Viessmann Vitodens 100-W Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 100-W
Type WB1B, 7.9 to 26.0 kW
Wall mounted gas fired condensing boiler
Natural gas and LPG version
Gas council no.: 41-819-21; 41-819-22; 41-819-23; 41-819-24
VITODENS 100-W
5368 662 GB 2/2009 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
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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.)
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Installation instructions
Preparing for installation
Product information.............................................................................................. 5
Preparing for installation....................................................................................... 5
Installation sequence
Installing the boiler and making all connections................................................... 8
Opening the control unit casing............................................................................ 11
Electrical connections........................................................................................... 12
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 15
Further details regarding the individual steps....................................................... 16
Troubleshooting
Function sequence and possible faults................................................................ 26
Fault messages on the display............................................................................. 27
Repairs................................................................................................................. 31
Gas type conversion
Converting from LPG to natural gas..................................................................... 37
Control unit
Functions and operating conditions in weather-compensated mode................... 39
Designs
Connection and wiring diagram............................................................................ 40
Parts lists............................................................................................................ 42
Specification....................................................................................................... 45
Certificates
Declaration of conformity...................................................................................... 46
Keyword index.................................................................................................... 47
Index
Index
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Vitodens 100-W, WB1B
Set up for operation with natural gas.
Preparing for installation
Preparing the boiler installation
Dimensions and connections
119
600 43
26
151
285
93
47
25
375
123
A B
C
D
AHeating flow
BHeating return
CCondensate drain: Plastic pipe 7
22 mm
Preparing for installation
Product information
5368 662 GB
Installation

6
DGas connection, 1/2" male iron
Fitting the wall retainer
25
150
Ø10
≥250
A
B
AVitodens installation template BOpening for the balanced flue
Preparing for installation
Preparing for installation (cont.)
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1. Position the installation template pro-
vided on the wall.
2. Mark out the rawl plug holes.
3. Drill 710 mm holes and insert the
rawl plugs provided.
4. Secure wall retainer with screws pro-
vided.
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 two-core min. 0.5 mm2.
Preparing for installation
Preparing for installation (cont.)
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Installation

8
Removing the front panel and mounting the boiler
3.
2.
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.
Installation sequence
Installing the boiler and making all connections
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Installing connections on the water side
A B
AHeating flow BHeating return
Gas connection
A
1. Connect gas shut-off valve to con-
nection A.
2. Carry out a tightness test.
!Please note
Excessive test pressure may
damage the boiler and gas
valve.
Max. test pressure 150 mbar.
Where higher pressure is
required for tightness tests,
separate the boiler and gas
valves from the gas supply
pipe (undo the fitting).
3. Vent the gas line.
Installation sequence
Installing the boiler and making all connections (cont.)
5368 662 GB
Installation

10
Condensate connection
A
Connect condensate drain A with a
slope and pipe vent to the public sewer.
Observe the local waste water regula-
tions.
Note
Fill the siphon with water before com-
missioning.
Filling the siphon with water
Fill the flue gas connection with a mini-
mum of 0.3 l of water.
!Please note
During commissioning, flue gas
may be emitted from the conden-
sate drain.
Fill the siphon with water imme-
diately prior to commissioning.
Installation sequence
Installing the boiler and making all connections (cont.)
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11
Balanced flue connection
A
B
AFlue gas
BVentilation air
Connect the balanced flue.
During installation and positioning of the
flue system, observe building regula-
tions part L, J and BS 5440 Part 1 and
2.
Flue system installation instruc-
tions.
Opening the control unit casing
!Please note
Electronic modules can be damaged by electrostatic discharge.
Before beginning work, touch earthed objects, such as heating or water pipes,
to discharge static loads.
Installation sequence
Installing the boiler and making all connections (cont.)
5368 662 GB
Installation

12
4x
3.
1.
2.
Electrical connections
Information regarding the connection of accessories
For connection of accesseries, observe the separate installation instructions
provided with the accessories.
Installation sequence
Opening the control unit casing (cont.)
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PUMP
X21
L N 1 L N?
GAS D
X7 FAN
X20
A
4 3 2 1
BFE
5
X1
C
Note
Pump can be connected externally of the
boiler through the external terminal box
AOnly for weather-compensated
mode:
Outside temperature sensor (acces-
sory)
BLead (accessory)
CTerminal box cylinder demand
(accessory; see separate installa-
tion instructions)
DJumper (remove when connecting a
room thermostat or switched live for
'Y' or 'S' Plan installation)
EPower supply (230 V, 50 Hz).
Danger
Incorrect wire allocation can
cause severe injuries and
damage to the equipment.
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 thermostat) or on-
site room temperature controller
Separate installation instruc-
tions
or
Input for Y-plan or S-plan heating
systems
Installation sequence
Electrical connections (cont.)
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Installation

