS) is
supplied to the operator/ultimate
owner of the system.
WARNING

General Information/Set-up
5
About these Instructions
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.
The following symbols and flag words may be utilized in these
Installation Instructions:
Warnings draw your attention to the
presence of potential hazards or
important product information.
Cautions draw your attention to the
presence of potential hazards or
important product information.
Helpful hints for installation, operation
or maintenance which pertain to the
product.
This symbol indicates that additional,
pertinent information is to be found in
column three.
This symbol indicates that other
instructions must be referenced.
Product Information
42 and 53 USG / 160 and 200 ltr capacities
Enameled indirect-fired domestic hot water storage tank with one heat exchanger
coil for use with hot water heating boilers.
Tank Set-up
HFor narrow passageways, remove
lower portion of crating and carry
DHW tank to its final installation site
by means of crating boards which are
mounted on the tank lengthwise.
See Installation Instructions of
the “Transport Handles”
(Accessory) to move the tank
into the mechanical room.
HThe tank does not require a special
foundation and can be placed directly
on the floor. If, for cleanliness
purposes, the tank is to be kept off
the floor, a foundation can be used for
each tank.
HLevel tank using leveling bolts on tank
frame.
5167 514 v1.1
Indicates an imminently hazardous
situation which, if not avoided, could
result in death, serious injury or
substantial product/property damage.
WARNING
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or
product/property damage.
CAUTION
IMPORTANT
5167 514 v1.1

Set-up/Connections
6
Tank Set-up (continued)
Recommended installation clearances for service access
Storage capacity USG
ltr
42
160
53
200
Rear inches
mm
18
460
18
460
Sides May be reduced if rear pipe
connections can be reached with
less clearance
inches
mm
12
300
12
300
Top inches
mm
36
900
36
900
Front inches
mm
24
600
24
600
Minimum clearances to combustibles
Storage capacity USG
ltr
42
160
53
200
All sides inches
mm
0
0
0
0
Orientation and Dimensions
Connections
Boiler supply and return
DCW, DHW and TPV
Sensor well for DHW tank
temperature sensor/aquastat
ø
ø
ø
1”
3/4”
1”
Domestic hot water and TPV
Boiler water supply
Sensor well for DHW tank temperature
sensor/aquastat
Domestic cold water
Boiler water return
Consumable anode with grounding
cable
Connection of thermometric sensor
See Installation Instruction
Supplement for fittings
supplied with tank.
5167 514 v1.1

Connections
7
Installation of Tank Temperature Sensor and/or Aquastat
1. Install reducing coupling (included in
Connection Fitting Package). Use
approved pipe sealant.
2. Install sensor well using sealant.
Where Vitotronic 200 or 300 is utilized
to control DHW production:
3. Insert DHW tank temperature sensor
(supplied with Vitotronic 200 or 300)
fully and completely into sensor well.
Due to the length of the stainless steel
well (8.7” / 220 mm), care must be taken
to ensure that the sensing bulb of the
aquastat limit is inserted and pushed to
the end of the stainless steel well.
Where a Vitotronic 100 and a
Viessmann Power/Pump Control Module
are utilized to control DHW production:
3. Insert the extended capillary of the
aquastat (supplied with Viessmann
Power/Pump Control Module, not
illustrated) fully and completely into
sensor well. Mount aquastat
inconspicuously on tank panelling.
Follow instructions below with regard
to sensor and spring clip installation.
... if aquastat is to be mounted remote
from the aquastat well:
4. Align sensor bulb with spring clip.
5. Slide assembly into well.
6. The retention spring clip must press
the bulb properly to ensure surface
contact with the well.
... if aquastat is to be mounted directly
on the tank well:
7. Mount aquastat with holding clip
supplied directly onto well. Bend
capillary tube into groove opening to
allow for mounting of aquastat.
5167 514 v1.1
1.
2.
To ensure optimum, safe operation,
the supplied stainless steel well must
be installed. The well diameter is
large enough to accommodate a wide
variety of sensing bulbs.
Always use spring clip to ensure
proper contact of capillary bulb
against the stainless steel well for
proper sensing/heat transfer!
WARNING
IMPORTANT

