Installation and service instructions for contractors VIESMANN Vitocell 340-M/360-M Type SVKA Type SVSA Combi cylinder 750 and 950 litre capacity VITOCELL 340-M/360-M 4/2009 Please keep safe.
Safety instructions Safety instructions 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 fitter. 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, the Code of Practice of relevant 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 lead to serious injury. Do not 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-threatening poisoning. Shut down the heating system. Ventilate the boiler room. Close all doors in the living space. 2
Safety instructions Safety instructions (cont.) Working on the system 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 main isolator. Safeguard the system against unauthorised reconnection. Please note! Electronic modules can be damaged by electrostatic discharges. Touch earthed objects, such as heating or water pipes, to discharge static loads. Ancillary components, spare and wearing parts Please note! Spare and wearing parts that have not been tested together with the heating system can compromise its function. Installing non-authorised components and non-approved modifications or conversions can compromise safety and may invalidate our warranty. For replacements, use only original spare parts supplied or approved by Viessmann. Repair work! Please note Repairing components that fulfil a safety function can compromise the safe operation of your heating system. Replace faulty components only with original Viessmann spare parts. 3
Index Index Installation instructions Preparing for installation Product information... 5 Installation sequence Siting the combi cylinder... 9 Fitting the thermal insulation... 10 Fitting the cylinder temperature sensor... 15 Connecting the equipotential bonding... 16 Installing an air vent valve on the solar side... 16 Installing a DHW circulation (accessory)... 17 Connecting the DHW side... 18 Connecting the heating water side... 19 Service instructions Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance... 22 Further details regarding the individual steps... 23 Parts lists... 25 Commissioning/service reports... 27 Product parameters... 28 Accessories Specification, immersion heater... 29 Certificates Declaration of conformity... 30 4
Preparing for installation Product information Vitocell 340-M and 360-M Combi cylinder made from steel for central heating backup with corrugated stainless steel pipe for DHW heating in conjunction with oil, gas and solid fuel boilers, solar thermal systems, heat pumps and/or an immersion heater. Suitable for systems conforming to DIN 1988, EN 12828 and DIN 4753. The Vitocell 360-M is also equipped with a stratification system. Capacity 750 litres 950 litres Heating water: 708 litres 906 litres DHW: 30 litres 30 litres Solar heat transfer medium: 12 litres 14 litres Installation 5
Preparing for installation Product information (cont.) Connections A Thermometer sensor retainer B Thermometer (TH) 2 pce in standard delivery, up to 4 pce can be installed C Female connection for immersion heater (ELH) Front 6
Preparing for installation Product information (cont.) A Heating water flow 1 (HV1) from the heat source/ventilation (EL) B DHW/DHW circulation (Z) C Thermometer sensor retainer D Sensor well for cylinder temperature sensor 1 (SPR1) E Heating water flow 2 (HV2)/heating water return 1 (HR1) Central heating backup F Sensor well for cylinder temperature sensor 2 (SPR2) and thermometer sensor G Heating water return 2 (HR2) Central heating backup H Sensor well for thermometer sensor and cylinder temperature sensor 3 (SPR3) K Heating water return 3 (HR3) to the heat source L Cold water (KW) M Drain (E) N Heating water flow solar (HVs)/drain solar (EL) O Thermometer sensor retainer P Heating water return solar (HRs) Installation Back 7
Preparing for installation Product information (cont.) Installation information Please note! To prevent material losses, install the combi cylinder in a draughtfree room free from the risk of frost. Otherwise the combi cylinder will have to be drained if there is a risk of frost and it is not in use. Please note! The thermal insulation must not be able to come into contact with naked flames. Exercise caution when welding and soldering. Maintain minimum clearance in front of the cylinder. Note The unheated length of any threaded immersion heater installed on site must be at least 100 mm. Output Dimension a Immersion heater 6 kw min. 650 mm 12 kw min. 950 mm Provide adequate clearance from the wall so that the thermostat can be operated (if installed). Installing the combi cylinder with an immersion heater a Installation instructions, immersion heater 8
