Viessmann VITODENS 050-W Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 050-W
Type BPJC, 6.5 to 35.0 kW
Wall mounted gas condensing boiler
For natural gas and LPG
Gas Council no.: 47 819 31, 47 819 32
For applicability, see the last page
VITODENS 050-W
5513 085 GB 9/2014 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■ Work on gas installations must only be
carried out by a registered gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental 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,
Gas Safety (Installation & Use) Regu-
lations the appropriate Building Regu-
lationeither the Building regulations,
theBuilding Regulation (Scotland),
Building Regulations (Northern Ire-
land), the Water Fittings Regulation or
Water Bylaws in Scotland, the current
I.E.E. Wiring Regulations.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Do not smoke. Prevent naked
flames and sparks. Do not
switch lights or electrical appli-
ances on or off.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Evacuate any people from the
danger zone.
■ Notify your gas or electricity
supplier and your local heating
contractor from outside the
building.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
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If you smell flue gas
Danger
Flue gas can lead to life threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the installation site.
■ Close all doors in the living
space.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems,
or an insufficient supply of com-
bustion air can cause life threat-
ening poisoning from carbon
monoxide in the flue gas.
Ensure the flue system is in
proper working order. Apertures
for supplying combustion air
must be non-closable.
Extractors
Operating appliances that extract air to
the outside (cooker hoods, extractors, air
conditioning units, etc.) can create neg-
ative pressure. If the boiler is operated at
the same time, this can lead to reverse
flow of the flue gas.
Danger
The simultaneous operation of
the boiler and appliances that
extract air to the outside can
result in life threatening poison-
ing due to reverse flow of the flue
gas.
Fit an interlock circuit or take suit-
able steps to ensure a sufficient
supply of combustion air.
Working on the system
■ Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■ Isolate the system from the power sup-
ply (e.g. by removing the separate fuse
or by means of a mains isolator) and
check that it is no longer 'live'.
■ Safeguard the system against recon-
nection.
Danger
Hot surfaces can cause burns.
■ Before maintenance or service
work, switch OFF the appli-
ance and let it cool down.
■ Never touch hot surfaces on
the boiler, burner, flue system
or pipework.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Safety instructions
Safety instructions (cont.)
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4
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of the sys-
tem.
Faulty components must be
replaced with original Viessmann
spare parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate the
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5513 085 GB

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Installation instructions
Preparing for installation................................................................................... 7
Installation sequence
Mounting the boiler and making the connections................................................. 13
Opening the programming unit............................................................................. 18
Electrical connections........................................................................................... 19
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 22
Further details regarding the individual steps....................................................... 23
Troubleshooting
Function sequence and possible faults................................................................ 45
Fault display......................................................................................................... 46
Repairs................................................................................................................. 50
Gas type conversion
Converting from LPG to natural gas..................................................................... 60
Control unit
Functions and operating conditions in weather-compensated mode................... 62
Designs
Connection and wiring diagrams.......................................................................... 63
Parts lists
Ordering parts...................................................................................................... 68
Overview of assemblies....................................................................................... 69
Casing assembly.................................................................................................. 70
Heat cell assembly............................................................................................... 71
Burner assembly.................................................................................................. 73
Hydraulic assembly.............................................................................................. 75
Grundfos hydraulic assembly............................................................................... 77
Control unit assembly........................................................................................... 79
Miscellaneous....................................................................................................... 80
Specification....................................................................................................... 81
Certificates
Declaration of conformity...................................................................................... 82
Index
Index
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Keyword index.................................................................................................... 83
Index
Index (cont.)
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Intended use
The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions. It is only designed
for the heating of water that is of potable
water quality.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than heating the building or
DHW shall be deemed inappropriate.
Any usage beyond this must be
approved by the manufacturer in each
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and will
result in an exclusion of liability. Incorrect
usage also occurs if the components in
the heating system are modified from
their intended use (e.g. if the flue gas and
ventilation air paths are sealed).
Product information
Vitodens 050-W, type BPJC
Preset for operation with natural gas.
Conversion to LPG P requires a gas con-
version kit.
Gas Council no.
■ 29 kW combi: 47 819 31
■ 35 kW combi: 47 819 32
Conversion for other countries
The Vitodens 050-W must only be deliv-
ered to the countries specified on the
type plate. For deliveries to alternative
countries, an approved contractor must
arrange individual approval on his/her
own initiative and in accordance with the
law of the country in question.
Product description
The Vitodens 050-W is available as a
gas condensing combi boiler with inte-
gral plate heat exchanger for DHW heat-
ing. For the connection of heating circuits
and DHW line, see page 12 onwards.
The Vitodens 050-W is set up for opera-
tion with a constant boiler water temper-
ature.
The appliance is equipped with a sealed
unvented hydraulic system with 2 con-
nections for heating flow and return and
2 connections for DHW heating.
The following components are integra-
ted into the hydraulic system:
■ Circulation pump
■ 3-way diverter valve
Preparing for installation
Preparing for installation
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Installation