ConnectionsConnections
8
Verification of Anode Connection
Check proper connection of grounding
cable at magnesium anode.
Grounding cable
Magnesium anode
Boiler Water Connections
Vitocell 100
DHW tank temperature sensor
and/or aquastat
Air vent
Flow check valve, spring-loaded
DHW recirculation pump
Boiler water supply
Boiler water return
Hot water heating boiler
Max. supply temp. 230 ºF / 110 ºC
....
Max. DHW temp. 150 ºF / 65.6 ºC......
Max. tank operating pressure
Hheating water side 150 psig
..............
HDHW side 150 psig...............................
Max. tank testing pressure
Hheating water side (primary)480 psig
HDHW side (secondary) 300 psig
.......
1.Connect heating water side (primary)
connections using supplied adaptors.
See Installation Instruction
Supplement for fittings
supplied with tank.
2. Control heat supply to the tank
according to illustration on the left.
3. Pipe supply connections with upward
slopes and install an air vent valve at
highest point.
4. Install supplied tank temperature
sensor into sensor well (see page 7).
5. Insulate pipe connections.
5167 514 v1.15167 514 v1.1
The operating aquastat and any
secondary high limit aquastat of the
tank must be set such that the DHW
temperature inside the tank never
exceeds 203 °F / 95 °C.
WARNING

Connections
IMPORTANT
This is a simplified conceptual drawing
only! Piping and necessary componentry
must be field verified. Proper installation
and functionality in the field is the
responsibility of the heating contractor.
9
Domestic Hot Water Connection
Domestic hot water
DHW recirculation line
DHW recirculation pump
Spring loaded check valve
Discharge pipe
Pressure and temperature relief valve
Shut-off valve
Drain
Domestic cold water supply lines
Back-flow preventer
Domestic cold water inlet
Precharged expansion tank
(required where back-flow preventer is
installed; check local plumbing codes
and requirements)
1. Connect DHW connections using
supplied adaptors.
See Installation Instruction
Supplement supplied with
tank.
2. Insulate DHW pipe connections.
Dishwashers and washing machines can
be connected to central domestic hot
water supply. Washing machines must be
supplied with a separate domestic cold
and hot water connection. Through water
supply directly from the DHW tank,
heat-up time for water in the dishwasher
or washing machine is reduced.
This saves time, energy and reduces
costs.
Please note recommendations by the
manufacturer.
5167 514 v1.1
IMPORTANT
The pressure and temperature relief
valve discharge must always point
toward the floor!
WARNING

