Viessmann Vitopend 100-W Installation And Service Instructions Manual
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Viessmann Vitopend 100-W Installation And Service Instructions Manual

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VIESMANN
Installation and service
instructions
for contractors
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
Please keep safe.
5441 514 UAE
9/2012

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Summary of Contents for Viessmann Vitopend 100-W

  • Page 1 VIESMANN Installation and service instructions for contractors 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 Please keep safe.

  • Page 2: Safety Instructions

    Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate- rial losses. Safety instructions explained ■ the Code of Practice of relevant trade associations. Danger ■ all current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury.
  • Page 3 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.

  • Page 4: Table Of Contents

    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...

  • Page 5: Product Information

    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.

  • Page 6: Installing The Boiler And Making All Connections

    Installation sequence Installing the boiler and making all connections 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. Ø10 A Installation template...
  • Page 7 Installation sequence Installing the boiler and making all connections (cont.)

  • Page 8: Flue Gas Connection

    Installation sequence Flue gas connection 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.

  • Page 9: Opening The Control Unit Casing

    Installation sequence Gas connection (cont.) Please note 3. Vent the gas line. 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).

  • Page 10: Electrical Connections

    Installation sequence Electrical connections PUMP FAN LN1 LN A Fuse 2.5 A (slow) D Potentiometer B Power supply E Accessories power supply (remove C Ionisation cable jumper when connecting) Low voltage plug Plug 230 V~ % Cylinder temperature sensor (if sup- sÖ...
  • Page 11 Installation sequence Electrical connections (cont.) ■ Install a circuit breaker in the power ■ Connect water pipes to the equipoten- supply line that simultaneously iso- tial bonding of the house in question. lates all non-earthed conductors from ■ Max. fuse rating 16 A. the mains with at least 3 mm contact ■...
  • Page 12 Installation sequence Electrical connections (cont.) 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.

  • Page 13: Steps - Commissioning, Inspection And Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance 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 • • •...

  • Page 14: Filling And Venting The Heating System

    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.

  • Page 15: Checking The Gas Type

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) ■ Turn rotary selector "tw" approx. 6. Close fill tap in the heating return (on 3 s into the control range and then site). back again. 7. Close the shut-off valves on the heat- The servomotor of the diverter valve ing water side.
  • Page 16 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Operation with LPG 6. Check the supply (flow) pressure. Flush the LPG tank twice during com- missioning or replacement. Vent the tank Set value: and gas supply line thoroughly after ■...

  • Page 17: Checking The Nozzle Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 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.
  • Page 18 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 04. Open the gas shut-off valve. Switch ON the system ON/OFF switch on the control unit. 05. Select the upper heating output: Turn rotary selector "tw" clockwise as far as it will go (leave at that posi- tion briefly), then turn it back.
  • Page 19 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 08. Setting the lower heating output: 10. Fit cap B. Note Adjust the upper rated heating out- 11. Check the setting values and record put before selecting the lower rated them in the "Reports"...

  • Page 20: Setting The Maximum Heating Output

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Rated heating output kW 10.5 Nozzle pressure based on a supply pressure of 37 mbar Nozzle ø in mm LPG P 0.84 mbar 6.8 10.4 14.8 20.2 26.4 13.5 to 30 kW Rated heating output kW 13.5 Nozzle pressure based on...
  • Page 21 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Turn the rotary selector "tr" anti- clockwise as far as it will go. Release the screw inside test nipple A, but do not remove, then connect the pressure gauge. Turn potentiometer B anti-clock- wise with a screwdriver until the noz- 04.

  • Page 22: Draining The Boiler Or Heating System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 11. Open the gas shut-off valve and Danger start the appliance. Gas escaping from the test nipple leads to a risk of explosion. Check the test nipple for gas tightness. Draining the boiler or heating system Please note Note...
  • Page 23 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Note Clean the burner if required with com- pressed air or with a soapy solution. Flush with clean water. Installation with new gaskets.

  • Page 24: Checking The Diaphragm Expansion Vessel And System Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the diaphragm expansion vessel and system pressure Check the diaphragm expansion vessel pre-charge pressure at test nipple A and recharge if required. Note Using key B supplied, you can refill the gas combi boiler at the fill valves.

  • Page 25: Checking And Cleaning The Flue Gas Heat Exchanger

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking and cleaning the flue gas heat exchanger When undoing the fittings on the heating Note water side, counterhold the torque with a Clean the flue gas heat exchanger if second open-ended spanner.

