Viessmann Vitodens 111-W Quick guide

Installation and service instructions
for contractors
VIESMANN
Vitodens 111-W
Type B1LD, 4.7 to 35.0 kW
Gas condensing storage combi boiler
Natural gas and LPG version
Gas Council Number: 47-819-43, 47-819-44
For applicability, see the last page
VITODENS 111-W
5697 789 GB 4/2016 Please keep safe.

2
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 intended for quali-
fied contractors.
■Work on gas installations must only be carried out by
a registered gas fitter.
■Work on electrical equipment must only be carried
out by a qualified electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW-TR Gas, ÖVGW-TRF and
ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
Safety instructions for working on the system
Working on the system
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■Isolate the system from the power supply, e.g. by
removing the separate fuse or by means of a mains
isolator, and check that it is no longer 'live'.
■Safeguard the system against reconnection.
Danger
Hot surfaces can cause burns.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the boiler, burner,
flue system or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in 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.
■Evacuate any people from the danger zone.
■Notify your gas or electricity supply utility from
outside the building.
■Have the power supply to the building shut off
from a safe place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to prevent flue
gases from spreading.
Safety instructions
Safety instructions
5697 789 GB

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What to do if water escapes from the appliance
Danger
When water escapes from the appliance there is
a risk of electrocution.
Switch off the heating system at the external iso-
lator (e.g. fuse box, domestic power distribu-
tion).
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of conden-
sate or other causes. Ensure an adequate supply of
combustion air.
Instruct system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be non-
closable.
Extractors
Operating appliances that extract air to the outside
(cooker hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to reverse flow of the
flue gas.
Danger
The simultaneous operation of the boiler and
appliances that extract air to the outside can
result in life threatening poisoning due to
reverse flow of the flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5697 789 GB

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1. Information Disposal of packaging ............................................................................ 6
Symbols ................................................................................................. 6
Intended use .......................................................................................... 6
Product information ................................................................................ 7
■Vitodens 111-W, type B1LD ................................................................ 7
Product description ................................................................................ 7
■Connecting accessories ..................................................................... 7
2. Installation information Preparing for boiler installation .............................................................. 8
■Dimensions and connections .............................................................. 8
■Preparing the connections .................................................................. 8
3. Installation sequence Fitting the wall mounting bracket ........................................................... 10
Mounting the boiler and making connections ........................................ 11
■Removing the front panel and mounting the boiler ............................. 11
■Fitting the connections on the water side ........................................... 11
■Gas connection ................................................................................... 13
■Condensate drain connection ............................................................. 13
■Filling the trap with water .................................................................... 13
■Balanced flue connection ................................................................... 14
Opening the control unit enclosure ........................................................ 15
Electrical connections ............................................................................ 15
■Connecting accessories ..................................................................... 16
■Power supply ...................................................................................... 16
■Routing connecting cables and closing the control unit enclosure ..... 17
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 18
5. Gas type conversion Converting from operation with LPG to operation with natural gas ....... 38
6. Troubleshooting Function sequence and possible faults .................................................. 39
Fault display ........................................................................................... 39
Repairs .................................................................................................. 42
■Removing the front panel ................................................................... 42
■Outside temperature sensor ............................................................... 43
■Boiler water temperature sensor ........................................................ 44
■Checking the cylinder temperature sensor ......................................... 45
■Checking the outlet temperature sensor ............................................. 45
■Checking the temperature limiter ........................................................ 46
■Checking the flue gas temperature sensor ......................................... 47
■Checking and cleaning the plate heat exchanger ............................... 47
■Checking the fuse ............................................................................... 48
7. Parts lists Overview of assemblies ......................................................................... 49
Casing assembly ................................................................................... 50
Heat cell assembly ................................................................................. 52
Burner assembly .................................................................................... 54
Hydraulic assembly ................................................................................ 56
Aqua-plate assembly ............................................................................. 58
Control unit assembly ............................................................................ 60
Cylinder module assembly ..................................................................... 62
Cylinder assembly ................................................................................. 64
Miscellaneous assembly ........................................................................ 66
8. Control unit Functions and operating conditions in weather-compensated mode .... 68
■Heating mode ..................................................................................... 68
■DHW heating ...................................................................................... 68
Index
Index
5697 789 GB

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9. Connection and wiring dia-
gram
................................................................................................................ 70
10. Reports ................................................................................................................ 71
11. Specification ................................................................................................................ 72
12. Disposal Final decommissioning and disposal ..................................................... 73
13. Certificates Declaration of conformity ....................................................................... 74
14. Keyword index ................................................................................................................ 75
Index
Index (cont.)
5697 789 GB

