Viessmann Vitodens 100 Quick guide

VIESMANN
Installation and service
instructions
for contractors
Vitodens 100
Type WB1A
Gas fired wall mounted condensing boiler
Natural gas version
For applicability, see the last page
VITODENS 100
5862 881 GB 10/2006 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 fitter.
&Electrical work must be compliant
with Part P of the building regula-
tions
&The system must be commissioned
by the system installer or a qualified
person authorised by the installer.
If you notice the 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.
&Notify your heating contrac-
tor from outside the building.
If you smell flue gas
Danger
Flue gas may lead to life-threa-
tening poisoning.
&Heating system shutdown
&Ventilate the boiler room.
&Close all doors leading to the
living space.
&Do not operate electrical
switches.
Safety instructions
2
Safety instructions
5862 881 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'.
&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 881 GB

Installation instructions
Preparing for installation
Product information .................................................................................... 5
Preparing for installation ............................................................................. 5
Installation sequence
Installing the boiler and making all connections ........................................... 31
Flue outlet .................................................................................................. 38
Electrical connections................................................................................. 40
Commissioning and testing ......................................................................... 45
Service instructions
Commissioning, inspection, maintenance............................................... 55
Service Instructions
Routine Servicing Instructions .................................................................... 55
Troubleshooting
Fault finding................................................................................................ 66
Repairs ...................................................................................................... 70
Designs
Connection and wiring diagrams –combi boiler .......................................... 78
Connection and wiring diagram - system boiler............................................ 80
Parts lists .................................................................................................. 82
Commissioning/service reports ............................................................... 88
Certificates
Declaration of conformity ............................................................................ 92
Keyword index .......................................................................................... 93
Index
4
Index
5862 881 GB

Vitodens100, WB1A
Set up for operation with natural gas.
Preparing for installation
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).
The Vitodens 100 is fully modulating
and provides central heating outputs
between 8.0 kW (27.300Btu/h) and
24.0 kW (84.300Btu/h)/30.0 kW
(93.550 Btu/h) and instantaneous hot
water at outputs between 8.0 kW
(27.300 Btu/h) and 24.0 kW
(84.300Btu/h)/30.0 kW (93.550 Btu/
h).
The appliance always gives priority to
domestic hot water supply.
The appliance is designed for use
with sealed primary water systems
(only) and incorporates a circulation
pump, diverter valve assembly, flow
switch (combi boiler only), DHW
plate-type heat exchanger (combi
boiler only), safety valve and CH
expansion vessel. A separate DHW
expansion vessel is not required.
Internal frost protection and an elec-
tronic control unit is fitted as standard
equipment and 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 prEN 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 or C33x depending upon whether
a horizontal or vertical flue terminal is
used.
Product information
5
Preparing for installation
5862 881 GB
Installation

Technical Specification
General Specifications and Performance Data
Rated output range
TV/TR50/30 °C kW 8 to 24 8 to 30
TV/TR80/60 °C kW 7.3 to 21.8 7.3 to 27.3
Rated output range kW 7.4 to 22.3 7.4 to 28.0
Maximum gas rate m
3
/h 2.36 2.96
Combi boiler:
Design domestic hot water performance
(specific rate)
l/min 8.0 10.0
Domestic hot water temperature range °C 30 - 60 30 - 60
Maximum mains water inlet pressure bar 10 10
Minimum mains water inlet pressure for
operation
bar 1 1
Total water capacity (including expansion
vessel)
l 3.5 3.5
Minimum CH system pressure (static
head) –Cold
bar 1.0 1.0
Maximum CH system pressure (static
head) –Hot
bar 3.0 3.0
Maximum CH flow temperature °C 80 80
Integral expansion vessel capacity l 8 8
Integral expansion vessel pre-charge
pressure
bar 0.75 0.75
Lift weight
- Combi boiler kg 43 43
- System boiler kg 42 42
Total weight inc. packaging
- Combi boiler kg 48 48
- System boiler kg 47 47
Electrical supply 230 V, 50Hz 230 V, 50Hz
Internal fuse A 4 4
Maximum power consumption W 145 145
Flue outlet (clearance 7): mm 60 60
Ventilation pipe (outside 7) mm 100 100
Gas Council Number
- Combi boiler 47–819–04 47–819–05
- System boiler 41–819–09 —
Product ID _-0085 BQ 0017
Preparing for installation (cont.)
6
Preparing for installation
5862 881 GB

