Installation Instructions

Introduction

Safety, Installation and Warranty Requirements

Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).

• Licensed professional heating contractor: The installation, adjustment, service and maintenance of this equipment must be performed by a licensed professional heating contractor. Please see section entitled "Important Regulatory and Installation Requirements".
• Product documentation: Read all applicable documentation before commencing installation. Store documentation near product in a readily accessible location for reference in the future by service personnel. For a listing of applicable literature, please see section entitled "Important Regulatory and Installation Requirements".
• Advice to owner: Once the installation work is complete, the heating contractor must familiarize the system operator/ultimate owner with all equipment, as well as safety precautions/requirements, shutdown procedure, and the need for professional service annually before the heating season begins.
• Warranty: Information contained in this and related product documentation must be read and followed. Failure to do so renders the warranty null and void.

General Information

About These Instructions

Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include "WARNING", "CAUTION", and "IMPORTANT".

• WARNING: Indicates an imminently hazardous situation which, if not avoided, could result in substantial product/property damage, serious injury or loss of life.
  Warnings draw your attention to the presence of potential hazards or important product information.
• CAUTION: Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or product/property damage.
  Cautions draw your attention to the presence of potential hazards or important product information.
• IMPORTANT: Helpful hints for installation, operation or maintenance which pertain to the product.
• This symbol indicates that additional, pertinent information is to be found.
• This symbol indicates that other instructions must be referenced.

Product Information

42 USG to 119 USG (160 L to 450 L) capacity

Enameled indirect-fired domestic hot water storage tank with one heat exchanger coil for use with hot water heating boilers, residential/commercial heating plants, and low-temperature heating systems. These tank versions are not suitable for steam heating applications.

Set-up and Connections

Tank Connections

The tank features various connection points for domestic hot water (DHW), recirculation tapping (RT), sensors (TS/AQ), boiler water supply (BWS), boiler water return (BWR), domestic cold water supply (DCW), and grounding (GND).

42 to 79 USG (160 to 300 L) Tanks

Supplied adaptor sizes:

Legend: DHW: Domestic hot water supply; RT: Recirculation tapping; TS/AQ: DHW temperature sensor or aquastat of boiler control (upper indirect coil); BWS: Boiler water supply; BWR: Boiler water return; DCW: Domestic cold water supply; GND: Grounding connection (casing) for 42 to 79 USG (160 to 300 L) only. The upper indirect coil is provided for connection to a boiler or a heat pump.

119 USG (450 L) Tank

Supplied adaptor sizes:

Tank Set-up

When transporting the tank through narrow passageways, remove upper and lower portions of the crating and use crating boards mounted on the tank. Position the tank carefully and remove wood crating. Locate the tank(s) on a floor or foundation capable of supporting the weight of the tank(s) when filled with water. The tank does not require a special foundation and can be placed directly on the floor. If desired for cleanliness, a foundation can be used to elevate the tank(s) off the floor.

Recommended installation clearances for service access

Minimum clearances to combustibles

42 to 79 USG (160 to 300 Liter) Tank Installation

Thermal insulation and thermometer installation

All required components are included in the insulation jacket carton. Note: The 42 to 79 USG (160 and 300 L) tank comes with the insulation jacket installed.

1. Position and level the DHW tank with its leveling bolts.
   IMPORTANT: Do not extend the leveling bolts beyond an overall length of 1½ in. (35 mm).
2. Mount the sensor on the outside of the sensor spring-clip (not in the center groove) so that it is flush with the front of the sensor spring-clip.
3. Snap the sensor cabling into the plastic clip of the sensor mounting equipment.
   IMPORTANT: Never wrap insulating tape around the sensor.
4. Completely insert sensor mounting hardware along with the sensor into the sensor well.
5. Remove the top cover and insulation blanket.
6. Remove the cap from the thermometer opening.
7. Slide the thermometer sensor cable through the thermometer opening in the panel and insert the thermometer.
8. Completely insert the sensor into the metal clip on the flange (check anode connection on page 9). Install the insulation blanket and top cover.

