Viessmann VITOCELL-V 100 Original operating manual

VIESMANN
Service instructions
for heating engineers
Vitocell-V 100
Type CVA
DHW cylinders, 160 to 1000 litres capacity
Vitocell-W 100
Type CVA
DHW cylinders, 160 to 300 litres capacity
VITOCELL-V 100
VITOCELL-W 100
5692 651 GB 3/2006 Please keep safe

Please follow these safety instructions closely to prevent accidents and
material 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
environmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
&Work on gas equipment must only
be carried out by a qualified gas fit-
ter.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
&The system must be commissioned
by the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&theCodeofPracticeofrelevant
trade associations,
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances ON or OFF.
&Close the gas shut‐off valve.
&Open windows and doors.
&Remove all people from the
danger zone.
&Notify your gas or electricity
supplier from outside the
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life‐threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Closealldoorsleadingtothe
living space.
Safety instructions
2
Safety instructions
5692 651 GB

Workingonthesystem
&When using gas as fuel, also close
the main gas shut‐off valve and
safeguard against unauthorised
reopening.
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a mains isola-
tor.
&Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electro‐static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which
fulfil a safety function can com-
promise the safe operation of
your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function. Instal-
ling non‐authorised compo-
nents and non‐approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 651 GB

Initial start-up, inspection, maintenance
Steps –initial start-up, inspection and maintenance .................................... 5
Further details regarding the individual steps .............................................. 6
Parts list 160 to 300 litres capacity........................................................... 13
Parts list 500 litres capacity ..................................................................... 14
Parts list 750 and 1000 litres capacity ...................................................... 16
Commissioning/service reports............................................................... 19
Product parameters .................................................................................. 20
Accessories
Specification –EHO electric immersion heater ............................................ 21
Certificates
Declaration of conformity ............................................................................ 22
Index
4
Index
5692 651 GB

For further information regarding individual steps, see the pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
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•1. Filling the DHW cylinder..................................................... 6
•• 2. Inspection and cleaning ..................................................... 6
•• 3. Shutting down the heating system
•• 4. Checking the function of all safety valves
•• 5. Testing the anode earth current with an anode
tester.......................................................................................... 7
•• 6. Cleaning the inside of the DHW cylinder...................... 9
•• 7. Testing and replacing the magnesium anode ............ 10
••• 8. Commissioning the DHW cylinder.................................. 11
••• 9. Checking all hydraulic connections for leaks
Steps –initial start-up, inspection and maintenance
5
Initial start-up, inspection, maintenance
5692 651 GB

Filling the DHW cylinder
1. Fill the DHW cylinder from the sec-
ondary side.
Note
When the DHW cylinder is pres-
surised, re-torque the flange lid
withatorqueof25Nm.
2. Check the compression fittings on
the primary and secondary side
and at the immersion heater (if
installed) for leaks.
Tighten, if required.
3. Check the function of the safety
valves according totheirmanufac-
turer's instructions.
Inspection and cleaning
DIN 1988 requires and we recom-
mend a visual inspection and cleaning
no later than after two years after the
cylinder has been taken into use,
thereafter as required.
Note
We recommend that the magnesium
anode function is checked annually.
The check can be carried out without
interrupting the operation. The earth
current is tested with an anode tester
(see page 7 and page 8).
Further details regarding the individual steps
6
Initial start-up, inspection, maintenance
5692 651 GB

Testing the anode earth current with an anode tester
Testing the anode earth current with an anode tester (160 to 500 litres
capacity)
1. Fit lid A, thermal insulation B
and the thermometer sensor (if
supplied).
&Remove EPS flange insulation
B(160 to 300 litres).
or
&Remove the thermal insulation
mats (500 litres).
2. Pull earth lead Coff tab D.
3. Connect the tester in series
between tab Dand earth cable
C.
&Current reading > 0.3 mA:
the anode functions OK.
&Current reading < 0.3 mA:
visually inspect the anode
(see page 10).
Further details regarding the individual steps (cont.)
7
Initial start-up, inspection, maintenance
5692 651 GB