14
Outside temperature sensor (accessory)
1. Plug the lead supplied with the out-
side temperature sensor into socket
"X21".
2. Connect the outside temperature
sensor to terminals 3 and 4.
Routing leads and closing control unit casing
!Please note
Leads will be damaged if they come into contact with hot parts.
When routing and securing leads on site, ensure that the maximum permis-
sible temperatures for these cables are not exceeded.
2.
3.
1.
Installation sequence
Electrical connections (cont.)
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Filling the heating system.............................................. 16
••• 2. Converting to operation with LPG................................ 16
•3. Checking the CO2 or O2 content.................................... 18
• • 4. Burner removal .............................................................. 20
• • 5. Checking the burner gasket and the burner gauze
assembly......................................................................... 21
• • 6. Checking and adjusting electrodes.............................. 22
• • 7. Cleaning the heat exchanger......................................... 22
• • 8. Checking the condensate drain and cleaning the
siphon.............................................................................. 23
• • 9. Burner installation ......................................................... 24
••• 10. Checking all connections on the heating water side
and DHW side for leaks
••• 11. Checking electrical connections for tightness
••• 12. Checking gas equipment for tightness at operating
pressure .......................................................................... 25
• • 13. Fitting the front panel..................................................... 25
•14. Instructing the system user........................................... 25
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Service

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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 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.
Fill and vent heating system.
Converting to operation with LPG
In the delivered condition, the boiler is
set up for operation with natural gas. For
operation with LPG, the gas nozzle must
be changed and the gas type converted
in the control unit.
Separate installation instruc-
tions.
Changing from LPG to natural gas - see
page 37.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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Checking and adjusting the ignition and ionisation electrodes
+2 -1
10
+0,5
5
AIgnition and ionisation electrode
Check the electrode for wear and con-
tamination
Clean the electrode with a small brush
(not with a wire brush) or emery paper.
Check all clearances. If the gaps are not
as specified or the electrode is damaged,
replace and align the electrode together
with new gaskets. Tighten the electrode
fixing screws. (2.5 Nm approx.).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5368 662 GB
Service

18
Checking the CO2 or O2 content
Vitodens 100-W is factory-set for natural
gas. During commissioning or mainte-
nance, the CO2 and CO have to be
measured at the boiler flue adaptor test
point to check the flue integrity. Subject
to the Wobbe index, the CO2 content
fluctuates between 7.4 % and 10.5 %.
And CO of up to 500 ppm is accepta-
ble.
We recommend to measure O2 as the
value is unmistakable regarding lambda
(air/gas). The O2-content fluctuates
between 7.5 % and 3.2 %. Or alterna-
tively CO/CO2 ratio has to be less than
0.004.
If the actual CO2 or O2 and CO values
deviate from the stated range, check the
balanced flue systems for leaks. If flue
installation is o.k., change the gas
valve.
A
1. Connect a flue gas analyser at flue
gas port A on the boiler flue con-
nection.
2. Start the boiler.
rr
3. Turn rotary selector "tr" clockwise
for less than 2 s and then anticlock-
wise back to the control range on the
right.
The display shows "SERV" and the
boiler water temperature is shown.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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4. Adjust the upper output:
Turn rotary selector "tr" to the con-
trol range on the right.
The display shows 5 bars for upper
output.
5. Measure the CO2 content for upper
output.
The CO2 content must be between
7.4 and 10.5 %.
6. Adjust the lower output:
Turn rotary selector "tr" to the left
control range.
The display shows 1 bar for lower
output.
7. Test the CO2 content for lower out-
put.
The CO2 content must be between
7.4 and 10.5 %.
8. If the CO2 content is not within the
given range, check the flue gas/ven-
tilation air system for tightness.
Remedy any leaks.
9. Shut the boiler down, remove flue gas
analyser and close flue gas port A.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5368 662 GB
Service

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Burner removal
E B A D
4x C
1. Switch OFF the power.
2. Shut off the gas supply.
3. Disconnect electrical cables from fan
motor A, gas valve B.
4. Open control unit casing (see
page 11) and pull out the lead to igni-
tion electrode C.
5. Disconnect the venturi extension
from fan A.
6. Disconnect gas supply pipe D fit-
ting.
7. Undo four screws E and remove the
burner.
!Please note
To prevent damage,
never rest the burner on the
gauze assembly.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5368 662 GB