Viessmann Vitodens 100-W WB1B Series Quick guide

VIESMANN
Installation and service
instructions
for contractors
Vitodens 100-W
Type WB1B, 9.0 to 35.0 kW
Wall mounted gas fired condensing boiler
Natural gas and LPG version
VITODENS 100-W
5354 802 GB 2/2008 Please keep safe.

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 fit-
ter.
&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 result in
serious injury.
&Never 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-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close all doors leading to the
living space.
Safety instructions
2
Safety instructions
5354 802 GB

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 electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which
fulfil a safety function can com-
promise the safe operation of
your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5354 802 GB

Installation instructions
Preparing for installation
Product information .................................................................................... 5
Preparing for installation ............................................................................. 5
Installation sequence
Installing the boiler and making all connections ........................................... 9
Opening the control unit .............................................................................. 13
Electrical connections................................................................................. 14
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance................................... 17
Further details regarding the individual steps .............................................. 18
Troubleshooting
Function sequence and possible faults........................................................ 32
Fault messages on the display .................................................................... 33
Repairs ...................................................................................................... 37
Gas type conversion
Converting from LPG to natural gas ............................................................ 47
Control unit
Functions and operating conditions in weather-compensated mode ............ 50
Designs
Connection and wiring diagram ................................................................... 51
Parts lists .................................................................................................. 53
Specification............................................................................................. 59
Certificates
Declaration of conformity ............................................................................ 61
Keyword index .......................................................................................... 62
Index
4
Index
5354 802 GB

Vitodens 100-W, WB1B
Set up for operation with natural gas.
Preparing for installation
Preparing the boiler installation
Dimensions and connections
ACondensate drain: Plastic pipe 7
22 mm
BHeating flow
Product information
5
Preparing for installation
5354 802 GB
Installation

CGas fired condensing boiler:
Cylinder flow
Gas fired condensing combi boil-
er:
DHW
DGas connection
EGas fired condensing boiler:
Cylinder return
Gas fired condensing combi boil-
er:
Cold water
FHeating return
GDrain safety valve
Rated output range kW 9 - 26 11 - 30 11 - 35
a mm 340 360 360
Preparing for installation (cont.)
6
Preparing for installation
5354 802 GB

Fitting the wall retainer
AInstallation template Vitodens
Preparing for installation (cont.)
7
Preparing for installation
5354 802 GB
Installation

1. Position the supplied installation
template on the wall.
2. Mark out the rawl plug holes.
3. Drill 710 mm holes and insert the
supplied rawl plugs.
4. Fit wall retainer with screws sup-
plied.
Preparing the connections
1. Prepare the water connections.
Flush the heating system.
2. Prepare gas connection.
3. Prepare the electrical connections.
Observe valid IEEE standards.
&A 1.5 m long power cable is fitted
as standard.
&Accessory cables:
&NYM-O 2-core min. 0.5 mm
2
.
Preparing for installation (cont.)
8
Preparing for installation
5354 802 GB

Removing the front panel and mounting the boiler
1. Release screws at the bottom of
the boiler; do not remove comple-
tely.
2. Remove front panel.
3. Hook the boiler into the wall retai-
ner.
Installing the boiler and making all connections
9
Installation sequence
5354 802 GB
Installation

Installing connections on the water side
For fittings on the heating water side and DHW side, see separate instal-
lation instructions.
AHeating flow
BGas fired condensing boiler:
Cylinder flow
Gas fired condensing combi boil-
er:
DHW
CGas connection
DGas fired condensing boiler:
Cylinder return
Gas fired condensing combi boil-
er:
Cold water
EHeating return
Installing the boiler and making all connections (cont.)
10
Installation sequence
5354 802 GB

Safety valve connection
Connect safety valve drain A
(715 mm) with visible outlet Bto
the dewatering system or route with
visible outlet through the external wall.
Gas connection
1. Connect gas shut-off valve to con-
nection A.
2. Carry out a leak/tightness test.
!Please note
Excessive test pressure may
damage the boiler and the
gas valve.
Max. test pressure
150 mbar. Where higher
pressure is required for tight-
ness tests, separate the boil-
er and the gas valves from
the gas supply pipe (undo
the fitting).
3. Vent the gas supply pipe.
Installing the boiler and making all connections (cont.)
11
Installation sequence
5354 802 GB
Installation

Condensate connection
Connect condensate drain Awith a
slope and a pipe vent to the public
sewer.
Observe the local waste water regula-
tions.
Note
Fill the siphon with water before start-
up.
Filling the siphon with water
Fill a minimum of 0.3 l of water into the
flue gas connection.
!Please note
At commissioning, flue gas may
be emitted from the condensate
drain.
Fill the siphon with water before
start-up.
Installing the boiler and making all connections (cont.)
12
Installation sequence
5354 802 GB