Testing the anode earth current with an anode tester (750 to 1000 litres
capacity)
1. Remove cover Aand the cover
hood with thermal insulation B.
2. Remove cover strips Cand
unhook the thermal insulation cas-
ing.
3. Pull earth leads Eoff tabs F.
4. Connect the tester in series
between tab Fand earth cable
E.
&Current reading > 0.3 mA:
the anode functions OK.
&Current reading < 0.3 mA:
visually inspect the anode
(see page 10).
Further details regarding the individual steps (cont.)
8
Initial start-up, inspection, maintenance
5692 651 GB

Cleaning the inside of the DHW cylinder
Cleaning the inside of the DHW cylinder (160 to 500 litres capacity)
1. Drain the DHW cylinder from the
secondary side.
2. 300 and 500 litres capacity:
Remove cover hood A, insulating
mat Band flange cover C.
3. Disconnect the DHW cylinder from
the pipework to prevent cleaning
agents and contaminants entering
the pipe system.
4. !Please note
Pointed, sharp and hard
objects can damage the
inside of the cylinder.
Only use plastic tools to
clean the interior.
Remove loose deposits with a high
pressure cleaner or manually.
5. Danger
Cleaning agent residues can
lead to poisoning.
Observe the cleaning agent
manufacturer's instructions.
!Please note
Cleaning agents containing
hydrochloric acid can
damage the cylinder interior.
Never use cleaning agents
containing hydrochloric
acid.
Use a chemical cleaning agent to
remove hard deposits that cannot
beremovedwithahighpressure
cleaner.
6. Fully drain any cleaning agent.
7. Thoroughly flush the DHW cylin-
der after cleaning.
Further details regarding the individual steps (cont.)
9
Initial start-up, inspection, maintenance
5692 651 GB

Cleaning the inside of the DHW cylinder (750 to 1000 litres capacity)
1. Drain the DHW cylinder from the
secondary side.
2. Remove cover hood Aand flange
cover B.
3. Disconnect the DHW cylinder from
the pipework to prevent cleaning
agents and contaminants entering
the pipe system.
4. !Please note
Pointed, sharp and hard
objects can damage the
inside of the cylinder.
Only use plastic tools to
clean the interior.
Remove loose deposits with a high
pressure cleaner or manually.
5. Danger
Cleaning agent residues can
lead to poisoning.
Observe the cleaning agent
manufacturer's instructions.
!Please note
Cleaning agents containing
hydrochloric acid can
damage the cylinder interior.
Never use cleaning agents
containing hydrochloric
acid.
Use a chemical cleaning agent to
remove hard deposits that cannot
beremovedwithahighpressure
cleaner.
6. Fully drain any cleaning agent.
7. Thoroughly flush the DHW cylin-
der after cleaning.
Testing and replacing the magnesium anode
Visual inspection of the magnesium
anode:
We recommend you change the mag-
nesium anode if it has been reduced
down to 10 –15 mm Ø.
Further details regarding the individual steps (cont.)
10
Initial start-up, inspection, maintenance
5692 651 GB

Note
160 to 500 litres capacity:
A chain anode (accessories) can be
installed where space is tight.
Commissioning the DHW cylinder
Commissioning the DHW cylinder (160 to 500 litres capacity)
1. Reconnect the DHW cylinder to the
pipework.
2. Insert new gaskets Aunderneath
flange lids B.
3. Fit flange lid Btogether with earth
cable Cand tighten the screws
with a maximum torque of 25 Nm.
4. Push earth lead Conto tab D.
5. Fill the DHW cylinder from the sec-
ondary side.
Then retighten the flange lid with a
maximum torque of 25 Nm.
6. Fit the thermometer sensor (if sup-
plied).
Note
160 to 300 litres capacity:
Guide the thermometer lead
through the groove in flange insula-
tion E.
7. Fit EPS flange insulation Eor
thermal insulation mats E, cover
hood Fand lid G.
Further details regarding the individual steps (cont.)
11
Initial start-up, inspection, maintenance
5692 651 GB

