Vitocell 200-V 200-B Cylinders (PDF 1 MB)

Vitocell 200-V 200-B Cylinders (PDF 1 MB)

Design, Installation,

User & Servicing

Instructions

An unvented hot water storage appliance complying with the requirements of Building Regulations

Approved Document G3 and manufactured in accordance with

BS EN 12897, the specification for unvented water storage vessels.

In the interest of continuously improving the Vitocell 200 Cylinder range, Viessmann reserve the right to modify the product without notice, and in these circumstances this booklet, which is accurate at the time of printing, should be disregarded.

CONTENTS

These instructions should be read in conjunction with the installation/servicing instructions issued by the manufacturer of the heat source being used.

ISSUE 22: JANUARY 2016

Any installation must be in accordance with the relevant requirements of the Gas

Safety Regulations, Building Regulations, I.E.E. Wiring Regulations and the Water Fitting

Regulations (England and Wales) or Water Byelaws (Scotland). It should be read in accordance with the relevant recommendations of the following:

BS 6798; BS EN 12828, BS EN 12831, BS EN 14336; BS 5546;

BS 5440:1; BS 5440:2; CP 331:3

BS EN 806-1 to 5, BS EN 8558:2011: BS EN 1458-1:2011 and BS 7593:2006

Section

DESIGN

Description

Technical Data

System Details

Page

3

6

8

Viessmann Vitocell 200 Cylinder is covered by Section G3 of the Building Regulations

(England and Wales) Technical Standard P3 (Scotland) and Building Regulation P5

(Northern Ireland. Compliance can be achieved via a Competent Person Self Certification

Scheme or notificaton of installation to the Local Authority Building Control Department.

INSTALLATION

Installation

Commissioning

10

20

It must be installed by a competent person as defined by the relevant regulations.

Manufacturers notes must NOT be taken as over-riding statutory obligations.

This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised at all times to ensure they do not play with the appliance.

USER INSTRUCTIONS 21

SERVICING

Servicing and Maintenance 22

Fault Finding

Spare Parts List

23

26

This information is provided to assist generally in the selection of equipment.

Responsibility for selection and specification of our equipment must however remain that of our customer and any experts or consultants concerned with the installation(s).

ADDENDIX

Addendix A

Addendix B

27

28

Please note: that we do not therefore accept any responsibility for matters of design selection or specification, for the effectiveness of an installation or system containing one of our products unless specifically requested to do so in writing.

Notes

All goods are sold subject to our conditions of sale which are set out at the rear of this specification. In the interest of continuously improving the Viessmann Vitocell 200

Cylinder range, Viessmann Limited reserve the right to modify the product without notice, and in these circumstances this booklet, which is accurate at the time of printing, should be disregarded. An updated set of instructions will be produced and supplied with new appliances and will be made available for other appliances on request.

BENCHMARK

Commissioning Checklist

Service Record

29

30

31

This product is approved by Advantica where it is sold as a package with a

Viessmann boiler.

Viessmann Vitocell 200 cylinders are produced under an ISO 9001:2008 Quality

Management System approved by BSI.

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturers instructions by competent persons and that it meets the requirements of the appropriate Building

Regulations. The Benchmark Checklist can be used to demonstrate compliance with

Building Regulations and should be provided to the customer for future reference.

Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hot Water Industry Council who manage and promote the Scheme. Visit www.

centralheating.co.uk for more information.

Page 2

DESIGN

Supplied By: Viessmann Ltd

Maintenance

Maximum inlet pressure to

Pressure valve

Operating pressure (PRV setting)

Expansion vessel charge pressure

Expansion relief valve setting

3 bar

3 bar

4.5 bar

Opening pressure of P & T Relief Valve

Opening temperature of P & T Relief Valve

6 bar

92-95°C

Energy cut-out thermostat setting 85°C

Max. working pressure - Primary heat exchanger (Indirect models) 6 bar

Max. working pressure - Solar heat exchanger (Solar models) 10 bar

Immersion heater rating 3kW, 240V AC

Modifications should not be made to this product. Replacement parts, including immersion heaters, should be purchased from Viessmann

Limited, or agents approved by them. Unvented hot water storage vessels need regular routine checks, and these are detailed below. It is for this reason that this manual must always be left with the Viessmann Vitocell 200 Cylinder.

Components supplied with Viessmann Vitocell 200 cylinders

• Cold water inlet PRV combination valve/expansion relief

• Pressure and temperature relief valve

• Tundish

• 3kW Immersion heater including control and cut out thermostats

• Expansion vessel/mounting bracket/flexible hose

• Cylinder temperature sensor and retaining clip (ZK00539)

• Technical/user product literature

It is essential that these checks be carried out at the time of boiler maintenance by a qualified installer:

All cylinders are manufactured in accordance with the requirements of BS EN 12897

The tundish must be positioned so that it is visible to the occupant and is away from electrical devices.

Optional Extras

• Control thermostat

• Energy cut-out thermostat

• Energy cut-out motorised valve

(Note: Please refer to tables 1 and 2 on pages 6-9 to confirm the quantity of immersion heaters supplied with the unit)

In any situation where the volume of heated pipework (eg. secondary circulation pipes or manifold pipework for multiple units) exceeds 10 litres, then an additional expansion vessel must be fitted to accommodate the extra expansion volume.

1. Manually open the relief valves in turn, and check that water is discharged from the valves and runs freely through the tundish and out at the discharge point. Ensure that the valves re-seat satisfactorily. (Note - the water may be very hot).

2. It is important to check that the discharge pipework is carrying the water away adequately. Check for blockages etc. if it is not.

3. Turn the mains water off and remove and clean the strainer element in the Pressure

Reducing Valve.

4. Check the charge pressure in the expansion vessel and repressurise if required

5. Re-fill the system and ensure that all relief valves have re-seated.

6. The Benchmark Service Record should be updated at each service.

7. Check the water pressure downstream of the combination valve is 3 bar in static condition.

8. Check and if necessary, descale the heat exchanger in hard water areas ie. above

200ppm (mg/l).

Handling Before Installation

Viessmann Vitocell 200 Cylinder must be handled with care and stored the correct way up in a dry place. Any manual handling/lifting operations will need to comply with the requirements of the Manual Handling Operations Regulations issued by the

H.S.E. The appliance can be moved using a sack truck on the rear face although care should be taken and the route should be even. In apartment buildings containing a number of storeys we would recommend that the appliances are moved vertically in a mechanical lift. If it is proposed to use a crane, expert advice should be obtained regarding the need for slings, lifting beams etc.

Note:

The cylinder is factory fitted with a temperature

& pressure relief valve that must not be used for any other purpose or removed.

The cylinder is factory fitted with immersion heaters with thermal cut outs. Immersions without thermal cut outs must not be fitted.

A specific manual handling assessment is shown in Appendix B at the rear of this manual.

Page 3

DESIGN

Figure 1

Viessmann Vitocell 200-V Cylinder

Pipework is not supplied by manufacturer, but to be supplied and fitted by installer.

Introduction

Viessmann Vitocell 200 Cylinder is a range of unvented hot water storage cylinders, manufactured in the latest high quality duplex stainless steel. They are designed to provide mains pressure hot water and are supplied as a package which complies with Section G3 of the

Building Regulations. The appliance is extremely well insulated using high density HCFC free foam insulation with an ozone depleting potential

(ODP) of zero and a global warming potential

(GWP) of 1. It is fitted with all necessary safety devices and supplied with all the necessary control devices to make installation on site as easy as possible.