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Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is intended solely for installation and
operation in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions. It is only designed for heating up heating water
that is of potable water quality.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Information
Disposal of packaging
5697 789 GB
Information

7
Commercial or industrial usage for a purpose other
than heating the building or DHW shall be deemed
inappropriate.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended use (e.g. if the
flue gas and ventilation air paths are sealed).
Product information
Vitodens 111-W, type B1LD
Preset for operation with natural gas The Vitodens 111-W may only be delivered to the
countries specified on the type plate. For deliveries to
other countries, approved contractors must arrange
individual approval on their own initiative and in
accordance with the law of the country in question.
The type plate is located behind the front panel (see
page 49).
Product description
The Vitodens 111-W is equipped with a cylinder and an
integral plate heat exchanger as a cylinder loading
system for DHW heating. For the connection of heating
circuits and DHW line, see page 11 onwards.
In the delivered condition, the Vitodens 111-W is set up
for operation with constant boiler water temperature.
By connecting an outside temperature sensor (acces-
sories), the boiler can be operated in weather-compen-
sated mode.
The appliance is equipped with a sealed unvented
hydraulic system with 2 connections for heating flow
and return and 2 connections for DHW heating.
The following components are integrated into the
hydraulic system:
■Circulation pump
■3-way diverter valve
■Safety valve
■Heating water expansion vessel and DHW expan-
sion vessel
■Cylinder and plate heat exchanger for DHW heating
Connecting accessories
Outside temperature sensor and time switch are con-
nected with low voltage to the control unit.
Information
Intended use (cont.)
5697 789 GB
Information

8
Dimensions and connections
35
480
945
1003
497
740
900
A
BC
D
E
F GH K
166
Fig. 1
AArea for electrical connections
BHeating flow 7 22 mm
CCondensate drain
DHeating return 7 22 mm
EFilling/draining
FGas connection 7 22 mm
GSafety valve (DHW side)
HCold water 7 15 mm
KDHW 7 15 mm
Preparing the connections
Note
This boiler (IP rating: IP X4) is approved for installation
in wet rooms inside safety zone 1 in accordance with
IEEE Wiring Regulations, providing the occurrence of
hosed water can be ruled out.
Observe the IEEE Wiring Regulations.
1. Prepare the water connections. Flush the heating
system.
2. Prepare the gas connection.
3. Prepare the electrical connections.
■Power cable:
A flexible cable 3 x 1.5 mm2, approx. 1.5 m long
is connected in the delivered condition.
■Cables for accessories:
2-core sheathed cable min. 0.5 mm2 for low volt-
age
Installation information
Preparing for boiler installation
5697 789 GB
Installation

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Safety assembly to DIN 1988 and EN 806 on the cold water connection
C
F
B
D E GH D
K
D H L M D N K
A
O
Fig. 2
ASafety assembly (accessory for connection sets for
unfinished walls)
BSafety valve
CVisible discharge pipe outlet point (tundish)
DShut-off valve
EFlow regulating valve (installation recommended)
FPressure gauge connection
GNon-return valve
HDrain
KCold water
LDrinking water filter
MPressure reducer to DIN 1988-2, Dec. 1988 issue
NNon-return valve/pipe separator
OCold water connection at connection set (accesso-
ries)
Installation information
Preparing for boiler installation (cont.)
5697 789 GB
Installation

10
Note
The installation surface must be vertical and level.
250
Ø10
147
497
Fig. 3
1. Mark out the rawl plug holes.
2. Drill 7 10 mm holes and insert the rawl plugs sup-
plied.
Note
The supplied rawl plugs are suitable for the follow-
ing materials:
■Concrete
■Vertically perforated bricks
■Hollow concrete breeze blocks
■Hollow brick and concrete ceilings
■Perforated sand lime bricks
■Solid sand lime bricks
■Natural stone with dense structure
■Porous concrete
■Solid gypsum panels
■Solid concrete breeze blocks
■Solid bricks
3. Fit the wall mounting bracket with the screws sup-
plied.
Installation sequence
Fitting the wall mounting bracket
5697 789 GB
Installation

11
Removing the front panel and mounting the boiler
Note
When mounting on the wall, observe the following: Weight excl. packaging: approx. 65 kg.
2x
3.
1.
2.
Fig. 4
1. Undo the screws on the underside of the boiler; do
not remove them completely.
2. Remove the front panel.
3. Hook the boiler into the wall mounting bracket.
Fitting the connections on the water side
For installation of fittings on the heating water
side and DHW side, see separate installation
instructions. !Please note
To prevent appliance damage,
connect all pipework free of load and torque
stress.
Installation sequence
Mounting the boiler and making connections
5697 789 GB
Installation

