Viessmann Vitodens 100 Series Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 100
6.5 to 35.0 kW
Wall mounted gas condensing boiler
Natural gas version
For applicability, see the last page
VITODENS 100
5837148 HK 11/2018 Please keep safe.

2
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 envi-
ronmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
intended for qualified contractors.
■ Work on gas installations may only
be carried out by a registered gas fit-
ter.
■ Work on electrical equipment may
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 to be observed
■ National installation regulations
■ Statutory regulations for the preven-
tion of accidents
■ Statutory regulations for environmen-
tal protection
■ Codes of practice of the relevant
trade associations
■ Relevant country-specific safety reg-
ulations
Safety instructions
Safety instructions
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Safety instructions for working on the system
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
supply, 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.
■ Wear suitable personal protective
equipment when carrying out any
work.
Danger
Hot surfaces and fluids can lead
to burns or scalding.
■ Before maintenance and serv-
ice work, switch OFF the
appliance 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.
Prior to commencing work,
touch earthed objects such as
heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil
a safety function can compro-
mise the safe operation of the
system.
Replace faulty components only
with genuine 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 compro-
mise its function. Installing non-
authorised components and
making non-approved modifica-
tions or conversions can com-
promise safety and may invalid-
ate our warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
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Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in seri-
ous injury.
■ Do not smoke. Prevent naked
flames and sparks. Never
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
supply utility from outside the
building.
■ Have the power supply to the
building shut off from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threat-
ening poisoning.
■ Shut down the heating sys-
tem.
■ Ventilate the installation site.
■ Close doors to living spaces
to prevent flue gases from
spreading.
What to do if water escapes from the
appliance
Danger
If water escapes from the appli-
ance there is a risk of electrocu-
tion.
Switch OFF the heating system
at the external isolator (e.g. fuse
box, domestic distribution
board).
Danger
If water escapes from the appli-
ance there is a risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be
harmful to health.
Never let condensate touch your
skin or eyes and do not swallow
it.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
external causes.
Ensure an adequate supply of combus-
tion air.
Inform system users that subsequent
modifications to the building character-
istics are not permissible (e.g. cable/
pipework routing, cladding or parti-
tions).
Safety instructions
Safety instructions (cont.)
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Danger
Leaking or blocked flue sys-
tems, or an inadequate supply
of combustion air can cause life
threatening poisoning from car-
bon monoxide in the flue gas.
Ensure the flue system is in
good working order. Vents for
supplying combustion air must
be non-sealable.
Extractors
Operating appliances that exhaust air
to the outside (extractor hoods, extrac-
tors, air conditioning units, etc.) can
create negative pressure. If the boiler is
operated at the same time, this can
lead to a reverse flow of 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 a reverse flow of flue
gas.
Fit an interlock circuit or take
suitable steps to ensure an ade-
quate supply of combustion air.
Safety instructions
Safety instructions (cont.)
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6
Service instructions
Warning notices
Warning notices according to GB25034-2010...................................................... 8
Frost protection.................................................................................................... 9
Intended use......................................................................................................... 9
Notes on siting, installation and operation............................................................ 10
Information
Symbols................................................................................................................ 11
Installation instructions
Preparing for installation................................................................................... 12
Installation sequence
Mounting the boiler and making connections....................................................... 15
Opening the control unit enclosure....................................................................... 25
Electrical connections........................................................................................... 26
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 33
Further details regarding the individual steps....................................................... 35
Parameter
Main parameter level............................................................................................ 55
Parameter level 1................................................................................................. 57
Parameter level 2................................................................................................. 59
Diagnostics
Function sequence and possible faults................................................................ 61
Overview of checks.............................................................................................. 62
Status checks....................................................................................................... 62
Meter checks........................................................................................................ 64
Troubleshooting
Fault display......................................................................................................... 66
Repairs................................................................................................................. 70
Control unit
Weather-compensated operation......................................................................... 81
Index
Index
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Designs
Connection and wiring diagram............................................................................ 83
Parts lists
Ordering parts...................................................................................................... 85
Overview of assemblies....................................................................................... 86
Casing assembly.................................................................................................. 87
Heat cell assembly............................................................................................... 89
Burner assembly.................................................................................................. 91
Hydraulic assembly.............................................................................................. 93
Hydraulic assembly, system boiler....................................................................... 95
Hydraulic assembly, combi boiler......................................................................... 97
Control unit assembly........................................................................................... 99
Miscellaneous assembly...................................................................................... 101
Specification....................................................................................................... 102
Certificates
Manufacturer's declaration for Vitodens 100 CC.................................................. 109
Keyword index.................................................................................................... 110
Index
Index (cont.)
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Warning against incorrect use:
■ A faulty installation can lead to injury
and material losses.
■ The appliance must be installed in
accordance with the instructions and
applicable legal regulations.
■ Only engineers or persons approved
by the manufacturer may repair the
appliance or replace parts of it.
■ To ensure the safety of the product,
only original accessories can be
used.
■ The original flue pipe must be used.
Flue pipes of any other type must not
be used. The concentric flue pipe
must not be replaced by a single flue
pipe.
■ If it is necessary to replace the gas
governor or controls, please contact
the manufacturer.
■ Do not purchase any equipment
modified by dealers; only purchase
the manufacturer's original product.
This is the only way to ensure the
safety of the appliance.
■ When installing the appliance, install
a shut-off valve in the gas supply line.
■ Do not install the appliance near
electrical equipment with a strong
electromagnetic field, such as an
electromagnetic oven or microwave.
■ Do not remove any sealed parts from
the appliance.
■ Do not use caustic cleaning agents to
clean the appliance.
■ The appliance must not be installed
in bedrooms, living rooms or bath-
rooms.
■ Ensure that the appliance is not oper-
ated by children or other persons
who do not use it. Ensure that chil-
dren do not play with the appliance.
■ The overheating safety valve and the
hot water drain valve may only be
operated by specialists or competent
persons.
■ Do not install the appliance in closed
rooms.
■ After maintenance or inspection of
the appliance, the results must be
noted on the appliance by the main-
tenance or inspection engineer.
■ The power supply to the room must
be earthed.
The switch connected to the appli-
ance must not be located in a room
with a bath or shower.
The closure and the closure seal
must be checked.
■ Explain the frost protection measures
for the appliance to the user. The
user can add antifreeze to the heat-
ing water circuit if the appliance is not
operated for a long period in winter.
Otherwise the appliance or pipes can
be damaged by freezing.
Warning notices
Warning notices according to GB25034-2010
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!Please note
Frost protection is only guaran-
teed with a reliable power sup-
ply, gas supply and sufficient
heating water content.
Following installation or repairs,
switch ON the power supply
(MCB/fuse, mains isolator) and
the control unit ON/OFF switch.
Open the gas shut-off valve to
ensure frost protection.
Intended use
The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828 and CECS 215, with due
attention paid to the associated installa-
tion, service and operating instructions.
It is only designed for heating up heat-
ing water that is of potable water qual-
ity.
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
purpose 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
appliance (e.g. the appliance being
opened by the system user) is prohibi-
ted and will result in an exclusion of lia-
bility. 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).
Warning notices
Frost protection
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Service