Installation sequence Siting the combi cylinder 1. 2. 4. Installation 3. 1. Remove all packs from the cylinder body, and keep safe. 2. Insert the adjustable feet into the hexagon nuts as far as they will go and level the cylinder. 3. Install the thermal insulation mat under the cylinder body. 4. If no immersion heater is installed, seal the front female connection with the plug supplied (R 1½). Note Never wind out the feet more than 35 mm. 9
Installation sequence Fitting the thermal insulation Fitting the thermometer sensor (if installed) 4. 2. 1. 3. 5. 6. 7. 1. Route the thermometer sensor through the cover strip and insert the thermometer. 2. Route the upper thermometer sensor through the lifting eye, insert it into the clamping bracket as far as it will go and tighten the wing nut. 10
Installation sequence Fitting the thermal insulation (cont.) Note The cover strip is held in its vertical position by the wound capillaries. This is necessary for the rest of the installation. 3. Route the thermometer sensor capillaries to the back of the cylinder. Note Repeat the following steps subject to the number of installed thermometers. 4. Depending on the fitting location, secure the thermometer sensor in the clamping bracket or pull the sensor retainer out of the sensor well. 5. Secure the sensor on the outside of the contact spring of the sensor retainer so that it is flush with the front of the spring. 6. Secure the thermometer sensor capillaries. Note Never wrap insulating tape around the thermometer sensor. 7. Insert sensor retainer as far as it will go. Installation 11
Installation sequence Fitting the thermal insulation (cont.) Fitting the thermal insulation jacket 3. 3. 1. 2. 0 45 15 30 min 1. Lay both parts of the thermal insulation jacket around the cylinder body and hook into the closure strip at the back. 2. Push the cover strips onto the closure strip at the back. 3. Close the thermal insulation jacket at the front and hook the closure strip into the first notch. 12
Installation sequence Fitting the thermal insulation (cont.) Fitting the cover strip Note After 30 min, the thermal insulation jacket will have adjusted to the cylinder and the closure strip can be more easily hooked into the final notch. 4. 2. Installation 1. 3. 1. Fit the thermal insulation jacket by patting it tightly against the cylinder body. 2. Hook the closure strip into the final notch. 3. Push the cover strip onto the closure strip and cover the unused openings with the covers. 4. Affix the type plate. 13
Installation sequence Fitting the thermal insulation (cont.) Fitting the top cover 3. 2. 1. A Viessmann logo 1. Fit the thermal insulation mat. 3. Affix the Viessmann logo. 2. Fit the top cover. 14
Installation sequence Fitting the cylinder temperature sensor Note The cylinder temperature sensor is supplied in the control unit pack. 1. 2. 3. 4. A Sensor wells for cylinder temperature sensor Installation 15
Installation sequence Fitting the cylinder temperature sensor (cont.) Note Never wrap insulating tape around the sensor. Secure the sensor on the outside of the contact spring of the sensor retainer (not in the groove) so that it is flush with the front of the spring. Insert the sensor retainer together with the sensor into the sensor well as far as it will go. Connecting the equipotential bonding Connect the equipotential bonding in accordance with the requirements stipulated by your local power supply utility and VDE [or local] regulations. Installing an air vent valve on the solar side 2. 1. 3. 16
Installing an air vent valve on the solar side (cont.) Installation sequence 1. Push the corrugated hose into the elbow fitting. 2. Insert the air vent plug into the elbow fitting. 3. Push the corrugated hose into the solar flow and seal in the elbow (flat gasket). Installing a DHW circulation (accessory) 2. Installation 1. 1. Seal the corrugated hose into the tee (connection R ½). 2. Fully push in and seal in the tee with the corrugated hose into the DHW connection. Note Rotating eases the entry of the corrugated hose. 17
