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.: 47-819-26 P25; 47-819-27 P29
For applicability, see the last page
VITODENS 100-W
5609 913 GB 2/2013 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 inten-
ded for qualified contractors.
■ Work on gas installations must only be
carried out by a registered 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:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental 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-TR Gas,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI,
SWKI, VKF and EKAS guideline
1942: LPG, part 2
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Do not smoke. Prevent naked
flames and sparks. Do not
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.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
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3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the installation site.
■ Close all doors in the living
space.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Life-threatening poisoning
caused by carbon monoxide in
the flue gas occurs as a result of
leaking or blocked flue systems
or an insufficient supply of com-
bustion air.
Ensure the flue system is in
proper working order. It must not
be possible to close apertures for
interconnected combustion air
supply.
Extractors
Operating appliances that extract air to
the outside (cooker hoods, extractors, air
conditioning units, etc.) can create neg-
ative 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 poison-
ing due to reverse flow of the flue
gas.
Fit an interlock circuit or take suit-
able steps to ensure a sufficient
supply of combustion air.
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 sup-
ply (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.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Prior to commencing any 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 compromise
the safe operation of your sys-
tem.
Defective components must be
replaced with genuine
Viessmann spare parts.
Safety instructions
Safety instructions (cont.)
5609 913 GB

4
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5609 913 GB

5
Installation instructions
Preparing for installation................................................................................... 6
Installation sequence
Fitting the boiler and making connections............................................................ 11
Opening the control unit casing............................................................................ 16
Electrical connections........................................................................................... 17
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 20
Further details regarding the individual steps....................................................... 21
Troubleshooting
Function sequence and possible faults................................................................ 35
Fault messages on the display............................................................................. 36
Repairs................................................................................................................. 40
Gas type conversion
Converting from LPG to natural gas..................................................................... 48
Designs
Connection and wiring diagram............................................................................ 50
Parts lists
Ordering parts...................................................................................................... 52
Overview of the assemblies................................................................................. 53
Sheet metal parts assembly................................................................................. 54
Heat cell assembly............................................................................................... 55
Burner assembly.................................................................................................. 56
Hydraulic assembly.............................................................................................. 58
Combi hydraulic assembly................................................................................... 60
Control unit assembly........................................................................................... 61
Miscellaneous assembly...................................................................................... 62
Specification....................................................................................................... 63
Certificates
Declaration of conformity...................................................................................... 64
Keyword index.................................................................................................... 65
Index
Index
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6
Intended use
The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions. It is only designed
for the heating of water that is of potable
water quality.
Intended usage presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than heating the building or
DHW does not comply with regulations.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect usage also occurs if the components
in the heating system are modified from
their intended function (e.g. if the flue
gas and ventilation air paths are
sealed).
Product information
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 must arrange individual
approval on his/her own initiative and in
accordance with the law of the country in
question.
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 10.
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, the DHW primary
connections are not used and must be
capped off.
Preparing for installation
Preparing for installation
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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
Accessory connection
A time switch is connected with low volt-
age to the control unit.
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
175
150
Shown without fittings
AHeating flow 7 22 mm
BDHW 7 15 mm
CGas connection 7 22 mm
DCold water 7 15 mm
Preparing for installation
Preparing for installation (cont.)
5609 913 GB
Installation

8
EHeating return 7 22 mm
FCondensate drain/safety valve
drain: Plastic hose 7 22 mm
Preparing for installation
Preparing for installation (cont.)
5609 913 GB

9
Fitting the wall mounting bracket
250
A
Ø10
145
AVitodens installation template
Preparing for installation
Preparing for installation (cont.)
5609 913 GB
Installation

10
1. Position the supplied installation tem-
plate on the wall.
2. Mark out the rawl plug holes.
3. Drill 7 10 mm holes and insert the
rawl plugs supplied.
4. Fit wall mounting bracket with screws
supplied.
Fitting installation aid or mounting
frame
Installation aid or mounting frame
installation instructions
Preparing the connections
!Please note
To prevent equipment 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.
■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