10
■ Installation, maintenance and service
must be carried out by an authorised
contractor.
■ The boiler installation must meet the
following local requirements:
– Safety conditions for the gas sup-
ply
– Guidelines for water supply and
waste water disposal
– Construction guidelines
■ The surface temperatures of the
boiler and flue system do not neces-
sitate any safety clearances for fire
protection.
■ After installation, the heating contrac-
tor should mark the position of the
flue system and instruct the system
user about operation and the safety
regulations.
■ The appliance power cable and leads
may only be replaced by an author-
ised contractor or a specialist author-
ised by the contractor.
■ To ensure trouble-free and efficient
operation, the heating system should
be checked and serviced once a year
by an authorised contractor.
Warning notices
Notes on siting, installation and operation
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11
Sym-
bol
Meaning
Reference to another docu-
ment containing further infor-
mation
1.
Step in a diagram:
The numbers correspond to
the order in which the steps
are carried out.
Warning of material losses and
environmental pollution
Live electrical area
Pay particular attention.
■ Component must audibly
click into place.
or
■ Acoustic signal
■ Fit new component.
or
■ Using a tool: Clean the sur-
face.
Dispose of component correct-
ly.
Dispose of component at a
suitable collection point. Do
not dispose of component in
domestic waste.
The sequences of steps for commis-
sioning, inspection and maintenance
are summarised in the section "Com-
missioning, inspection and mainte-
nance" and are identified as follows:
Sym-
bol
Meaning
Steps required during commis-
sioning
Not required during commis-
sioning
Steps required during inspec-
tion
Not required during inspection
Steps required during mainte-
nance
Not required during mainte-
nance
Information
Symbols
5837148
Service

