Viessmann Vitodens 111-W Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 111-W
Type B1LA, 6.5 to 35.0 kW
Gas condensing storage combi boiler
Natural gas and LPG version
Gas Council no.: 47-819-23; 47-819-24; 47-819-25
For applicability, see the last page
VITODENS 111-W
5618 648 GB 3/2012 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,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never 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).
Safety instructions
Safety instructions
5618 648 GB

3
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 leading to the
living space.
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 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 ful-
fil a safety function can compro-
mise 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 com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5618 648 GB

4
Service instructions
Product information
Product information.............................................................................................. 6
Preparing for the boiler installation....................................................................... 7
Installation instructions
Installation sequence
Fitting the wall mounting bracket.......................................................................... 9
Fitting the boiler and making connections............................................................ 10
Opening the control unit enclosure....................................................................... 16
Electrical connections........................................................................................... 16
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 20
Further details regarding the individual steps....................................................... 22
Troubleshooting
Function sequence and possible faults................................................................ 42
Fault messages on the display............................................................................. 43
Repairs................................................................................................................. 47
Gas type conversion
Converting from LPG to natural gas..................................................................... 56
Control unit
Functions and operating conditions in weather-compensated mode................... 58
Designs
Connection and wiring diagram............................................................................ 60
Parts lists
Ordering parts...................................................................................................... 62
Overview of the assemblies................................................................................. 63
Casing assembly.................................................................................................. 64
Heat cell assembly............................................................................................... 65
Burner assembly.................................................................................................. 66
Hydraulic assembly.............................................................................................. 68
Aqua-plate assembly............................................................................................ 70
Control unit assembly........................................................................................... 71
Cylinder assembly................................................................................................ 73
Miscellaneous assembly...................................................................................... 74
Index
Index
5618 648 GB

5
Specification....................................................................................................... 76
Certificates
Declaration of conformity...................................................................................... 77
Keyword index.................................................................................................... 78
Index
Index (cont.)
5618 648 GB

6
Vitodens 111-W, type B1LA
Preset for operation with natural gas.
Conversion to LPG P requires a gas con-
version kit.
Conversion for other countries
The Vitodens 111-W should generally
only be supplied to countries listed on
the type plate. For deliveries to alterna-
tive countries, an approved contractor
must arrange individual approval on his
own initiative and in accordance with the
law of the country in question.
Product description
The Vitodens 111-W is equipped with a
cylinder and an integral plate heat
exchanger as primary store system for
DHW heating. For the connection of
heating circuits and the DHW line, see
from page 11.
In the delivered condition, the
Vitodens 111-W is set up for operation
with constant boiler water temperature.
By connecting an outside temperature
sensor (accessory), the boiler can be
operated in weather-compensated
mode.
The following are integrated: one sealed
unvented hydraulic system with 2 con-
nections for heating flow and return and
2 connections for DHW heating.
The following components are integra-
ted into the hydraulic system:
■ Circulation pump
■ 3-way diverter valve
■ Safety valve
■ Heating water expansion vessel and
DHW expansion vessel
■ Cylinder and plate heat exchanger for
DHW heating
Accessory connection
Outside temperature sensor and time
switch are connected with low voltage to
the control unit.
Product information
Product information
5618 648 GB

7
Dimensions and connections
26
480
945
1003
497
740
900
A
BC
DE
F
G
H
5
E
150
166
AArea for electrical connections
BHeating flow 7 22 mm
CCondensate drain
DHeating return 7 22 mm
EFilling loop
FGas connection 7 22 mm
GCold water 7 15 mm
HDHW 7 15 mm
Product information
Preparing for the boiler installation
5618 648 GB
Service

8
Preparing the connections
Note
This boiler (IP rating: IP X4 D) 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.
■ In the delivered condition, the
power cable with mains plug is con-
nected inside the control unit.
■ Accessory cables:
NYM-O two-core min. 0.5 mm2.
Product information
Preparing for the boiler installation (cont.)
5618 648 GB

9
250
Ø10
129
497
Installation sequence
Fitting the wall mounting bracket
5618 648 GB
Installation

10
Removing the front panel and mounting the boiler
Note
When mounting on the wall, observe the
following: Weight excl. packaging:
approx. 65 kg.
2x
2.
3.
1.
1. Undo screws at the bottom of the
boiler; do not remove completely.
2. Remove front panel.
3. Hook the boiler into the wall mounting
bracket.
Installation sequence
Fitting the boiler and making connections
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Making the connections on the water side
For fittings on the heating water
side and DHW side, see separate
installation instructions.
!Please note
To prevent equipment damage,
install all pipework free of load
and torque stresses.
BA DC E
¨
zz
AHeating flow
BHeating return
CGas connection
DCold water
EDHW
DHW connection
Permiss. operating pressure, cylinder:
10 bar.
A safety valve and pressure reducer
manifold is provided as standard and has
to be fitted into the cold water supply.
The blow off pipe of the safety valve can
be routed into the household drain pipe.
No flow limiter is fitted into the cold water
supply.
Installation sequence
Fitting the boiler and making connections (cont.)
5618 648 GB
Installation

12
Fitting the connection set
Gas connection
A
1. Connect gas shut-off valve to con-
nection A.
Installation sequence
Fitting the boiler and making connections (cont.)
5618 648 GB

