Viessmann Vitodens 100-W Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 100-W
Type WB1C, 6.5 to 35.0 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 100-W
5624 622 GB 9/2012 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
5624 622 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.)
5624 622 GB

4
Installation instructions
Preparing for installation
Product information.............................................................................................. 6
Preparing for installation....................................................................................... 6
Installation sequence
Fitting the boiler and making connections............................................................ 10
Opening the control unit casing............................................................................ 14
Electrical connections........................................................................................... 15
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 19
Further details regarding the individual steps....................................................... 20
Troubleshooting
Function sequence and possible faults................................................................ 36
Fault messages on the display............................................................................. 37
Repairs................................................................................................................. 41
Gas type conversion
Converting from LPG to natural gas .................................................................... 53
Control unit
Functions and operating conditions in weather-compensated mode................... 55
Designs
Connection and wiring diagram............................................................................ 56
Parts lists
Ordering parts...................................................................................................... 58
Overview of the assemblies................................................................................. 59
Sheet metal parts assembly................................................................................. 60
Heat cell assembly............................................................................................... 61
Burner assembly.................................................................................................. 62
Hydraulic assembly.............................................................................................. 64
Hydraulic assembly circulation............................................................................. 66
Combi hydraulic assembly................................................................................... 67
Control unit assembly........................................................................................... 68
Miscellaneous assembly...................................................................................... 70
Specification....................................................................................................... 71
Index
Index
5624 622 GB

5
Certificates
Declaration of conformity...................................................................................... 72
Keyword index.................................................................................................... 73
Index
Index (cont.)
5624 622 GB

6
Vitodens 100-W, WB1C
Preset for operation with natural gas.
Preparing for installation
Product information
Vitodens 100-W, type WB1C
Preset for operation with natural gas.
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 own initiative and in
accordance with the law of the country in
question.
Preparing for installation
Product information
5624 622 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
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/safety valve
drain: Plastic hose 7 22 mm
Preparing for installation
Preparing for installation (cont.)
5624 622 GB
Installation

8
Fitting the wall mounting bracket
250
A
Ø10
145
AVitodens installation template
Preparing for installation
Preparing for installation (cont.)
5624 622 GB

9
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.
Fit installation aid or mounting frame
Installation aid or mounting frame
installation instructions
Preparing the connections
!Please note
To prevent appliance damage,
install 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 two-core min. 0.5 mm2.
Preparing for installation
Preparing for installation (cont.)
5624 622 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
5624 622 GB

11
Making the connections on the water side
For 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 connection
A
1. Connect gas shut-off valve to con-
nection A.
Installation sequence
Fitting the boiler and making connections (cont.)
5624 622 GB
Installation

12
2. Carry out a tightness test.
Note
Only use suitable leak detection
agents (EN 14291) and devices to
check for leaks. Leak detection
agents with unsuitable constituents
(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.
Where higher pressure is
required for tightness tests,
disconnect 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.)
5624 622 GB

13
Connection, safety valve and condensate drain
A
Connect condensate drain A with a
constant fall and pipe vent to the public
sewage system.
Observe the local waste water regula-
tions.
Note
Fill the siphon with water before com-
missioning.
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.
Installation sequence
Fitting the boiler and making connections (cont.)
5624 622 GB
Installation

14
Balanced flue connection
Connect the balanced flue.
Flue system installation instruc-
tions.
Opening the control unit casing
3.
2.
4x 1.
2x
Installation sequence
Fitting the boiler and making connections (cont.)
5624 622 GB

15
!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.
Electrical connections
Information on connecting
accessories
When connecting accessories
observe the separate installation
instructions provided with them.
PUMP
X21
L N 1 L N?
GAS
D
X7 FAN
X20
A B
4 3 2 1
OT
CFE
X1
%
AOnly for weather-compensated
mode:
Outside temperature sensor (acces-
sory)
BOpenTherm device
Remove jumper D when making
this connection.
CConnecting cable (accessory)
DJumper
EPower supply (230 V, 50 Hz).
See page 17.
FVitotrol 100
Remove jumper D when making
this connection.
Separate installation instruc-
tions
Installation sequence
Opening the control unit casing (cont.)
5624 622 GB
Installation

16
%Cylinder temperature sensor (plug
on the cable harness outside the
control unit)
Note
Gas condensing boiler without DHW
cylinder:
For operation without a DHW cylin-
der, set rotary selector "
tw
" to "0".
Cable entry
B
A
APower cable, remote control con-
necting cable
BLV leads (sensor leads)
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.
Installation sequence
Electrical connections (cont.)
5624 622 GB

17
Vitotrol 100 connection
1 L N
C
X1
NO
NC
COM
B
A
AVitotrol 100, type UTDB
BTerminals "X1" 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~
Power supply
Installation sequence
Electrical connections (cont.)
5624 622 GB
Installation

18
Routing cables/leads and closing the control unit casing
!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.)
5624 622 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. Checking the static and supply pressure..................... 22
•5. Reducing the max. heating output................................ 24
•6. Checking the CO2 content............................................. 25
• • 7. Burner removal .............................................................. 28
• • 8. Checking the burner gasket and burner gauze
assembly......................................................................... 29
• • 9. Checking and adjusting electrode................................ 30
• • 10. Cleaning the heat exchanger......................................... 30
• • 11. Checking the condensate drain and cleaning the
siphon.............................................................................. 31
• • 12. Burner installation ......................................................... 32
• • 13. Checking the diaphragm expansion vessel and
system pressure............................................................. 33
••• 14. Checking all connections on the heating water side
and DHW side for leaks
••• 15. Checking the flue system for unrestricted flow and
tightness
••• 16. Checking firm seating of electrical connections
••• 17. Checking all gas equipment for tightness at operating
pressure .......................................................................... 34
• • 18. Mounting the front panel................................................ 34
•19. Instructing the system user........................................... 35
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5624 622 GB
Service

20
Filling the heating system
Fill water
!Please note
Unsuitable fill water increases
the level of deposits and corro-
sion and may lead to boiler dam-
age.
■ Flush the heating system thor-
oughly before filling.
■ Only use fill water of potable
quality.
■ An antifreeze additive suitable
for heating systems can be
added to the fill water. The anti-
freeze manufacturer must ver-
ify its suitability.
■ Fill and top-up water with a
water hardness in excess of
the following values must be
softened, e.g. with a small soft-
ening system for heating water.
Total permissible hardness of the fill and top-up water
Total heating
output
Specific system volume
kW < 20 l/kW ≥ 20 l/kW to
< 50 l/kW
≥ 50 l/kW
≤ 50 ≤ 3.0 mol/m3
(16.8 °dH)
≤ 2.0 mol/m3
(11.2 °dH)
< 0.02 mol/m3
(0.11 °dH)
> 50 to ≤ 200 ≤ 2.0 mol/m3
(11.2 °dH)
≤ 1.5 mol/m3
(8.4 °dH)
< 0.02 mol/m3
(0.11 °dH)
> 200 to ≤ 600 ≤ 1.5 mol/m3
(8.4 °dH)
≤ 0.02 mol/m3
(0.11 °dH)
< 0.02 mol/m3
(0.11 °dH)
> 600 < 0.02 mol/m3
(0.11 °dH)
< 0.02 mol/m3
(0.11 °dH)
< 0.02 mol/m3
(0.11 °dH)
1. Close the gas shut-off valve.
2. Switch ON the power supply.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5624 622 GB