Commissioning the DHW cylinder (750 and 1000 litres capacity)
1. Reconnect the DHW cylinder to the
pipework.
2. Insert a new gasket Aunderneath
flange lid B.
3. Fit flange lid Band tighten the
screws with a maximum torque of
25 Nm.
4. Push earth leads Conto tabs D.
5. Fill the DHW cylinder from the sec-
ondary side.
Then retighten flange lid Bwith a
maximum torque of 25 Nm.
6. Close thermal insulation casing E
and push on cover strips F.
7. Fit lid Gand cover hood with ther-
mal insulation H.
Further details regarding the individual steps (cont.)
12
Initial start-up, inspection, maintenance
5692 651 GB

When ordering spare parts:
Quote the type and serial no. (see type plate) and the item no. of the required
part (as per this parts list).
Obtain standard parts from your local supplier.
Parts
002 Gasket –only for 300 litres capa-
city
003 Front flange (with item 002) –
only for 300 litres capacity
004 Top flange (with item 002, 006,
014)
005 Sensor attachment
006 Clamping bracket
007 Adjustable foot
008 Thermometer
010 Flange insulation
011 Top panel
012 Thermal insulation mat hood –
only for 300 litres capacity
013 Hood –only for 300 litres capa-
city
016 Viessmann logo
028 Thermometer cover
029 Centering sleeve
Parts not shown
020 Installation instructions
023 Service instructions
024 Spray paint
025 Touch-up paint stick
Wearing part
014 Magnesium anode AType plate
Parts list 160 to 300 litres capacity
13
Parts list 160 to 300 litres capacity
5692 651 GB

Parts list 160 to 300 litres capacity (cont.)
14
Parts list 160 to 300 litres capacity
5692 651 GB

Information regarding spare part orders.
Quote the type and serial no. (see type plate) and the item no. of the required
part (as per this parts list).
Obtain standard parts from your local supplier.
Parts
002 Gasket
003 Dummy flange (with item 002)
004 Top flange (with item 002, 006,
014)
005 Sensor attachment
006 Clamping bracket
007 Adjustable foot
008 Thermometer
009 Lower thermal insulation mat
010 Upper thermal insulation mat 2
011 Lid
013 Hood with thermal insulation
015 Viessmann logo
017 Insulation casing
018 Hood with thermal insulation
019 Upper thermal insulation mat 1
028 Thermometer cover
Parts not shown
020 Installation instructions
023 Service instructions
Wearing part
014 Magnesium anode AType plate
Parts list 500 litres capacity
15
Parts list 500 litres capacity
5692 651 GB

Parts list 500 litres capacity (cont.)
16
Parts list 500 litres capacity
5692 651 GB

When ordering spare parts:
Quote the type and serial no. (see type plate) and the item no. of the required
part (as per this parts list).
Obtain standard parts from your local supplier.
Parts
001 Lid
002 Upper thermal insulation mat 1
003 Upper thermal insulation mat 2
004 Lower thermal insulation mat
005 Right hand thermal insulation
casing
006 Left hand thermal insulation cas-
ing
007 Cover strip
008 Cover hood with thermal insula-
tion
009 Thermometer
010 Sealing washer –only for 1000
litres capacity
011 Sensor attachment
012 Dummy flange DN 100 (with item
013)
013 Gasket DN 100
014 Clamping bracket
015 Adjustable foot
017 Viessmann logo
018 Gasket DN 180
019 Dummy flange DN 180 (with item
018)
Parts not shown
020 Installation instructions
021 Service instructions
Wearing part
016 Magnesium anode AType plate
Parts list 750 and 1000 litres capacity
17
Parts list 750 and 1000 litres capacity
5692 651 GB

Parts list 750 and 1000 litres capacity (cont.)
18
Parts list 750 and 1000 litres capacity
5692 651 GB

Initial start-up Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Commissioning/service reports
19
Commissioning/service reports
5692 651 GB

The following standard values and product details can be used to determine the
system values for the product Vitocell as specified by the EnEV [Germany] to
assess the energy consumption of heating and ventilation equipment to DIN V
4701-10.
Cylinder capacity l 160 200 300 500 750 1000
Standby loss heat demand*1
q,S at 45 K temperature differ-
ential
kWh/
24 h
1.50 1.70 2.20 2.80 3.23 3.57
Product parameters
20
Product parameters
5692 651 GB
*1Standard parameter 500, 700 and 1000 litres