  • Page 26: Checking And Adjusting The Ignition And Ionisation Electrodes

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking and adjusting the ignition and ionisation electrodes +2.5 -3.5 ±2.5 -0.3 Note Clean the ignition electrodes with a small brush or sandpaper.

  • Page 27: Flow Limiter

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Flow limiter If required, flush flow limiter A with clean water. Identification of flow limiter A Rated heating output Flow rate Colour 10.5 to 24 kW 10 l/min Black 13.5 to 30 kW 12 l/min Red Checking all gas equipment for tightness at operating pressure Danger...

  • Page 28: Flue Gas Emissions Test

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Flue gas emissions test 4. Setting the lower heating output (see page 19). Measure the CO or O and CO con- tent. Record the values in the "Reports" table. 5. Switch off the control unit ON/OFF switch.
  • Page 29 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Note 6. Shut down the boiler. After no later than approx. 2 min, the flue gas monitoring device should 7. Clear the aperture and push the flue switch off the burner and should not pipe onto the draught hood.

  • Page 30: Checking The Ionisation Current

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the ionisation current A Adaptor cable (available as acces- sory) 1. Connect the test equipment accord- 4. Switch off the control unit ON/OFF ing to the diagram. switch. Operation with the upper rated heat- 2.

  • Page 31: Instructing The System User

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Instructing the system user The system installer must hand the oper- ating instructions to the system user and instruct him/her in the operation of the system.

  • Page 32: Function Sequence And Possible Faults

    Troubleshooting Function sequence and possible faults Display Measure Control unit issues Increase set value a heat demand and ensure heat is drawn off Ignition Fault "F4" Check the ignition module connec- tion Gas train opens Fault "F4" Check the gas train (control volt- age 230 V);...

  • Page 33: Fault Messages On The Display

    Troubleshooting Fault messages on the display Faults are indicated by a flashing fault code (e.g. "F2") and the fault symbol U on the display. Displayed System characteris- Cause Measures fault code tics Burner blocked Gas supply pres- Check the gas pressure sure too low and the gas pressure switch.
  • Page 34 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics Burner in a fault No flame signal Check the ionisation elec- state trode and connecting ca- bles, check the gas pres- sure, check the gas train, check the ignition and ig- nition module.

  • Page 35: Repairs

    Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics Burner blocked Short circuit, flue Check the sensor (see gas monitoring page 38). sensor Burner blocked Lead break, flue Check the sensor (see gas monitoring page 38).
  • Page 36 Troubleshooting Repairs (cont.) 45° E Heating water flow G Cold water F Heating water return H DHW Check the connections on the DHW side 2. Turn the stepper motor adaptor B for scale build-up and the connections on with stepper motor A anti-clockwise the heating water side for contamination.
  • Page 37 Troubleshooting Repairs (cont.) 4. Install plate heat exchanger D in 5. Reassemble the boiler in reverse reverse order using new gaskets. order. Fixing screw torque: 5.5 Nm. 6. Fill the boiler with water, flush (vent) and check for leaks. Note During installation, ensure that fixing holes are aligned and gaskets seated correctly.
  • Page 38 Troubleshooting Repairs (cont.) Checking temperature limiter and sensors A Temperature limiter D Flue gas monitoring sensor B Boiler water temperature sensor % Cylinder temperature sensor (gas C Outlet temperature sensor system boiler)
  • Page 39 Troubleshooting Repairs (cont.) 2. Boiler water temperature sensor: ■ Pull the leads from the sensor. ■ Check the sensor resistance and compare it with the curve. ■ Replace the sensor in the case of severe deviation. Please note The boiler water tempera- ture sensor is immersed in the heating water (risk of scalding).
  • Page 40 Troubleshooting Repairs (cont.) 4. Flue gas monitoring sensor: 5. Cylinder temperature sensor (gas ■ Pull the leads from the sensor. system boiler): ■ Check the sensor resistance and ■ Pull plug % from the cable har- compare it with the curve. ness outside the control unit.

  • Page 41: Control And Display Elements

    Function description Control and display elements A Pressure gauge D Rotary selector for heating water B Display temperature E ON/OFF switch C Rotary selector for DHW tempera- ture Heating mode The set boiler water temperature adjus- The boiler water temperature will be ted at rotary selector "tr"...

  • Page 42: Extension For External Connections (Accessory)

    Extension for external connections (accessory) The external extension H3 can be con- Installation instructions nected to the Vitopend 100-W control External extension H3 unit. With the external extension H3, extractor fans can be locked out in the case of...

