Viessmann Vitodens 111-W Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 111-W
Type B1LA, 6.5 to 35.0 kW
Gas condensing storage combi boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 111-W
5618 689 UAE 3/2012 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.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may lead to serious
injury.
■ Do not 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).
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 in the living
space.
Safety instructions
Safety instructions
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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 electrostatic dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
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 that
have not been tested together
with the heating system can com-
promise its function. Installing
non-authorised components and
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
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Service instructions
Installation information
Product information.............................................................................................. 6
Preparing for the boiler installation....................................................................... 7
Installation instructions
Installation sequence
Fitting the wall mounting bracket.......................................................................... 9
Fitting the boiler and making connections............................................................ 10
Opening the control unit casing............................................................................ 15
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................................................................ 38
Fault messages on the display............................................................................. 39
Repairs................................................................................................................. 43
Gas type conversion
Converting from LPG to natural gas .................................................................... 52
Control unit
Functions and operating conditions in weather-compensated mode................... 54
Designs
Connection and wiring diagram............................................................................ 56
Parts lists
Ordering parts...................................................................................................... 58
Overview of the assemblies................................................................................. 59
Casing assembly.................................................................................................. 60
Heat cell assembly............................................................................................... 61
Burner assembly.................................................................................................. 63
Hydraulic assembly.............................................................................................. 65
Aqua plate assembly............................................................................................ 67
Control unit assembly........................................................................................... 68
Cylinder assembly................................................................................................ 70
Miscellaneous assembly...................................................................................... 71
Index
Index
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Specification....................................................................................................... 73
Certificates
Declaration of conformity...................................................................................... 74
Keyword index.................................................................................................... 75
Index
Index (cont.)
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Vitodens 111-W, type B1LA
Preset for operation with natural gas. Conversion to LPG P requires a gas con-
version kit.
Conversion for other countries
The Vitodens 111-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.
Installation information
Product information
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Dimensions and connections
35
480
945
1003
497
740
900
A
BC
D
E
F GH K
166
AArea for electrical connections
BHeating flow
CCondensate drain
DHeating return
EFilling/draining
FGas connection
GSafety valve (on the DHW side)
HCold water
KDHW
Installation information
Preparing for the boiler installation
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Service

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Preparing the connections
Note
This boiler (IP rating: IP X4D) is
approved for installation in wet rooms
inside safety zone 1 in accordance with
DIN VDE 0100, providing the occurrence
of hosed water can be ruled out.
Observe the requirements of DIN VDE
0100.
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.
Installation information
Preparing for the boiler installation (cont.)
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250
Ø10
Installation sequence
Fitting the wall mounting bracket
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Installation

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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.
Making the connections on the water side
For fittings on the heating water
side and DHW side, see separate
installation instructions. !Please note
To prevent equipment damage,
install all pipework free of load
and torque stresses.
Installation sequence
Fitting the boiler and making connections
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BA DC E
¨
zz
AHeating flow
BHeating return
CGas connection
DCold water
EDHW
Gas connection
A
1. Connect gas shut-off valve to con-
nection A.
Installation sequence
Fitting the boiler and making connections (cont.)
5618 689 UAE
Installation

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2. Carry out a tightness test.
Note
For tightness tests, use only
approved leak detection agents
(EN 14291) and devices. Leak detec-
tion agents with unsuitable constitu-
ents (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.)
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Condensate drain connection
A
Connect the condensate pipe A with a
constant fall and a 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
!Please note
At commissioning, flue gas may
be emitted from the condensate
drain.
Fill the siphon with water before
commissioning.
Installation sequence
Fitting the boiler and making connections (cont.)
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Installation

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Fill in at least 0.3 l of water into the flue
outlet.
!Please note
Water in the ventilation air supply
can be detrimental to the com-
bustion quality.
Never pour water into the exter-
nal vent.
Balanced flue connection
Connect the balanced flue.
Flue system installation instruc-
tions.
Installation sequence
Fitting the boiler and making connections (cont.)
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3.
4x
2.
1.
2x
!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.
Installation sequence
Opening the control unit casing
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Installation

