Viessmann Vitopend 100-W Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitopend 100-W
Type WH1D, 10.7 to 24.8 kW and 13.2 to 31 kW
Gas system and combi boilers
for balanced flue operation
Natural gas and LPG version
For applicability, see the last page
VITOPEND 100-W
5441 429 UAE 9/2012 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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4
Installation instructions
Preparing for installation
Product information.............................................................................................. 5
Preparing for installation....................................................................................... 5
Installation sequence
Installing the boiler and making all connections................................................... 6
Flue gas connection............................................................................................. 7
Gas connection.................................................................................................... 11
Opening the control unit casing............................................................................ 12
Electrical connections........................................................................................... 13
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 16
Further details regarding the individual steps....................................................... 18
Troubleshooting
Function sequence and possible faults................................................................ 35
Fault messages on the display............................................................................. 36
Repairs................................................................................................................. 38
Function description
Control and display elements............................................................................... 44
Heating mode....................................................................................................... 44
DHW heating........................................................................................................ 44
Designs
Connection and wiring diagram............................................................................ 46
Parts lists............................................................................................................ 48
Commissioning/service reports........................................................................ 57
Specification....................................................................................................... 58
Certificates
Declaration of Conformity for the Vitopend 100-W............................................... 60
Keyword index.................................................................................................... 61
Index
Index
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Vitopend 100-W, WH1D
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 specified
on the type plate. For deliveries to alternative countries, an approved contractor, on
his own initiative, must arrange individual approval in accordance with the law of the
land.
Preparing for installation
Cold water installation
ACold water connection, boiler
BDrain
CVisible discharge pipe outlet point
DSafety valve
ENon-return valve
FShut-off valve
GCold water
HSafety assembly
Safety assembly H to DIN 1988 is
required, if the mains water supply pres-
sure exceeds 10 bar, and no DHW pres-
sure 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 a safety valve is installed, remove the
toggle from the cold water shut-off valve
of the boiler, preventing the valve being
closed manually.
Anti-water hammer device
We recommend the installation of an
anti-water hammer device near pressure
shock generators if the pipework to
which the boiler is connected comprises
taps where water hammer may be cre-
ated (e.g. pressure washers, washing
machines or dishwashers).
Preparing for installation
Product information
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Installation

6
!Please note
To prevent equipment damage,
install all pipework free of load and torque stresses.
Note
Prepare the gas, water and power connections using the installation template A
supplied.
≥ 350
Ø10
AInstallation template
Installation sequence
Installing the boiler and making all connections
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2.
1.
3.
2x
Flue gas connection
Prior to installation check whether a flue gas orifice plate is required (see the following
table).
Installation sequence
Installing the boiler and making all connections (cont.)
5441 429 UAE
Installation

8
Flue gas orifice plate (internal 7)
Routing Type
(de-
sign)
Bal-
anced
flue sys-
tem
24.8 kW 31 kW
Flue gas +
ventilation
air pipe
length
Re-
stric-
tor
7
Flue gas +
ventilation
air pipe
length
Re-
stric-
tor 7
mm m mm m mm
External wall con-
nection
C12x 60/100 ≤ 1 41 ≤ 1 47
> 1 ≤ 3 44 > 1 ≤ 3 —
80/125 ≤ 10 41 ≤ 6 46
> 6 ≤ 8 —
Vertical roof out-
let
C32x 60/100 ≤ 1.25 43 ≤ 2 47
> 1.25 ≤ 5 44 > 2 ≤ 3 —
80/125 ≤ 1.25 38 ≤ 1.25 44
> 1.25 ≤ 11 41 > 1.25 ≤ 6 46
> 11 ≤ 12 43 > 6 ≤ 10 —
Connection to a
concentric chim-
ney
C42x 60/100 ≤ 2 44 ≤ 2 44
Installation sequence
Flue gas connection (cont.)
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Routing Type
(de-
sign)
Bal-
anced
flue sys-
tem
24.8 kW 31 kW
Flue gas +
ventilation
air pipe
length
Re-
stric-
tor
7
Flue gas +
ventilation
air pipe
length
Re-
stric-
tor 7
mm m mm m mm
Flue gas over the
roof, ventilation
air from a differ-
ent pressure area
(outside wall)
C52x 60/100 ≤ 10 44 ≤ 10 44
Separate ventila-
tion air and flue
gas routing
C82x 60/100 ≤ 2 + ≤ 4 44 ≤ 2 + ≤ 4 44
80/125 ≤ 2.5 + ≤ 4.5 44 ≤ 2.5 + ≤ 4.5 44
Flue gas over the
roof, ventilation
air from a differ-
ent pressure area
(indoor air)
B22/
B32
≤ 10 41 ≤ 4 44
> 10 ≤ 14 44 > 4 ≤ 12 46
> 14 ≤ 30 46 > 12 ≤ 20 —
Installation sequence
Flue gas connection (cont.)
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Installation

