Viessmann Vitodens 100 Quick guide

VIESMANN
Installation and service
instructions
for heating engineers
Vitodens 100
Type WB1A
Gas fired wall mounted condensing boiler
Natural gas version
For applicability, see the last page
VITODENS 100
5862 757 GB 7/2005 Please keep safe

Please follow these safety instructions closely to prevent accidents and
material 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
environmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
&Work on gas equipment must only
be carried out by a CORGI regis-
tered gas engineer.
&Electrical work must be compliant
with Part P of the building regula-
tions.
&The system must be commissioned
by a CORGI registered gas engi-
neer.
If you notice the smell of gas
Danger
Escaping gas can cause explo-
sionswhichmayleadtoser-
ious injury.
&Do not smoke. Prevent
naked flames and sparks.
Never operate light switches
or those of electrical equip-
ment.
&Open windows and doors.
&Close the gas shut-off valve.
&Remove all personnel from
the danger zone.
&Observe the safety regula-
tions of your local gas sup-
plier.
If you smell flue gas
Danger
Flue gas may lead to life-threa-
tening poisoning.
&Heating system shutdown
&Ventilate the area where the
boiler is fitted.
&Closealldoorsleadingtothe
living space.
&Do not operate electrical
switches.
Safety instructions
2
Safety instructions
5862 757 GB

Workingontheheatingsystem
&Isolate the system from the mains
electric power supply, e.g. by
removingaseparatefuseorbya
localised isolator and check that is
is no longer 'live' using a approved
test instrument.
&Isolate the gas supply and safe-
guard against unauthorised reopen-
ing.
Repair work
!Please note
Repairing components which
fulfil a safety function can com-
promise 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
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
infringe our warranty condi-
tions.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5862 757 GB

Installation instructions
Preparing the installation
Product information .................................................................................... 5
General Information .................................................................................... 5
Technical Specification ............................................................................... 6
Installation Requirements ........................................................................... 14
Preparations for boiler installation ............................................................... 25
Installation steps
Installing the boiler and making all connections ........................................... 29
Flue outlet .................................................................................................. 34
Electrical connections................................................................................. 36
Commissioning and testing ......................................................................... 41
Service instructions
Initial start-up, inspection, maintenance ................................................. 48
Service Instructions
Routine Servicing Instructions .................................................................... 48
Troubleshooting
Fault finding................................................................................................ 58
Repairs ...................................................................................................... 63
Designs
Connection and wiring diagram ................................................................... 68
Parts lists .................................................................................................. 70
Commissioning/service reports .............................................................. 73
Certificates
Declaration of conformity ............................................................................ 77
Keyword index .......................................................................................... 78
Index
4
Index
5862 757 GB

Vitodens 100, Type WB1A
Set up for operation with natural gas.
General Information
Appliance description
The Vitodens 100 is a fully automatic,
wall hung, fan assisted balanced flue
condensing boiler for use with Natural
Gas (G20) and is designed for use
with fully pumped systems only.
There are two models of the Vitodens
100 in the range which are fully modu-
lating between 8.00kW (27,300 Btu/h)
and 18kW (61,400 Btu/h)/24.0kW
(84,300 Btu/h).
Internal frost protection and an elec-
tronic control unit is fitted as standard
equipment. The boiler may be used
with any suitable room thermostat and
/ or time clock in addition to the
optional controls available from
Viessmann.
Asbestos, mercury or CFC´s have not
andwillnotbeusedinthisproduct.
Certification details
The Vitodens 100 is certified to com-
ply with the requirements of pr EN 483
and EN 625 for use in GB and IE
(Great Britain and Ireland) using gas
category 2H (G20) with a governed
gas supply at 20 mbar (8 in.wg) inlet
pressure.
The appliance classification is either
C13x,C33x,C63 or C63x depending
upon whether horizontal or vertical
flue termination is used.
Product information
5
Preparing the installation
5862 757 GB
Installation

