Viessmann Vitodens 100-W Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 100-W
Type BPJA, 6.5 to 25.0 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
Gas Council no.: 41-819-30, 25 kW; 41-819-31, 29 kW
For applicability, see the last page
VITODENS 100-W
5609 913 GB 1/2012 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
5609 913 GB

3
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.)
5609 913 GB

4
Installation instructions
Product information........................................................................................... 6
Preparing for installation................................................................................... 7
Installation sequence
Fitting the boiler and making connections............................................................ 10
Opening the control unit casing............................................................................ 15
Electrical connections........................................................................................... 16
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 19
Further details regarding the individual steps....................................................... 20
Troubleshooting
Function sequence and possible faults................................................................ 38
Fault messages on the display............................................................................. 39
Repairs................................................................................................................. 43
Gas type conversion
Converting from LPG to natural gas .................................................................... 51
Designs
Connection and wiring diagram............................................................................ 53
Parts lists
Ordering parts...................................................................................................... 55
Overview of the assemblies................................................................................. 56
Sheet metal parts assembly................................................................................. 57
Heat cell assembly............................................................................................... 58
Burner assembly.................................................................................................. 59
Hydraulic assembly.............................................................................................. 61
Combi hydraulic assembly................................................................................... 63
Control unit assembly........................................................................................... 64
Miscellaneous assembly...................................................................................... 65
Specification....................................................................................................... 66
Certificates
Declaration of conformity...................................................................................... 67
Index
Index
5609 913 GB

5
Keyword index.................................................................................................... 68
Index
Index (cont.)
5609 913 GB

6
Vitodens 100-W, type BPJA
Preset for operation with natural gas.
Conversion to LPG P requires a gas con-
version kit.
Conversion for other countries
The Vitodens 100-W should generally
only be delivered to those countries
specified on the type plate. For deliveries
to alternative countries, an approved
contractor, on his own initiative, must
arrange individual approval in accord-
ance with the law of the country in ques-
tion.
Product description
The Vitodens 100-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 9.
The Vitodens 100-W is set up for opera-
tion with constant boiler water tempera-
ture.
The following are integrated: one sealed
unvented hydraulic system with 2 con-
nections for heating flow and return and
2 connections for DHW heating.
If the Vitodens 100-W is installed in an S
plan or Y plan system, both of the inter-
nal connections must be sealed off, as
they are not required.
The following components are integra-
ted into the hydraulic system:
■ Circulation pump
■ 3-way diverter valve
■ Safety valve
■ Diaphragm expansion vessel
■ Plate heat exchanger for DHW heating
Connection accessories
A time switch is connected with low volt-
age to the control unit.
Product information
Product information
5609 913 GB

7
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 7 22 mm compression
fitting
BHot water 7 15 mm compression
fitting
CGas connection 7 22 mm
DCold water 7 15 mm compression
fitting
EHeating return 7 22 mm compres-
sion fitting
FCondensate drain/safety valve
drain: Plastic hose 7 22 mm
Preparing for installation
Preparing for installation
5609 913 GB
Installation

8
Fitting the wall mounting bracket
250
A
Ø10
187
AVitodens installation template
Preparing for installation
Preparing for installation (cont.)
5609 913 GB

9
1. Align the supplied installation tem-
plate on the wall.
2. Mark out the rawl plug holes.
3. Drill 7 10 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 the 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.)
5609 913 GB
Installation

10
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 into the wall mounting
bracket.
Installation sequence
Fitting the boiler and making connections
5609 913 GB

11
Making connections on the water side
BA DC E
¨
zz
AHeating flow G¾
BHot water G½
CGas connection G¾
DCold water G½
EHeating return G¾
For fittings on the heating water
side and DHW side, see separate
installation instructions.
Gas connection
A
1. Connect gas shut-off valve to con-
nection A.
Installation sequence
Fitting the boiler and making connections (cont.)
5609 913 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 result in material losses.
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 making connections (cont.)
5609 913 GB

