Viessmann Vitopend 100-W Operating instructions

Installation and service
instructions
for contractors
VIESMANN
Vitopend 100-W
Type WH1D, 10.5 to 24 kW and 13.5 to 30 kW
Gas system and combi boilers
For open flue operation
Natural gas and LPG version
For applicability, see the last page
VITOPEND 100-W
5848 649 GB 10/2013 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 inten-
ded for qualified 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 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:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations 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
aÖNORM, EN, ÖVGW-TR Gas,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI,
SWKI, VKF and EKAS guideline
1942: LPG, part 2
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Do not smoke. Prevent naked
flames and sparks. Do not
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
supplier and your local heating
contractor from outside the
building.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
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If you smell flue gas
Danger
Flue gas can lead to life threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the installation site.
■ Close all doors in the living
space.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems,
or an insufficient supply of com-
bustion air can cause life threat-
ening poisoning from carbon
monoxide in the flue gas.
Ensure the flue system is in
proper working order. Apertures
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 neg-
ative 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 poison-
ing due to reverse flow of the flue
gas.
Fit an interlock circuit or take suit-
able steps to ensure a sufficient
supply of combustion air.
Working on the system
■ Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■ Isolate the system from the power sup-
ply (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 recon-
nection.
Danger
Hot surfaces can cause burns.
■ Before maintenance or service
work, switch OFF the appli-
ance 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 electrostatic dis-
charge.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Safety instructions
Safety instructions (cont.)
5848 649 GB

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Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of the sys-
tem.
Faulty components must be
replaced with original Viessmann
spare parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate the
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5848 649 GB

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Installation instructions
Preparing for installation................................................................................... 7
Installation sequence
Mounting the boiler and making connections....................................................... 9
Flue gas connection............................................................................................. 11
Gas connection.................................................................................................... 12
Opening the control unit enclosure....................................................................... 13
Electrical connections........................................................................................... 14
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 17
Further details regarding the individual steps....................................................... 18
Troubleshooting
Function sequence and possible faults................................................................ 37
Fault indicators on the display.............................................................................. 38
Repairs................................................................................................................. 40
Function description
Control and display elements............................................................................... 46
Heating mode....................................................................................................... 46
DHW heating........................................................................................................ 46
Extension for external connections (accessory)................................................... 47
Designs
Connection and wiring diagram............................................................................ 48
Parts lists
Ordering parts...................................................................................................... 50
Overview of the assemblies................................................................................. 51
Casing assembly.................................................................................................. 52
Heat cell assembly............................................................................................... 53
Burner assembly.................................................................................................. 55
Hydraulic assembly.............................................................................................. 56
Hydraulic assembly, system boiler....................................................................... 58
Hydraulic assembly, combi boiler......................................................................... 60
Control unit assembly........................................................................................... 62
Miscellaneous assembly...................................................................................... 64
Commissioning/service reports........................................................................ 65
Index
Index
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Specification....................................................................................................... 66
Certificates
Declaration of Conformity for the Vitopend 100-W............................................... 68
Keyword index.................................................................................................... 69
Index
Index (cont.)
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Vitopend 100-W, type WH1D
Set up for operation with natural gas E.
May be converted to alternative gas
types with a conversion kit.
The Vitopend 100-W must only be deliv-
ered to the countries specified on the
type plate. For deliveries to alternative
countries, approved contractors must
arrange individual approval on their own
initiative and in accordance with the law
of the land.
Intended use
The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions. It is only designed
for the heating of water that is of potable
water quality.
Intended usage presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than heating the building or
DHW does not comply with regulations.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect usage also occurs if the components
in the heating system are modified from
their intended function (e.g. if the flue
gas and ventilation air paths are
sealed).
Preparing for installation
Preparing for installation
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Installation

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Cold water installation
ACold water connection, boiler
BDrain outlet
CVisible discharge pipe outlet point
DSafety valve
ENon-return valve
FShut-off valve
GCold water
HSafety assembly
A safety assembly H to DIN 1988 and
EN 806 is required if the mains water
supply pressure exceeds 10 bar (1.0
MPa), and no DHW pressure reducing
valve is installed (to DIN 4753).
Only use a non-return valve or a com-
bined shut-off and non-return valve in
conjunction with a safety valve.
If the safety valve is used, the cold water
shut-off valve on the boiler must not be
shut off.
Remove the toggle on the cold water
shut-off valve (if installed) to prevent it
being shut off manually.
Shock arrestor
If draw-off points that could cause pres-
sure peaks (water hammer/shock) are
connected to the same pipework as the
boiler (such as pressure washers, wash-
ing machines or dishwashers), we would
recommend the installation of a shock
arrestor near the source of such pres-
sure shocks.
g: Fit a small domestic expansion ves-
sel if water hammer occurs.
Preparing for installation
Preparing for installation (cont.)
5848 649 GB

