Viessmann Vitodens 100-W Quick guide

Installation and service instructions
for contractors
VIESMANN
Vitodens 100-W
Type B1HC, B1KC, 4.7 to 35.0 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
Gas Council Number: 41-819-40, 41-819-41, 41-819-42, 41-819-43, 47-819-40,
47-819-41, 47-819-42
For applicability, see the last page
VITODENS 100-W
5697 787 GB 6/2017 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 environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■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 prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW G K Guidelines,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
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 safeguard it against unintentional
reopening.
■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 reconnection.
■Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces can cause burns.
■Before maintenance and service 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 elec-
trostatic discharge.
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 func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
5697 787 GB

3
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious 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 threatening poisoning.
■Shut down the heating system.
■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 appliance there is a
risk of electrocution.
Switch OFF the heating system at the external
isolator (e.g. fuse box, domestic distribution
board).
Danger
If water escapes from the appliance 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 conden-
sate or other causes. Ensure an adequate supply of
combustion air.
Inform system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be non-
closable.
Extractors
Operating appliances that extract air to the outside
(extractor hoods, extractors, air conditioning units, etc.)
can create negative 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 poisoning due to
reverse flow of the flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5697 787 GB

4
1. Information Disposal of packaging ............................................................................ 6
Symbols ................................................................................................. 6
Intended use .......................................................................................... 7
Product information ................................................................................ 7
■Vitodens 100-W, type B1HC, B1KC .................................................... 7
Product description ................................................................................ 7
■DHW heating with DHW cylinder ........................................................ 7
■Connecting accessories ..................................................................... 8
2. Preparing for installation ................................................................................................................ 9
3. Installation sequence Mounting the boiler and making connections ........................................ 12
■Hooking the boiler onto the wall mounting bracket ............................. 12
■Fitting the connections on the water side ........................................... 12
■Gas connection ................................................................................... 14
■Connecting the safety valve and condensate drain ............................ 14
■Filling the trap with water .................................................................... 15
■Balanced flue connection ................................................................... 15
Removing the front panel ....................................................................... 16
Opening the control unit enclosure ........................................................ 16
Electrical connections ............................................................................ 17
■Cable entry ......................................................................................... 19
■Outside temperature sensor (accessories) ......................................... 19
■Vitotrol 100 connection ....................................................................... 19
■Power supply ...................................................................................... 20
■Routing cables/leads and closing the control unit enclosure .............. 20
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 21
5. Changing the gas type Changing from operation with LPG to operation with natural gas ......... 47
■Checking the CO2 content .................................................................. 48
6. Troubleshooting Function sequence and possible faults .................................................. 49
Fault display ........................................................................................... 49
Repairs .................................................................................................. 52
■Removing the front panel ................................................................... 52
■Outside temperature sensor ............................................................... 53
■Boiler water temperature sensor ........................................................ 54
■Checking the cylinder temperature sensor (gas condensing system
boiler) .................................................................................................. 55
■Checking the temperature limiter ........................................................ 56
■Checking the outlet temperature sensor (gas condensing combi
boiler) .................................................................................................. 56
■Checking the flue gas temperature sensor ......................................... 57
■Replacing the flow limiter (gas condensing combi boiler) ................... 58
■Checking or replacing the plate heat exchanger (gas condensing
combi boiler) ....................................................................................... 59
■Checking the fuse ............................................................................... 60
7. Parts lists Overview of assemblies ......................................................................... 61
Casing assembly ................................................................................... 62
Heat cell assembly ................................................................................. 64
Burner assembly .................................................................................... 66
Hydraulic assembly ................................................................................ 68
Hydraulic assembly, system boiler ......................................................... 70
Hydraulic assembly, combi boiler .......................................................... 72
Control unit assembly ............................................................................ 74
Miscellaneous assembly ........................................................................ 76
Index
Index
5697 787 GB