Viessmann Vitocell 200 Cylinder is available in two basic variants:

1. Viessmann Vitocell 200-V Cylinder - For use with gas or oil boilers (Figure 1). Vitocell

200 Cylinders must not be used with solid fuel boilers or steam as the energy source.

2. Viessmann Vitocell 200-B Solar Cylinder

- For providing hot water by solar gains and gas or oil boilers (Figure 2). Unvented cylinders must not be used with solid fuel boilers or steam as the energy source.

Viessmann Vitocell 200-V Cylinder

Viessmann Vitocell 200-V Cylinder is an unvented hot water storage cylinder and is provided with a high efficiency internal primary coil which is designed for use with a gas or oil boiler and is suitable for both open vented and sealed pumped primary systems.

When used with a sealed heating system the boiler must incorporate its own energy cut-out overheat thermostat.

Viessmann Vitocell 200-V Cylinder models are listed in Table 1 on Page 6 & 7.

Page 4

Figure 2

Viessmann Vitocell 200-B Solar Cylinder

Pipework is not supplied by manufacturer, but to be supplied and fitted by installer.

DESIGN

Viessmann Vitocell 200-B Solar Cylinder

Viessmann Vitocell 200-B Solar Cylinder is an unvented hot water storage cylinder and is provided with a high efficiency internal primary coil which is designed for use with a gas or oil boiler and is suitable for both open vented and sealed pumped primary systems.

When used with a sealed heating system the boiler must incorporate its own energy cut-out overheat thermostat.

A high efficiency second solar coil is positioned below the primary coil to ensure maximum benefit of solar gain energy.

Viessmann Vitocell 200-B Solar Cylinder models are listed in Table 1 on Page 6 & 7.

Note:

The cold supply elbow c/w drain tapping must be fitted as shown in figs 1, 2, 3 and 4.

A flexible hose can then be connected to the drain tapping and, providing the hose runs below the lowest level of the cylinder, then all the water contents can be drained out by syphonic action. (The cold feed pipe dips internally to the base of the cylinder.)

Page 5

DESIGN

Vitocell 200-V

Vitocell 200-B Solar

Table 1

Vitocell 200-V

90

120

150

180

210

250

300

Vitocell 200-B Solar

210

250

300

7572707

7572708

7572709

7572710

7572711

7572712

7572713

7572714

7572715

7572716

Watts Litres kg kg bar Litres A=mm mm B=mm C=mm D=mm E=mm F=mm Litres G=mm H=mm I=mm J=mm K=mm L=mm M=mm N=mm P=mm kW m

2 bar m

2 bar min Litres

C

C

C

B

B

B

B

65

75

85

51

54

35

44

210

250

300

90

120

150

180

33

38

44

19

22

26

28

243

288

344

109

142

176

208

3

3

3

3

3

3

3

12

12

745 550 490 n/a 352 367 n/a

930 550 678 n/a 352 367 n/a

40

67

367 367 223 312 n/a

367 367 223 312 n/a

18 1120 550 865 n/a 392 442 n/a 92 407 407 223 392 n/a

18 1305 550 1053 n/a 432 442 n/a 116 447 447 223 392 n/a

24 1495 550 1241 1127 432 442 n/a 145 482 482 223 392 n/a n/a

24 1745 550 1491 1377 927 522 512 109 577 577 223 472 n/a n/a

35 1992 550 1720 1577 1077 522 512 130 677 677 223 522 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 16.5

0.59

0.165

n/a n/a 18 0.59

0.165

n/a n/a 18.5

0.68

0.191

n/a n/a 19 0.78

0.216

n/a n/a 25.6

1.37

0.297

n/a n/a 27.1

1.37

0.297

n/a n/a 24.9

1.37

0.297

n/a n/a n/a n/a n/a n/a n/a n/a

32

36

38

25

30

17

21 n/a n/a n/a n/a n/a n/a n/a

C

C

C

65

75

85

210

250

300

35

40

46

245

290

346

3

3

3

24 1495 550 1240 1127 723 437 n/a 95 888 n/a 758 1018 223 352 419 1000 233 18.5

0.68

0.191 0.680 0.191

35

24 1745 550 1491 1377 785 522 n/a 115 970 n/a 820 1120 223 472 539 1180 294 19 0.78

0.216 0.970 0.241

38

35 1992 550 1720 1577 910 522 n/a 140 1095 n/a 945 1245 223 472 539 1367 300 20.5

0.78

0.216 0.970 0.241

41

101

107

125

Page 6

40,00º

25,00º

15,00º

35,0

45,0

DESIGN

NOTES

1. Not all models - see table 1.

2. Recovery times based on Primary

Coil/I.H. duty (ie. assumes the boiler output is adequate).

3. All connections are supplied with compression fittings for direct connection to copper pipework.

4. The diagrams shown are generic.

For exact product specification refer to the table eg. the number of immersion heaters varies depending on model.

5. Heat up and recovery times based on 0.25 l/s primary flow rate and at

82°C flow temperature.

Table 1

Vitocell 200-V

90

120

150

180

210

250

300

Vitocell 200-B Solar

210

250

300

7572707

7572708

7572709

7572710

7572711

7572712

7572713

7572714

7572715

7572716

Watts Litres kg kg bar Litres A=mm mm B=mm C=mm D=mm E=mm F=mm Litres G=mm H=mm I=mm J=mm K=mm L=mm M=mm N=mm P=mm kW m

2 bar m

2 bar min Litres

C

C

C

B

B

B

B

65

75

85

51

54

35

44

210

250

300

90

120

150

180

33

38

44

19

22

26

28

243

288

344

109

142

176

208

3

3

3

3

3

3

3

12

12

745 550 490 n/a 352 367 n/a

930 550 678 n/a 352 367 n/a

40

67

367 367 223 312 n/a n/a

367 367 223 312 n/a n/a

18 1120 550 865 n/a 392 442 n/a 92 407 407 223 392 n/a n/a

18 1305 550 1053 n/a 432 442 n/a 116 447 447 223 392 n/a n/a

24 1495 550 1241 1127 432 442 n/a 145 482 482 223 392 n/a n/a

24 1745 550 1491 1377 927 522 512 109 577 577 223 472 n/a n/a

35 1992 550 1720 1577 1077 522 512 130 677 677 223 522 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a 16.5

0.59

0.165

n/a n/a 18 0.59

0.165

n/a n/a 18.5

0.68

0.191

n/a n/a 19 0.78

0.216

n/a n/a 25.6

1.37

0.297

n/a n/a 27.1

1.37

0.297

n/a n/a 24.9

1.37

0.297

n/a n/a n/a n/a n/a n/a n/a n/a

32

36

38

25

30

17

21 n/a n/a n/a n/a n/a n/a n/a

C

C

C

65

75

85

210

250

300

35

40

46

245

290

346

3

3

3

24 1495 550 1240 1127 723 437 n/a 95 888 n/a 758 1018 223 352 419 1000 233 18.5

0.68

0.191 0.680 0.191

35

24 1745 550 1491 1377 785 522 n/a 115 970 n/a 820 1120 223 472 539 1180 294 19 0.78

0.216 0.970 0.241

38

35 1992 550 1720 1577 910 522 n/a 140 1095 n/a 945 1245 223 472 539 1367 300 20.5

0.78

0.216 0.970 0.241

41

101

107

125

Page 7

DESIGN

3

4

7

8

6

10

1

2

5

9

Typical arrangement of component kit shown fitted to the appliance for clarity

Pipework to be supplied and fitted by installer.