12
BA DC E
¨
zz
Fig. 5
AHeating flow
BHeating return
CGas connection
DCold water
EDHW
FSafety assembly
Connection on the DHW side
Permiss. cylinder operating pressure: 10 bar.
Install supplied safety assembly F in the cold water
connection.
No flow limiter is fitted in the cold water supply.
Mounting the connection set
Fig. 6
Installation sequence
Mounting the boiler and making connections (cont.)
5697 789 GB
Installation

13
Gas connection
A
Fig. 7
1. Connect the gas shut-off valve to connection A.
2. Carry out a tightness test.
Note
Only use suitable and approved leak detection
agents (EN 14291) and devices for the tightness
test. Leak detection agents with unsuitable constit-
uents (e.g. nitrides, sulphides) can cause material
damage.
Remove leak detection agent residues after test-
ing.
!Please note
Excessive test pressure will damage the
boiler and the gas train.
Max. test pressure 150 mbar (15 kPa). If a
higher pressure is required for tightness
tests, disconnect the boiler and the gas train
from the main supply pipe. Undo the fitting.
3. Vent the gas line.
Condensate drain connection
A
Fig. 8
■The condensate pipe is connected to the discharge
pipe of the safety valve. The supplied condensate
hose meets the temperature requirements for CE
certification.
■We recommend connecting the condensate pipe
internally to the domestic waste water system, either
directly or via a tundish.
■If the condensate pipe is routed outside the building,
use a pipe with min. 7 30 mm and protect the pipe
from frost. Avoid long external pipe runs.
!Please note
A frozen condensate pipe can result in faults
and damage to the boiler.
Always protect condensate pipes against frost.
■Observe local building regulations.
Connect condensate pipe A to the public sewage sys-
tem with a constant fall and a pipe vent.
Observe local waste water regulations.
Note
Fill the trap with water before commissioning.
Filling the trap with water
!Please note
During commissioning, flue gas may escape
from the condensate drain.
Always fill the trap with water before commis-
sioning.
Installation sequence
Mounting the boiler and making connections (cont.)
5697 789 GB
Installation

14
Fig. 9
Pour at least 0.3 l of water into the flue gas connection.
!Please note
Water in the ventilation air supply can be detri-
mental to the combustion quality.
Never pour water into the external vent.
Balanced flue connection
Fig. 10
Connect the balanced flue pipe.
During installation and positioning of the flue system,
observe building regulations part L and BS 5440.
Flue system installation instructions.
Connecting several Vitodens 111-W to a shared
flue system
Adjust the burner setting of each connected boiler to
match the flue system:
■For shared connection, see page 25.
Note
The back draught safety device available as an acces-
sory must be installed on every boiler.
Do not carry out commissioning until the following
conditions are met:
■Free passage through the flue gas pipes.
■Flue system with positive pressure is gas-tight.
■Apertures for ensuring sufficient combustion air sup-
ply are open and cannot be closed off.
■Applicable regulations on installing and commission-
ing flue systems have been followed.
Danger
Leaking or blocked flue systems or an insuffi-
cient supply of combustion air cause life threat-
ening poisoning due to carbon monoxide in the
flue gas.
Ensure the flue system functions correctly. Aper-
tures for combustion air supply must not be able
to be closed off.
Installation sequence
Mounting the boiler and making connections (cont.)
5697 789 GB
Installation

15
2.
3.
4x
2x
1.
Fig. 11
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing any work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Electrical connections
Information on connecting accessories
When connecting accessories observe the sep-
arate installation instructions provided with
them.
X7
X20
A B
4 3 2 1
OT
C
X21
L N 1 L N?
FE
DX1
96
Fig. 12
AOnly for weather-compensated mode:
Outside temperature sensor (accessories)
BOpenTherm device
Remove jumper D when making this connection.
CConnecting cable
DJumper
EPower supply (230 V, 50 Hz)
See page 16.
FVitotrol 100 or on-site room temperature controller
(230 V switched input)
Remove jumper D when making this connection.
Separate installation instructions
Installation sequence
Opening the control unit enclosure
5697 789 GB
Installation