13
Connection, safety valve and condensate drain
A
■ The condensate line is connected with
the safety valve discharge pipe. The
condensate hose supplied meets the
temperature requirements that are
part of the CE certification.
■ Connecting the condensate hose
internally to the domestic waste water
system, either directly or via a drip
water funnel (tundish) is recommen-
ded.
■ If the condensate line is routed outside
the building, use a pipe of at least
7 30 mm and insulate it against frost.
Avoid long external pipelines.
!Please note
A frozen condensate pipe can
result in faults and boiler dam-
age.
Always insulate condensate
lines against frost.
■ Observe the local building regulations.
Connect condensate line A with a con-
stant 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.
Installation sequence
Fitting the boiler and making connections (cont.)
5609 913 GB
Installation

14
Filling the siphon with water
Fill a minimum of 0.3 l of water into the
flue outlet.
!Please note
At commissioning, flue gas may
be emitted from the condensate
drain.
Fill the siphon with water before
commissioning.
Balanced flue connection
Connect the balanced flue.
During installation and positioning of the
flue system, observe Part L and
BS 5440 building regulations.
Flue system installation instruc-
tions.
Installation sequence
Fitting the boiler and making connections (cont.)
5609 913 GB

15
3.
2.
4x 1.
2x
!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.
Installation sequence
Opening the control unit casing
5609 913 GB
Installation

16
PUMP
L N 1 L N?
GAS
D
X7 FAN
X20
FE
X1
X21
A B
4 3 2 1
OT
C
AOnly for weather-compensated
mode:
Outside temperature sensor (acces-
sory)
BOpenTherm device
CConnecting cable (accessory)
DJumper
EPower supply (230 V, 50 Hz).
See page 17.
FVitotrol 100 or on-site room temper-
ature controller (230 V switched
input)
Remove jumper D when making
this connection.
Separate installation instruc-
tions
Information on connecting
accessories
For this connection, observe the
separate installation instructions
provided with the accessories.
Installation sequence
Electrical connections
5609 913 GB

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Cable entry
B
A
APower cable, remote control con-
necting cable
BLV leads (sensor leads)
Power supply
Regulations and Directives
Danger
Incorrect electrical installations
can result in injuries from electri-
cal current and in appliance dam-
age.
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 [IEE or local
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 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".
Installation sequence
Electrical connections (cont.)
5609 913 GB
Installation

18
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.
Routing connecting cables and closing the control unit
!Please note
Power cables will be damaged if
they contact hot components.
When routing and securing
cables/leads on site, ensure that
the maximum permissible tem-
peratures for these cables/leads
are not exceeded.
3.
2.
1.
Installation sequence
Electrical connections (cont.)
5609 913 GB

19
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........... 23
•5. Adjusting the circulation pump to the heating system 24
••• 6. Checking the static and supply pressure..................... 25
•7. Checking the CO2 content............................................. 27
• • 8. Burner removal .............................................................. 30
• • 9. Checking the burner gasket and burner gauze
assembly......................................................................... 31
• • 10. Checking and adjusting electrodes.............................. 32
• • 11. Cleaning the heat exchanger......................................... 33
• • 12. Checking the condensate drain and cleaning the
siphon.............................................................................. 33
• • 13. Burner installation ......................................................... 34
• • 14. Checking the diaphragm expansion vessel and
system pressure............................................................. 35
••• 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 .......................................................................... 36
• • 18. Fitting the front panel..................................................... 36
•19. Instructing the system user........................................... 37
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5609 913 GB
Service

20
Filling the heating system
!Please note
Unsuitable fill water increases
the level of deposits and corro-
sion and may lead to boiler dam-
age.
■ Thoroughly flush the entire
heating system prior to filling it.
■ Only fill with water of potable
quality.
■ Soften fill water harder than
300 ppm.
■ An antifreeze additive 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" fully anti-
clockwise for less than 2 s and then
clockwise back to the control range.
The display shows "SERV", "r"
and "w". The filling function has been
activated.
This function will end automatically
after 20 min or after the ON/OFF
switch has been turned off.
AB
4. Open shut-off valves A and B.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5609 913 GB