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X7
X20
A B
4 3 2 1
OT
C
X21
L N 1 L N?
FE
DX1
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
Accessory connection
Accessory installation instruc-
tions
When connecting a Vitotrol 100 or an
OpenTherm remote control, remove the
jumper across L and 1.
Outside temperature sensor (acces-
sory)
1. Fit outside temperature sensor.
Installation site:
■ North or north-westerly wall, 2 to
2.5 m above ground level; in multi
storey buildings, in the upper half of
the second floor
■ Not above windows, doors or ven-
tilation outlets
Installation sequence
Electrical connections (cont.)
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■ Not immediately below balconies
or gutters
■ Never render over
■ Connection:
2-core lead, length max. 35 m with
a cross-section of 1.5 mm2
2. Plug the power cable supplied with
the outside temperature sensor into
slot "X21".
3. Connect the outside temperature
sensor to terminals 3 and 4 (see
page 16).
Power supply
Regulations and Directives
Danger
Incorrectly executed electrical
installations may result in injuries
through electric shock and to
appliance damage.
Connect the power supply and
implement all safety measures
(e.g. RCD circuit) in accordance
with the following regulations:
■ IEC 60364-4-41
■ VDE regulations
■ Connection requirements
specified by your local power
supply utility
Install an isolator in the power cable
which simultaneously separates all non-
earthed conductors from the mains with
contact separation of at least 3 mm.
We additionally recommend installing an
AC/DC-sensitive RCD (RCD class B
) for DC (fault) currents that can
occur with energy efficient equipment.
Protect the power cable with max. 16 A.
Danger
Incorrect core allocation can
result in serious injury and dam-
age to the appliance.
Take care not to interchange
wires "L1" and "N".
Danger
The absence of component
earthing in the system can lead to
serious injury from electrical cur-
rent if an electrical fault occurs.
Connect the appliance and pipe-
work to the equipotential bonding
of the building in question.
Installation sequence
Electrical connections (cont.)
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Installation

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Routing connecting cables 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.
1.
2.
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.............................................. 20
••• 2. Venting the boiler by flushing....................................... 22
••• 3. Changing to operation with LPG................................... 23
•4. Matching the burner output to the flue system........... 23
•5. Reducing the max. heating output................................ 24
•6. Checking the CO2 content............................................. 26
• • 7. Burner removal .............................................................. 29
• • 8. Checking the burner gasket and burner gauze
assembly......................................................................... 30
• • 9. Checking and adjusting electrode................................ 31
• • 10. Cleaning the heat exchanger......................................... 32
• • 11. Checking the condensate drain and cleaning the
siphon.............................................................................. 33
• • 12. Burner installation ......................................................... 34
• • 13. Checking the diaphragm expansion vessel and
system pressure............................................................. 36
• • 14. Checking the function of safety valves
••• 15. Checking all connections on the heating water side
and DHW side for leaks
••• 16. Checking flue system for unrestricted flow and
tightness
••• 17. Checking firm seating of electrical connections
••• 18. Checking gas equipment for tightness at operating
pressure .......................................................................... 36
• • 19. Fitting the front panel..................................................... 37
•20. Instructing the system user........................................... 37
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 corro-
sion and may lead to boiler dam-
age.
■ Thoroughly flush the entire
heating system prior to filling it
with water.
■ Only use fill water of potable
quality.
■ Soften fill water harder than
16.8 °dH (3.0 mmol/l).
■ An antifreeze additive suitable
for heating systems can be
added to the fill water.
1. Close the gas shut-off valve.
2. Switch ON power and wait until the
display shows the boiler water tem-
perature.
rr
3. Turn rotary selector "rt" fully anti-
clockwise, until the display shows
"SERV".
Within 2 s return the rotary selector to
the r.h. control range.
The display shows "r" and "w".
Filling is active.
This function will end automatically
after 20 min or after the ON/OFF
switch has been turned off.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5618 689 UAE