Installation sequence Connecting the DHW side For connecting on the DHW side, observe DIN 1988 and DIN 4753. Connect all pipework with detachable fittings. Seal connections that are not required with red brass caps. Equip the DHW circulation pipe with a DHW circulation pump, check valve and time switch. Connect the DHW circulation pump either to the control unit or the separate time switch Permiss. temperature: 95 C Permiss. operating pressure: 10 bar Test pressure: 16 bar WW ZP KW Z SIV AV MA EV EV DMV RV2 MAG-W DFR RV1 AV AV TF AV KW EV A Spring-loaded check valve B Visible discharge pipe outlet AV Shut-off valve DFR Flow regulating valve DMV Pressure reducer EV Drain KW Cold water MA Pressure gauge connection MAG-W Diaphragm expansion vessel (suitable for DHW) RV1 RV2 SIV TF WW Z ZP Non-return valve Non-return valve/pipe separator Safety valve Drinking water filter DHW DHW circulation pipe DHW circulation pump 18
Installation sequence Connecting the DHW side (cont.) Information regarding the safety valve The system must be equipped with a type-tested diaphragm safety valve as protection against overpressure. Permiss. operating pressure: 10 bar. The connection diameter of the safety valve must be R ¾ (DN 20). Consequently, the max. permissible heat input would be 150 kw. If the heat input of the Vitocell exceeds 150 kw, select a larger safety valve that is able to cope with the respective heat input (see DIN 4753-1, issue 3/88, section 6.3.1). Install the safety valve in the cold water pipe. It must not be able to be isolated from the DHW cylinder. The pipework between the safety valve and the DHW cylinder must not be restricted in any way. The safety valve discharge pipe must not be able to be closed. Expelled water should be safely and visibly drained into a sewer. Place a sign close to the safety valve discharge pipe or on the safety valve itself with the following inscription: "For safety reasons, water may be discharged from the discharge pipe during heating. Never seal off!" Install the safety valve above the top edge of the DHW cylinder. Installation Connecting the heating water side Adjust the thermostat and high limit safety cut-out so that the DHW temperature in the cylinder never exceeds 95 ºC. Connect all pipework with detachable fittings. Permissible temperatures on the solar side: 140 C on the heating water side: 110 C Permissible operating pressure on the solar side: 10 bar on the heating water side: 3 bar 1. Install the flow pipes with an incline and fit an air vent valve at the highest point. 2. Install control equipment that ensures the permissible temperatures on the heating side are maintained. 3. Install an additional type-tested high limit safety cut-out, if none has been installed so far in the system. For this, use a twin thermostat (temperature limiter and high limit safety cut-out). Test pressure on the solar side: on the heating water side: 16 bar 4.8 bar 4. Seal all unused connections with plugs or caps. 19
Installation sequence Connecting the heating water side (cont.) Installation example P HC WW Z HV1/EL WW/Z A EA B M K SPR1 HV2/HR1 SPR2 HR2 SPR3 HR3 KW E HVs/HRs A Solar collector B Combi cylinder 20 KW
Installation sequence Connecting the heating water side (cont.) C HC K Solar control unit Heating circuit Oil/gas boiler KW Cold water WW DHW Z DHW circulation For combi cylinder connections, see page 6. Installation 21
Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page 1. Filling the DHW cylinder... 23 2. Inspection and maintenance... 23 3. Shutting down the system 4. Cleaning the inside of the DHW cylinder... 24 5. Checking connections on the water side for leaks 6. Instructing the system user... 24 22
Further details regarding the individual steps Filling the DHW cylinder Commissioning, inspection, maintenance 1. Fill the DHW cylinder from the DHW side. Note Initially fill the cylinder on the DHW side, then on the heating water side. If the DHW side of your cylinder cannot be filled yet, but you want to commission your heating system, then you can operate your cylinder with a pressure of 2.5 bar on the heating water side. 2. Check the fittings on the heating water and DHW side for leaks and retighten if required. 3. Check the function of the safety valves according to manufacturer's instructions. Operation without DHW heating: Operating instructions for the heating system Note The solar coils are vented via the solar flow. Collect excess solar heat transfer medium with a flexible hose above the air vent plug and restart the system. Alternatively: Service instructions for the solar thermal system Inspection and maintenance DIN 1988 requires a visual inspection and (if required) cleaning no later than two years after commissioning of the cylinder and thereafter according to requirements. Service 23