General Specifications and Performance Data
Rated output range
TF/TR50/30 °C kW 8 to 18 8 to 24
TF/TR80/60 °C kW 7.3 to 16.4 7.3 to 21.8
Rated heat load range kW 7.4 to 16.7 7.4 to 22.3
Maximum gas rate m
3
/h 1.77 2.36
Minimum CH system pressure (static
head) –Cold
bar 0.2 0.2
Maximum CH system pressure (static
head) –Hot
bar 1.0 1.0
Maximum CH flow temperature °C 80 80
Lift weight kg 37 37
Total weight inc. packaging kg 39 39
Electrical supply 230 V, 50Hz 230 V, 50Hz
Internal fuse A 4 4
Maximum power consumption W 55 55
Flue outlet (clearance 7): mm 60 60
Ventilation pipe (outside 7) mm 100 100
Product ID _-0085 BQ 0017
Gas Council Number 41-819-12 41-819-10
Technical Specification
6
Preparing the installation
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Overall Appliance Dimensions
AHeating return: 722 mm
BHeating flow: 722 mm
CCondensate drain: Plastic pipe
722 mm
DGas connection: R ½ FBSP
Minimum installation clearances
The following minimum clearances (mm) must be maintained for installing and
servicing the appliance.
Technical Specification (cont.)
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Preparing the installation
5862 757 GB
Installation

AFront (behind removable panel) BFront (for service)
Flue System Specifications
Concentric Horizontal Flue System
Standard horizontal flue kit: The appli-
ance is supplied complete with a stan-
dard concentric horizontal balanced
flue terminal assembly, suitable for
flue lengths of up to 620 mm from the
centre of the flue outlet, which
equates to wall thicknesses of up to
480 mm for rear flues and 463 mm for
side flues, including minimum clear-
ances.
Extensionductscanbeusedto
increase the straight flue length up to
6 m and include one 87° elbow.
Technical Specification (cont.)
8
Preparing the installation
5862 757 GB

An extra 87° elbow can be used but
this reduces the maximum permissi-
ble length by 1 m . An extra 45° elbow
can be used but this reduces the max-
imum permissible length by 0.5 m .
ACombined length of flue outlet/
ventilation pipe max 6m.
BFlue outlet/ventilation pipe (can
be shortened as necessary)
Concentric Vertical Flue System
Theverticalfluekit(optionalextra)
with extensions may be used for up
to10 m applications.
An extra 87° elbow can be used but
this reduces the maximum permissi-
ble length by 1 m. An extra 45° elbow
can be used but this reduces the max-
imum permissible length by 0.5 m.
Technical Specification (cont.)
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Preparing the installation
5862 757 GB
Installation

Before commencing the installation
refer to diagram below to determine
which optional extension kits are
required,ifany.
ACombined length of flue outlet/
ventilation pipe max. 10 m.
BFlue outlet/ventilation pipe (can
be shortened as necessary)
Technical Specification (cont.)
10
Preparing the installation
5862 757 GB

Elbows and extensions
Extension
Elbow 87°
Elbow 45°
Technical Specification (cont.)
11
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Installation

Hydraulic circuit
Y-Plan System
ADHW cylinder
BBoiler
Cheat exchanger
Dcirculation pump
EThree-way diverter valve
FHeating circuit
GFeed & expansion tank
Technical Specification (cont.)
12
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S-Plan System
ADHW cylinder
BBoiler
Cheat exchanger
Dcirculation pump
EZone2PortValve
FHeating circuit
GFeed & expansion tank
Technical Specification (cont.)
13
Preparing the installation
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Installation

Sectional Diagram
Installation Requirements
Statutory Requirements
Gas safety (installation and use) regulations (current issue)
This appliance must be installed in
accordance with the gas safety regu-
lations.
Technical Specification (cont.)
14
Preparing the installation
5862 757 GB

In addition to the above regulations,
this appliance must be installed in
accordance with the current IEE Wir-
ing Regulations for electrical installa-
tion (BS 7671), local building
regulation, the Building Standards
(Scotland) (Consolidation) Regula-
tions, bye laws of the local water
undertaking and Health and Safety
Document No. 635 ‘The Electricity at
Work regulations 1989’.
Itshouldalsobeinaccordancewith
the relevant recommendations in the
current editions of the following British
Standards and Codes of Practice: BS
5449, BS 5546, BS 5440:1, BS
5440:2, BS 6798, BS 7593, BS 6891.
From 1 April 2005, all CORGI Regis-
tered Installers will be required to
notify CORGI when they have
installed or exchanged a gas appli-
ance in a residential dwelling.
CORGI will then issue either a Build-
ing Compliance Certificate (for Eng-
land and Wales) or a Declaration of
Safety (for Scotland, Northern Ireland,
Isle of Man or appliances out of the
scope of Building Regulations) to the
homeowner, which will confirm that
the work has been carried out by a
competent CORGI Registered Instal-
ler. This document will be used to
form part of the Home Information
Pack (HIP) that becomes a require-
ment from January 2007 in order to
sell your house.
!Please note
Manufacturers instructions
must not be taken
in any way as overriding statu-
tory obligations.
Boiler Position
The following limitations must be
observed when siting the boiler:
&The boiler is not suitable for exter-
nal installation. The position
selected for installation should be
within the building, unless otherwise
protected by a suitable enclosure
and must allow adequate space for
installation, servicing and operation
of the appliance and for air circula-
tion around it.
&This position must allow for a suita-
ble flue system and terminal posi-
tion. The boiler must be installed on
a flat vertical wall capable of sup-
porting the weight of the appliance
and any ancillary equipment when
full.
Installation Requirements (cont.)
15
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Installation

