Viessmann Vitodens 100-W Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 100-W
Type WB1C, 7.4 to 35.0 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 100-W
5603 938 GB 3/2011 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
designed for qualified personnel.
■ Work on gas equipment must only be
carried out by a qualified 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
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions 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 Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never 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.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the build-
ing.
■ 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 boiler room.
■ Close all doors leading to the
living space.
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 sup-
ply 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 unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged 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 ful-
fil a safety function can compro-
mise 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 com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
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Installation instructions
Preparing for installation
Product information.............................................................................................. 6
Preparing for installation....................................................................................... 6
Installation sequence
Fitting the boiler and assembling connections..................................................... 10
Opening the control unit....................................................................................... 14
Electrical connections........................................................................................... 15
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 19
Further details regarding the individual steps....................................................... 20
Troubleshooting
Function sequence and possible faults................................................................ 36
Fault messages on the display............................................................................. 37
Repairs................................................................................................................. 41
Gas type conversion
Converting from LPG to natural gas .................................................................... 52
Control unit
Functions and operating conditions in weather-compensated mode .................. 54
Designs
Connection and wiring diagram............................................................................ 55
Parts lists
Ordering parts...................................................................................................... 57
Overview of the assemblies................................................................................. 58
Sheet metal parts assembly................................................................................. 59
Heat cell assembly............................................................................................... 60
Burner assembly.................................................................................................. 61
Vitodens hydraulic assembly................................................................................ 63
System boiler hydraulic assembly........................................................................ 65
Combi hydraulic assembly................................................................................... 65
VBC LCV control unit assembly........................................................................... 68
Miscellaneous assembly...................................................................................... 68
Specification....................................................................................................... 70
Index
Index
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Certificates
Declaration of conformity...................................................................................... 71
Keyword index.................................................................................................... 72
Index
Index (cont.)
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6
Vitodens 100-W, WB1C
Preset for operation with natural gas.
Preparing for installation
Preparing for the boiler installation
Dimensions and connections
34
5
250
68
400
700
58 58
123123
B
AC E
F
D
156
350
125
860
AHeating flow
BGas condensing boiler:
Cylinder flow
Gas condensing combi boiler:
DHW
CGas connection
DGas condensing boiler:
Cylinder return
Gas condensing combi boiler:
Cold water
Preparing for installation
Product information
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EHeating return
FCondensate drain/safety valve
drain: Plastic hose 7 22 mm
Preparing for installation
Preparing for installation (cont.)
5603 938 GB
Installation

8
Fitting the wall mounting bracket
250
A
Ø10
AInstallation template Vitodens
Preparing for installation
Preparing for installation (cont.)
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1. Position the supplied installation tem-
plate on the wall.
2. Mark out the rawl plug holes.
3. Drill 710 mm holes and insert the
supplied rawl plugs.
4. Fit wall mounting bracket with screws
supplied.
Fit installation aid or mounting frame
Installation aid or mounting frame
installation instructions
Preparing the connections
!Please note
To prevent equipment damage,
install all pipework free of load
and torque stresses.
1. Prepare the water connections. Flush
the heating system.
2. Prepare gas connection.
3. Prepare the electrical connections.
■Power cable NYM-J 3 x 1.5 mm2.
■ Accessory cables:
NYM-O 2-core min. 0.5 mm2.
Preparing for installation
Preparing for installation (cont.)
5603 938 GB
Installation

10
Removing the front panel and mounting the boiler
2x
2.
3.
1.
1. Release screws at the bottom of the
boiler; do not remove completely.
2. Remove front panel.
3. Hook the boiler into the wall mounting
bracket.
Installing connections on the water side
For fittings on the heating water side and DHW side, see separate installation
instructions.
Installation sequence
Fitting the boiler and assembling connections
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BA DC E
¨
zz
AHeating flow
BGas condensing boiler:
Cylinder flow
Gas condensing combi boiler:
DHW
CGas connection
DGas condensing boiler:
Cylinder return
Gas condensing combi boiler:
Cold water
EHeating return
Gas connection
A
1. Connect gas shut-off valve to con-
nection A.
Installation sequence
Fitting the boiler and assembling connections (cont.)
5603 938 GB
Installation

12
2. Carry out a tightness test.
Note
For the tightness test, use only suita-
ble and approved leak detecting
agents (EN 14291) and devices.
Leak detecting agents with unsuita-
ble contents (e.g. nitrites, sulphides)
can lead to material damage.
Remove residues of the leak detect-
ing agent after testing.
!Please note
Excessive test pressure may
damage the boiler and the gas
valve.
Max. test pressure 150 mbar.
Where higher pressure is
required for tightness tests,
separate the boiler and the
gas valves from the gas sup-
ply pipe (undo the fitting).
3. Vent the gas line.
Installation sequence
Fitting the boiler and assembling connections (cont.)
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Connection, safety valve and condensate drain
A
Connect condensate drain pipe A with
a constant fall and a pipe vent to the
public sewage system.
Observe the local waste water regula-
tions.
Note
Fill the siphon with water before com-
missioning.
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
commissioning.
Installation sequence
Fitting the boiler and assembling connections (cont.)
5603 938 GB
Installation

