Viessmann Vitodens 100 Quick guide

VIESMANN
Installation and service
instructions
for contractors
Vitodens 100
Type WB1A
18 - 24 kW Compact
Gas fired wall mounted condensing boiler
Natural gas version
For applicability, see the last page
VITODENS 100
5862 757 GB 3/2006 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 installer.
If you notice a smell of gas
Danger
Escaping gas can cause explo-
sions which may lead to ser-
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, found on the gas meter.
&Contact your heating installer
or TRANSCO 0800 111999.
If you smell flue gas
Danger
Flue gas may lead to life-threa-
tening poisoning.
&Heating system shutdown
&Ventilate the area where the
smell of gas if found.
&Close all doors leading to the
living space.
&Do not operate electrical
switches.
Safety instructions
2
Safety instructions
5862 757 GB

Working on the heating system
&Isolate the system from the mains
electric power supply, e.g. by
removing a separate fuse or by
means of a mains electrical isolator,
and check that it is no longer 'live'
using an approved test instrument.
&Isolate the gas supply and safe-
guard against unauthorised recon-
nection.
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 for installation
Product information .................................................................................... 5
Preparing for installation ............................................................................. 5
Installation sequence
Installing the boiler and making all connections ........................................... 30
Flue outlet .................................................................................................. 35
Electrical connections................................................................................. 37
Commissioning and testing ......................................................................... 42
Service instructions
Commissioning, inspection, maintenance............................................... 51
Service Instructions
Routine Servicing Instructions .................................................................... 51
Troubleshooting
Fault finding................................................................................................ 61
Repairs ...................................................................................................... 65
Designs
Connection and wiring diagram .................................................................. 70
Parts lists .................................................................................................. 72
Commissioning/service reports ............................................................... 75
Certificates
Declaration of conformity ............................................................................ 79
Keyword index .......................................................................................... 80
Index
4
Index
5862 757 GB

Vitodens 100, WB1A
Set up for operation with natural gas.
Preparing for installation
General Information
Appliance description
The Vitodens 100 Compact 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
open vented or sealed systems only.
There are two models of the Vitodens
100 in the range which are fully modu-
lating between 8.0 kW (27,300 Btu/h)
and 18.0 kW (61,400 Btu/h)/24.0 kW
(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
and will not be used in this product.
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 for installation
5862 757 GB
Installation

Technical Specification
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 input 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 3.0 3.0
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
Preparing for installation (cont.)
6
Preparing for installation
5862 757 GB

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.
Preparing for installation (cont.)
7
Preparing for 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 can be supplied complete with a
standard concentric horizontal flue
terminal assembly, suitable for flue
lengths of up to 620 mm from the cen-
tre 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 clearances.
Extensions can be used to increase
the straight flue length up to 6 m and
include one 87° elbow.
Preparing for installation (cont.)
8
Preparing for 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
The vertical flue kit (optional extra)
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.
Preparing for installation (cont.)
9
Preparing for installation
5862 757 GB
Installation

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

Elbows and extensions
Extension
Elbow 87°
Elbow 45°
Preparing for installation (cont.)
11
Preparing for installation
5862 757 GB
Installation

Hydraulic circuit
Y-Plan System
ADHW cylinder
BBoiler
Cheat exchanger
Dcirculation pump
EThree-way diverter valve
FHeating circuit
GFeed & expansion tank
Notes for Y and S plan systems The
flow and return to the cylinder can be
connected either way round, however
the optimum method would be to con-
nect the flow to the bottom connection
of the cylinder. A combined feed and
vent arrangement can be installed if
preferred.
Preparing for installation (cont.)
12
Preparing for installation
5862 757 GB

S-Plan System
ADHW cylinder
BBoiler
Cheat exchanger
Dcirculation pump
EZone 2 Port Valve
FHeating circuit
GFeed & expansion tank
HBypass with Lockshield Valve
Notes for Y and S plan systems The
flow and return to the cylinder can be
connected either way round, however
the optimum method would be to con-
nect the flow to the bottom connection
of the cylinder. A combined feed and
vent arrangement can be installed if
preferred.
Preparing for installation (cont.)
13
Preparing for installation
5862 757 GB
Installation

Low Head Installation
Typical Low Head Installation
A722 mm Open Vent
B715 mm Cold Feed
CHeating Flow
DHeating Return
EAutomatic Air Vent
Preparing for installation (cont.)
14
Preparing for installation
5862 757 GB

If Conditions require, this System
is possible
A722 mm Open Vent
B715 mm Cold Feed
CHeating Flow
DHeating Return
EAutomatic Air Vent
Preparing for installation (cont.)
15
Preparing for installation
5862 757 GB
Installation

Alternative Low Head Installation
A722 mm Feed and Vent Pipe
BAir Separator
CHeating Flow
DHeating Return
EAutomatic Air Vent
Note: The volume of the water con-
tained in the cold feed cistern must be
at least 10% of the system water. eg;
100 liters of water in system 10 liters
of water required in cistern
Preparing for installation (cont.)
16
Preparing for installation
5862 757 GB

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.
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’.
Preparing for installation (cont.)
17
Preparing for installation
5862 757 GB
Installation

It should also be in accordance with
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.
&Due consideration should be given
to the routing of the condensate
drain from the chosen position.
&If the boiler is to be fitted in a timber
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.
Preparing for installation (cont.)
18
Preparing for installation
5862 757 GB

&A compartment used to enclose the
appliance must be designed and
constructed specifically for this pur-
pose. An existing cupboard or com-
partment may be used provided it is
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.
Flue terminal position
Horizontal flue system
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
Preparing for installation (cont.)
19
Preparing for installation
5862 757 GB
Installation

Position Minimum spacing
mm
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 600
i Facing terminals 1200
jFrom opening door/window in carport into
dwelling 1200
k Vertically from a terminal on same wall 1500
l Horizontally from a terminal on same wall 300
m Adjacent to opening 300
n Below carport/roof 200
Vertical flue systems
Preparing for installation (cont.)
20
Preparing for installation
5862 757 GB