Viessmann Vitodens 100-W Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 100-W
Type B1HA, B1KA, 6.5 to 35.0 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
Gas Council Number: 41-819-36 - 39, 47-819-33 - 35
For applicability, see the last page
VITODENS 100-W
5677 216 GB 3/2015 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 authorised 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 to be observed
■ National installation regulations
■ Statutory regulations for the preven-
tion of accidents
■ Statutory regulations for environmen-
tal 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
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 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.
Danger
Hot surfaces can cause burns.
■ Before maintenance and serv-
ice work, switch OFF the appli-
ance and let it cool down.
■ Never touch hot surfaces on
the boiler, burner, flue system
or pipework.
Safety instructions
Safety instructions
5677 216 GB

3
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Prior to commencing work, touch
earthed objects such as heating
or water pipes to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of the sys-
tem.
Replace faulty components only
with genuine Viessmann spare
parts.
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 for operating the
system
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.
■ 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 threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the installation site.
■ Close doors to living spaces to
prevent flue gases from
spreading.
Safety instructions
Safety instructions (cont.)
5677 216 GB

4
What to do if water escapes from the
appliance
Danger
When water escapes from the
appliance there is a risk of elec-
trocution.
Switch off the heating system by
means of an external isolator (for
example fuse box, domestic
power distribution).
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 an adequate 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
Leaking or blocked flue systems,
or an inadequate supply of com-
bustion air can cause life threat-
ening poisoning from carbon
monoxide in the flue gas.
Ensure the flue system is in good
working order. Apertures for sup-
plying combustion air must be
non-closable.
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 an adequate
supply of combustion air.
Safety instructions
Safety instructions (cont.)
5677 216 GB

5
Installation instructions
Information
Disposal of packaging.......................................................................................... 7
Symbols................................................................................................................ 8
Intended use......................................................................................................... 9
Product information.............................................................................................. 9
Preparing for installation................................................................................... 11
Installation sequence
Mounting the boiler and making the connections................................................. 14
Opening the control unit enclosure....................................................................... 20
Electrical connections........................................................................................... 21
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 28
Further details regarding the individual steps....................................................... 30
Troubleshooting
Function sequence and possible faults................................................................ 61
Fault display......................................................................................................... 62
Repairs................................................................................................................. 66
Gas type conversion
Converting from LPG to natural gas..................................................................... 76
Control unit
Functions and operating conditions in weather-compensated mode................... 78
Designs
Connection and wiring diagram............................................................................ 79
Parts lists
Ordering parts...................................................................................................... 81
Overview of assemblies....................................................................................... 82
Sheet metal parts assembly................................................................................. 83
Heat cell assembly............................................................................................... 85
Burner assembly.................................................................................................. 87
Hydraulic assembly.............................................................................................. 89
Hydraulic assembly, system boiler....................................................................... 91
Hydraulic assembly, combi boiler......................................................................... 92
Index
Index
5677 216 GB

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Control unit assembly........................................................................................... 94
Miscellaneous....................................................................................................... 95
Specification....................................................................................................... 97
Disposal
Final decommissioning and disposal.................................................................... 99
Certificates
Declaration of conformity...................................................................................... 100
Keyword index.................................................................................................... 101
Index
Index (cont.)
5677 216 GB

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Please dispose of waste packaging in
line with statutory regulations.
Information
Disposal of packaging
5677 216 GB
Installation

8
Sym-
bol
Meaning
Reference to other document
containing further information
1.
Step in a diagram:
The numbers correspond to the
order in which the steps are car-
ried out.
Warning of material losses and
environmental 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 surface.
Dispose of component correct-
ly.
Dispose of component at a suit-
able collection point. Do not
dispose of component in do-
mestic waste.
Information
Symbols
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9
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 use 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 shall be deemed inappropriate.
Any usage beyond this must be
approved by the manufacturer in each
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited 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 B1HA, B1KA
Preset for operation with natural gas.
Conversion to LPG P requires a gas con-
version kit.
Conversion for other countries
The Vitodens 100-W must only be deliv-
ered to the 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 boiler for the connection
of one DHW cylinder and as a gas con-
densing combi boiler with an integral
plate heat exchanger for DHW heating.
For the connection of heating circuits
and the DHW cylinder or the DHW line,
see from page 13.
In the delivered condition, the
Vitodens 100-W is set up for operation
with constant boiler water temperature.
By connecting an outside temperature
sensor (accessories), the boiler can be
operated in weather-compensated
mode.
Information
Intended use
5677 216 GB
Installation

