Viessmann Vitodens 100-W Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 100-W
Type WB1B, 9.0 to 35.0 kW
Wall mounted gas fired condensing boiler
Natural gas and LPG version
Gas Council no.
41-819-12; 41-819-13; 41-819-14 (gas fired condensing boilers)
47-819-18; 47-819-19; 47-819-20 (gas fired condensing combi boil-
ers)
VITODENS 100-W
5366 836 GB 9/2008 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
5366 836 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.)
5366 836 GB

4
Installation instructions
Preparing for installation
Product information.............................................................................................. 5
Preparing for installation....................................................................................... 5
Installation sequence
Installing the boiler and making all connections................................................... 9
Opening the control unit....................................................................................... 13
Electrical connections........................................................................................... 14
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 17
Further details regarding the individual steps....................................................... 18
Troubleshooting
Function sequence and possible faults................................................................ 32
Fault messages on the display............................................................................. 33
Repairs................................................................................................................. 37
Gas type conversion
Converting from LPG to natural gas .................................................................... 49
Control unit
Functions and operating conditions in weather-compensated mode .................. 52
Designs
Connection and wiring diagram............................................................................ 53
Parts lists............................................................................................................ 55
Specification....................................................................................................... 61
Certificates
Declaration of conformity...................................................................................... 63
Keyword index.................................................................................................... 64
Index
Index
5366 836 GB

5
Vitodens 100-W, WB1B
Set up for operation with natural gas.
Preparing for installation
Preparing the boiler installation
Dimensions and connections
≥ 5
≥ 250
68
400
725
58 58
123123
B
A
C E FD
G
156
a
125
31
ACondensate drain: Plastic pipe 7
22 mm
BHeating flow
CGas fired condensing boiler:
Cylinder flow
Gas fired condensing combi boiler:
DHW
DGas connection
Preparing for installation
Product information
5366 836 GB
Installation

6
EGas fired condensing boiler:
Cylinder return
Gas fired condensing combi boiler:
Cold water
FHeating return
GDrain safety valve
Rated output range kW 9 - 26 11 - 30 11 - 35
a mm 340 360 360
Preparing for installation
Preparing for installation (cont.)
5366 836 GB

7
Fitting the wall retainer
250
A
Ø10
B
155
115
AInstallation template Vitodens BOpening for the balanced flue
1. Position the supplied installation tem-
plate on the wall.
2. Mark out the rawl plug holes.
Preparing for installation
Preparing for installation (cont.)
5366 836 GB
Installation

8
3. Drill 710 mm holes and insert the
supplied rawl plugs.
4. Fit wall retainer with screws sup-
plied.
Preparing the connections
1. Prepare the water connections. Flush
the heating system.
2. Prepare gas connection.
3. Prepare the electrical connections.
Observe valid IEEE standards.
■ A 1.5 m long power cable is fitted
as standard.
■ Accessory cables:
NYM-O 2-core min. 0.5 mm2.
Preparing for installation
Preparing for installation (cont.)
5366 836 GB

9
Removing the front panel and mounting the boiler
2.
3.
1.
2x
1. Release screws at the bottom of the
boiler; do not remove completely.
2. Remove front panel.
3. Hook the boiler into the wall
retainer.
Installing connections on the water side
For fittings on the heating water side and DHW side, see separate installation
instructions.
Installation sequence
Installing the boiler and making all connections
5366 836 GB
Installation

10
BA DC E
¨
zz
AHeating flow
BGas fired condensing boiler:
Cylinder flow
Gas fired condensing combi boiler:
DHW
CGas connection
DGas fired condensing boiler:
Cylinder return
Gas fired condensing combi boiler:
Cold water
EHeating return
Safety valve connection
A
B
Connect safety valve drain A
(7 15 mm) with visible outlet B to the
dewatering system or route with visible
outlet through the external wall.
Installation sequence
Installing the boiler and making all connections (cont.)
5366 836 GB

11
Gas connection
A
1. Connect gas shut-off valve to con-
nection A.
2. Carry out a leak/tightness test.
!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 supply pipe.
Installation sequence
Installing the boiler and making all connections (cont.)
5366 836 GB
Installation

12
Condensate connection
A
Connect condensate drain A with a
slope and a pipe vent to the public
sewer.
Observe the local waste water regula-
tions.
Note
Fill the siphon with water before start-
up.
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
start-up.
Installation sequence
Installing the boiler and making all connections (cont.)
5366 836 GB