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■ Safety valve
■ Diaphragm expansion vessel
■ Plate heat exchanger for DHW heating
Connecting accessories
A time switch (accessories) can be con-
nected to the control unit with a low volt-
age supply.
Siting
Suitable siting locations include:
■ Recreational rooms and other living
spaces
■ Ancillary rooms without own ventila-
tion
■ Cupboards (open at the top)
■ Recesses without compulsory clear-
ance towards combustible materials
■ Attic rooms (pitched attics and long
panes) where the balanced flue can be
routed directly through the roof
Since the flue pipe connection for room-
sealed operation is surrounded by com-
bustion air (coaxial pipe), no clearances
towards combustible materials need be
maintained. For further details, see the
technical guide "Flue systems for the
Vitodens".
The installation area must be safe from
the risk of frost.
Operation of the Vitodens 050-W in wet rooms
Area 0
Area 1
Area
2
Area 2
600
2250
The Vitodens is approved for installation
in wet rooms (e.g. bathroom or shower
rooms) (protection IP X4 D, splash-
proof).
When installing the Vitodens in wet
areas, observe the safety zones and
minimum wall clearances according to
VDE 0100 [or local regulations] (see also
"Electrical safety zone"). The Vitodens
may be installed in area 1 if hosed water
(e.g. from massage showers) is preven-
ted.
Preparing for installation
Preparing for installation (cont.)
5513 085 GB

9
Electrical equipment in rooms containing
a bathtub or a shower must be installed
in such a way that users cannot be
exposed to dangerous body currents.
VDE 0100 specifies that cables supply-
ing permanently installed consumers in
zones 1 and 2 should only be run verti-
cally and routed into the equipment from
the back.
Preparing for boiler installation
Dimensions and connections
41
5
250
400
58 58
123123
B
AC E
F
D
156
350
125
867
68
707
150
642
F
700
Shown without fittings
AHeating flow 7 22 mm
BDHW 7 15 mm
CGas connection 7 22 mm
DCold water 7 15 mm
EHeating return 7 22 mm
FCondensate drain / safety valve
drain: Plastic hose 7 22 mm
Preparing for installation
Preparing for installation (cont.)
5513 085 GB
Installation

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Minimum clearances
Maintain a clearance of 700 mm in front
of the Vitodens for maintenance purpo-
ses. Maintenance clearances to the l.h.
or r.h. side of the Vitodens are not
required.
Preparing for installation
Preparing for installation (cont.)
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Fitting the wall mounting bracket
250
A
Ø10
145
AVitodens installation template
Preparing for installation
Preparing for installation (cont.)
5513 085 GB
Installation

12
1. Position the supplied installation tem-
plate on the wall.
2. Mark out the rawl plug holes.
3. Drill 7 10 mm holes for the rawl plugs
and insert the rawl plugs supplied.
4. Fit wall mounting bracket with screws
supplied.
Fitting the pre-plumbing jig or mount-
ing frame
Pre-plumbing jig or mounting
frame installation instructions
Preparing the connections
!Please note
To prevent appliance damage,
connect all pipework free of load
and torque stress.
1. Prepare the water connections. Flush
the heating system.
2. Prepare the gas connection.
3. Prepare the electrical connections.
■ The appliance is delivered fitted
with a 1.5 m long power cable:
NYM-J 3 x 1.5 mm2
■ Accessory cables:
NYM-O 2-core min. 0.5 mm2 or 2-
core cable for LV
Installation in a cupboard
Any cupboard enclosing the appliance
must be designed and constructed spe-
cifically for this purpose. An existing cup-
board or closet may be used, provided it
is modified accordingly. BS 7698:2000
gives details of the essential design fea-
tures for cupboards and closets, includ-
ing airing cupboards. The Vitodens
range does not require the cupboard to
be ventilated.
Preparing for installation
Preparing for installation (cont.)
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13
Removing the front panel and mounting the boiler
2x
2.
1.
3.
1. Undo the screws at the bottom of the
boiler; do not remove completely.
2. Remove front panel.
3. Hook the boiler onto the wall mount-
ing bracket.
Installation sequence
Mounting the boiler and making the connections
5513 085 GB
Installation

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Making the connections on the water side
A
¨
zz
B C D
AHeating flow G ¾
BDHW G ½
CCold water G ½
DHeating return G ¾
1. Mount fittings with gaskets. 2. Install filling equipment on site.
The filling equipment must meet the
Fittings Directive G24.2a.
Installation sequence
Mounting the boiler and making the connections (cont.)
5513 085 GB