Viessmann Vitocell 200-V Cylinder

Basic Appliance

1. Hot water draw off (22mm) compression

2. Temperature & pressure relief valve 92-95°/6 bar

3. Hot water secondary return 22mm

(not fitted to smaller sizes, see table 1)

4. Immersion heater 1¾” BSP 3kW

5. 22mm cold supply compression

6. Immersion heater 1¾” BSP 3kW

7. Dual control/overheat stat pocket (22mm)

8. Boiler control sensor pocket (spare)

9. Primary return (22mm)

10. Primary flow (22mm))

Part G3 loose components supplied in a separate box

A. Combination inlet group incorporating pressure reducing valve, strainer, check valve, balanced cold take off point, expansion relief valve and expansion vessel connection points.

B. Potable expansion vessels c/w flexible hose and wall bracket

C. Tundish

D. Wiring junction box for primary system

E. Cylinder temperature sensor and fixing clip

(part number ZK00539)

Optional components available

A. Dual control thermostat and combined overheat thermostat

B. Two port (22mm) zone valve for

primary circuit

Page 8

DESIGN

3

12

9

7

6

11

12

1

2

4

8

5

10

Typical arrangement of component kit shown fitted to the appliance for clarity

Pipework to be supplied and fitted by installer.

Viessmann Vitocell 200-B Solar Cylinder

Basic Appliance

1. Hot water draw off (22mm) compression

2. Temperature & pressure relief valve 92-95°/6 bar

3. Hot water secondary return 22mm

(not fitted to smaller sizes, see table 1)

4. Immersion heater 1¾” BSP 3kW

5. 22mm cold supply

6. Dual control/Overheat stat pocket (solar)

7. Primary return (22mm)

8. Primary flow (22mm)

9. Dual control/Overheat stat pocket (boiler)

10. Solar coil return to panel collector (22mm) compression

11. Solar coil flow from panel (22mm) compression

12. Solar thermostat pocket

Part G3 loose components supplied in a separate box

A. Combination inlet group incorporating pressure reducing valve, strainer, check valve, balanced cold take off point, expansion relief valve and expansion vessel connection points.

B. Potable expansion vessels c/w flexible hose and wall bracket

C. Tundish

D. Wiring junction box for primary system

E. Cylinder temperature sensor and fixing clip

(part number ZK00539)

Optional components available

A. Dual control thermostat and combined overheat thermostat (x2)

B. Two port (22mm) zone valve for

primary circuit

Page 9

INSTALLATION

General Design Considerations

The cupboard footprint needs to be at least 650mm square for units.

The base chosen for the cylinder should be level and capable of supporting the weight of the unit when full of water as shown in General Data. The discharge pipework for the safety valves must have a minimum fall of 1 : 40 from the unit to a safe discharge point. All exposed pipework and fittings on the cylinder should be insulated, and the unit should NOT be fixed in a location where the contents could freeze.

Insulation of pipework

Pipe outside diameter

Maximum heat loss

15mm 7.89W/m

22mm

28mm

35mm

9.12W/m

10.07W/m

11.08W/m

In new systems, pipes should be insulated to comply with building regs, the maximum permissible heat loss is indicated in the table opposite, and labelled accordingly as follows: i. Primary circulation pipes for domestic hot water circuits should be insulated throughout their length, subject only to practical constraints imposed by the need to penetrate joists and other structural elements.

ii. All pipes connected to hot water storage vessels, including the vent pipe, should be insulated for at least 1 metre from their points of connection to the cylinder (or they should be insulated up to the point where they become concealed).

In replacement systems, whenever a boiler or hot water storage vessel is replaced in an existing system, any pipes that are exposed as part of the work or are otherwise accessible should be insulated as recommended for new systems, or to some lesser standard where practical constraints dictate.

The pipe connecting the boiler flow to the appliance must not be less than 22mm copper or equivalent.

Further guidance on converting heat loss limits to insulation thickness for specific thermal conductivities is available in TIMSA “HVAC guidance for achieving compliance with Part L of the Building Regulations”.

Mains Water Supply

Existing properties with a 15mm supply will be satisfactory provided the local mains pressure is good, but should be confined to single bathroom properties. For new properties where simultaneous demand is required to more than one bathroom or a bathroom and one or more en-suites, the communication and service pipe into the dwelling should be a minimum of 22mm (usually in the form of a 25mm MDPE supply). The optimum performance is achieved if the inet pressure is 3 bar dynamic. However, the Viessmann Vitocell 200 cylinder will function with lower inlet pressures, but this will reduce the performance. For optimum performance, 30L per minute incoming mains flow should be present, however the Viessmann Vitocell will work at lower flow rates, although performance will be affected.

Normally Viessmann Vitocell 200 Cylinder provides well in excess of 40 litres/min in most conditions. Flow rates for ALL mains pressure systems are subject to district pressures and system dynamic loss. Particularly on larger properties with more than one bathroom, the pipe sizes should be calculated in accordance with BS EN 806-3:2006 and BS 8558:2011.

Model Selection Guide

Max hot water demand

Max number of bed spaces

(Bedrooms)

1 shower room Bedsit (0)

1 bathroom

1 bathroom

1 bathroom + separate shower room

1 bathroom + 2 separate shower rooms or 2 bathrooms

2 bathrooms + separate shower room

2 bathrooms + 2 separate shower rooms

3 bathrooms + 2 separate showers rooms

2 (2)

4 (3)

6 (4)

7 (5)

7 (5)

7 (5)

9 (6)

Litres

90

120

120

150

180

210

250

300

Model Selection

The suggested model sizes are based on typical hot water usage. For high specification dwellings an increase of one model size should be considered.

Solar Model Selection Guide

Max hot water demand Bedrooms

1 bathroom + 1 shower room

1 bathroom + 2 shower rooms

2 bathrooms + 1 shower room

1-3

2-4

3-4

Litres

210

250

300

Page 10

INSTALLATION

General Restrictions

The shower head provided must also be suitable for mains pressure supplies.

a. The highest hot or cold water draw off point should not exceed 10 metres above the

Pressure Reducing Valve.

b. An ascending spray type bidet or any other appliance with a Class 1 back-syphonage risk requiring a type A air gap should not be used. c. Viessmann Vitocell 200 Cylinder should not be used where steam is the primary heating medium, or in a situation where maintenance is likely to be neglected.

d. Unvented cylinders are not suitable for use with solid fuel boilers.

e. If the supply to the mixer fittings (other than a dual outlet type) is not taken

from the balanced supply the system will become over pressurized and cause the pressure relief valve to discharge. Over time this could also cause the premature failure of the appliance itself which will not be covered by the warranty,

f. In larger properties with a number of bathrooms/en-suites and long pipe runs we would recommend that the balanced cold supply is provided with its own pressure reducing valve and is not taken from the balanced cold connection on the combination valve. In this case it will also be necessary to fit a small expansion vessel on the balanced cold water system to accommodate the pressure rise caused by the increase in temperature of the balanced cold water.

g. Check the performance requirements of the terminal fittings with regard to flow/ pressure are suitable.

h. In relation to potable water systems, expansion vessels shall be installed in a vertical orientation and located so that the length of the connecting pipe work is kept to a minimum.

Pipe Layout

In all mains pressure installations it is important to remember that the incoming cold supply must be shared between all terminal fittings. It is important that a 22mm supply is brought to the appliance and a 22mm take-off is continued at least to the bath.

If there are two baths, 28mm pipework should be considered. One metre of smaller diameter pipework, or flow restrictors, should be provided on the final connection to all outlets so as to balance the water available. In any event the distribution pipework should generally be in accordance with BS EN806-1 to 5.

Plastic Pipework

This appliance is suitable for use with plastic pipework as long as the material is recommended for the purpose by the manufacturer and is installed fully in accordance with their recommendations.

