Viessmann Vitopend 100-W Quick guide

VIESMANN
Installation and service
instructions
for contractors
Vitopend 100-W
Type WH1B, 10.5 to 24 kW and 13 to 30 kW
Gas fired central heating and combi boilers
for open flue operation
Natural gas and LPG version
For applicability, see the last page
VITOPEND 100-W
5592 841 GB 3/2007 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 qualified gas fit-
ter.
&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
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental 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
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances 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
building.
&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-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close all doors leading to the
living space.
Safety instructions
2
Safety instructions
5592 841 GB

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
supply 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
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
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
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5592 841 GB

Installation instructions
Preparing for installation
Product information .................................................................................... 5
Installation sequence
Installing the boiler and making all connections ........................................... 6
Flue gas connection.................................................................................... 7
Gas connection .......................................................................................... 7
Opening the control unit .............................................................................. 8
Electrical connections................................................................................. 9
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance ................................... 12
Further details regarding the individual steps .............................................. 14
Troubleshooting
Control unit diagnostics .............................................................................. 32
Repairs ...................................................................................................... 34
Function description
Control and display elements ...................................................................... 39
Heating mode ............................................................................................. 39
DHW heating .............................................................................................. 40
Extension for external connections (accessory)........................................... 40
Designs
Connection and wiring diagrams ................................................................. 41
Parts lists .................................................................................................. 43
Commissioning/service reports ............................................................... 54
Specification............................................................................................. 55
Certificates
Declaration of conformity ............................................................................ 57
Keyword index .......................................................................................... 58
Index
4
Index
5592 841 GB

Vitopend 100-W, WH1B
Set up for operation with natural gas E.
May be converted to alternative gas types with a conversion kit.
The Vitopend 100-W should generally only be delivered to those countries spe-
cified on the type plate. For deliveries to alternative countries, an approved con-
tractor, on his own initiative, must arrange individual approval in accordance
with the law of the land.
Product information
5
Preparing for installation
5592 841 GB
Installation

Note
Prepare the gas, water and power connections using the installation template
supplied.
Installing the boiler and making all connections
6
Installation sequence
5592 841 GB

ATest port Ø 10 mm
B2 x flue pipe diameter
1. Connect the flue outlet with the
shortest possible run of flue pipe to
the chimney. Avoid sharp bends.
Note
The cross-section of the flue pipe
and the chimney must match that of
the draught hood connector. Main-
tain a clearance of at least 100 mm
between the flue pipe and combus-
tible materials.
2. Create a test port in the flue pipe
(see diagram).
3. Thermally insulate the flue pipe (if
required).
Gas connection
1. Install a gas shut-off valve A.
Conversion to other gas
types:
Conversion kit installation
instructions
2. Carry out a leak/soundness test.
!Please note
Excessive test pressure
may damage the boiler and
the gas valve.
Max. test pressure
150 mbar. Where higher
pressure is required for
soundness tests, separate
the boiler and the gas valves
from the gas supply pipe
(undo the fitting).
3. Vent the gas supply pipe.
Flue gas connection
7
Installation sequence
5592 841 GB
Installation

Opening the control unit
8
Installation sequence
5592 841 GB

AFuse 2.5 A (slow)
BPower supply
CIonisation lead
DPotentiometer
EVitotrol 100, type UTD (acces-
sory)
Low voltage plug
%Cylinder temperature sensor (if
installed)
Plug 230 V~
sÖ (internal connection)
dG Gas solenoid valve (internal con-
nection)
a-Ö Interlocking, extraction devices
Connection via external exten-
sion H3 (accessory)
Electrical connections
9
Installation sequence
5592 841 GB
Installation