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Product information
Vitodens 100
Preset for operation with natural gas.
The Vitodens 100 may only be deliv-
ered to countries listed on the type
plate. For deliveries to other countries,
approved contractors must arrange
individual approval on their own initia-
tive and in accordance with the law of
the country in question.
Product description
The Vitodens 100 is supplied as a gas
condensing boiler for connection to a
DHW cylinder, or as a gas condensing
combi boiler with an integral instantane-
ous water heater for DHW heating.
The boiler is equipped with a hydraulic
system with the following components:
■ Circulation pump
■ 3-way diverter valve
■ Safety valve
■ Diaphragm expansion vessel
■ Plate heat exchanger (gas condens-
ing combi boiler)
■ Connections for heating water flow
and return
■ Connections for cylinder flow and
return (gas condensing system
boiler)
■ Connections for cold water and DHW
(gas condensing combi boiler)
In the delivered condition, the
Vitodens 100 CC is set up for operation
with a constant boiler water tempera-
ture. By connecting an outside temper-
ature sensor, available as an acces-
sory, the boiler can be operated in
weather-compensated mode. In this
case, a room temperature controller
should always be connected as well.
This prevents heat being generated
unnecessarily, for example at night, due
to the lower outside temperatures.
If a Viessmann DHW cylinder is con-
nected, the request for cylinder heating
is made via a cylinder temperature sen-
sor. The cylinder temperature sensor is
connected to the control unit.
Preparing for installation
Preparing for installation
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Dimensions and connections
5
250
69
400
700
158
350
225
860
58 58
123123
BA C E
F
D
128
AHeating flow G ¾
BGas condensing system boiler:
Cylinder flow G ¾
Gas condensing combi boiler:
DHW G ½
CGas connection G ¾
DGas condensing system boiler:
Cylinder return G ¾
Gas condensing combi boiler:
Cold water G ½
EHeating return G ¾
FCondensate drain/safety valve
drain: Plastic hose 7 22 mm
Preparing for installation
Preparing for installation (cont.)
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Installation

14
Preparing for boiler installation
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 1.3 m long (outside the
boiler) power cable NYM-J
3 x 1.5 mm2 with plug.
■ Cables for accessories:
NYM-O 2-core min. 0.5 mm2 or 2-
core LV lead.
Preparing for installation
Preparing for installation (cont.)
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15
Fitting the wall mounting bracket
250
A
Ø10
146
AVitodens installation template
Installation sequence
Mounting the boiler and making connections
5837148
Installation

16
1. Position the supplied installation
template on the wall.
2. Mark out the rawl plug holes.
3. Drill 7 10 mm holes and insert the
rawl plugs supplied.
4. Fit the wall mounting bracket with
the screws supplied.
Installation sequence
Mounting the boiler and making connections (cont.)
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Removing the front panel and mounting the boiler
2x
3.
1.
2.
1. Undo the screws on the underside
of the boiler; do not remove them
completely.
2. Remove front panel.
3. Hook the boiler into the wall mount-
ing bracket.
Installation sequence
Mounting the boiler and making connections (cont.)
5837148
Installation

18
Fitting connections on water side
BA DC E
¨
zz
AHeating flow
BGas condensing system boiler:
Cylinder flow
Gas condensing combi boiler:
DHW
CGas connection
DGas condensing system boiler:
Cylinder return
Gas condensing combi boiler:
Cold water
EHeating return
Fitting the connection set
Connection set installation
instructions
Installation sequence
Mounting the boiler and making connections (cont.)
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Connection set for gas condensing
boiler (accessories)
A
C
E
Connection set for gas condensing
combi boiler (accessories)
A
C
E
B
D
Gas connection
■ Gas supply pressure: 15 - 30 mbar
(1.5 - 3.0 kPa)
■ Set value: 20 mbar (2.0 kPa)
A
1. Connect the gas shut-off valve (on-
site) to adaptor A.
Installation sequence
Mounting the boiler and making connections (cont.)
5837148
Installation

20
2. 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 unsuita-
ble constituents (e.g. nitrides, sul-
phides) can cause material dam-
age.
Remove residues of the leak detec-
tion agent after testing.
!Please note
Excessive test pressure will
damage the boiler and the
gas train.
Max. test pressure 150 mbar
(15 kPa). If a higher pres-
sure is required for tightness
tests, disconnect the boiler
and the gas train from the
main supply pipe. Undo the
fitting.
3. Purge the gas line.
Installation sequence
Mounting the boiler and making connections (cont.)
5837148