Temperature sensor installation for solar operation using 42 to 79 USG (160 to 300 L) tanks

The temperature sensor for solar operation is included in the solar control unit package. The brass elbow with sensor well is available as an option and must be used when solar connection is required.

1. For solar operation, install the sensor well into the brass elbow and connect the assembly to the solar return line.
2. Insert the temperature sensor until it bottoms out inside the sensor well.
   IMPORTANT: Never wrap insulating tape around the sensor. Do not install solar tank sensor anywhere other than the brass elbow with sensor well.

Checking anode connections

Ensure the grounding wire is properly secured to the magnesium anode.

119 USG (450 Liter) Tank Installation

Temperature sensor installation (when using a Vitotronic 200 / 300 or Vitodens 200)

1. Mount the sensor on the outside of the sensor spring-clip (not in the center groove) so that it is flush with the front of the sensor spring-clip.
2. Snap the sensor cabling into the plastic clip of the sensor mounting equipment.
   IMPORTANT: Never wrap sensor with any type of tape or insulation.
3. Completely insert sensor mounting equipment along with the sensor into the sensor well. Note: When using a Vitotronic 100 boiler control, refer to page 14 for aquastat installation.
   IMPORTANT: Always use spring clip to ensure proper contact of capillary bulb against the stainless steel well for proper sensing/heat transfer!

Temperature sensor installation for solar operation using 119 USG (450 L) tank

The temperature sensor for solar operation is included in the solar control unit package. The brass elbow with sensor well is available as an option and must be used when solar connection is required.

1. For solar operation, install the sensor well/brass elbow and connect the assembly to the solar return line.
2. Insert the temperature sensor until it bottoms out inside the sensor well.
   IMPORTANT: Never wrap insulating tape around the sensor. Do not install solar tank sensor anywhere other than the brass elbow with sensor well.
3. Tighten screws to secure sensor (do not over tighten).

Levelling and bottom thermal insulation

All necessary parts for enclosure assembly are packaged in a separate carton.

1. Fit the thermal insulation blanket below the tank prior to the installation of the tank itself.
2. Position and level the DHW tank with its leveling bolts.
   IMPORTANT: Do not extend the leveling bolts beyond an overall length of 1½ in. (35 mm).

Fitting the thermal insulation jacket

Note: Insulation remnants must not enter the tank through the tank connections. 2 people are recommended to complete this work.

1. Fit both halves of the insulation jacket close to the tank. Orient the jacket so the profile cutouts match the tank fittings.
2. At the rear of the tank, install all 6 clip closures evenly to both halves of the insulation jacket.
3. At the front of the tank, install all 6 clip closures evenly to both halves of the insulation jacket.
4. At the rear of the tank, tighten all 6 clip closures until both halves of the insulation jacket meet.
5. At the front of the tank, tighten all 6 clip closures until both halves of the insulation jacket meet.

Fitting the thermometer and thermometer sensor and covers

1. Smooth out the insulation jacket by tapping the jacket evenly against the tank.
2. Route the thermometer capillary tube through the front cover hole and insulation jacket, then snap the thermometer in place.
3. Insert the thermometer probe under the clip.
4. Install the front cleanout cover and the front lower seam cover.
5. Install the upper front seam cover.
6. Install the back seam cover.
7. Install the top insulation and press down the edges as shown.
8. Install the top lid and press the logo A into the lid. Note: Seal the hole in the seam cover below the thermometer with a cover.

Aquastat Installation (when using a Vitotronic 100)

Where a Vitotronic 100 and a Viessmann Power/Pump Control Module (accessory) are utilized to control DHW production, follow these aquastat mounting instructions:

Probe style aquastat:

1. Insert the extended capillary of the aquastat (supplied with Viessmann Power/Pump Control Module, not illustrated) fully and completely into the sensor well. Mount the aquastat inconspicuously on the tank paneling. Follow instructions below with regard to sensor and spring clip installation.
2. If the aquastat is to be mounted remote from the tank well, align the sensor bulb with the spring clip.
3. Slide the assembly into the well.
4. The retention spring clip must press the bulb properly to ensure surface contact with the well.
5. If the aquastat is to be mounted directly on the tank well, mount the aquastat with the holding clip supplied directly onto the well. Bend the capillary tube into the groove opening to allow for mounting of the aquastat.