Shower Fittings

Secondary Hot Water Circulation

Aerated taps are recommended to prevent splashing. Any type of shower mixing valve can be used as long as both the hot and cold supplies are mains fed. However, all mains pressure systems are subject to dynamic changes particularly when other hot and cold taps/showers are opened and closed, which will cause changes in the water temperature at mixed water outlets such as showers. For this reason and because these are now no more expensive than a manual shower we strongly recommend the use of thermostatic showers with this appliance. These must be used in 3 storey properties where the impact on pressure/temperature of opening another tap in the system is greater than normal.

Some models are fitted with a secondary return tapping as standard (see table 1 for details).

If fitted, an extra expansion vessel may be necessary. A non-return valve MUST be FITTED near the return connection. No valve or terminal fitting should be installed between the non return valve and the cylinder. (See schematic arrangement on page 13.) All pipes kept hot by the secondary circulation should be insulated.

DHW

P&T

ERV/NRV

PRV

SCV

SH

SCV

WHB

WC BATH

Note:

Cold supplies to single taps must be taken from the mains cold water system.

Cold supplies to mixer taps must be taken from the balanced cold water connection on the combination valve.

WM or DWM

TO

EXTERNAL

TAP

DC

M

DC

DC

SINK

INCOMING COLD SUPPLY

DCV

WATER SOFTENER (IF NECESSARY)

Page 11

DC

WHB W.C.

DC

INSTALLATION

Typical Discharge Pipe Arrangement

Typical Discharge Pipe Arrangement

15 mm discharge pipe

Expansion relief valve

P & T

Relief

Valve

600 mm max.

300 mm min.

22 mm metal pipe with continuous fall up to 9m equivalent length (D2).

NOTES:

The discharge will consist of scalding waterand steam. Asphalt, roofing felt and non-metallic rainwater goods may be damaged by such discharges.

It is not acceptable to discharge straight into a soil pipe.

Dotted line showing alternative route with single tundish being used

Discharge below fixed grating

Fixed Grating

Trapped gully

WORKED EXAMPLE

The example below is for G1/2 temperature relief valve with a discharge pipe (D2) having 4 elbows and length of 7m from the tundish to the point of discharge.

From the table below:

Maximum resistance allowed for a straight length of 22mm copper discharge pipe

(D2) from a G1/2 temperature relief valve is: 9m subtract the resistance for 4 x 22mm elbows at 0.8m each = 3.2m.

Therefore the maximum permitted length equates to: 5.8m.

5.8m is less than the actual length of 7m therefore calculate the next largest size.

Maximum resistance allowed for a straight length of 28mm pipe (D2) from a G1/2 temperature relief valve equates to: 14m.

As the actual length is 7m, a 28mm (D2) copper pipe will be satisfactory.

Sizing of copper discharge pipe ‘D2’ for a temperature relief valve

Size of discharge pipework

22mm

28mm

35mm

with a G1/2 outlet size (as supplied)

Maximum length of straight pipe

(no bends or elbows)

Up to 9m

Up to 18m

Up to 27m

Deduct the figure below from the maximum length for each bend or elbow in the discharge pipe

0.8m

1m

1.4m

Pressure & Temperature/expansion Relief

Valve Pipework

The relief valve should be installed to discharge in accordance with G3 of the Approved

Document of the Building Regulations and should be piped to where it is visible, but will not cause danger to persons or damage to materials.

The following information is taken from

Approved Document G3 of the Building

Regulations and is provided to assist with the design and installation of the discharge pipework. However, the information is not exhaustive and reference should always be made to Approved Document G3 of the Building

Regulations. The final decision regarding any arrangements rests with Building Control and it is recommended that their advice is sought if you have any concerns regarding this aspect of the installation.

The two safety valves will only discharge water under fault conditions. When operating normally water will not be discharged.

The tundish should be vertical, located in the same space as the unvented hot water storage system and be fitted as close as possible and within 600mm of the safety device e.g. the temperature relief valve.

The discharge pipe (D2) from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge, be of metal and: a) Be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long i.e. discharge pipes between 9m and 18m equivalent resistance length should be at least two sizes larger than the nominal outlet size of the safety device, between 18 and

27m at least 3 sizes larger, and so on. Bends must be taken into account in calculating the flow resistance. Refer to the table and the worked example.

An alternative approach for sizing discharge pipes would be to follow BS EN 806-2:2005

Specification for design installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages.

b) Have a vertical section of pipe at least

300mm long, below the tundish before any elbows or bends in the pipe work.

c) Be installed with a continuous fall.

Page 12

INSTALLATION

d) It is preferable for the discharge to be visible at both the tundish and the final point of discharge but where this is not possible or practically difficult there should be clear visibility at one or other of these locations. Examples of acceptable discharge arrangements are:

1. Ideally below the fixed grating and above the water seal in a trapped gulley.

2. Downward discharges at a low level; i.e. up to 100mm above external surfaces such as car parks, hard standings, grassed areas etc are acceptable providing that where children play or otherwise come into contact with discharges, a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility.

3. Discharges at a high level; e.g. into metal hopper and metal down pipe with the end of the discharge pipe clearly visible (tundish visible or not) or onto a roof capable of withstanding high temperature discharges of water and 3m from any plastic guttering systems that would collect such discharges.

4. Where a single pipe serves a number of discharges, such as in blocks of flats, the number served should be limited to not more than 6 systems so that any installation can be traced reasonably easily. The single common discharge pipe should be at least one pipe size larger than the largest individual discharge pipe to be connected. If unvented hot water storage systems are installed where discharges form safety devices may not be apparent i.e. in dwellings occupied by blind, infirm or disabled people, consideration should be given to the installation of an electronically operated device to warn when discharge takes place.

Safety

The safety devices supplied or fitted on a Viessmann Vitocell 200 Cylinder are selected for their suitability for the temperatures and pressures involved. They must not be changed, removed or by-passed and it is essential that only genuine replacement parts supplied or approved by Viessmann Limited are used. This includes the immersion heaters, which must incorporate an energy cut-out. All parts are available to approved installers from Viessmann Limited. Where the boiler and cylinder are supplied as a package we have Advantica approval.

Schematic Diagram

Hot Outlet

Secondary

Return Circuit

P&T Relief Valve

Pump Non Return

Valve

Tundish

Combination Inlet Group

Combines elements 1, 2 and 3 below.

1. Pressure Reducing Valve - This must be fixed near the cylinder. The cold water supply to any mixer taps/showers must be taken from the cold water tapping of this valve to ensure balanced hot and cold pressures.

This valve is factory set to ensure the correct operating pressure for the Viessmann

Vitocell 200 Cylinder.

To Drain

Expansion

Vessel

Balanced

Cold

Outlets

Stop

Tap

Immersion Heater

Boiler

Flow

2 Port Valve

ERV

NRV

PRV

2. Non Return Valve - This is integral with the pressure reducing valve to prevent backflow of hot water towards cold water draw off points.

Kitchen

Cold

Tap

Boiler

Return

Combination

Valve

3. Cold Water Expansion Relief Valve - This safety device is preset at the factory and will relieve excess cold water pressure resulting from a fault condition.

Page 13

INSTALLATION

Combination Valve

I.V.

I.V.

Line Strainer

This is integral within the combination inlet group to reduce the likelihood of contaminants fouling the valve seat. Following installation this line strainer must be cleaned and replaced.

This needs to be carried out on a regular basis. as part of the annual maintenance/service check.

Tundish

This is to allow the discharge from any Relief

Valve to be seen. It must be fitted away from any electrical devices. See page 12 for discharge pipework details.

Safety

If two Viessmann Vitocell 200 Cylinders are coupled together the secondary inlet and outlet pipes must be balanced. The units must be fitted on the same level.

Note: No valves must be fitted between the expansion vessel and the storage cylinder(s).

The immersion heaters must be earthed and they must be isolated from the mains before the cover is removed on every occasion.