14
Balanced flue connection
Connect the balanced flue.
Flue system installation instruc-
tions.
Opening the control unit
3.
2.
2x 1.
2x
Installation sequence
Fitting the boiler and assembling connections (cont.)
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!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.
Electrical connections
Information about connecting accessories
For this connection, observe the separate installation instructions provided
with the accessories.
PUMP
X21
L N 1 L N?
GAS
D
X7 FAN
X20
A B
4 3 2 1
OT
CFE
X1
%
Installation sequence
Opening the control unit (cont.)
5603 938 GB
Installation

16
%Gas condensing boilers only:
Cylinder temperature sensor (plug
on the cable harness outside the
control unit) or connect the control
box (supplied with the system boiler)
if a 230V 2-port valve and cylinder
stat are used in a 4-pipe installation
(see separate installation instruc-
tions)
Note
Gas condensing boiler without DHW
cylinder:
For operation without a DHW cylin-
der, set rotary selector "
tw
" to "0".
AOnly for weather-compensated
mode:
Outside temperature sensor (acces-
sory)
BOpen Therm device
Remove jumper D when making
this connection.
CConnecting cable (accessory)
DJumper
EPower supply (230 V, 50 Hz).
See page 17.
FVitotrol 100
Remove jumper D when making
this connection.
Separate installation instruc-
tions
Cable entry
B
A
APower cable, remote control con-
necting cable
BLV leads (sensor leads)
Installation sequence
Electrical connections (cont.)
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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.
Power supply
Regulations and Directives
Danger
Incorrectly executed electrical
installations can lead to injury
from electrical current and result
in equipment damage.
Make the power supply connec-
tion and implement all protective
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 supply line
that simultaneously isolates all non-
earthed conductors from the mains with
at least 3 mm contact separation.
We additionally recommend installing an
AC/DC-sensitive RCD (RCD class B
) for DC (fault) currents that can
occur with energy efficient equipment.
Protect the power cable with max. 16 A.
Danger
Incorrect wire termination can
cause severe injury and damage
the appliance.
Take care not to interchange
wires "L1" and "N".
Danger
The absence of component
earthing in the system can lead to
serious injury from electrical cur-
rent if an electrical fault occurs.
Connect the appliance and pipe-
work to the equipotential bonding
of the building in question.
Installation sequence
Electrical connections (cont.)
5603 938 GB
Installation

18
Routing connecting cables and closing control unit
!Please note
Power cables will be damaged if they touch hot components.
When routing and securing power cables on site, ensure that the maximum
permissible temperatures for these cables are not exceeded.
3.
2.
1.
Installation sequence
Electrical connections (cont.)
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Filling the heating system.............................................. 20
••• 2. Venting the boiler by flushing....................................... 22
••• 3. Changing to operation with LPG................................... 22
•4. Matching the burner output to the flue system........... 22
•5. Reducing the max. heating output................................ 24
•6. Matching the circulation pump to the heating system 25
•7. Checking the CO2 content............................................. 26
• • 8. Burner removal .............................................................. 29
• • 9. Checking the burner gasket and burner gauze
assembly......................................................................... 30
• • 10. Checking and adjusting electrodes.............................. 31
• • 11. Cleaning the heat exchanger......................................... 31
• • 12. Checking the condensate drain and cleaning the
siphon.............................................................................. 32
• • 13. Burner installation ......................................................... 33
• • 14. Checking the diaphragm expansion vessel and
system pressure............................................................. 34
••• 15. Checking all connections on the heating water side
and DHW side for leaks
••• 16. Checking firm seating of electrical connections
••• 17. Checking gas equipment for tightness at operating
pressure .......................................................................... 34
• • 18. Fitting the front panel..................................................... 35
•19. Instructing the system user........................................... 35
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5603 938 GB
Service

20
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 16.8 °dH (3.0 mmol/l).
■ An antifreeze suitable for heating systems can be added to the fill water.
1. Close the gas shut-off valve.
2. Switch ON the power supply.
rr
3. Turn rotary selector "rt" anticlock-
wise for less than 2 s and then clock-
wise back to the control range on the
right.
"SERV", "r" and "w" appear on
the display. Filling function is ena-
bled.
This function will end automatically
after 20 min or after ON/OFF switch
has been turned OFF.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5603 938 GB