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8. Control unit Functions and operating conditions in weather-compensated mode .... 78
■Heating curve for weather-compensated control ................................ 78
■Frost protection function ..................................................................... 78
9. Connection and wiring dia-
gram
................................................................................................................ 79
10. Reports ................................................................................................................ 80
11. Specification ................................................................................................................ 81
12. Disposal Final decommissioning and disposal ..................................................... 83
13. Certificates Declaration of conformity ....................................................................... 84
■Manufacturer's declaration ................................................................. 84
14. Keyword index ................................................................................................................ 85
Index
Index (cont.)
5697 787 GB

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Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Information
Disposal of packaging
5697 787 GB
Information

7
The appliance is intended solely for installation and
operation in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions. It is only designed for heating up heating water
that is of potable water quality.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents 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 man-
ufacturer 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 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 100-W, type B1HC, B1KC
Preset for operation with natural gas
The Vitodens 100-W may only be delivered to the
countries specified on the type plate. For deliveries to
other countries, approved contractors must arrange
individual approval on their own initiative and in
accordance with the law of the country in question.
The type plate is located on the top of the boiler (see
page 61).
Product description
The Vitodens 100-W is available as a gas condensing
system boiler for the connection of one DHW cylinder
and as a gas condensing combi boiler with an integral
plate heat exchanger for DHW heating. For the con-
nection of heating circuits and the DHW cylinder or the
DHW line, see page 12 onwards.
In the delivered condition, the Vitodens 100-W is set
up for operation with a constant boiler water tempera-
ture. By connecting an outside temperature sensor
(accessories), the boiler can be operated in weather-
compensated mode.
The following are integrated: one sealed unvented
hydraulic system with 2 connections for heating flow
and return, and 2 connections for cylinder heating (gas
condensing system boiler) or DHW heating (gas con-
densing combi boiler).
These boilers are only intended for installation in
sealed unvented heating systems. Boilers for open
vented heating systems are also available.
If the Vitodens 100-W is installed in an S plan or Y
plan system, the two internal connections are not used
and must be capped off during installation.
The following components are integrated into the
hydraulic system:
■Circulation pump
■3-way diverter valve
■Safety valve
■Diaphragm expansion vessel
■Plate heat exchanger for DHW heating (gas con-
densing combi boiler)
DHW heating with DHW cylinder
If a Viessmann Vitocell is connected, a cylinder tem-
perature sensor will issue the heat demand (accesso-
ries). The cylinder temperature sensor is connected to
the boiler control unit. A 230 V cylinder temperature
controller is not required.
If a different DHW cylinder is connected, the cylinder
temperature sensor (accessories) may also be used
on this cylinder. Alternatively, a 230 V cylinder temper-
ature controller should be connected via the cylinder
demand junction box (part of the boiler standard deliv-
ery).
Information
Intended use
5697 787 GB
Information

8
Connecting accessories
Cylinder temperature sensor, outside temperature sen-
sor and time switch are connected to the control unit
with low voltage.
Information
Product description (cont.)
5697 787 GB
Information

9
Preparing for boiler installation
Dimensions and connections
34
5
250
68
400
700
58 58
123123
B
AC E
F
D
156
350
125
860
1800 G 1925 H
Fig. 1
AHeating flow 7 22 mm
BGas condensing system boiler:
Cylinder flow G ¾
Gas condensing combi boiler:
DHW 7 15 mm
CGas connection
DGas condensing system boiler:
Cylinder return G ¾
Gas condensing combi boiler:
Cold water 7 15 mm
EHeating return 7 22 mm
FCondensate drain/safety valve drain: plastic hose
7 22 mm
GCompulsory in conjunction with DHW cylinder
below the boiler
HRecommendation for installation without DHW cyl-
inder below the boiler
Note
Dimensions of connections in conjunction with the con-
nection accessories provided.
Preparing for installation
Preparing for installation
5697 787 GB
Installation