Replacement immersion heaters should be obtained from Viessmann Limited.

Temperature/Pressure Relief Valve

This safety device is also pre-set at the factory and relieves before the temperature reaches 100°C. It is also a Pressure Relief Valve, and is pre-set to 6 bar.

Immersion Heaters

Solar Thermistors / sensors

Care must be taken to ensure that the solar probes are fully inserted into the pockets provided. A fixing clip is supplied.

Important

Failure to follow the drain down procedure will invalidate the warranty. (see page 20)

These are 3kW 240V AC heaters and incorporate a thermostat and a manually reset energy cut-out which operates at 85°C. They have incalloy elements to prolong their life expectancy in aggressive water conditions. Please refer to table 1 to clarify how many off peak and on peak immersions are included with the unit you require.

E

L

N

Thermostat

Safety

Cut-out

Where it is intended that units are fitted to offpeak circuits, then suitable controllers such as the Horstmann off peak electric time controller will be

Immersion Heater Wiring

required. External wiring to the immersion heaters must be in accordance with the relevant IEE Wiring Regulations and the circuit must be protected by a suitable fuse and a double pole isolating switch.

The correct method of terminating the wiring to the immersion heater is shown above.

NEVER

Gate Valve

drain the cylinder of hot water and then close all cylinder inlets and outlets.

REASON as the air remaining in the cylinder cools the pressure inside the cylinder will fall below atmospheric and cause damage to the cylinder.

NEVER close the cold main and drain the cylinder via any tap connected to it.

REASON as the water drains, the pressure inside the cylinder may decrease below atmospheric and this may cause damage to the cylinder.

In line with good plumbing practice, use of excessive flux should be avoided.

Usage of the product in non-domestic commercial applications can be extremely intensive and stressful to various components. We recommend that titanium immersion heaters are fitted in such situations, rather than the incoloy heater supplied as standard. Titanium immersion heaters offer superior strength, weight and a smoother finish which enable them to better withstand the extreme stress and temperature fluctuation often encountered within non-domestic environments and situations where water quality is poor – ensuring improved performance and extended operational life.

All our cylinders are tested to BS EN 12897 at

15 l/min at which they exceed the minimum requirements for heat up performance and reheat in less time than the maximum reheat times.

If a flow rate above 25 l/min is present in the primary cylinder heating circuit, a gate valve can be fitted in this circuit to reduce the flowrate. This may be required if flow noises become apparent.

Page 14

Schematic Open Vented Primary System

Warming/Overflow

Pipe

F & E Cistern

Motorised Valve

Minimum distance as required by boiler manufacturers instructions

Motorised Valve

Pump

150mm max.

Boiler

Schematic Sealed Primary System

Safety Valve

Expansion

Vessel

Gauge

Motorised Valve

Motorised Valve

Pump

Boiler

INSTALLATION

Heating/primary Systems

The boiler and primary/heating systems should be sized and installed in accordance with BS

EN 12828:2003, BS EN 12831:2003 & BS EN

14336:2004.

Safety

Viessmann Vitocell 200 Cylinder is fitted with a

Combined Temperature/Pressure Relief Valve to cope with any increase in system temperature and pressure above the design limitations, when used with boilers up to 45kW output, which is the maximum allowed by section G3 of the Building Regulations. The primary water temperatures should be controlled as outlined below.

Primary Circuit

The cylinder primary circuit must be pumped. No further controls or safety devices are required for an all-Viessmann installation. Any other make of boiler may require a limit thermostat and 2 port valve to be fitted.

Sealed Primary Circuit

Any boiler used must be fitted with an over temperature cut-out. Unvented primary circuits may be filled or replenished by means of a temporary connection between the circuit and a supply pipe provided a ‘Listed’ double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use. Alternatively, a CA device can be used, which will allow the system to be permanently connected to the cold mains supply. The primary system can then be topped up, when required, in the same way as an open vented system fitted with an

F&E Cistern.

Page 15

INSTALLATION

Hydraulic schematics of a Viessmann 4-pipe installation

Note

It is recommended that the cylinder coil output is >10 kW to prevent long hot water re-heat periods.

Domestic hot water has priority.

Energy cutout devices fitted in the

Viessmann boiler

Boiler

4-Pipe System

If the Vitocell 200 is installed with a Viessmann

Vitodens condensing system boiler then it is recommended to install the system to a 4-pipe system as shown in the diagram opposite.

Viessmann Vitodens system boilers operate on a sealed primary circuit and are factory fitted with an integral diverter valve, PRV and expansion vessel, and a suitable energy cut-out device to comply with G3 requirements. If any Vitodens system boiler is installed with a Vitocell 200, please use the DHW cylinder sensor (ZK00539).

Wiring plan for connecting the cylinder temperature sensor to aViessmann system boiler

All Viessmann Vitodens System boilers have an on-board diverter valve and 4-pipe connections.

The outer pipes are for the central heating circuit, and the inner pipes are for the cylinder heat exchanger coil circuit. The built-in diverter valve gives domestic hot water priority and may be under the control of a Viessmann cylinder temperature sensor.

If this Viessmann Vitodens System boiler is connected correctly to a Vitocell 200 or 300 unvented water cylinder as a 4 pipe boiler and controlled by a Viessmann cylinder temperature sensor, it does not require additional safety devices such as a cylinder limit thermostat or

2 port valve.

Note: This does not apply if either the boiler or the cylinder or the controls are exchanged for other makes or models.

The cylinder temperature sensor connects to red minature spade terminals numbered 5 on the boiler wiring loom - not the pcb. Look for a coil of wire at the lower rear of a Vitodens

100-W or to the left of the pcb on a Vitodens

200-W. Fixing clips for this and the solar sensor are included.

A Optional outside temperature sensor for weather compensated operation

B Optional Open Therm device

C Connecting plug and terminal block

D Remove the link 1 - L if external mains voltage switching is required for central heating control

E Mains power connecting lead into the boiler

F Connection for external mains voltage switching for central heating control

5 Connection for cylinder temperature sensor

Gas condensing boiler:

• For Viessmann DHW cylinders:

Cylinder temperature sensor (plug on the cable harness outside the control unit)

Page 16

Schematic Solar System With Viessmann Boiler As Solar Controller

Solar Panel

INSTALLATION

Solar

Controller

Expansion

Vessel

Solar Pumping Station

A typical arrangement of a solar system incorporating a Viessmann Vitocell 200-B Solar

Cylinder appliance is shown above. All components in a solar primary system must be marked or identifiable in such a way that their design pressure and temperature can be readily determined.

A pressure relief valve to control the risk of over-pressure in system components should be fitted. A termination from a pressure relief valve should minimise the risk of damage to persons or materials. Suitable locations are into a high temperature receptacle, an internal gully or externally at ground level. High level termination from walls or on roofs could cause injury to people or animals below if the valve were to release scalding water and steam.

The pipe leading to the safety device and the collector should be of rigid and nondeformable construction, without any possibility of restriction or blockage by any other fitted component. A more detailed diagram of our recommended arrangement for a typical solar system is shown on page 18.

The solar pocket provided accommodates a 6mm diameter sensor which, with the sensor located in the solar collector (or in the flow pipe immediately adjacent to the collector), will provide the information required by the Vitosolic 100 controller.

All our cylinders are tested to BS EN 12897 at 15 l/min primary flow at which they exceed the minimum requirements for heat up performance and reheat in less time than the maximum reheat times.

In situations where excessive flow primary rates above 25 l/min are present, fit a regulating valve in the cylinder primary circuit.