Power supply (on-site)
Danger
Incorrect core terminations can
cause severe injuries and
damage to the equipment.
Take care not to interchange
cores "L1" and "N".
&Install an isolator in the power sup-
ply line that simultaneously isolates
all non-earthed conductors from the
mains with at least 3 mm contact
separation.
&The power supply must be equipped
with a neutral conductor.
&Water pipes should be connected to
the earth bonding of the house in
question.
&Max. fuse rating 16 A.
&Recommended power supply cable:
&NYM-J 3 x 1.5 mm
2
, max. fuse 16 A,
230 V~, 50 Hz.
Power supply for accessories (on-site)
Where the boiler is installed in a wet
area, the connection of accessories to
the power supply must not be carried
out at the control unit. The power sup-
ply connection for accessories can be
made immediately at the control unit,
if the boiler is installed outside wet
areas. This connection is controlled
directly with the system ON/OFF
switch (max. 3 A)
&Vitotrol 100 , type RT
&Vitotrol 100, type UTA
&Vitotrol 100, type UTD
Recommended power supply cable:
NYM with the required number of con-
ductors for the external connections.
Connection of accessories
Accessory installation instruc-
tions
Note
When connecting a Vitotrol 100,
remove the jumper between "1" and
"L".
Electrical connections (cont.)
10
Installation sequence
5592 841 GB

Routing connecting cables
!Please note
If power cables touch hot components they will be damaged.
When routing and securing power cables on site, ensure that the maxi-
mum permissible temperatures for these cables are not exceeded.
Close and flip up the control unit.
Hook in and secure the front panel.
Electrical connections (cont.)
11
Installation sequence
5592 841 GB
Installation

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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••• 01. Filling and venting the heating system......................... 14
••• 02. Checking all connections on the heating water
side and DHW side for leaks
•03. Checking the power supply connection
• • 04. Checking the gas type......................................................... 15
•05. Gas type conversion (see separate installation
instructions)
••• 06. Checking the static and supply pressure .................... 16
••• 07. Checking the nozzle pressure.......................................... 18
•08. Setting the maximum output ............................................ 20
• • 09. Draining the boiler or heating system........................... 22
• • 10. Checking and cleaning the burner ................................. 22
••• 11. Checking the diaphragm expansion vessel and
system pressure.................................................................... 24
• • 12. Checking and cleaning the flue gas heat
exchanger ................................................................................ 25
• • 13. Checking and adjusting the ignition and ionisation
electrodes ................................................................................ 26
•14. Flow limiter.............................................................................. 27
••• 15. Checking the function of all safety valves
••• 16. Checking the tightness of electrical connections
••• 17. Checking all gas equipment for soundness at
operating pressure............................................................... 27
••• 18. Flue gas emissions test...................................................... 28
••• 19. Checking the flue gas monitoring device .................... 28
••• 20. Checking the ionisation current...................................... 30
Steps - commissioning, inspection and maintenance
12
Commissioning, inspection, maintenance
5592 841 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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••• 21. Checking the external LPG safety valve (if
installed)
•22. Instructing the system user .............................................. 31
Steps - commissioning, inspection and . . . (cont.)
13
Commissioning, inspection, maintenance
5592 841 GB
Service

Filling and venting the heating system
!Please note
Unsuitable fill water increases the level of deposits and corrosion and
may lead to boiler damage.
&Thoroughly flush the entire heating system prior to filling it with water.
&Only use fill water of potable quality.
&Soften fill water with hardness exceeding 3.0 mol/m
3
, e.g. with a small
softening system for heating water (see Vitoset pricelist).
&An anti-freeze additive suitable for heating systems can be mixed with
the fill water. The antifreeze manufacturer must verify its suitability.
1. Check the inlet pressure of the dia-
phragm 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.
Note
If the control unit has not been
switched ON prior to filling the sys-
tem, then the servomotor of the
diverter valve will still be in its cen-
tral position, and the system will be
completely filled.
Further details regarding the individual steps
14
Commissioning, inspection, maintenance
5592 841 GB

