Viessmann Vitopend 100-W Quick guide

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
5441 514 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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3
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............................................................................................. 8
Gas connection.................................................................................................... 8
Opening the control unit casing............................................................................ 9
Electrical connections........................................................................................... 10
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 13
Further details regarding the individual steps....................................................... 14
Troubleshooting
Function sequence and possible faults................................................................ 32
Fault messages on the display............................................................................. 33
Repairs................................................................................................................. 35
Function description
Control and display elements............................................................................... 41
Heating mode....................................................................................................... 41
DHW heating........................................................................................................ 41
Extension for external connections (accessory)................................................... 42
Designs
Connection and wiring diagram............................................................................ 43
Parts lists............................................................................................................ 45
Commissioning/service reports........................................................................ 54
Specification....................................................................................................... 55
Certificates
Declaration of Conformity for the Vitopend 100-W............................................... 57
Keyword index.................................................................................................... 58
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 must
arrange individual approval on his own initiative and in accordance with the law of
the country in question.
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
5441 514 UAE
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
5441 514 UAE

7
2.
1.
3.
2x
Installation sequence
Installing the boiler and making all connections (cont.)
5441 514 UAE
Installation

8
ATest port Ø 10 mm
B2 x flue pipe diameter
1. Connect the flue outlet with the short-
est possible run of flue pipe to the
chimney. 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).
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
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.
Installation sequence
Flue gas connection
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!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.)
5441 514 UAE
Installation

10
?
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 Interlocking extractor fans
Connection via external extension
H3 (accessory)
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".
Installation sequence
Electrical connections
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■ 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.
■ 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 wet areas,
accessories outside the wet area must
not be connected to the power supply at
the control unit. The power supply con-
nection 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. 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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Installation

12
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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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........................ 14
••• 2. Checking all connections on the heating water side
and DHW side for leaks
•3. Checking the power supply
• • 4. Checking the gas type.................................................... 15
•5. Gas type conversion (see separate installation
instructions)
••• 6. Checking the static pressure and supply pressure.... 15
••• 7. Checking the nozzle pressure....................................... 17
•8. Setting the maximum heating output........................... 20
• • 9. 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 safety valves
••• 16. Checking firm seating of electrical connections
••• 17. Checking all gas equipment for tightness at operating
pressure........................................................................... 27
••• 18. Flue gas emissions test................................................. 28
••• 19. Checking the flue gas monitoring device..................... 28
••• 20. Checking the ionisation current.................................... 30
••• 21. Checking the external LPG safety valve (if installed)
•22. Instructing the system user........................................... 31
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Service

14
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
5441 514 UAE

15
■ 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.)
5441 514 UAE
Service

16
Operation with LPG
Flush the LPG tank twice during com-
missioning 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.)
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Supply pressure (flow pressure) Action
For natural gas H For LPG P
Below 17 mbar Below 25 mbar Do not start the boiler. Notify your gas
supply utility or LPG supplier.
17 to 25 mbar 25 to 45 mbar Start the boiler.
Above 25 mbar Above 45 mbar Install a separate gas pressure governor
upstream of the system and regulate the
pre-charge pressure to 20 mbar for natu-
ral gas or 37 mbar for LPG. Notify your
gas supply utility or LPG supplier.
Checking the nozzle pressure
Note
When operating with natural gas E+, the
factory settings must not be altered.
Only check the nozzle pressure at the
lower and upper rated heating output
(with cap B on).
The values given in the following tables
are control values for adjusting the max.
heating output (see page 20).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5441 514 UAE
Service

18
ATest nipple
BCap
CScrew
DPhillips screw
01. Switch OFF the control unit ON/OFF
switch (the boiler shuts down).
1
2
34
5
6
Turn the rotary selector "tr" anti-
clockwise as far as it will go.
02. Close the gas shut-off valve.
03. Release the screw inside test nipple
A, but do not remove, then connect
the pressure gauge.
04. Open the gas shut-off valve. Switch
ON the system ON/OFF switch on
the control unit.
05. Select the upper heating output:
1
2
34
5
6
Turn rotary selector "tw" clockwise
as far as it will go (leave at that posi-
tion briefly), then turn it back.
"Serv" appears.
Note
The operation with the upper rated
heating output is automatically reset
after approx. 30 min or by switching
the power OFF and ON again.
06. Remove cap B from the gas train.
07. Test the nozzle pressure at the
upper rated heating output. In case
of deviations from the value shown
in the following table, adjust screw
C (SW 10) for the upper rated heat-
ing output.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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19
08. Setting the lower heating output:
Note
Adjust the upper rated heating out-
put before selecting the lower rated
heating output. The operation with
the lower rated heating output is
automatically cancelled after
approx. 30 min or by switching the
power OFF and ON again.
1
2
34
5
6
Turn the rotary selector "tw" anti-
clockwise as far as it will go.
"Serv" appears.
09. Test the nozzle pressure at the
lower rated heating output. In case
of deviations from the value shown
in the following table, adjust the noz-
zle pressure for the lower rated
heating output using cross-head
screw D. Counterhold screw C
(SW 10).
10. Fit cap B.
11. Check the setting values and record
them in the "Reports" table.
12. Switch OFF the ON/OFF switch at
the control unit (the boiler shuts
down), close the gas shut-off valve,
remove the pressure gauge and
close test nipple A with the
screw.
13. Turn the rotary selectors "tw" and
"tr" back to their original posi-
tions.
14. Open the gas shut-off valve and
start the appliance.
Danger
Gas escaping from the test
nipple leads to a risk of
explosion.
Check the test nipple for gas
tightness.
10.5 to 24 kW
Rated heating 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 H 1.25 mbar 2.6 2.9 3.4 5.3 7.6 10.3 13.5
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5441 514 UAE
Service

20
Rated heating output kW 10.5 11 12 15 18 21 24
Nozzle pressure based on
a supply pressure of
37 mbar
Gas Nozzle ø
in mm
LPG P 0.84 mbar 5.6 6.0 6.8 10.4 14.8 20.2 26.4
13.5 to 30 kW
Rated heating output kW 13.5 15 18 21 24 27 30
Nozzle pressure based on
a supply pressure of
20 mbar
Gas Nozzle ø
in mm
Natural gas H 1.25 mbar 2.3 3.2 4.7 6.5 8.5 10.8 13.3
Nozzle pressure based on
a supply pressure of
37 mbar
Gas Nozzle ø
in mm
LPG P 0.84 mbar 5.2 6.8 9.6 12.9 16.8 21.2 26.1
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 15.
Setting the maximum heating output
The maximum heating output for heat-
ing operation can be limited. The limit is
set via the modulation range.
01. Switch OFF the control unit ON/OFF
switch (the boiler shuts down).
02.
1
2
34
5
6
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5441 514 UAE