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 2/2014 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
orWater Bylaws in Scotland, the cur-
rent 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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3
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

5
Installation instructions
Preparing for installation................................................................................... 6
Installation sequence
Mounting the boiler and making connections....................................................... 12
Opening the programming unit............................................................................. 17
Electrical connections........................................................................................... 18
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 21
Further details regarding the individual steps....................................................... 22
Troubleshooting
Function sequence and possible faults................................................................ 38
Fault display showing........................................................................................... 39
Repairs................................................................................................................. 43
Gas type conversion
Converting from LPG to natural gas..................................................................... 53
Designs
Connection and wiring diagrams.......................................................................... 55
Parts lists
Ordering parts...................................................................................................... 60
Overview of the assemblies................................................................................. 61
Casing assembly.................................................................................................. 62
Heat cell assembly............................................................................................... 64
Burner assembly.................................................................................................. 66
Hydraulic assembly.............................................................................................. 68
Grundfos hydraulic assembly............................................................................... 70
Control unit assembly........................................................................................... 72
Miscellaneous assembly...................................................................................... 73
Specification....................................................................................................... 75
Certificates
Declaration of conformity...................................................................................... 76
Keyword index.................................................................................................... 77
Index
Index
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6
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 usage 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 does not comply with regulations.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect usage also occurs if the components
in the heating system are modified from
their intended function (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 the DHW line, see from page 11.
The Vitodens 050-W is set up for opera-
tion with a constant boiler water temper-
ature.
The following are integrated: one 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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■ Safety valve
■ Diaphragm expansion vessel
■ Plate heat exchanger for DHW heating
Accessory connection
A time switch (accessory) can be con-
nected to the control unit and supplied
with low voltage.
Siting
Siting is possible, for example, in the fol-
lowing locations:
■ Recreation rooms and other living
spaces
■ Ancillary rooms without their own ven-
tilation
■ Compartments (open at the top)
■ Recesses without compulsory clear-
ance towards combustible materials
■ Attic rooms (pitched attics) 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), maintaining
clearances from combustible materials
is not required. 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
regulation (see also "Electrical safety
zone"). The Vitodens may be installed in
safety zone 1 if hosed water (e.g. from
massage showers) is prevented.
Preparing for installation
Preparing for installation (cont.)
5513 085 GB
Installation

8
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.
The IEEE Regulation specifies that
cables supplying permanently installed
consumers in zones 1 and 2 should only
be run vertically 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
700
68
707
150
642
F
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
Preparing for installation
Preparing for installation (cont.)
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FCondensate drain/safety valve
drain: Plastic hose 7 22 mm
Preparing for installation
Preparing for installation (cont.)
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Installation

10
Fitting the wall mounting bracket
250
A
Ø10
145
AVitodens installation template
Preparing for installation
Preparing for installation (cont.)
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11
1. Position the supplied installation tem-
plate on the wall.
2. Mark out the rawl plug holes.
3. Drill 7 10 mm holes and insert the
rawl plugs supplied.
4. Fit wall mounting bracket with screws
supplied.
Fitting pre-plumbing jig or mounting
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.
■ A 1.5 m long power cable is fitted in
the delivered condition:
NYM-J 3 x 1.5 mm2
■ Accessory cables:
NYM-O 2-core min. 0.5 mm2 or 2-
core cable for LV
Compartment installation
A compartment used to enclose the
appliance must be designed and con-
structed specifically for this purpose. An
existing cupboard or compartment may
be used provided it is modified accord-
ingly. The Vitodens range does not
require compartment ventilation.
Preparing for installation
Preparing for installation (cont.)
5513 085 GB
Installation

12
Removing the front panel and mounting the boiler
2x
2.
3.
1.
1. Undo 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 connections
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Making the connections on the water side
A
¨
zz
B C D
AHeating flow G¾
BDHW G½
CCold water G½
DHeating return G¾
1. Mount fittings with gaskets. 2. Install filling equipment on site.
The filling equipment must meet Fit-
tings Directive G24.2a.
Installation sequence
Mounting the boiler and making connections (cont.)
5513 085 GB
Installation

14
Gas connection
A
¨
zz
1. Mount gas shut-off valve with bend to
connection A.
2. Connect 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 residues of the leak detec-
tion agent after testing.
Installation sequence
Mounting the boiler and making connections (cont.)
5513 085 GB

15
!Please note
Excessive test pressure will
damage the boiler and the gas
train.
Max. test pressure 150 mbar
(15 kPa). Where higher pres-
sure is required for tightness
tests, disconnect the boiler
and the gas train from the
main supply pipe (undo the fit-
ting).
4. Purge the gas line.
Connection, safety valve and condensate drain
A
■ The condensate pipe is connected
with the discharge pipe of the safety
valve. The condensate hose supplied
meets the temperature requirements
that are part of the CE certification.
■ Connecting the condensate pipe inter-
nally to the domestic waste water sys-
tem, either directly or via a tundish, is
recommended.
■ If the condensate pipe is routed out-
side the building, use a pipe with at
least 7 30 mm and protect this pipe
from frost. Avoid long external pipe-
lines. Install a tundish.
!Please note
A frozen condensate pipe can
result in faults and damage to
the boiler.
Always insulate 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 trap with water before commis-
sioning.
Installation sequence
Mounting the boiler and making connections (cont.)
5513 085 GB
Installation

16
Filling the trap 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 trap with water
before commissioning.
Balanced flue connection
Connect the balanced flue.
Flue system installation instruc-
tions
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.
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.
Installation sequence
Mounting the boiler and making connections (cont.)
5513 085 GB

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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
Opening the programming unit
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Installation

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B
1 2 3 4
A
OT+ OT-
C
ATerminals at bottom of appliance
BOutside temperature sensor
CVitotrol 100 or on-site room temper-
ature controller with LV (Low volt-
age) switching contact and low tran-
sition resistance
Note: This is not a 240V switched
live input
Separate installation instruc-
tions
Information on connecting
accessories
When connecting accessories
observe the separate installation
instructions provided with them.
Installation sequence
Electrical connections
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Outside temperature sensor (accessory)
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 second 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
(underneath the 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 conditions speci-
fied by your local power supply
utility
Install an isolator in the power cable
which simultaneously isolates all non-
earthed conductors from the mains with
contact separation of at least 3 mm.
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".
Danger
If system components are not
earthed, serious injury from elec-
tric current can result if an elec-
trical fault occurs.
Connect the appliance and pipe-
work to the equipotential bonding
of the building in question.
Installation sequence
Electrical connections (cont.)
5513 085 GB
Installation

20
Routing the connecting cables
!Please note
Connecting cables will be dam-
aged if they touch hot compo-
nents.
When routing and securing
cables/leads on site, ensure that
the maximum permissible tem-
perature for these cables/leads is
not exceeded.
Installation sequence
Electrical connections (cont.)
5513 085 GB