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!Please note
To prevent appliance damage,
connect all pipework free of load
and torque stress.
Note
Prepare the gas, water and power con-
nections using installation template A
supplied.
≥ 350
Ø10
AInstallation template
Installation sequence
Mounting the boiler and making connections
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Installation

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2.
1.
3.
2x
Installation sequence
Mounting the boiler and making connections (cont.)
5848 649 GB

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ATest port Ø 10 mm
B2 x flue pipe diameter
1. Using flue pipe, connect the flue out-
let to the chimney with the shortest
possible run. Avoid sharp bends.
Note
The cross-sections of the flue pipe
and the chimney must match that of
the draught hood connector. Maintain
a distance of at least 100 mm
between the flue pipe and combusti-
ble materials.
2. Create a test port in the flue pipe (see
diagram).
3. Thermally insulate the flue pipe (if
required).
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 com-
bustion air supply are open and cannot
be closed off.
■ Applicable regulations on installing
and commissioning flue systems have
been followed.
Danger
Leaking or blocked flue systems
or an insufficient supply of com-
bustion air cause life threatening
poisoning due to carbon monox-
ide in the flue gas.
Ensure the flue system functions
correctly. Apertures for combus-
tion air supply must not be able to
be closed off.
Installation sequence
Flue gas connection
5848 649 GB
Installation

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A
1. Fit gas shut-off valve to gas connec-
tion A.
Torque 30 ±2 Nm.
Conversion to alternative
gas types:
Conversion kit installation
instructions
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 con-
stituents (e.g. nitrites, sulphides) can
cause material damage. Remove
leak detection agent residues after
testing.
!Please note
Excessive test pressure may
damage the boiler and the gas
valve.
Maximum test pressure
150 mbar (15 kPa). Where
higher pressure is required for
tightness tests, disconnect
the boiler and the gas valves
from the gas supply pipe
(undo the fitting).
3. Purge the gas line.
Installation sequence
Gas connection
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4x
1.
2x
2.
3.
Installation sequence
Opening the control unit enclosure
5848 649 GB
Installation

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?
5
PUMP FAN
LN1 LN
GAS
E
D ABC
AFuse 2.5 A (slow)
BPower supply
CIonisation cable
DPotentiometer
EPower supply accessories (remove
jumper when connecting)
Low voltage plug
%Cylinder temperature sensor (if fit-
ted)
Plugs 230 V~
sÖ Circulation pump (internal connec-
tion)
dG Gas solenoid valve (internal con-
nection)
a-Ö Extractor interlock
Connection only via external H3
extension (accessory)
Power supply (on site)
Danger
Incorrect wire assignment can
result in serious injury and dam-
age to the appliance.
Never interchange cores "L" and
"N".
Installation sequence
Electrical connections
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■ Install an isolator in the power cable
which simultaneously separates all
non-earthed conductors from the
mains with at least 3 mm contact sep-
aration.
■ Wire the power supply with a neutral
conductor.
■ Connect water pipes to the equipoten-
tial bonding of the building in question.
■ Max. fuse rating 16 A
■ Recommended power cable:
NYM-J 3 x 1.5 mm2, max. fuse rating
16 A, 230 V~, 50 Hz
Power supply for accessories (on site)
Where the boiler is sited in a wet area,
the power supply for accessories must
not be connected at the control unit.
Where the boiler is sited outside wet
areas, the power supply for accessories
can be connected at the control unit. This
connection is controlled directly with the
control unit ON/OFF switch (max. 1 A)
Recommended power cable:
NYM with the required number of con-
ductors for the external connections
Accessories:
■ Vitotrol 100, type RT
■ Vitotrol 100, type UTA
■ Vitotrol 100, type UTDB
■ Vitotrol 100, type UTDB-RF
Connection of accessories
Accessory installation instruc-
tions
Note
When connecting a Vitotrol 100, remove
the jumper between "1" and "L".
Routing connecting cables
!Please note
If connecting cables touch hot
components they will be dam-
aged.
When routing and securing
cables/leads on site, ensure that
the maximum permissible tem-
perature for these cables/leads is
not exceeded.
1.
Note
Step 1: Secure power cable to the con-
trol unit support with cable ties.
Installation sequence
Electrical connections (cont.)
5848 649 GB
Installation