10
The following are integrated: one sealed
unvented hydraulic system with 2 con-
nections for heating flow and return, and
2 connections for cylinder heating (gas
condensing boiler) or DHW heating (gas
condensing 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 DHW primary
connections are not used and must be
capped off.
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
(gas condensing combi boiler)
DHW heating with DHW cylinder
If a Viessmann Vitocell is connected, a
cylinder temperature sensor will issue
the heat demand (accessories). The cyl-
inder 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 (acces-
sories) may also be used on this cylin-
der. Alternatively, a 230 V cylinder tem-
perature controller should be connected
via the cylinder demand junction box
(part of the boiler standard delivery).
Connecting accessories
Cylinder temperature sensor, outside
temperature sensor and time switch are
connected to the control unit with low
voltage.
Information
Product information (cont.)
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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
150
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
FCondensate drain/ drain safety
valve: Plastic hose 7 22 mm
Preparing for installation
Preparing for installation
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Installation

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Fitting the wall mounting bracket
250
A
Ø10
145
AVitodens installation template
1. Position the supplied installation tem-
plate on the wall.
2. Mark out the rawl plug holes.
Preparing for installation
Preparing for installation (cont.)
5677 216 GB

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3. Drill 7 10 mm holes and insert the
rawl plugs supplied.
4. Fit wall mounting bracket with screws
supplied.
Fitting the pre-plumbing jig or mount-
ing frame
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.
1. Prepare the water connections. Flush
the heating system.
2. Prepare the gas connection.
3. Prepare the electrical connections.
■ Power cable:
Flexible cable 3 x 1.5 mm2
Leave the earth conductor (PE)
longer than the 'live' conductors L1
and N.
■ Accessory cables:
NYM-O 2-core min. 0.5 mm2.
Preparing for installation
Preparing for installation (cont.)
5677 216 GB
Installation

14
Removing the front panel and mounting the boiler
2x
1.
2.
3.
1. Undo the screws at the bottom of the
boiler; do not remove completely.
2. Remove the front panel.
3. Hook the boiler onto the wall mount-
ing bracket.
Installation sequence
Mounting the boiler and making the connections
5677 216 GB

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Making 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
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 condensing boiler
AC
E
Installation sequence
Mounting the boiler and making the connections (cont.)
5677 216 GB
Installation

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Gas condensing combi boiler
A
B
C
DE
F
FFilling loop
Permiss. DHW operating pressure:
10 bar (1.0 MPa)
Note
Install a pressure reducer if required.
Gas connection
A
1. Connect gas shut-off valve to con-
nection A.
Installation sequence
Mounting the boiler and making the connections (cont.)
5677 216 GB

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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. nitrides, sulphides) can
result in material damage.
Remove leak detection agent resi-
dues after testing.
!Please note
Excessive test pressure will
damage the boiler and the gas
train.
Max. test pressure 150 mbar.
If a higher pressure is
required for tightness tests,
disconnect the boiler and the
gas train from the main supply
pipe (undo the fitting).
3. Purge the gas line.
Installation sequence
Mounting the boiler and making the connections (cont.)
5677 216 GB
Installation

18
Connecting the safety valve and condensate drain
A
■ The condensate pipe is connected to
the discharge pipe of the safety valve.
The supplied condensate hose meets
the temperature requirements for CE
certification.
■ We recommend connecting the con-
densate pipe to the internal domestic
waste water system, either directly or
via a tundish.
■ 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
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 pub-
lic sewage system with a constant fall
and a pipe vent.
Observe the local waste water regula-
tions.
Note
Fill the trap with water before commis-
sioning.
Installation sequence
Mounting the boiler and making the connections (cont.)
5677 216 GB

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Filling the trap with water
Pour at least 0.3 l of water into the flue
outlet.
!Please note
During commissioning, flue gas
may escape from the condensate
drain.
Always fill the trap with water
before commissioning.
Balanced flue connection
Note
Only use the "System certificate" and
"Skoberne GmbH flue system" labels in
conjunction with the Viessmann flue sys-
tem made by Skoberne.
Connect the balanced flue.
During installation and positioning of the
flue system, observe Building regula-
tions Part L and BS 5440.
Flue system installation instruc-
tions.
Connecting several Vitodens 100-W
to a shared flue system
Adjust the burner setting of each con-
nected boiler to match the flue system:
■ For shared connection, see
page 40.
■ For flue gas cascade, see page 47.
Do not carry out commissioning until
the following conditions are met:
■ Free passage through the flue gas
pipes.
■ Flue system with positive pressure is
gas-tight.
Installation sequence
Mounting the boiler and making the connections (cont.)
5677 216 GB
Installation

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■ Apertures for ensuring sufficient com-
bustion air supply are open and cannot
be closed off.
■ Applicable regulations on installing
and commissioning flue systems have
been followed.
Danger
Leaking or blocked flue systems
or an insufficient supply of com-
bustion air cause life threatening
poisoning due to carbon monox-
ide in the flue gas.
Ensure the flue system functions
correctly. Apertures for combus-
tion air supply must not be able to
be closed off.
Opening the control unit enclosure
3.
2.
4x 1.
2x
Installation sequence
Mounting the boiler and making the connections (cont.)
5677 216 GB