Grounding connection: Connect the grounding in accordance with the requirements stipulated by your local electricity supply company and current local regulations.

Boiler Water Connections (heat exchanger connection)

Recommended piping for solar application with an additional tank

Diagram Description: The diagram illustrates a solar heating system connected to a Vitocell 100-V tank. Components include a solar collector (A), high limit safety cut-out (B), filling valve (C), Solar-Divicon (D), Vitocell 100-V (E), individual DHW tank heating system (F), and an anti-scald tempering valve (G).

1. For boiler water supply temperatures over 203°F (95°C): Remove plastic supply and return grommets (grommets are left-threaded).
2. Pipe the supply line with an incline and install an air vent valve at the highest point.
3. For boiler water supply temperatures over 230°F (110°C): Install a type-tested high limit safety cut-out, if no other has previously been installed in this system. For this purpose, install a dual thermostat (high limit thermostat and high limit safety cut-out).
4. Close off test nipples which are not used for the installation of a probe or sensor.

Domestic Water Connections

Notes: Connect all pipe work with detachable fittings. Seal connections that are not required with red brass caps. Equip the DHW circulation pipe with a circulation pump, check valve, and time switch. Gravity operation is only feasible to a limited degree. Always install DHW group of tanks with connected DHW circulation.

1. Pipe together the boiler and tank as illustrated. Connections must be accessible for service (use factory supplied adaptors).
2. Insulate domestic hot water supply piping.

Legend: A: Spring-loaded flow check valve, B: Discharge pipe, C: Anti-scald tempering valve (field supplied), SV: Shut-off valve, FV: Flow check valve, PR: Pressure reducing valve, D: Drain, DCW: Cold water supply lines, PGC: Pressure gage connection, E: Precharged expansion tank (required where backflow preventer is installed; check local plumbing codes and requirements), BP1: Backflow preventer, BP2: Backflow preventer, T&P: Temperature and pressure relief valve, DW: Water filter, DHW: Domestic hot water supply, RP: Recirculation pipe, RPU: Recirculation pump.

Domestic Water Connections (continued)

Always ensure the use of type approved devices. Safety devices include:

• Isolation valves
• Drain valve
• Pressure reducing valve (where required by local jurisdiction)
• Drinking water filter (where required by local jurisdiction)
• Backflow preventer: Where backflow preventers are required, a domestic water expansion tank installation is required in the cold water inlet piping before the cold water enters the tank. The backflow device must be installed according to the manufacturer's installation instructions. Observe local codes and regulations.
• Tempering valve: A tempering valve must be field installed where storage tank (domestic hot water temperature) exceeds local restricted temperatures or 140°F (60°C). Check code requirements.

Temperature and pressure relief valve (T&P valve): A T&P valve is supplied with the tank. The heating contractor must install the valve on each tank in a method meeting code requirements. If local codes require a different relief valve, consult Viessmann Manufacturing for a substitute valve. The tank is approved for 150 psig. Maximum operating pressure is 150 psig. The T&P valve supplied with the tank is tested under ANSI Z21.22 Code for Relief Valves and Automatic Gas Shut-off Devices for Hot Water Supply Systems.

Proper installation of the T&P valve shall include all of the following:

• The T&P valve shall be installed in the pipe connection point marked TPV in the tank instruction manual.
• The discharge line from the T&P valve shall be 3/4 in. (1.9 cm) and run to a safe place of discharge approximately 1 ft. (30 cm) above the floor, close to a floor drain.
• The discharge line must be as short as possible and pitch downward from the T&P valve and terminate plain, not threaded.

T&P Valve Specifications:

• CSA discharge capacity: 205 MBH
• Relief temperature: 210°F (99°C)
• Inlet thread: 3/4" male
• Outlet thread: 3/4" female

Recirculation Connections

Pipe domestic hot water supply piping with the tank as illustrated. Connections must be accessible for service (use factory supplied adaptors). Install recirculation pump, flow check valve, and recirculation timer (for shut-down during off-hours where feasible) on the recirculation piping side. Gravity circulation of the recirculation system is restricted due to the upward-curved domestic hot water discharge piping inside the tank.