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CBA
ABoiler flue connection bend for the
horizontal installation of a flue sys-
tem 60/100
BFlue gas orifice plate
CCoaxial boiler flue connection for the
vertical installation of the flue sys-
tems 60/100 and 80/125
Install the flue system.
Flue system installation instruc-
tions
Note
An inspection piece with condensate
trap must be installed in the balanced
flue and must be connected to the con-
densate drain.
Balanced flue system 80/80 mm
Always thermally insulate the ventilation air pipe in unheated rooms.
Installation sequence
Flue gas connection (cont.)
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Opening the flue gas bypass
ASheet steel knock-out
Note
Only carry out the flue gas emissions test
with fitted cover panel.
Gas connection
A
1. Fix gas shut-off valve to gas connec-
tion A.
Torque 30 ±2 Nm.
Conversion to other gas
types:
Conversion kit installation
instructions
Installation sequence
Flue gas connection (cont.)
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Installation

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2. Carry out a tightness test.
Note
For the tightness test, use only suita-
ble and approved leak detecting
agents (EN 14291) and devices.
Leak detecting agents with unsuita-
ble constituents (e.g. nitrides, sul-
phides) can lead to material damage.
Remove residues of the leak detect-
ing 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,
separate the boiler and the
gas valves from the gas sup-
ply pipe (undo the fitting).
3. Vent the gas line.
Opening the control unit casing
4x
1.
2x
2.
3.
Installation sequence
Gas connection (cont.)
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?
5
PUMP FAN
LN1 LN
GAS
E
D ABC
AFuse 2.5 A (slow)
BPower supply
CIonisation cable
DPotentiometer
EAccessories power supply (remove
jumper when connecting)
Low voltage plug
%Cylinder temperature sensor (if sup-
plied)
Plug 230 V~
sÖ Circulation pump (internal connec-
tion)
dG Gas solenoid valve (internal con-
nection)
a-Ö Flue gas fan (internal connection)
Power supply (on-site)
Danger
Incorrect core allocation can
result in serious injury and dam-
age to the appliance.
Never interchange cores "L" and
"N".
■ Install a circuit breaker in the power
supply line that simultaneously iso-
lates all non-earthed conductors from
the mains with at least 3 mm contact
separation.
■ Wire the power supply with a neutral
conductor.
Installation sequence
Electrical connections
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Installation

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■ Connect water pipes to the equipoten-
tial bonding of the house in question.
■ Max. fuse rating 16 A.
■ Recommended power cable:
NYM-J 3 x 1.5 mm2, max. fuse 16 A,
230 V~, 50 Hz.
Power supply for accessories (on-site)
If the boiler is installed in a wet area, the
power supply of accessories outside the
wet area must not be connected at the
control unit. The power supply connec-
tion for accessories can be made imme-
diately at the control unit, if the boiler is
installed outside wet areas. This connec-
tion is controlled directly with the system
ON/OFF switch (max. 1A)
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 power cables
!Please note
If power cables touch hot components they will be damaged.
When routing and securing cables/leads on site, ensure that the maximum
permissible temperatures for these cables/leads are not exceeded.
Installation sequence
Electrical connections (cont.)
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1.
Note
Step 1: Secure power cable to the con-
trol unit support with the cable ties sup-
plied.
Close and flip up the control unit.
Hook in and secure the front panel.
Installation sequence
Electrical connections (cont.)
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Installation