  • Page 43: Connection And Wiring Diagram

    Designs Connection and wiring diagram PCB inside the boiler Vitotrol 100, RT Gas pressure switch (acces- Vitotrol 100, UTD sory) Vitotrol 100, UTD-RF Power supply Stepper motor for diverter Vitotrol 100, UTA valve...
  • Page 44 Designs Connection and wiring diagram (cont.) Ignition transformer and ioni- sÖ Internal circulation pump sation Gas solenoid valve § Boiler water temperature sen- Temperature limiter Flow switch Outlet temperature sensor a-Ö/aBL Interlocking of extractors via (only gas combi boilers) external extension H3 Cylinder temperature sensor Flue gas monitoring sensor (only gas system boilers)

  • Page 45: Parts Lists

    Parts lists Parts lists Information for ordering spare parts 049 Wall mounting bracket Quote the part no. and serial no. (see 055 Quick-action air vent valve car- type plate) and the position no. of the tridge required part (as per this parts list). 056 Safety valve Standard parts are available from your 057 Plate heat exchanger...
  • Page 46 Parts lists Parts lists (cont.) 315 Intermediate gas piece G¾ x R¾ 087 Power cable, gas valve/auxiliary 316 Heating water fittings for mounting earth panel 088 Power cable, stepper motor 317 DHW fittings for mounting panel 090 Cable ties (10 pce) 318 Angle gas valve 100 O-ring 19.8 x 3.6 (5 pce) 319 Straight-through gas valve without...
  • Page 47 Parts lists Parts lists (cont.)
  • Page 48 Parts lists Parts lists (cont.)
  • Page 49 Parts lists Parts lists (cont.)
  • Page 50 Parts lists Parts lists (cont.)
  • Page 51 Parts lists Parts lists (cont.)
  • Page 52 Parts lists Parts lists (cont.)
  • Page 53 Parts lists Parts lists (cont.)

  • Page 54: Commissioning/Service Reports

    Commissioning/service reports Commissioning/service reports Setting and test val- Set value Commis- Mainte- sioning nance/serv- Date: Static pressure mbar max. 57.5 mbar Supply pressure (flow pressure) = for natural gas H mbar 17-25 mbar = for LPG P mbar 25-45 mbar Tick gas type Carbon dioxide con- tent CO...

  • Page 55: Specification

    Specification Specification Rated voltage 230 V Temperature control- Rated frequency 50 Hz 40 to 76 °C Rated current 2.5 A Power consumption Safety category incl. circulation IP rating IP X 4 D to pump EN 60529 ■ 10.5 - 24 kW Max.
  • Page 56 Specification Specification (cont.) Connection values 13.5 to 30 kW Rated heating 13.5 output Rated heat in- 14.5 16.7 20.0 23.3 26.7 30.0 33.3 Supply values relative to the max. load Natural gas H 1.53 1.77 2.12 2.47 2.82 3.17 3.53 l/min 25.29 29.18...

  • Page 57: Declaration Of Conformity For The Vitopend 100-W

    Certificates Declaration of Conformity for the Vitopend 100-W We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm as sole respon- sible body that the product Vitopend 100-W complies with the following standards: EN 297 EN 60 335 EN 625 EN 61 000-3-2...

  • Page 58: Keyword Index

    Keyword index Keyword index Boiler water temperature sensor..38 Gas connection........8 Burner..........22 Gas solenoid valve......10 Gas supply pressure......16 Gas train ...........16 Circuit breaker........11 Gas type..........15 Circulation pump........10 Commissioning........14 Connection diagrams......43 Heating mode........41 Controls..........41 Heating output, max......20 Cylinder temperature sensor....38 Ignition electrode........26 Declaration of Conformity....57 Installing the boiler.......6 DHW heating........41...
  • Page 59 Keyword index Keyword index (cont.) Small softening system......14 Upper heating output......18 Specification ........55 Static pressure........16 Supply pressure.........15 Wiring diagram........43 System pressure........14 Wobbe index........15 Temperature limiter......38 Test pressure........9...
  • Page 60 Serial No.: 7427721 7427723 7427725 7427727 7427730 7427732 7428245 7428247 7464529 Viessmann Middle East FZE Viessmann Werke GmbH&Co KG E-Wing, Office 603 D-35107 Allendorf HQ Building Telephone: +49 6452 70-0 Dubai Silicon Oasis Fax: +49 6452 70-2780 PO Box 341330 www.viessmann.com...

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