10
Fitting the wall mounting bracket
Only for installation without pre-plumbing jig or mount-
ing frame.
250
A
Ø10
146
109
Fig. 2
AVitodens installation template
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 sup-
plied.
Note
The supplied rawl plugs are suitable for the follow-
ing materials:
■Concrete
■Vertically perforated bricks
■Hollow concrete breeze blocks
■Hollow brick and concrete ceilings
■Perforated sand lime bricks
■Solid sand lime bricks
■Natural stone with dense structure
■Porous concrete
■Solid gypsum panels
■Solid concrete breeze blocks
■Solid bricks
4. Fit the wall mounting bracket with the screws sup-
plied.
Fitting the pre-plumbing jig or mounting frame
(accessories)
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.
Note
This boiler (IP rating: IP X4) is approved for installation
in wet rooms inside safety zone 1 in accordance with
IEEE Wiring Regulations, providing the occurrence of
hosed water can be ruled out.
Observe the IEEE Wiring Regulations.
1. Prepare the water connections. Flush the heating
system.
2. Prepare the gas connection.
Preparing for installation
Preparing for installation (cont.)
5697 787 GB
Installation

11
3. Prepare the electrical connections.
■Power cable:
A flexible cable 3 x 1.0 mm2, approx. 1.5 m long
is connected in the delivered condition.
■Cables for accessories:
2-core sheathed cable min. 0.5 mm2 for low volt-
age
Preparing for installation
Preparing for installation (cont.)
5697 787 GB
Installation

12
Hooking the boiler onto the wall mounting bracket
Fig. 3
Fitting the connections on the water side
For installation of fittings on the heating water
side and DHW side, see separate installation
instructions.
BA DC E
¨
zz
Fig. 4
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
Installation sequence
Mounting the boiler and making connections
5697 787 GB
Installation

13
Gas condensing system boiler
A
C
E
Fig. 5
Gas condensing combi boiler
A
B
D
E
F
C
Fig. 6
FFilling device
Permiss. DHW operating pressure: 10 bar (1.0 MPa)
Note
Install a pressure reducer if required.
Installation sequence
Mounting the boiler and making connections (cont.)
5697 787 GB
Installation

14
Gas connection
A
Fig. 7
1. Connect the gas shut-off valve to connection A.
2. Check gas connections for tightness.
Note
Only use suitable and approved leak detection
agents (EN 14291) and devices for the tightness
test. Leak detection agents with unsuitable constit-
uents (e.g. nitrides, sulphides) can cause material
damage.
Remove residues of the leak detection agent after
testing.
!Please note
Excessive test pressure will damage the
boiler and the gas train.
Max. test pressure 150 mbar (15 kPa).
Where higher pressure is required for tight-
ness tests, disconnect the boiler and the gas
train from the main supply pipe (undo the fit-
ting).
3. Purge the gas line.
Connecting the safety valve and condensate drain
A
Fig. 8
■The condensate pipe is connected to the discharge
pipe of the safety valve. The condensate hose sup-
plied meets the temperature requirements that are
part of the CE certification.
■We recommend connecting the condensate pipe to
the internal domestic waste water system, either
directly or via a tundish.
■If the condensate pipe is routed outside the building,
use a pipe with min. 7 30 mm and protect the pipe
from frost. Avoid long external pipe runs.
!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 public sewage sys-
tem with a constant fall and a pipe vent.
Observe local waste water regulations.
Note
Fill the trap with water before commissioning.
Installation sequence
Mounting the boiler and making connections (cont.)
5697 787 GB
Installation

15
Filling the trap with water
Fig. 9
Pour at least 0.3 l of water into the flue gas connection.
!Please note
During commissioning, flue gas may escape
from the condensate drain.
Always fill the trap with water before commis-
sioning.
Balanced flue connection
Note
Only use the "System certificate" and "Skoberne
GmbH flue system" labels in conjunction with the
Viessmann flue system made by Skoberne.
Fig. 10
Connect the balanced flue pipe.
During installation and positioning of the flue system,
observe Building Regulations Part L and BS 5440.
Flue system installation instructions
Connecting several Vitodens 100-W to a shared
flue system
Adjust the burner settings of each connected boiler to
match the flue system:
■For shared connection, see page 28.
■For flue gas cascade, see page 34.
Note
The back draught safety device available as an acces-
sory must be installed on every boiler.
Only carry out commissioning when the following
conditions have been met:
■Unrestricted flow in the flue gas routes.
■Positive pressure flue system is gas-tight.
■Inspection port covers checked for secure and tight
seating.
■Apertures for supplying sufficient combustion air are
open and cannot be closed.
■All current regulations on installing and commission-
ing flue systems have been observed.
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be non-
closable.
Installation sequence
Mounting the boiler and making connections (cont.)
5697 787 GB
Installation