Overall Appliance Dimensions
Combi boiler
ACondensate drain: Plastic pipe
722 mm
BHeating flow: 722 mm
CDHW: 715 mm
DGas connection: Rp ½"
ECold water: 715 mm
FHeating return: 722 mm
GSafety valve drain: 715 mm
Preparing for installation (cont.)
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Preparing for installation
5862 881 GB
Installation

System boiler
ACondensate drain: Plastic pipe
722 mm
BHeating flow: 722 mm
CDHW cylinder flow: 722 mm
DGas connection: Rp ½"
EDHW return: 722 mm
FHeating return: 722 mm
GSafety valve drain: 715 mm
Preparing for installation (cont.)
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Preparing for installation
5862 881 GB

Minimum installation clearances
The following minimum clearances (mm) must be maintained for installing and
servicing the appliance.
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.
Extension ducts can be used to
increase the straight flue length up to
6 m and include one 87° elbow.
Preparing for installation (cont.)
9
Preparing for installation
5862 881 GB
Installation

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.)
10
Preparing for installation
5862 881 GB

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.)
11
Preparing for installation
5862 881 GB
Installation

Elbows and extensions
Extension
Elbow 87°
Elbow 45°
Preparing for installation (cont.)
12
Preparing for installation
5862 881 GB

Hydraulic circuit
Combi boiler
ABoiler
Bheat exchanger
Ccirculation pump
DThree-way diverter valve
EPlate-type heat exchanger
FDHW outlet
GCold water inlet
HHeating circuit
Preparing for installation (cont.)
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Preparing for installation
5862 881 GB
Installation

System boiler
ADHW cylinder
BBoiler
Cheat exchanger
Dcirculation pump
EThree-way diverter valve
FHeating circuit
Preparing for installation (cont.)
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5862 881 GB

Sectional Diagram
Combi boiler illustrated
Installation Requirements
Statutory Requirements
Gas safety (installation and use) regulations (current issue)
It is in your own interest and safety, to
ensure that the law is complied with.
Preparing for installation (cont.)
15
Preparing for installation
5862 881 GB
Installation

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’.
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
and IGE/UP/7.
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 suport-
ing 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 the British Gas
publication ‘Guide for Gas Installa-
tions In Timber Frame Housing’,
reference DM2. If in doubt, advice
must be sought from British Gas.
Preparing for installation (cont.)
16
Preparing for installation
5862 881 GB

&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 Builing 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-
partment may be used provided it is
odified 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.)
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5862 881 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.)
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Preparing for installation
5862 881 GB

Position Minimum spacing
mm
o From adjacent wall 300
p From adjacent opening window 1000
q From another terminal 600
r Minimum height 300
Flue Terminal Location
Detailed recommendations for flue
installation are given in BS 5440:1.
The following notes are for general
guidance.
&The boiler must be installed so that
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, other sources of nat-
ural air infiltration or forced
ventilation / air conditioning.
&The minimum acceptable dimen-
sions from the terminal to obstruc-
tions and ventilation openings are
specified in on page 16(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
not be closer than 25 mm to com-
bustible material.
&Due to the high efficiency of the
boiler the terminal may emit a plume
of vapour. This is normal but posi-
tions where thiswould cause a nui-
sance should be avoided.
Preparing for installation (cont.)
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Preparing for installation
5862 881 GB
Installation

Ventilation Requirements
Detailed recommendations for air
supply are given in BS 5440:2. The
following notes are for general gui-
dance.
&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.
&If the boiler is to be installed in a
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 9 are
maintained.
Central Heating System (typical system designs)
&The Vitodens 100 is designed for connection to sealed central heating water
systems.
&A sealed system must only be filled by a competent person.
&Filling the heating system see page 47.
Combination boiler
Note
The boiler incorporates an internal bypass to ensure adequate water flow. Cer-
tain thermostatic radiator valve manufacturers may require that a bypass valve
is fitted in addition to the integral by pass. Specifications as to the individual
requirements should be sought prior to installation.
Preparing for installation (cont.)
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5862 881 GB