&Due consideration should be given
to the routing of the condensate
drain from the chosen position.
&Iftheboileristobefittedinatimber
framed building it should be fitted in
accordance with IGE/UP/7. If in
doubt advice must be sought from
the institute of gas engineers.
&If the appliance is to be installed in a
room containing a bath or shower,
any electrical switch or control utilis-
ing mains electricity, it must be so
situated, that it cannot be touched
by a person using the bath or
shower. Attention is drawn to the
requirements of BS 7671 (the cur-
rent I.E.E Wiring Regulations) and
in Scotland the electrical provisions
of the Building Regulations applic-
able in Scotland.
&A compartment used to enclose the
appliance must be designed and
constructed specifically for this pur-
pose. An existing cupboard or com-
partmentmaybeusedprovideditis
modified accordingly. BS 5376:2
gives details of the essential fea-
tures of cupboard / compartment
design, including airing cupboards
&Where installation will be in an unu-
sual location, special procedures
may be necessary. BS 6798 gives
detailed guidance on this aspect.
Installation Requirements (cont.)
16
Preparing the installation
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Flue terminal position
Horizontal flue systems
AWalkway or patio
BCar space
Position Minimum spacing
mm
aDirectly below an window that can be opened,
air vent or any other ventilation opening 300
b Below gutter drain or soil pipe 75
c Below eaves 200
d Below a balcony 200
e From vertical drain or soil pipes 150
f From internal and external corners 300
g Above adjacent ground or balcony level/roof 300
h From a surface facing the terminal 2500
i Facing terminals 1200
jFrom opening door/window in carport into
dwelling 1200
Installation Requirements (cont.)
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Installation

Position Minimum spacing
mm
k Vertically from a terminal on same wall 1500
l Horizontally from a terminal on same wall 300
m Adjacent to opening 300
Vertical flue systems
Position Minimum spacing
mm
o From adjacent wall 300
p From adjacent opening window 1000
q From another terminal 600
r Minimum height 300
Installation Requirements (cont.)
18
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Flue Terminal Location
Detailed recommendations for flue
installation are given in BS 5440:1.
The following notes are for general
guidance.
&Theboilermustbeinstalledsothat
the terminal is exposed to external
air.
&It is important that the position of the
terminal allows free passage of air
across it at all times.
&It is essential to ensure that pro-
ducts of combustion discharging
from the terminal cannot re-enter
the building or any other adjacent
building, through ventilators, win-
dows,doors,othersourcesofnat-
ural air infiltration or forced
ventilation / air conditioning.
&The minimum acceptable dimen-
sions from the terminal to obstruc-
tions and ventilation openings are
specifiedinonpage15andalsoin
BS 5440 Part 1.
&If the terminal discharges into a
pathway or passageway check that
combustion products will not cause
nuisance and that the terminal will
not obstruct the passageway.
&Where the lowest part of the term-
inal is fitted less than 2 m above
ground, above a balcony or above a
flat roof to which people have
access, the terminal must be pro-
tected by a purpose designed
guard. (Available as an optional
extra).
&Where the terminal is fitted within
850 mm of a plastic or painted gut-
ter, or 450 mm of painted eaves, an
aluminium shield, at least 750 mm
long, must be fitted to the underside
of the painted surface.
&The air inlet / flue outlet duct must
notbecloserthan25mmtocom-
bustible material.
&Due to the high efficiency of the boi-
ler the terminal may emit a plume of
vapour. This is normal but positions
where this would cause a nuisance
should be avoided.
Ventilation Requirements
Detailed recommendations for air
supply are given in BS 5440:2. The
following notes are for general gui-
dance.
Installation Requirements (cont.)
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Installation

&It is not necessary to have a pur-
pose provided air vent in the room
or internal space in which the appli-
ance is installed.
&Iftheboileristobeinstalledina
cupboard or compartment, no per-
manent air vents are required for
cooling purposes in the cupboard or
compartment, however, it is essen-
tial to ensure that the minimum
clearances stated in page 7 are
maintained.
Seealso"Boilerposition"on
page 15.
Installation Requirements (cont.)
20
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5862 757 GB