Connect tanks to existing recirculation piping. Cap off unused recirculation connections of individual tanks.

Saving Energy

A timer on the recirculation pump reduces heat loss significantly in commercial applications during times when no or reduced demand for domestic hot water occurs.

Connection of a recirculation system in a multiple tank installation for systems utilizing boilers or remote heating plants without low temperature boiler return water:

Diagram Description: Illustrates recirculation connections for multiple tanks, showing drawpoints, recirculation piping, circulation pump, flow check valve, domestic cold water supply, domestic hot water supply, secondary high limit aquastat location, and air vent.

Legend: A: Drawpoints, B: Recirculation piping, C: Circulation pump, D: Spring-loaded flow check valve, E: Domestic cold water supply, F: Domestic hot water supply, G: Secondary high limit aquastat location, H: Air vent.

Connection of a recirculation system in a multiple tank installation for remote heating plants with low temperature boiler return water limit and/or for multiple recirculation lines:

Diagram Description: Similar to the above, illustrating recirculation connections for multiple tanks in a remote heating plant setup.

Legend: A: Drawpoints, B: Recirculation piping, C: Circulation pump, D: Spring-loaded flow check valve, E: Domestic cold water supply, F: Domestic hot water supply, G: Secondary high limit aquastat location, H: Air vent.

Multiple Tank Set-up [only for 79 and 119 USG (300 and 450 L) capacities]

Two tanks, each with 79 USG (300 L) content, or up to four tanks, each with 119 USG (450 L) content, may be installed side-by-side. The tanks are controlled via one DHW tank aquastat; individual control of tanks within the group is not possible. If individual tank control is necessary, a 4-tank group can be separated into smaller groups (e.g., two batteries of two tanks each), or all tanks can be installed individually.

1. Install aquastat in the boiler water supply of the last tank receiving the boiler water in a group of tanks (see illustration).
2. Install domestic cold and hot water header lines (see illustration).
3. Install boiler water supply and return header lines (see illustration).
4. Make final cold and hot water connections.
5. Insulate header piping lines.

Storage capacity / tank:

Recommended piping of multiple tanks

All piping should be reverse return or use balancing valves. Connections must be accessible for service (use factory supplied adaptors).

1. Pipe together boiler and tanks as illustrated.
2. For boiler water supply temperatures over 203°F (95°C): Remove plastic supply and return grommets (grommets are left-threaded).
3. Pipe the supply line with an incline and install an automatic air vent at the highest point.
4. Install boiler sensor in sensor well (see pages 8 and 10).
5. Insulate piping.

Additional Information

Pressure Drop Information

Pressure drop on heating water side (primary circuit): Graphs show pressure drop in w.c./mbar versus flow rate in L/min and GPM for different storage capacities (A: 42/53 USG, B: 79 USG, C: 119 USG).

Pressure drop on domestic hot water side (secondary circuit): Graphs show pressure drop in w.c./mbar versus flow rate in L/min and GPM for different storage capacities (A: 42/53 USG, B: 79 USG, C: 119 USG).

Inspection Opening

Inspection opening for 79 USG (300 L) tank

1. Install front insulation blanket.
2. Install inspection cover and front cover.
3. Tighten screws.

Inspection opening for 119 USG (450 L) tank

1. Install front insulation blanket.
2. Install inspection cover.

Post Installation

Service binder

1. File all Parts Lists, Operating and Service Instructions in the Service Binder.
2. Install a protective hanging case near the boiler and store the Service Binder in this location. For a listing of applicable Viessmann literature, please see Important Regulatory and Installation Requirements on page 4.

Start-up information

Refer to DHW Tank Start-up/Service Instructions.

Installation Set

Parts:

• 0301 Tee
• 0302 Hex bushing *1
• 0303 Temperature and pressure relief valve, 3/4" 150 psi
• 0304 Cap

*1 Not on models: CVA 42 USG (160 L), CVA 53 USG (200 L)