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Close and pivot up the control unit.
Hook in and secure the front panel.
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 and venting the heating system........................ 18
••• 2. Checking all connections on the heating water side
and DHW side for leaks
•3. Checking the power supply
• • 4. Checking the gas type.................................................... 19
•5. Gas type conversion (see separate installation
instructions)
••• 6. Checking the static pressure and supply pressure.... 20
••• 7. Checking the nozzle pressure....................................... 22
•8. Setting the maximum heating output........................... 25
• • 9. Draining the boiler or heating system.......................... 27
• • 10. Checking and cleaning the burner................................ 27
••• 11. Checking the diaphragm expansion vessel and
system pressure............................................................. 29
• • 12. Checking and cleaning the flue gas heat exchanger.. 30
• • 13. Checking and adjusting the ignition and ionisation
electrodes........................................................................ 31
•14. Flow limiter...................................................................... 32
••• 15. Checking the function of safety valves
••• 16. Checking firm seating of electrical connections
••• 17. Checking all gas equipment for tightness at operating
pressure........................................................................... 32
••• 18. Flue gas emissions test................................................. 33
••• 19. Checking the flue gas monitoring device..................... 33
••• 20. Checking the ionisation current.................................... 35
••• 21. Checking the external LPG safety valve (if installed)
•22. Instructing the system user........................................... 36
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Service

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Filling and venting the heating system
!Please note
Unsuitable fill water increases
the level of deposits and corro-
sion and may lead to boiler dam-
age.
■ Flush the heating system thor-
oughly before filling.
■ Only use fill water of potable
quality.
■ Soften fill water with a hard-
ness above 16.8 °dH
(3.0 mol/m3), e.g. with a small
water softening system for
heating water (see the Vitoset
pricelist).
■ Antifreeze suitable for heating
systems can be added to the fill
water. The antifreeze manufac-
turer must verify its suitability,
as damage to gaskets or dia-
phragms and noise during
heating operation may other-
wise occur. Viessmann
accepts no liability for any
resulting damage or conse-
quential losses.
1. Check the pre-charge pressure of the
diaphragm expansion vessel.
2. Close the gas shut-off valve.
3. Fill the heating system at the fill valve
in the heating return (on site).
Minimum system pressure > 0.8 bar
(80 kPa).
Note
If the control unit was not switched on
prior to filling the system, then the
servomotor of the diverter valve will
still be in its central position and the
system will be completely filled.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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4. If the control unit was already on
before filling begins:
■ Simultaneously turn both rotary
selectors anti-clockwise as far as
they will go.
■ Switch OFF the ON/OFF switch on
the control unit and switch it ON
again after 3 s.
1
2
34
5
6
3s
1
2
34
5
6
■ Turn rotary selector "tw" into the
control range for approx. 3 s and
then back again.
The servomotor of the diverter valve
moves to its centre position.
Note
The pump will run for approx.
10 min.
5. After the system has been fully
charged and vented, switch OFF the
ON/OFF switch at the control unit.
6. Close the fill valve in the heating
return (on site).
7. Close the shut-off valves on the heat-
ing water side.
Checking the gas type
In the delivered condition, the boiler is
preset for natural gas E.
The boiler can be operated in the Wobbe
index range Ws 11.4 to 15.2 kWh/m3
(40.9 to 54.8 MJ/m3).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5848 649 GB
Service

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1. Check the gas type and Wobbe index
(Ws) with your gas supply utility or
LPG supplier and compare them with
the details above.
2. If the details do not match, convert
the burner to the available gas type,
in accordance with the details provi-
ded by the gas supply utility or your
LPG supplier.
3. Record the gas type in the "Reports"
table.
Wobbe index range Ws
WskWh/m3MJ/m3
Natural gas H 12.7 to
15.2
45.6 to
54.8
LPG P 20.3 to
24.4
72.9 to
87.8
Note
The indicated Wobbe index Ws values
apply to the following ambient condi-
tions:
■ Air pressure: 1013 mbar (101.3 kPa)
■ Temperature: 15 °C
Checking the static pressure and supply pressure
Danger
CO formation as a result of incor-
rect burner adjustment can have
serious health implications.
Carry out a CO test before and
after work on gas appliances.
Note
The cover panel must be fitted to prevent
infiltrating air.
Operation with LPG
Purge the LPG tank twice during com-
missioning or replacement. Vent the tank
and gas connection line thoroughly after
purging.
1. Close the gas shut-off valve.
2.
Release the screw inside test con-
nector A on the gas train but do not
remove, then connect the pressure
gauge.
3. Open the gas shut-off valve.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5848 649 GB