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Connecting accessories
Accessory installation instructions
When connecting a Vitotrol 100 or an OpenTherm
remote control, remove the jumper across L and 1.
Outside temperature sensor (accessories)
1. Fit the outside temperature sensor.
Installation location:
■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 vents
■Not immediately below balconies or gutters
■Never render over
■Connection:
2-core lead, length up to 35 m with a cross-sec-
tion of 1.5 mm2
2. Connect the outside temperature sensor to termi-
nals 3 and 4 of the power cable (see page 15).
Power supply
Regulations and directives
Danger
Incorrectly executed electrical installations can
result in injuries from electrical current and dam-
age to the appliance.
Connect the power supply and implement all
safety measures (e.g. RCD circuit) in accord-
ance with the following regulations:
■IEC 60364-4-41
■IEEE Wiring Regulations
■Connection requirements specified by your
local power supply utility
Install an isolator in the power cable that simultane-
ously isolates all non-earthed conductors from the
power supply with at least 3 mm contact separation.
We also 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 an external 3 A fuse to
BS 1362.
Danger
Incorrect core assignment can result in serious
injury and damage to the appliance.
Take care not to interchange wires "L1" and "N".
Danger
The absence of component earthing for the sys-
tem can lead to serious injury from electric cur-
rent if an electrical fault occurs.
Connect the appliance and pipework to the equi-
potential bonding of the building.
Installation sequence
Electrical connections (cont.)
5697 789 GB
Installation

17
Routing connecting cables and closing the control unit enclosure
!Please note
Connecting cables/leads will be damaged if they
touch hot components.
When routing and securing cables/leads on site,
ensure that the maximum permissible tempera-
ture for these is not exceeded.
1.
2.
Fig. 13
Installation sequence
Electrical connections (cont.)
5697 789 GB
Installation

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Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Filling the heating system................................................................................................. 19
•2. Filling the loading cylinder on the DHW side.................................................................. 20
••• 3. Venting the boiler by flushing........................................................................................... 20
••• 4. Converting the gas type ................................................................................................... 21
••• 5. Checking the static pressure and supply pressure........................................................ 22
•6. Reducing the maximum heating output........................................................................... 23
•7. Matching the circulation pump rate to the heating system............................................ 23
•8. Matching the burner output to the flue system............................................................... 24
•9. Burner adjustment when connecting multiple flues to a shared flue system.............. 25
•10. Checking the CO2 content................................................................................................. 29
• • 11. Removing the burner ........................................................................................................ 31
• • 12. Checking the burner gasket and burner gauze assembly.............................................. 32
• • 13. Checking and adjusting the electrode............................................................................. 32
• • 14. Cleaning the heat exchanger............................................................................................ 33
• • 15. Checking the condensate drain and cleaning the trap................................................... 34
• • 16. Installing the burner .......................................................................................................... 34
• • 17. Checking the diaphragm expansion vessel and system pressure................................ 35
• • 18. Checking the safety valve function
••• 19. Checking all connections on the heating water and DHW sides for leaks
••• 20. Checking the flue system for unrestricted flow and tightness
••• 21. Checking the firm seating of electrical connections
••• 22. Checking all gas equipment for tightness at operating pressure ................................ 36
• • 23. Fitting the front panel........................................................................................................ 36
•24. Setting display backlighting for standby......................................................................... 36
•25. Setting the display contrast.............................................................................................. 37
•26. Setting the signal tone for display operation.................................................................. 37
•27. Instructing the system user.............................................................................................. 37
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5697 789 GB

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!Please note
Unsuitable fill water increases the level of
deposits and corrosion and may lead to appli-
ance damage.
■Flush the heating system thoroughly before
filling.
■Only fill with water of potable quality.
■Fill water with a hardness above 300 ppm
must be softened.
■Special antifreeze suitable for heating systems
can be added to the fill water. The antifreeze
manufacturer must verify its suitability.
01. Close the gas shut-off valve.
02. Switch ON the power supply.
03. Tap MODE.
04. / until CONFI flashes.
05. OK to confirm.
"P" is displayed in l.h. display area. The r.h. dis-
play area flashes.
06. Use / to select "12".
07. OK to confirm.
"1" flashes in l.h. display area.
08. OK to confirm.
"0" flashes in r.h. display area.
09. Use / to select "1".
10. OK to confirm.
Filling is activated. The boiler circuit pump is run-
ning, the 3-way diverter valve moves to its centre
position. This function terminates automatically
after 30 min or when the ON/OFF switch is
switched off.
AB
CC
Fig. 14
11. Open shut-off valves A and (if fitted) B.
12. Open valves C and fill the heating system. Mini-
mum system pressure > 0.8 bar (80 kPa).
13. Close valves C.
14. Remove connection line between both valves C.
During operation, the connection must be inter-
rupted.
Commissioning, inspection, maintenance
Filling the heating system
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AB
Fig. 15
1. Valves A and B must be in the "top" position.
2. Open the cold water supply and a DHW draw-off
point.
3. Once air stops coming out of the DHW draw-off
point, the loading cylinder is completely filled.
Venting the boiler by flushing
Note
Inadequate ventilation can result in damage due to
steam blasts in the heat exchanger.
Commissioning, inspection, maintenance
Filling the loading cylinder on the DHW side
5697 789 GB