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the inside of the DHW cylinder 1. Drain the cylinder from the DHW side. 2. Disconnect the cylinder on the DHW side from the pipework to prevent cleaning agents and contaminants entering the pipework. 3. You can also carry out cleaning on the DHW side with chemical cleaning agents.! Please note Never use cleaning agents containing hydrochloric acid, to prevent material losses. 4. Fully drain any cleaning agent. 5. Thoroughly flush the indirect coil on the DHW side after cleaning. 6. Reconnect the cylinder to the pipework. 7. Fill the cylinder from the DHW side. Danger Cleaning agent residues can lead to poisoning. Always observe the details provided by the manufacturer of the cleaning agent. Instructing the system user The installer must instruct the user in the operation of the system. 24
Parts lists Parts lists When ordering spare parts: Quote the part no. and serial no. (see type plate) and the pos. no. of the required part (as per this parts list). Obtain standard parts from your local supplier. 001 Cover 002 Upper thermal insulation mat 003 Lower thermal insulation mat 004 Thermal insulation mat (right) 005 Thermal insulation mat (left) 006 Front cover strip 007 Thermometer 008 Sensor retainer 009 Adjustable foot 010 Viessmann logo 011 Air vent plug 012 Plug 013 Elbow with gasket 014 Clamping bracket 015 Air vent hose 016 Plug Parts not shown 300 Installation and service instructions A Type plate Service 25
Parts lists Parts lists (cont.) 010 007 004 005 001 002 016 A 014 006 012 014 008 014 003 013 015 008 011 009 26
Commissioning/service reports (cont.) Commissioning Service Service date: by: Service Service Service date: by: Service Service Service date: by: Service Service Service date: by: date: by: Service Service Service Service 27
Product parameters Product parameters Cylinder capacity l 750 950 Standby heat loss *1 kwh/24 h 1.49 1.61 q B,S with 45 K temperature differential V aux (Standby capacity) l 346 435 V sol (Solar capacity) l 404 515 *1 Standard parameter 28
Accessories Specification, immersion heater Immersion heater 6 kw Rated output in standard operation kw 2 4 6 Rated voltage 3/N/PE 400 V /50 Hz Rated current A 8.7 Type SVKA/SVSA, 750 litres Heat-up time from 10 to 60 C h 10 5 3.4 Capacity that can be heated with the immersion heater l 346 Type SVKA/SVSA, 950 litres Heat-up time from 10 to 60 C h 12.6 6.3 4.3 Capacity that can be heated with the immersion heater 435 Immersion heater 12 kw Rated output in standard operation kw 4 8 12 Rated voltage 3/N/PE 400 V /50 Hz Rated current A 17.4 Type SVKA/SVSA, 750 litres Heat-up time from 10 to 60 C h 5.0 2.5 1.7 Capacity that can be heated with the immersion heater l 346 Type SVKA/SVSA, 950 litres Heat-up time from 10 to 60 C h 6.3 3.2 2.1 Capacity that can be heated with the immersion heater l 435 Service 29
Certificates Declaration of conformity We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, declare as sole responsible body, that the product Vitocell 340-M and Vitocell 360-M conforms to the following standards: DIN 4753 DIN EN 12897 AD2000 datasheets This product is identified with _-0036 in accordance with the following Directives: 97/23/EC Details according to the Pressure Equipment Directive (97/23/EC): Heated pressure vessel (not at risk from overheating) DHW and heating water proportion according to article 3, section (3) Solar part according to category II, diagram 5 Modules B and C 1 according to appendix III Materials according to AD2000 regulations, individual assessment and appendix I, 4.2, b) Corrosion supplement to appendix I, 2.2 and AD2000 regulations The pressure device was tested without fitted equipment (safety assembly). It must be equipped in accordance with current national regulations before installation and commissioning. The product characteristics determined as system values for the products Vitocell 340-M and Vitocell 360-M as part of the EC type testing according to the Efficiency Directive (see table on page 28) can be utilised to assess the energy consumption of heating and ventilation equipment to DIN V 4701-10 which is specified by the EnEV [Germany]. Allendorf, 30 March 2009 Viessmann Werke GmbH&Co KG pp. Manfred Sommer 30
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Printed on environmentally friendly, chlorine-free bleached paper 32 Viessmann Werke GmbH&Co KG D-35107 Allendorf Telephone: +49 6452 70-0 Fax: +49 6452 70-2780 www.viessmann.com Subject to technical modifications.