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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.... 19
••• 7. Checking the nozzle pressure....................................... 21
•8. Setting the maximum heating output........................... 24
•9. Checking the balanced flue system for tightness
(annular gap check)........................................................ 26
• • 10. Draining the boiler or heating system.......................... 26
• • 11. Checking and cleaning the burner................................ 26
••• 12. Checking the diaphragm expansion vessel and
system pressure............................................................. 28
• • 13. Checking and cleaning the flue gas heat exchanger.. 29
• • 14. Checking and adjusting the ignition and ionisation
electrodes........................................................................ 30
•15. Flow limiter...................................................................... 31
••• 16. Checking the function of safety valves
••• 17. Checking firm seating of electrical connections
••• 18. Checking all gas equipment for tightness at operating
pressure........................................................................... 31
••• 19. Flue gas emissions test................................................. 32
••• 20. Checking the ionisation current.................................... 33
••• 21. Checking the external LPG safety valve (if installed)
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
• • 22. Checking the flue gas routing
•23. Instructing the system user........................................... 34
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
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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 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 16.8 °dH (3.0 mol/m3), e.g. using
a small softening system for heating water (see Vitoset price list).
■ An antifreeze additive suitable for heating systems can be mixed with the
fill water. The antifreeze manufacturer must verify its suitability, since oth-
erwise damage to gaskets and diaphragms can occur as well as noise dur-
ing heating operation. Viessmann accepts no liability for damage or conse-
quential damage as a result.
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.
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 central
position, and the system will be com-
pletely filled.
4. If the control unit had already been
switched ON before filling began:
■ Turn both rotary selectors simulta-
neously anticlockwise to the end
stop.
■ Switch OFF the ON/OFF switch on
the control unit and switch ON
again after 3 s.
1
2
34
5
6
3s
1
2
34
5
6
Commissioning, inspection, maintenance
Further details regarding the individual steps
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■ 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 fill tap 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).
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. 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.
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
■ Temperature: 15 °C
Checking the static pressure and supply pressure
Danger
CO build-up as a result of incorrect burner adjustment can have serious health
implications.
Carry out a CO test before and after work on gas appliances.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Service

20
Note
The cover plate must be fitted to prevent air infiltrating.
Operation with LPG
Flush the LPG tank twice during commissioning or replacement. Vent the tank and
gas supply line thoroughly after flushing.
1. Close the gas shut-off valve.
2.
Release screw inside test nipple A
on the gas train, but do not remove it;
then connect the pressure gauge.
3. Open the gas shut-off valve.
4. Test the static pressure and record it
in the "Reports" table.
Set value: max. 57.5 mbar
5. Start the boiler.
Note
During commissioning, the boiler can
enter a fault state because of airlocks
in the gas line.
To reset, switch OFF the ON/OFF
switch on the control unit and switch
ON again after approx. 3 s. The igni-
tion process will then be repeated.
6. Check the supply (flow) pressure.
Set value:
■ Natural gas: 20/25 mbar
■ LPG: 28/30/37/50 mbar
Note
Use a suitable measuring device with
a resolution of at least 0.1 mbar to
check the supply pressure.
7. Record the actual value in the
"Reports" table.
Take the action shown in the follow-
ing table.
8. Switch OFF the system at the control
unit (the boiler shuts down), close the
gas shut-off valve, remove the pres-
sure gauge and close test nipple A
with the screw.
9. Open the gas shut-off valve and start
the appliance.
Danger
Gas escaping from the test
nipple leads to a risk of explo-
sion.
Check the test nipple for gas
tightness.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5441 429 UAE