4. If the control unit had already been
switched ON before filling began:
&Turn both rotary selectors simul-
taneously counterclockwise to
the end stop.
&Switch the ON/OFF switch on the
control unit first OFF and then
ON again after 3 s.
&Turn rotary selector "tw"
approx. 3 s into the control range
and then back again.
The servomotor of the diverter
valve goes into its centre position.
Note
The pump runs for approx. 10 min.
5. After the system has been fully
filled and vented, switch OFF the
ON/OFF switch at the control unit.
6. Close boiler fill & drain valve A.
7. Close the shut-off valves on the
heating water side.
Checking the gas type
In the delivered condition, the
Vitopend 100-W is set up for natural
gas E.
The boiler can be operated in the
Wobbe index range 12.0 to 16.1 kWh/
m
3
(43.2 to 58.0 MJ/m
3
).
1. Check the gas type and Wobbe
index (Ws) with your gas supply uti-
lity or LPG supplier and compare
them with the details on the burner
label.
Further details regarding the individual steps (cont.)
15
Commissioning, inspection, maintenance
5592 841 GB
Service

2. Convert the burner to the available
gas type in accordance with the
details provided by the gas supply
utility or your LPG supplier, if the
details do not match.
Conversion kit installation
instructions.
3. Record the gas type in the service
report on page 54.
Wobbe index range Ws
WskWh/m
3
MJ/m
3
Natural gas E 12.0 to
16.1
43.2 to
58.0
Natural gas LS8.45 to
10.0
30.4 to
36.0
Natural gas LW9.86 to
12.0
35.5 to
43.4
LPG P 20.3 to
21.3
72.9 to
76.8
Checking the static and supply pressure
Danger
CO build-up as a result of an incorrect burner setup can have serious
health implications.
Carry out a CO test prior to and after work on gas equipment.
Note
The cover plate must be fitted to prevent air infiltrating.
Operation with LPG
Flush the LPG tank twice during commissioning/replacement. Thoroughly vent
the tank and gas supply lines after flushing.
1. Close the gas shut-off valve.
2.
Release the screw inside test nip-
ple Aat the gas train, but do not
remove it, and connect the pres-
sure gauge.
3. Open the gas shut-off valve.
4. Measure the static pressure and
record it in the service report on
page 54.
Set value: max. 57.5 mbar
Further details regarding the individual steps (cont.)
16
Commissioning, inspection, maintenance
5592 841 GB

5. Start the boiler.
Note
During commissioning, the boiler
can enter a fault state because of
airlocks in the gas pipe.
To reset, switch the ON/OFF switch
on the control unit first OFF and
then ON again after approx. 3 s.
The ignition procedure will then be
repeated.
6. Check the supply (flow) pressure.
Set value:
&Natural gas: 20/25 mbar
&LPG: 37/50 mbar
Note
Use suitable test equipment with a
resolution of at least 0.1 mbar to
measure the supply pressure.
7. Record the actual value in the ser-
vice report on page 54.
Take the action shown in the follow-
ing table.
8. Switch OFF the system at the con-
trol unit (the boiler shuts down),
close the gas shut-off valve,
remove the pressure gauge and
close test nipple Awith the screw.
9. Open the gas shut-off valve and
start the boiler.
Danger
Gas escaping from the test
port leads to a risk of explo-
sion.
Check the test nipple for
soundness.
Supply (flow)
pressure for nat-
ural gas
Supply (flow)
pressure for
LPG
Measures
below 17.4 mbar below 42.5 mbar Do not start the boiler. Notify your
mains gas or LPG supplier.
17.4 to 25 mbar 42.5 to 57.5 mbar Start the boiler.
in excess of
25 mbar
in excess of
57.5 mbar
Install a separate gas pressure gover-
nor upstream of the system and regu-
late the inlet pressure to 20 mbar for
natural gas or 50 mbar for LPG. Notify
your mains gas or LPG supplier.
Further details regarding the individual steps (cont.)
17
Commissioning, inspection, maintenance
5592 841 GB
Service