16
2x
2.
1.
Fig. 11
1. Undo the screws on the underside of the boiler; do
not remove them completely.
2. Remove front panel.
Opening the control unit enclosure
3.
2.
4x 1.
2x
Fig. 12
Installation sequence
Removing the front panel
5697 787 GB
Installation

17
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing any work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Electrical connections
Information on connecting accessories
When connecting accessories observe the sep-
arate installation instructions provided with
them.
L?
D
A B
4 3 2 1
CFE
%
96
Fig. 13
AOnly for weather-compensated mode:
Outside temperature sensor (accessories)
BOpenTherm device
Remove jumper D when making this connection.
CConnecting cable
DJumper
EPower supply (230 V, 50 Hz).
See page 20.
FVitotrol 100 or on-site room temperature controller
(230 V switched input)
Remove jumper D when making this connection.
Separate installation instructions
%Gas condensing system boiler:
■With Viessmann DHW cylinders: cylinder tem-
perature sensor (plug on the cable harness out-
side the control unit)
■In the case of alternative DHW cylinders compli-
ant with the G3 Directive:
Cylinder demand junction box (for connection of
a cylinder temperature controller and a 2-way
shut-off valve)
■Operation without DHW cylinder:
Set the set DHW temperature to "OFF".
Operating instructions
Installation sequence
Opening the control unit enclosure (cont.)
5697 787 GB
Installation

18
Connection of room temperature controller with time switch and DHW cylinder with 2-way valve and 230 V cylin-
der temperature controller
F
E
C
%
G
A H
D
M
1~
Fig. 14
ACylinder demand junction box (accessories)
BJumper; remove when making this connection
CPower supply (230 V, 50 Hz).
See page 20.
D230 V cylinder temperature controller
E2-way shut-off valve
FHigh limit safety cut-out
GTime switch
HRoom temperature controller
Installation sequence
Electrical connections (cont.)
5697 787 GB
Installation

19
Cable entry
B
A
Fig. 15
APower cable, remote control connecting cable
BLV leads (sensor leads)
Outside temperature sensor (accessories)
1. Fit the outside temperature sensor.
Installation location:
■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-sec-
tion of 1.5 mm2
2. Connect the outside temperature sensor to the
connecting cable across terminals 3 and 4 at slot
"X21" (see page 17).
Vitotrol 100 connection
1 L N
C
X1/96
B
ANO
NC
COM
Fig. 16 Example: Vitotrol 100, type UTDB
AVitotrol 100, type UTDB
BTerminals "X1/96" on the control unit
CJumper; remove when making this connection
Recommended connecting cable
■2-core cable with a cross-section of 1.5 mm² for
230 V~
Installation sequence
Electrical connections (cont.)
5697 787 GB
Installation

20
Power supply
Regulations and directives
Danger
Incorrectly executed electrical installations can
result in injuries from electrical current and dam-
age to the appliance.
Connect the power supply and implement all
safety measures (e.g. RCD circuit) in accord-
ance with the following regulations:
■VDE regulations
■Connection requirements specified by your
local power supply utility
Install an isolator in the power cable to provide omnip-
olar separation from the mains for all active conduc-
tors, corresponding to overvoltage category III (3 mm)
for complete isolation. The isolator must be fitted in the
permanent electrical installation, in line with installation
requirements.
We also 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 a fuse/MCB of up to 16 A.
Danger
Incorrect core assignment can result in serious
injury and damage to the appliance.
Take care not to interchange wires "L1" and "N".
Danger
The absence of component earthing for the sys-
tem can lead to serious injury from electric cur-
rent if an electrical fault occurs.
The appliance and pipework must be connected
to the equipotential bonding of the building.
Routing cables/leads and closing the control unit enclosure
!Please note
Connecting cables/leads will be damaged if they
touch hot components.
When routing and securing cables/leads on site,
ensure that the maximum permissible tempera-
ture for these is not exceeded.
3.
2.
1.
Fig. 17
Installation sequence
Electrical connections (cont.)
5697 787 GB
Installation