If the solar controller can cause the cylinder temperature to exceed 80°C, then a Solar tempering valve must be fitted to the domestic hot water outlet of the cylinder. This must limit the hot water temperature to a maximum of 60°C. (ref building regulations part G3 3.63). Suitable plumbing configurations for installing this valve are shown on page 18.

Page 17

INSTALLATION

Figure 1: Cold port of the blending valve connected to mains supply

NOT ALLOWED

Mixed HW out

Mains CW in

Figure 2: Cold port of the blending valve connected to balanced cold supply - NON-RETURN VALVE MUST BE FITTED

Mixed HW out

Non-Return Valve (must be fitted)

Figure 3: Cold port of the blending valve connected to mains supply to the vessel after the inlet control group

Mains CW in

Mixed HW out

Mains CW in

Fitting Blending Valves To The Unvented

Viessmann Vitocell Appliances

When fitting a blending valve to the unvented appliances, it is important that the installation does not contravene the G3, WRC and Health and Safety directives or the manufacturers recommendations. If this is the case, then the warranty should be null & void. The key requirements to comply with these regulations are: -

1. Any fitting or material in contact with potable water (e.g. a blending valve) must be approved by WRC or an equivalent body.

2. Connections or wiring arrangements must not bypass any safety devices.

3. Any expansion due to heating must not be allowed to expand back into the cold mains.

4. The settings of any safety devices must not be tampered with or adjusted.

The diagrams opposite shows how the blending valve can be piped onsite.

Figure 1 shows the cold water port of the blending valve connected to the mains cold water supply before the inlet control group.

This arrangement is completely unacceptable and illegal because: -

• the water is allowed to expand in to mains cold water supply.

• the vessel will be charged to the incoming mains supply which may be considerably higher than the working pressure of the vessel.

If this arrangement is used then the warranty will not be valid.

Figure 2 shows the cold water port of the blending valve connected to the balanced cold water outlet. This arrangement will only be acceptable if a WRAS approved non-return valve is fitted, otherwise: -

• during the heating cycle, the water will expand back into the mains supply, as the regulating valve must not be relied upon to act as a check valve under all operating conditions.

• depending upon the characteristics of the blending valve, hot water may also flow from the balanced cold water taps.

Figure 3 shows the cold port of the blending valve connected to the cold water supply to the vessel after the inlet control group. This should be the preferred method. It is recommended that the installer should ensure that there is no gravity circulation in the pipework connected to the cold port. If necessary, this can be achieved by fitting a non-return valve or using a thermal trap.

Page 18

INSTALLATION

Schematic Showing Solar Wiring Requirements

Collector temperature sensor S1

Vitosolic 100 Type SD1

1

S1

2 3

S2

4 5

S3

6 9

PWM

10

145

11 12 13 14 15

N

16

R2

17

N

18

R1

19

N

20

L

21

Red/White Brown/Blue

C 1 2 C 1

No isolation valve should be installed between the solar circuit and the safety valve (pressure relief valve)

1 bar

Viessmann

Vitocell 200-B

Solar Cylinder

Pocket numbers as on Page 9

Solar

Pumping

Station

T

T

Anti Gravity

Check Valve

Pressure

Relief Valve

Anti Gravity

Check Valve

Pocket 9 Sensor

ZK00539 for boiler

Boiler

Coil

Solar

Coil

Pocket 6

Dual Thermostat

Set the control thermostat to maximum

Pocket 12

Solar Cylinder Temperature Sensor

1 2

L N

230 VAC 5 amp

Mains Supply

3 4 5 6 7 8 9 10

Standard 10 way wiring junction box

(Not supplied)

Page 19

INSTALLATION

Commissioning

Damage caused through a failure to do this adequately will not be covered by the warranty.

Connections can come loose in transit, and all should be checked before installation.

The 90 degree elbow fitted on the hot draw off needs to be positioned and tightened by installer.

The control thermostat of the immersion heaters for direct heating of our cylinders are set at 60°C. The control thermostat for indirect heat exchanger heat up of our cylinders are usually set at between 60°C - 65°C. During commissioning the actual temperature that the cylinder reaches when the thermostat(s) operate should be tested and adjusted so that it achieves a minimum of 60°C. This temperature needs to be achieved on a regular basis.

For the above reasons we recommend the use of a non chlorine dased disinfectant such as

Fernox LP Sterox as manufactured by Cookson

Electronics when carrying out disinfection of systems incorporating these appliances.

Remove the filter from the combination inlet group clean and replace. Refill the system and open all hot taps until there is no air in the pipe work. ENSURE CYLINDER IS DRAINED PRIOR

TO CHECKING OR REMOVING FILTER FROM

THE COMBINATION INLET GROUP.

Check the pressure on the air side of the expansion vessel = 3 bar. This must be done when the water in the cylinder is free to expand in atmospheric pressure or the cylinder and relevant pipe work is empty.

Check that the drain cock is closed, and open all the cold and hot water taps and other terminal fittings. Allow the system to fill with water, and to run until there is no air left in the system. Close the taps and inspect the system closely for leaks.

Allow the cylinder to heat to normal working temperature with whatever heat source is to be used, and check again for leaks. The pressure relief valve or the P&T valve should not operate during the heating cycle. If the P&T valve operates before the pressure relief valve due to high pressure, check that the inlet control group is fitted correctly.

Manually open the Relief Valves one by one and check that water is discharged and run freely through the tundish and out at the discharge point. The pipework should accept full bore discharge without overflowing at the tundish, and the valve should seat satisfactorily.

The boiler/heating systems should be filled and commissioned in accordance with good practice following the guidance in BS 7593:2006/the boiler manufacturers instructions.

In line with good plumbing practice, use with excessive flux should be avoided. When soldering above the cylinder, ensure flux/solder does not contaminate the cylinder below, since this can cause corrosion. Flushing should be done performed as per BS

EN 806:4 2010 section 6.2.

NOTE

Allow the cylinder to heat to normal working temperature, then thoroughly flush the domestic hot and cold water pipework through each tap.

At the time of commissioning, complete all relevant sections of the Benchmark Checklist located on the inside back pages of this document.

NOTE: If this appliance is to be installed in other than a single domestic dwelling ie. in an apartment block or student flats etc., the hot and cold water system will need to be disinfected in accordance with BS EB 806:4 2010 section 6.3 and the Water Regulations.

Because the Viessmann appliance is stainless steel, the use of chlorine as the disinfection agent can cause damage unless the appliance is adequately flushed and refilled with the mains water immediately on completion of the disinfection procedure.

This must be completed during commissioning and left with the product to meet the warranty conditions.

IMPORTANT - DRAIN DOWN PROCEDURE

1 Switch off both the boiler and the immersion heater

2 Open the nearest hot tap and run all hot water until cold, then close it

3 Close the incoming cold main at the stop tap

4 Hold open the pressure and temperature relief valve until water stops

discharging into the tundish and leave it open

5 Open the cold taps starting from the highest point and working down to the lowest tap, leaving them open

6 When the cold taps have stopped draining, open the hot taps starting from the highest and working down to the lowest tap

7 Open the drain cock and ensure the pressure and temperature relief valve is held open until the cylinder is empty

Page 20

USER INSTRUCTIONS

User Instructions

Your Viessmann Vitocell 200 Cylinder is automatic in normal use, but requires routine maintenance which is normally carried out at least annually along with the boiler service. The maintenance must be carried out by a suitably competent tradesperson who is qualified to work on unvented cylinders. The checks/work needed are listed in the maintenance part of these Instructions.

The control thermostat of the immersion heaters for direct heating of our cylinders are set at 60°C. The control thermostat for indirect heat exchanger heat up of our cylinders are usually set at between 60°C - 65°C. During commissioning the actual temperature that the cylinder reaches when the thermostat(s) operate should be tested and adjusted so that it achieves a minimum of 60°C, in order to comply with the Legionella pasteurisation requirements.