Checking the nozzle pressure
ATest nipple
BCap
CScrew
DPhillips screw
1. Switch OFF the control unit ON/
OFF switch (the boiler shuts
down).
Turn rotary selector "tr" fully
anti-clockwise.
2. Close the gas shut-off valve.
3. Release the screw inside test nip-
ple A, but do not remove, then
connect the pressure gauge.
4. Open the gas shut-off valve.
Switch ON the system ON/OFF
switch on the control unit.
5. Select the upper output:
Turn rotary selector "tw" fully
clockwise (leave at that position
briefly), then turn it back.
LEDs "tw" and "tr" flash
simultaneously.
Note
The operation with the upper
rated output is automatically reset
after approx. 30 min or by switch-
ing the power OFF and ON again.
6. Remove cap Bfrom the gas
train.
7. Test the nozzle pressure at the
upper rated output. In case of
deviations from the value shown
in the following table, adjust
screw Cfor the upper rated out-
put (SW 10).
Further details regarding the individual steps (cont.)
18
Commissioning, inspection, maintenance
5592 841 GB

8. Selecting the lower output:
Note
Adjust the upper rated output
before selecting the lower rated
output. The operation with the
lower rated output is automati-
cally cancelled after approx.
30 min or by switching the power
OFF and ON again.
Turn rotary selector "tw" fully
anti-clockwise.
LEDs "tw" and "tr" flash alter-
nately.
9. Test the nozzle pressure at the
lower rated output. In case of
deviations from the value shown
in the following table, adjust the
nozzle pressure for the lower
rated output using cross-head
screw D. Hold screw C(SW 10)
to counter the torque applied.
10. Snap cap Binto place.
11. Record the setting values in the
service report on page 54.
12. Switch OFF the system at the
control unit (the boiler shuts
down), close the gas shut-off
valve, remove the pressure gauge
and close test nipple Awith the
screw.
13. Return both rotary selectors "tw"
and "tr" to their original posi-
tions.
14. Open the gas shut-off valve and
start the boiler.
Danger
Gas escaping from the test
nipple leads to a risk of
explosion.
Check the test nipple for
soundness.
10.5 to 24 kW
Rated output kW 10.5 11 12 15 18 21 24
Nozzle pressure based
on a supply pressure of
20 mbar
Gas Nozzle ø
in mm
Natural gas E 1.25 mbar 3.0 3.2 3.6 5.5 7.7 10.4 13.6
Natural gas LS1.8 mbar 1.5 1.6 1.8 2.8 4.0 5.4 7.1
Natural gas
LL/LW
1.4 mbar 2.8 3.0 3.4 5.2 7.4 9.9 13.0
Further details regarding the individual steps (cont.)
19
Commissioning, inspection, maintenance
5592 841 GB
Service

Rated output kW 10.5 11 12 15 18 21 24
Nozzle pressure based
on a supply pressure of
50 mbar
Gas Nozzle ø
in mm
LPG 0.84 mbar 6.5 6.9 7.5 11.1 15.7 21.4 28.0
13 to 30 kW
Rated output kW 13 15 18 21 24 27 30
Nozzle pressure based
on a supply pressure of
20 mbar
Gas Nozzle ø
in mm
Natural gas E 1.25 mbar 2.8 3.6 5.0 6.6 8.6 10.8 13.3
Natural gas LS1.8 mbar 1.6 2.0 2.7 3.5 4.5 5.6 6.9
Natural gas
LL/LW
1.4 mbar 2.7 3.3 4.5 5.9 7.7 9.7 11.9
Nozzle pressure based
on a supply pressure of
50 mbar
Gas Nozzle ø
in mm
LPG 0.84 mbar 4.9 6.4 8.9 12.1 15.7 19.8 24.4
Note
The values in the nozzle pressure table apply to the following ambient condi-
tions:
&Air pressure: 1013 mbar
&Temperature: 15 °C
Wobbe index see page 16.
Setting the maximum output
Note
You can limit the maximum output for heating operation. The limit is set via the
modulation range.
Further details regarding the individual steps (cont.)
20
Commissioning, inspection, maintenance
5592 841 GB