Balanced flue connection
Connect the balanced flue.
During installation and positioning of
the flue gas system, observe building
regulations part L and BS 5440.
Flue gas system installation
instructions.
Opening the control unit
Installing the boiler and making all connections (cont.)
13
Installation sequence
5354 802 GB
Installation

!Please note
Electronic modules can be
damaged by electrostatic dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Electrical connections
Information regarding the connection of accessories
For details of accessories, also observe their separate installation
instructions provided.
Opening the control unit (cont.)
14
Installation sequence
5354 802 GB

%Gas fired condensing boilers only:
Cylinder temperature sensor (plug
on the cable harness outside the
control unit)
Note
Gas fired condensing boiler with-
out DHW cylinder:
For operation without a DHW
cylinder, set rotary selector "tw"
to "0".
AOnly for weather-compensated
mode:
Outside temperature sensor
(accessory)
BOpen room thermostat
Remove jumper Dwhen making
this connection.
CConnection line (accessory)
DJumper
EPower supply (230 V, 50 Hz).
Danger
Incorrect core termination
can cause severe injuries
and damage to the equip-
ment.
Take care not to inter-
change wires "L1" and "N".
The power supply must be
equipped with a neutral conduc-
tor. Water pipes should be con-
nected to the earth bonding of the
house in question.
FVitotrol 100
Separate installation
instructions
Outside temperature sensor (accessory)
1. Plug the power cable supplied with
the outside temperature sensor
into slot "X21".
2. Connect the outside temperature
sensor to terminals 3 and 4.
Electrical connections (cont.)
15
Installation sequence
5354 802 GB
Installation

Routing connecting cables and closing control unit
!Please note
Power cables will be damaged if they contact hot parts.
When routing and securing power cables on site, ensure that the maxi-
mum permissible temperatures for these cables are not exceeded.
Electrical connections (cont.)
16
Installation sequence
5354 802 GB

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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••• 01. Filling the heating system ................................................. 18
••• 02. Venting the boiler by flushing out (after venting
system) ..................................................................................... 20
•03. Adjusting circulation pump to suit heating system .20
••• 04. Changing to operation with LPG ..................................... 21
•05. Checking the CO2content ................................................. 22
• • 06. Burner removal ..................................................................... 24
• • 07. Checking the burner gasket and the burner gauze
assembly .................................................................................. 25
• • 08. Checking and adjusting electrodes ............................... 26
• • 09. Cleaning the heat exchanger............................................ 27
• • 10. Checking the condensate drain and cleaning the
siphon........................................................................................ 28
• • 11. Burner installation ............................................................... 29
••• 12. Checking all connections on the heating water
side and DHW side for leaks
••• 13. Checking the tightness of electrical connections
••• 14. Checking all gas equipment for tightness at
operating pressure .............................................................. 30
• • 15. Fitting the front panel .......................................................... 30
•16. Instructing the system user .............................................. 31
Steps - commissioning, inspection and maintenance
17
Commissioning, inspection, maintenance
5354 802 GB
Service

Filling the heating system
!Please note
Unsuitable fill water increases the level of deposits and corrosion and
may lead to boiler damage.
&Thoroughly flush the entire heating system prior to filling it with water.
&Only use fill water of potable quality.
&Soften fill water harder than 150 ppm.
&An antifreeze additive suitable for heating systems can be mixed with
the fill water.
1. Close the gas shut-off valve.
2. Switch ON the power.
3. Turn rotary selector "rt" antic-
lockwise for less than 2 s and then
clockwise back to the control range
on the right.
Filling function is enabled. This
function will end automatically after
20 min or after ON/OFF switch has
been turned OFF.
Further details regarding the individual steps
18
Commissioning, inspection, maintenance
5354 802 GB

4. Open shut-off valves Aand (if
installed) B.
5. Connect filling hose to valve C
and open valve C.
6. Fill heating system. (Minimum sys-
tem pressure > 0.8 bar).
7. Close valve C.
Note
If external filling equipment is
installed, it must meet the require-
ments of the Water Fittings Regula-
tions 1999 Section G 24.1 and G 24.2.
Further details regarding the individual steps (cont.)
19
Commissioning, inspection, maintenance
5354 802 GB
Service

Venting the boiler by flushing out (after venting system)
1. Connect the drain hose on shut-off
valve Ato a drain.
2. Close shut-off valve B.
3. Open valves Aand Cand flush
at mains pressure, until no sound of
escaping air can be heard.
4. First shut off valve Athen valve
C.
5. Operating pressure ≥0.8 bar;
adjust with valve C.
6. Open shut-off valve B.
Adjusting circulation pump to suit heating system
In the delivered condition, the circulation pump in heating mode is set to stage
1. If necessary to suit the heating system, the circulation pump can be adjusted
to stage 2.
1. Turn ON/OFF switch ON.
Further details regarding the individual steps (cont.)
20
Commissioning, inspection, maintenance
5354 802 GB