When initially opening the taps, a small surge in flow may be experienced, which disappears as the pressure in the system stabilises. This is quite normal with these types of systems and does not indicate a fault.

In some areas the water will initially appear cloudy, but will quickly clear when left to stand. This is nothing to be concerned about and is due to aeration of the water.

WARNING - If water is seen flowing through the tundish, this indicates a fault condition which needs action.

If the discharge is hot and continuous, turn the boiler and/or the immersion heaters off, but do not turn off the cold water to the appliance until the discharge is cold.

Note: The discharge may stop by itself as the discharge cools.

If the discharge is cold and intermittent, no immediate action is needed but this indicates a problem with the expansion vessel.

However, in both cases you must call the Registered Installer / a suitably qualified, competent tradesperson, advise them that you have an unvented cylinder and request a maintenance visit.

DO NOT, at any time, tamper in any way with the safety valves or overheat thermostats/ wiring.

Page 21

SERVICING

Maintenance

The Registered Installer is responsible for the safe installation and operation of the system. The installer must also make his customer aware that periodic maintenance of the equipment is essential for safety.

Maintenance periods will vary for many reasons. Viessmann Ltd recommend a maximum of 12 months to coincide with boiler maintenance. Experience of local water conditions may indicate that more frequent maintenance is desirable, eg, when water is particularly hard, scale-forming or where the water supply contains a high proportion of solids, eg, sand. Maintenance must include the following:

1. Check and clean filter

2. Manually check the operation of the temperature relief valve.

3. Manually check the operation of the expansion relief valve.

4. Check discharge pipes from temperature and expansion relief valves are free from obstruction and blockage and are not passing any water.

5. Check the condition and if necessary descale the heat exchangers in hard water areas.

6. Check that water pressure downstream of pressure reducing valve is within the manufacturer’s limits.

7. Check operation of motorised valve.

8. Check the pressure on the air side of the expansion vessel. This must be done when the water in the cylinder is cold.

9. Check and advise the householder not to place any clothing or other combustible materials against or on top of this appliance.

10. On completion of the work, fill in the Service Record part of the Benchmark section of the manual.

IMPORTANT NOTE

When draining down the appliance for any reason, the instructions provided in the Commissioning Section (Page 20) MUST be followed to prevent potential damage to the cylinder.

When carrying out the annual service on the appliance/boiler, it is recommended that with solar appliances, a check is made of the solar system pressure/expansion vessel charge pressure along with a visual check of the solar panels.

It is recommended that after a maximum of five years, the concentration/quality of the solar system antifreeze solution is checked and, if necessary, replaced.

After servicing, complete the relevant Service Interval Record section of the Benchmark

Checklist located on the inside back pages of this document.

Page 22

Problems And Remedial Action

Scale

In hard water areas it is recommended that an in-line scale inhibitor is fitted. Reducing the temperature of the stored water will reduce the rate at which scale forms. If the recovery rate is badly affected, this is an indication that scaling may have occurred.

In this event, follow the procedures as recommended by a reputable Water Treatment

Company.

General

No water at the tap. Check that the mains water supply is turned ON. Check the line strainer is not blocked. Check that the combination valve has been fitted so that water is flowing in the correct direction.

If the water at the tap is cold, ensure that the boiler has been switched ON and is working correctly. Check that there are no air locks in the primary system. ISOLATE

THE UNIT AT THE MAINS ELECTRIC SUPPLY AND THEN CHECK THE FOLLOWING: i. The cylinder thermostat ii. The thermal cut-out, which can be re-set by pushing the red button iii. The motorised valve iv. The boiler thermostat v. The boiler thermostat cut-out (if fitted)

ANY ENERGY CUT-OUT MUST NEVER BE BY-PASSED UNDER ANY CIRCUMSTANCES.

If the units are not getting hot and the heat source is electrical, ensure that the immersion heaters are isolated from the mains before re-setting the energy cut-out.

If the immersion heater(s) need replacing this should be done with the units supplied from Viessmann Limited.

Discharge From Relief Valves

If cold water is discharging from the expansion relief valve into the tundish check the pressure on the expansion vessel when cold and recharge if necessary.

If the fault continues and the problem cannot be stopped by operating the easing control a few times then either the Pressure Reducing Valve or the Relief Valve may be at fault. If the cold water pressure is too high, this would suggest that the Pressure

Reducing Valve is at fault and the Viessmann approved replacement should be fitted.

If the pressure is correct then the Relief Valve will require replacing with a Viessmann approved component.

See Commissioning for drain down procedure.

If there is an overheat fault and very hot water is being discharged, turn off the heat source, but not the water supply.

When the supply is cool, check thermostats and energy cut-outs in the boiler and immersion heaters and replace the faulty component with a unit supplied by Viessmann and check that it works correctly before returning the system to full operation.

SERVICING

Page 23

SERVICING

START

YES

Is boiler on?

YES

Is hot water programmer in ‘on’ position?

YES

Is zone valve in correct position?

YES

Is control temperature set at 60ºC - 65ºC?

YES

Has high limit cut out?

YES

Re-set

NO

NO

NO

NO

NO

NO

Switch on

Set programmer

Re-set, check wiring & plumbing is correct

Re-set

Is all wiring to the controls ok?

YES

Replace thermostat

NO

Re-wire

END

Fault - No Hot Water

Page 24

SERVICING

Fault - Poor Water Flow At Hot Taps

START

YES

Is incoming mains supply flow/pressure adequate?

YES

Is in-line strainer

(in combination valve) clean?

YES

Is pressure reducing valve

(in combination valve) working?

YES

Is system free from restrictions/blockages?

YES

END

NO

NO

NO

NO

Water service check by supply company required

Clean or replace strainer as appropriate

Service /replace PRV as appropriate

Clear obstructions

START

NO

Is pressure downstream of pressure reducing valve correct?

YES

Is valve seal and seat clean & undamaged?

YES

Is heater operating at less than 60ºC?

NO

NO

YES

Re-set temperature

Clean or replace as required

Is expansion vessel charge pressure correct?

YES

Replace ERV/TPRV

NO

YES

Recommission expansion vessel pressure

Replace PRV

Is ERV/TPRV discharging?

NO

END

Fault - Water Discharge Into Tundish

Page 25

SERVICING

SPARE PARTS LIST

Description

5

7

8

1

2

3

4

3kW immersion element

22mm 90° compression elbow c/w/drain

Pressure and temperature relief valve 6 bar 92-95°C

Inlet group set at 3 bar c/w expansion relief valve set at 4.5 bar

¾” flexible hose

12 litre expansion vessel

18 litre expansion vessel

9 24 litre expansion vessel

10 35 litre expansion vessel

11 Wall mounting bracket for 35 litre expansion vessel

12 22mm 2 port valve / Control and overheat limit thermostat

13 Junction wiring box (12 way)

14 15mm x 22mm tundish

15 Cylinder temperature sensor and retaining clip (ZK00539)

Quantity

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Gledhill Code

No.

SH001

SF003

SG019

SG021

SG024

XG190

XG191

XG192

XG193

XG058

EX042

XG129

XG207

GT530

Spares Part No.

7160753

7160754

7663214

7160765

Page 26

APPENDIX

Water Savings

Water Related Costs Can Be Reduced By Good Plumbing Practice

1

2

1

1

2 tap half open

Unregulated

Over

20 l/m

Fitted with regulator

5, 6 or

8 l/m

TAPS & MIXERS

2

2

4 Fixing Options For Taps & Mixers

1. MK Range - Combined Regulators & Aerator for screwing onto Taps & Mixers with internal or external threads on their noses. Anti Vandal models also available.