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Gas connection
A
¨
zz
1. Fit the the gas shut-off valve with
bend to connection A.
2. Connect the gas supply to connection
A.
3. Carry out a tightness test.
Note
Only use suitable and approved leak
detection agents (EN 14291) and
devices for the tightness test. Leak
detection agents with unsuitable con-
stituents (e.g. nitrides, sulphides) can
cause material damage.
Remove leak detection agent resi-
dues after testing.
Installation sequence
Mounting the boiler and making the connections (cont.)
5513 085 GB
Installation

16
!Please note
Excessive test pressure will
damage the boiler and the gas
train.
Max. test pressure 150 mbar
(15 kPa). If a higher pressure
is required for tightness tests,
disconnect the boiler and the
gas train from the main supply
pipe (undo the fitting).
4. Purge the gas line.
Connecting the safety valve and condensate drain
A
■ The condensate pipe is connected to
the discharge pipe of the safety valve.
The supplied condensate hose meets
the temperature requirements for
CE certification.
■ We recommend connecting the con-
densate pipe to the internal domestic
waste water system, either directly or
via a tundish.
■ If the condensate pipe is routed out-
side the building, use a pipe with min.
7 30 mm and protect it from frost.
Avoid long external pipe runs. Install a
tundish.
!Please note
A frozen condensate pipe can
result in faults and damage to
the boiler.
Always protect condensate
pipes against frost.
■ Observe local building regulations.
Connect condensate pipe A to the pub-
lic sewage system with a constant fall
and a pipe vent.
Observe the local waste water regula-
tions.
Note
Fill the siphon with water before com-
missioning.
Installation sequence
Mounting the boiler and making the connections (cont.)
5513 085 GB

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Filling the siphon with water
Pour at least 0.3 l of water into the flue
outlet.
!Please note
During commissioning, flue gas
may escape from the condensate
drain.
Always fill the siphon with water
before commissioning.
Balanced flue connection
Connect the balanced flue.
During installation and positioning of the
flue system, observe Part J of building
regulations and BS 5440.
Flue system installation instruc-
tions
Connecting several Vitodens 050-W
to a shared flue system
Adjust the burner setting of each con-
nected boiler to match the flue system.
See page 29.
Do not carry out commissioning until
the following conditions are met:
■ Free passage through the flue gas
pipes.
■ Flue system with positive pressure is
gas-tight.
■ Apertures for ensuring sufficient com-
bustion air supply are open and cannot
be closed off.
■ Applicable regulations on installing
and commissioning flue systems have
been followed.
Installation sequence
Mounting the boiler and making the connections (cont.)
5513 085 GB
Installation

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Danger
Leaking or blocked flue systems
or an insufficient supply of com-
bustion air cause life threatening
poisoning due to carbon monox-
ide in the flue gas.
Ensure the flue system functions
correctly. Apertures for combus-
tion air supply must not be able to
be closed off.
Opening the programming unit
Only required if a wireless receiver or
time switch (accessories) is to be con-
nected.
1.
3.
2. 2x
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Prior to commencing any work,
touch earthed objects such as
heating or water pipes to dis-
charge static loads.
Installation sequence
Mounting the boiler and making the connections (cont.)
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B
C
4 3 2 1
A
OT+OT-
ATerminals on underside of appli-
ance
BOutside temperature sensor
CVitotrol 100 or on-site room temper-
ature controller with LV switching
contact and low transition resist-
ance
Remove jumper when connecting.
Separate installation instruc-
tions
Note: the terminal C is not suitable
for 230V room thermostats.
Information on connecting
accessories
When connecting accessories
observe the separate installation
instructions provided with them.
Installation sequence
Electrical connections
5513 085 GB
Installation

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Outside temperature sensor (accessories)
1. Fit outside temperature sensor.
Installation site:
■ North or north-westerly wall, 2 to
2.5 m above ground level; in multi
storey buildings, in the upper half of
the 2nd floor
■ Not above windows, doors or vents
■ Not immediately below balconies
or gutters
■ Never render over
■ Connection:
2-core lead, length up to 35 m with
a cross-section of 1.5 mm2
2. Connect the outside temperature
sensor across terminals 3 and 4
(underside of appliance).
Power supply
Connect the power cable to the building
mains.
Regulations and Directives
Danger
Incorrectly executed electrical
installations can result in injuries
from electrical current and in
appliance damage.
Connect the power supply and
implement all safety measures
(e.g. RCD circuit) in accordance
with the following regulations:
■ IEC 60364-4-41
■ VDE regulations
■ Connection requirements
specified by your local power
supply utility
Install an isolator in the power cable to
provide omnipolar separation from the
mains for all active conductors, corre-
sponding to overvoltage category III
(3 mm) for full isolation. This isolator
must be fitted in the permanent electrical
installation in line with installation
requirements.
Protect the power cable with an external
3 A fuse to BS 1362.
Danger
Incorrect core allocation can
result in serious injury and dam-
age to the appliance.
Take care not to interchange
wires "L1" and "N".
Installation sequence
Electrical connections (cont.)
5513 085 GB