Connections
½’’
ID 15
ID 19.2
AF 24
220
10
Domestic Hot Water Connection (continued)
Sensor Well
Vitocell-H 100,
with 42 and 53 USG / 160 and 200 ltr
capacities
Vitocell-H 100 domestic hot water
tank positioned under the boiler
Please note that only the boiler/tank
combinations stated in the Price List are
possible.
Backflow preventers
Where backflow preventers are required, a
domestic water expansion tank installation
is recommended in the cold water inlet
piping before the cold water enters the
Vitocell. For the backflow device, observe
local plumbing codes and regulations.
Temperature and pressure
relief valve
A temperature and pressure relief valve
(T&P relief valve) is supplied with the tank.
The heating contractor must install the valve
on each tank in a method meeting code
requirements.
If local codes require a different relief valve,
consult Viessmann Manufacturing for a
substitute valve. The tank is approved for
150 psig. Maximum operating pressure is
150 psig.
The T&P relief valve supplied with the tank
is manufactured by Watts Industries (Model
40XL-8), set to 150 psig for US and
Canadian installations. The valve is ASME
pressure steam rated for 998 MBH and CSA
temperature steam rated for 200 MBH. It is
tested under ANSI Z21.22 code for Relief
Valves and Automatic Gas Shut-off Devices
for Hot Water Supply Systems. The relief
temperature is set at 210°F / 99°C. The
valve has a male threaded inlet and female
threaded outlet, both ¾” sizes.
Since the heat exchanger coil allows for
high MBH input (see Vitocell flow charts),
confirmation that the appropriate and
correct size pressure and temperature relief
valve is used and installed, is necessary.
Warranty
Our warranty for domestic hot water tanks
states that the water heated must be of
drinking water quality and that any water
treatment equipment in use must function
correctly.
Viessmann accepts no responsibility for
damage howsoever caused and reserves the
right to withdraw the product warranty if
the product has been improperly installed or
misapplied by the installer, contractor or
final user. In order to qualify for product
warranty, strict adherence to the installation
and service manuals must be observed. In
the event that Viessmann non-approved
components are utilized, Viessmann
reserves the right to withdraw all expressed
or implied warranties without written notice.
The water to be heated with the Vitocell
must be drinking (potable) water quality. If
the tank is used to heat other media, the
warranty will be null and void. Damage
resulting from excessive pressure or
temperature is clearly not the responsibility
of Viessmann.
The amount of chloride and sulfate
acceptable to the tank is limited. In areas
where high concentrations of chloride and
sulfate are present in drinking water, please
consult Viessmann for directions.
5167 514 v1.1
To ensure optimum, safe operation,
the supplied stainless steel well must
be installed. The well diameter is
large enough to accommodate a wide
variety of sensing bulbs.
Always use spring clip to ensure
proper contact of capillary bulb
against the stainless steel well for
proper sensing/heat transfer!
WARNING
IMPORTANT
The heating contractor must ensure
the T&P relief valve is sized correctly.
If the factory supplied T&P relief
valve is too small, it must be
upgraded in the field by installing an
adequately sized valve.
WARNING

Appendix
11
Pressure Drop Information
Pressure drop on heating water side
(primary circuit)
42 and 53 USG / 160 and 200 ltr storage capacities
Pressure drop
Waterflow
ltr/h
USGPM
400 1000
“w.c. mbar
44 10 000
16 40
20 50
24 60
32 80
40 100
80 200
120 300
160 400
200 500
240 600
320 800
1.6 4
25
2.4 6
3.2 8
410
820
12 30
1.2 3
2.2 500 2.6 600 3.5 800 4.4 1 000
9 2 000
13 3 000 18 4 000 22 5 000 26 6 000 35 8 000
5167 514 v1.1
Pressure drop on domestic hot water side
(secondary circuit)
Pressure drop
Waterflow
ltr/min
USGPM
40 100
“w.c. mbar
1.2 3
1.6 4
25
2.4 6
3.2 8
410
10
3
820
12 30
16 40
20 50
24 60
32 80
167
44
133
35
100
26
83
22
67
18
50
13
33
9
17
3
13
5
8
2

Appendix
Viessmann Manufacturing Company Inc.
750 McMurray Road
Waterloo, Ontario xN2V 2G5 xCanada
Tel. [phone] xFax [phone]
www.viessmann.ca x[email protected]
Viessmann Manufacturing Company (U.S.) Inc.
45 Access Road
Warwick, Rhode Island x02886 xUSA
Tel. [phone] xFax [phone]
www.viessmann-us.com x[email protected]
12
Post Installation ....
Start-up information
Start-up/Service Instructions
DHW Tank
Service Binder
1. File all Parts Lists, Operating and
Service Instructions in the Service
Binder.
2. Install a protective hanging case near
the boiler and store the Service
Binder in this location.
For a listing of applicable Viessmann
literature, please see Important
Regulatory and Installation
Requirements.
Technical information subject to change without notice Printed on environmentally friendly
(recycled and recyclable) paper.
5167 514 v1.1