2. MR05-T Range - Internal Regulators. Pushfit into Tap or Mixer seats. Produced in three sizes - 12.5mm (BS1010), 12mm &

10mm, Flangeless models also available for

Taps with Low Lift washers.

Unregulated

25 - 30 l/m

Regulated

10 - 12 l/m

SHOWERS

3. MXF Standard Range - Screw on tail

models for Taps & Mixers. Fix onto the tails before fitting the tap connectors. Available in 3/8", 1/2", 3/4" and 1" BSP.

Vast quantities of water are needlessly run off to waste due to Taps, Mixers and Showers discharging flow rates far in excess of the rates required for them to perform their duties.

The contrasting flow rates shown on this leaflet clearly illustrate the savings that can be made whilst still providing a good performance.

British made Aquaflow Regulators provide constant flow rates by automatically compensating for supply pressure changes between 1 bar & 10 bars.

4. Compression Fitting Range - “In Line” regulators housed in 15mm & 22mm CXC

Couplers & Isolating Valves. “ ”UK WFBS listed by the Water Research Centre. Isolation valves available for slotted screwdriver operation or with coloured plastic handles. Now available also in plastic bodied push-fit couplers & valves.

To facilitate installation into the wide range of plumbing equipment which is encountered in the U.K, Four Fixing Options are available:-

3

Options For Showers

3

1. MXF “DW” Range - For fitting behind Fixed Shower Heads or onto Flexible Hoses for Handshowers (preferably onto the inlet end when lightweight hoses are used).

2. Compression Fitting Range. “In Line” regulators as in Option 4 for Taps & Mixers.

Information by courtesy of

AQUAFLOW REGULATORS LTD

Haywood House, 40 New Road, Stourbridge, West Midlands DY8 1PA

TELEPHONE (01384) 442611 FAX: (01384) 442612

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Page 27

APPENDIX

a. b. c. d. e.

MANUAL HANDLING OF APPLIANCE PRODUCTS

Description

Manual handling means any transporting or supporting of a load (including lifting, putting down, pushing, pulling, carrying or moving) by hand or bodily force.

Scope

This assessment will cover the largest unit within each product range.

For specific weights and dimensions please refer to technical data section.

Main Hazards

Vision may not be clear due to the size of the products.

Adopting an incorrect method of lifting may cause injury, attempting to lift these products will require help from others. (Team lifts)

Control Measures

Manual lifting procedure

e. Taking the lead for team lifts- As more than one person is required for these products ensure that one person is taking the lead. This may

be you so ensure that each person that is helping is made aware of the weight and of the items listed within this assessment. Make sure you and any others helping know the route you intend to take that it is clear of any obstructions. Never jerk the load as this will add a little extra force and can cause severe strain to the arms, back and shoulders. If there are steps involved decide on where you will stop and take a rest period. Move smoothly and in unison taking care to look and listen to others helping with the lift. Where possible use a sack truck to move the product over long flat distances, only lift the products when necessary. If in doubt stop and get more help.

The lift, key factors in safe lifting are:

Individual capability

a. b. c. d.

Balance

Position of back

Positioning of the arms and body

The hold

Taking the lead for team lifts

Individual capability plays an important part in handling these products. Persons above average build and strength will find it easier and should be in good health. Persons below average build and strength may require more rest periods during the handling process.

Balance - Since balance depends essentially upon the position of the feet, they should be apart about hip breadth with one foot advanced giving full balance sideways and forward without tension. In taking up this position, lifting is done by bending at the knees instead of the hips and the muscles that are brought into use are those of the thigh and not the back.

Pregnant women should not carry out this operation.

Position of back - Straight - not necessary vertical. The spine must be kept rigid, this coupled with a bent knee position, allows the centre line of gravity of the body to be over the weight so reducing strain.

Persons who are not in good health should seek medical advice prior to commencing any lifting or manual handling operation.

Residual risk

Positioning of arms and body - The further arms are away from the side, the greater the strain on the shoulders, chest and back. Keep elbows close to the body arms should be straight.

Following the guidelines given above will reduce any risk to injury.

The hold - Before lifting ensure you have a good hold.

All persons carrying out this operation must be fully trained and copies of the specific risk assessment made available for inspection and use in their training process.

Further guidance on Manual Handling can be obtained from the Health and

Safety Executive. Manual Handling

Operations Regulations 1992.

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Page 29

NOTES

MAINS PRESSURE HOT WATER STORAGE SYSTEM COMMISSIONING CHECKLIST

BENCHMARK

Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

This Commissioning Checklist is to be completed in full by the competent person who commissioned the storage system as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

Commissioned by (PRINT NAME): Registered Operative ID Number

Company name: Telephone number:

Telephone number:

Commissioning date:

Address:

Cylinder Make and Model

Registered Operative ID Number

Open

°C

ALL SYSTEMS

Commissioning date:

Sealed

Yes

Yes

Yes bar

No

No

ALL SYSTEMS

What is the incoming static cold water pressure at the inlet to the system?

What type of scale reducer has been fitted?

What is the hot water thermostat set temperature?

Y Plan

Yes

Yes

°C bar

No

°C

No

No

°C

Yes

I/min

Yes

°C

Y Plan S Plan

Yes

Yes

°C

Yes

No

Yes

Yes

Yes bar

No

Yes

°C

°C

The system has been installed and commissioned in accordance with the manufacturer’s instructions

The system controls have been demonstrated to and understood by the customer

The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer

Commissioning Engineer’s Signature

Customer’s Signature

(To confirm satisfactory demonstration and receipt of manufacturer’s literature)

Yes

Yes

°C

°C

Yes

Yes

Yes

Yes

* All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a

Competent Persons Scheme. A Building Regulations Compliance Certificate will then be issued to the customer.

© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk

While this Checklist can be used for any installation covered by its description, only appliances manufactured by Scheme Members will be covered by the rules and requirements of the Benchmark Scheme.

* All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a

Competent Persons Scheme. A Building Regulations Compliance Certificate will then be issued to the customer.

© Heating and Hotwater Industry Council (HHIC)

Page 30

www.centralheating.co.uk

BENCHMARK

SERVICE RECORD

It is recommended that your hot water system is serviced regularly and that the appropriate Service Record is completed.

Service Provider

Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.

SERVICE 01

Engineer name:

Company name:

Telephone No:

Comments:

Date:

SERVICE 02

Engineer name:

Company name:

Telephone No:

Comments:

Date:

Signature

SERVICE 03

Engineer name:

Company name:

Telephone No:

Comments:

Date:

Signature

SERVICE 05

Engineer name:

Company name:

Telephone No:

Comments:

Date:

Signature

SERVICE 04

Engineer name:

Company name:

Telephone No:

Comments:

Date:

Signature

SERVICE 06

Engineer name:

Company name:

Telephone No:

Comments:

Date:

Signature

SERVICE 07

Engineer name:

Company name:

Telephone No:

Comments:

Date:

Signature

SERVICE 09

Engineer name:

Company name:

Telephone No:

Comments:

Date:

Signature

Signature

SERVICE 08

Engineer name:

Company name:

Telephone No:

Comments:

Date:

Signature

SERVICE 10

Engineer name:

Company name:

Telephone No:

Comments:

Date:

Signature

Page 31

Viessmann Werke GmbH&Co KG

D-35107 Allendorf

Telephone: +49 6452 70-0

Fax: +49 6452 70-2780 www.viessmann.com

Viessmann Limited

Hortonwood 30, Telford

Shropshire, TF1 7YP, GB

Telephone: +44 1952 675000

Fax: +44 1952 675040

E-mail: [email protected]

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