13
Balanced flue connection
Connect the balanced flue.
During installation and positioning of the
flue gas system, observe building regu-
lations part L and BS 5440.
Flue gas system installation
instructions.
Opening the control unit
4x
3.
2.
1.
2x
Installation sequence
Installing the boiler and making all connections (cont.)
5366 836 GB
Installation

14
!Please note
Electronic modules can be dam-
aged by electrostatic dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Electrical connections
Information regarding the connection of accessories
For details of accessories, also observe their separate installation instructions
provided.
PUMP
X21
L N 1 L N?
GAS
D
X7 FAN
X20
A B
4 3 2 1
OT
CFE
5
X9
Installation sequence
Opening the control unit (cont.)
5366 836 GB

15
%Gas fired 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 fired 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
CConnection line (accessory)
DJumper (remove when connecting a
room thermostat)
EPower supply (230 V, 50 Hz).
Danger
Incorrect core termination
can cause severe injuries
and damage to the equip-
ment.
Take care not to interchange
wires "L1" and "N".
The power supply must be equipped
with a neutral conductor. Water
pipes should be connected to the
earth bonding of the house in ques-
tion.
FVitotrol 100 (room temperature con-
troller) or on-site room temperature
controller
Separate installation instruc-
tions
or
Input for Y-plan or S-plan heating
systems using gas fired condensing
boilers
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.
NOTE: If an outside temperature sensor
is used it is recommended not to install
the system boiler to a 'Y' or 'S' plan heat-
ing system.
Installation sequence
Electrical connections (cont.)
5366 836 GB
Installation

16
Routing connecting cables and closing control unit
!Please note
Power cables will be damaged if they contact hot parts.
When routing and securing power cables on site, ensure that the maximum
permissible temperatures for these cables are not exceeded.
1.
3.
2.
Installation sequence
Electrical connections (cont.)
5366 836 GB

17
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Filling the heating system.............................................. 18
••• 2. Venting the boiler by flushing out (after venting
system)............................................................................ 20
•3. Adjusting circulation pump to suit heating system.... 20
••• 4. Changing to operation with LPG................................... 21
•5. Checking the CO2 or O2 content.................................... 22
• • 6. Burner removal .............................................................. 24
• • 7. Checking the burner gasket and the burner gauze
assembly......................................................................... 25
• • 8. Checking and adjusting electrodes.............................. 26
• • 9. Cleaning the heat exchanger......................................... 26
• • 10. Checking the condensate drain and cleaning the
siphon.............................................................................. 28
• • 11. Burner installation ......................................................... 29
••• 12. Checking all connections on the heating water side
and DHW side for leaks
••• 13. Checking electrical connections for tightness
••• 14. Check gas equipment for tightness at operating
pressure .......................................................................... 30
• • 15. Fitting the front panel..................................................... 30
•16. Instructing the system user........................................... 31
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5366 836 GB
Service

18
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 300 ppm.
■ An antifreeze additive suitable for heating systems can be mixed with the
fill water.
1. Close the gas shut-off valve.
2. Switch ON the power.
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.
Filling function is enabled. This func-
tion will end automatically after
20 min or after ON/OFF switch has
been turned OFF.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5366 836 GB

19
close
open
B A
4. Open shut-off valves A and (if instal-
led) B.
5. Fill the heating system via an external
filling facility. (Minimum system pres-
sure > 0.8 bar).
Note
The external filling facility must meet
the requirements of the Water Fit-
tings Regulations 1999 Section G
24.1 and G 24.2.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5366 836 GB
Service

20
Venting the boiler by flushing out (after venting system)
A
BC
1. Connect the drain hose on shut-off
valve A to a drain.
2. Close shut-off valve B.
3. Open valves A and C and flush at
mains pressure, until no sound of
escaping air can be heard.
4. First shut off valve A then valve
C.
5. Operating pressure ≥ 0.8 bar; adjust
with valve C.
6. Open shut-off valve B.
Adjusting circulation pump to suit heating system
Only for gas fired condensing combi boilers:
In the delivered condition, the circulation pump in heating mode is set to stage 1. If
necessary to suit the heating system, the circulation pump can be adjusted to stage
2.
1. Turn ON/OFF switch ON.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5366 836 GB