13
2. Carry out a tightness test.
Note
For tightness tests, use only
approved leak detection agents
(EN 14291) and devices. Leak detec-
tion agents with unsuitable constitu-
ents (e.g. nitrites, sulphides) can
cause material damage.
Remove residues of the leak detec-
tion 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,
disconnect the boiler and the
gas valves from the gas sup-
ply pipe (undo the fitting).
3. Vent the gas line.
Installation sequence
Fitting the boiler and making connections (cont.)
5618 648 GB
Installation

14
Condensate drain connection
A
■ The condensate pipe is connected to
the safety valve discharge pipe. The
condensate hose supplied meets the
temperature requirements that are
part of the CE certification.
■ We recommend the internal connec-
tion of the condensate pipe to the
domestic drain, either directly or via a
tundish.
■ If the condensate pipe is routed out-
side the building, use a pipe with at
least 7 30 mm and protect this pipe
from frost. Avoid long outdoor pipe-
work.
!Please note
Frozen condensate pipes can
result in faults and damage to
the boiler.
Always insulate condensate
pipes against frost.
■ Observe local building regulations.
Connect the condensate pipe A with a
constant fall and a pipe vent to the public
sewage system.
Observe the local waste water regula-
tions.
Note
Fill the siphon with water before com-
missioning.
Filling the siphon with water
!Please note
At commissioning, flue gas may
be emitted from the condensate
drain.
Fill the siphon with water before
commissioning.
Installation sequence
Fitting the boiler and making connections (cont.)
5618 648 GB

15
Fill the flue outlet with at least 0.3 l of
water.
!Please note
Water in the ventilation air supply
can be detrimental to the com-
bustion quality.
Never pour water into the exter-
nal vent.
Balanced flue connection
Connect the balanced flue.
During installation and positioning of the
flue system, observe building regula-
tions part L and BS 5440.
Flue system installation instruc-
tions.
Installation sequence
Fitting the boiler and making connections (cont.)
5618 648 GB
Installation

16
3.
4x
2.
1.
2x
!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.
Electrical connections
Information on connecting
accessories
When connecting accessories
observe the separate installation
instructions provided with them.
Installation sequence
Opening the control unit enclosure
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X7
X20
A B
4 3 2 1
OT
C
X21
L N 1 L N?
FE
DX1
AOnly for weather-compensated
mode:
Outside temperature sensor (acces-
sory)
BOpenTherm device
Remove jumper D when making
this connection.
CConnecting cable (accessory)
DJumper
EPower supply (230 V, 50 Hz).
See page 18.
FVitotrol 100 or on-site room temper-
ature controller (switched 230 V
input)
Remove jumper D when making
this connection.
Separate installation instruc-
tions
Accessory connection
Accessory installation instruc-
tions
When connecting a Vitotrol 100 or an
OpenTherm remote control, remove the
jumper across L and 1.
Outside temperature sensor (acces-
sory)
1. Fit outside temperature sensor.
Installation sequence
Electrical connections (cont.)
5618 648 GB
Installation

18
Installation site:
■ 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 ven-
tilation outlets
■ Not immediately below balconies
or gutters
■ Never render over
■ Connection:
Two-core lead, length max. 35 m
with a cross-section of 1.5 mm2
2. Plug the power cable supplied with
the outside temperature sensor into
slot "X21".
3. Connect the outside temperature
sensor to terminals 3 and 4 (see
page 17).
Power supply
Regulations and directives
Danger
Incorrect electrical installations
can result in injuries from electri-
cal current and in appliance dam-
age.
Connect the power supply and
implement all safety measures
(e.g. RCD circuit) in accordance
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 supply line
that simultaneously isolates all non-
earthed conductors from the mains with
at least 3 mm contact separation.
We additionally 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 allocation can
result in serious injury and dam-
age to the appliance.
Take care not to interchange
wires "L1" and "N".
Danger
The absence of component
earthing in the system can lead to
serious injury from electrical cur-
rent if an electrical fault occurs.
Connect the appliance and pipe-
work to the equipotential bonding
of the building in question.
Installation sequence
Electrical connections (cont.)
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Routing connecting cables and closing the control unit enclo-
sure
!Please note
Connecting cables will be dam-
aged if they touch hot compo-
nents.
When routing and securing
cables/leads on site, ensure that
the maximum permissible tem-
peratures for these cables/leads
are not exceeded.
1.
2.
Installation sequence
Electrical connections (cont.)
5618 648 GB
Installation

20
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Filling the heating system.............................................. 22
••• 2. Venting the boiler by flushing....................................... 24
••• 3. Changing to operation with LPG................................... 25
••• 4. Checking the static and supply pressure..................... 25
•5. Matching the burner output to the flue system........... 26
•6. Reducing the max. heating output................................ 27
•7. Adjusting the circulation pump to the heating system 29
•8. Checking the CO2 content............................................. 31
• • 9. Burner removal .............................................................. 33
• • 10. Checking the burner gasket and burner gauze
assembly......................................................................... 34
• • 11. Checking and adjusting the electrode.......................... 35
• • 12. Cleaning the heat exchanger......................................... 36
• • 13. Checking the condensate drain and cleaning the
siphon.............................................................................. 37
• • 14. Burner installation ......................................................... 38
• • 15. Checking the diaphragm expansion vessel and
system pressure............................................................. 39
• • 16. Checking the function of safety valves
••• 17. Checking all connections on the heating water side
and DHW side for leaks
••• 18. Checking flue system for unrestricted flow and
tightness
••• 19. Checking firm seating of electrical connections
••• 20. Checking gas equipment for tightness at operating
pressure .......................................................................... 40
• • 21. Fitting the front panel..................................................... 41
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5618 648 GB