11
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
Installation

12
Making the connections on the water side
¨
zz
A B C D E
AHeating flow 7 22 mm
BDHW 7 15 mm
CGas connection 7 22 mm
DCold water 7 15 mm
EHeating return 7 22 mm
For installation of fittings on the
heating water side and DHW
side, see separate installation
instructions.
Installation sequence
Fitting the boiler and making connections (cont.)
5609 913 GB

13
Gas connection
A
1. Connect gas shut-off valve to con-
nection A.
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 unsuitable con-
stituents (e.g. nitrites, sulphides) can
cause material damage.
Remove residues of the leak detec-
tion agent after testing.
!Please note
Excessive test pressure may
damage the boiler and the gas
valve.
Max. test pressure 150 mbar
(15 kPa). Where higher pres-
sure is required for tightness
tests, disconnect the boiler
and the gas valves from the
gas supply pipe (undo the fit-
ting).
3. Vent the gas line.
Installation sequence
Fitting the boiler and making connections (cont.)
5609 913 GB
Installation

14
Connection, safety valve and condensate drain
A
■ The condensate pipe is connected
with the discharge pipe of the safety
valve. The condensate hose supplied
meets the temperature requirements
that are part of the CE certification.
■ Connecting the condensate pipe inter-
nally to the domestic waste water sys-
tem, either directly or via a tundish or
washing machine trap, is recommen-
ded.
■ If the condensate pipe is routed out-
side the building, use a pipe with at
least 7 30 mm and protect this pipe
from frost. Avoid long external pipe-
lines.
!Please note
Frozen condensate pipes can
result in faults and damage to
the boiler.
Always insulate condensate
pipes against frost.
■ Observe local building regulations.
Connect condensate pipe A to the pub-
lic sewage system with a constant fall
and a pipe vent.
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

15
Filling the siphon with water
Pour a minimum of 0.3 l of water into the
flue outlet.
!Please note
During commissioning, flue gas
may escape from the condensate
drain.
Always fill the siphon with water
before commissioning.
Balanced flue connection
Connect the balanced flue.
Flue system installation instruc-
tions
Installation sequence
Fitting the boiler and making connections (cont.)
5609 913 GB
Installation

16
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

17
?
C
ED
X1
A
4 3 2 1
B
AOutside temperature sensor (acces-
sories)
BConnecting cable (accessories)
CJumper
DPower supply (230 V, 50 Hz).
See page.
EVitotrol 100 or on-site room temper-
ature controller (230 V switched
input)
Remove jumper C when making
this connection.
Separate installation instruc-
tions
Information on connecting
accessories
When connecting accessories
observe the separate installation
instructions provided with them.
Installation sequence
Electrical connections
5609 913 GB
Installation

18
Cable entry
B
A
APower cable, remote control con-
necting cable
BLV leads (sensor leads)
Power supply
Regulations and Directives
Danger
Incorrectly executed electrical
installations can result in injuries
from electrical current and in
appliance damage.
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 cable that
simultaneously isolates all non-earthed
conductors from the power supply with at
least 3 mm contact separation.
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

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Danger
The absence of component
earthing can lead to serious injury
from electric current if an electri-
cal 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 enclo-
sure
!Please note
Connecting cables will be dam-
aged if they touch hot compo-
nents.
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
Installation

20
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Filling the heating system.............................................. 21
••• 2. Changing to operation with LPG................................... 22
•3. Matching the burner output to the flue system........... 22
••• 4. Checking the static and supply pressure..................... 23
•5. Checking the CO2 content............................................. 25
• • 6. Burner removal .............................................................. 27
• • 7. Checking the burner gasket and burner gauze
assembly......................................................................... 28
• • 8. Checking and adjusting electrode................................ 29
• • 9. Cleaning the heat exchanger......................................... 30
• • 10. Checking the condensate drain and cleaning the
siphon.............................................................................. 31
• • 11. Burner installation ......................................................... 32
• • 12. Checking the diaphragm expansion vessel and
system pressure............................................................. 33
••• 13. Checking all connections on the heating water side
and DHW side for leaks
••• 14. Checking firm seating of electrical connections
••• 15. Checking all gas equipment for tightness at operating
pressure .......................................................................... 33
• • 16. Fitting the front panel..................................................... 34
•17. Instructing the system user........................................... 34
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5609 913 GB