Viessmann VITODENS 111-W Installation And Service Instructions Manual
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Viessmann VITODENS 111-W Installation And Service Instructions Manual

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VIESMANN
Installation and service
instructions
for contractors
Vitodens 111-W
Type B1LA, 6.5 to 35.0 kW
Gas condensing storage combi boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 111-W
Please keep safe.
5618 689 UAE
3/2012

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Summary of Contents for Viessmann VITODENS 111-W

  • Page 1 VIESMANN Installation and service instructions for contractors Vitodens 111-W Type B1LA, 6.5 to 35.0 kW Gas condensing storage combi boiler Natural gas and LPG version For applicability, see the last page VITODENS 111-W Please keep safe. 5618 689 UAE 3/2012...

  • 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

    Index Index Service instructions Installation information Product information....................Preparing for the boiler installation............... Installation instructions Installation sequence Fitting the wall mounting bracket................Fitting the boiler and making connections............10 Opening the control unit casing................15 Electrical connections................... 15 Service instructions Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance..........
  • Page 5 Index Index (cont.) Specification....................... 73 Certificates Declaration of conformity..................74 Keyword index....................75...

  • Page 6: Installation Information

    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 delivered to those countries specified on the type plate. For deliveries to alternative countries, an approved...

  • Page 7: Preparing For The Boiler Installation

    Installation information Preparing for the boiler installation Dimensions and connections F GH K A Area for electrical connections F Gas connection B Heating flow G Safety valve (on the DHW side) C Condensate drain H Cold water D Heating return K DHW E Filling/draining...

  • Page 8: Preparing The Connections

    Installation information Preparing for the boiler installation (cont.) Preparing the connections Note This boiler (IP rating: IP X4D) is approved for installation in wet rooms inside safety zone 1 in accordance with DIN VDE 0100, providing the occurrence of hosed water can be ruled out. Observe the requirements of DIN VDE 0100.

  • Page 9: Installation Sequence

    Installation sequence Fitting the wall mounting bracket Ø10...

  • Page 10: Fitting The Boiler And Making Connections

    Installation sequence Fitting the boiler and making connections Removing the front panel and mounting the boiler 1. Undo screws at the bottom of the 3. Hook the boiler into the wall mounting boiler; do not remove completely. bracket. 2. Remove front panel. Making the connections on the water side For fittings on the heating water Please note...

  • Page 11: Gas Connection

    Installation sequence Fitting the boiler and making connections (cont.) ¨ A Heating flow D Cold water B Heating return E DHW C Gas connection Gas connection 1. Connect gas shut-off valve to con- nection A.
  • Page 12 Installation sequence Fitting the boiler and making connections (cont.) 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.

  • Page 13: Condensate Drain Connection

    Installation sequence Fitting the boiler and making connections (cont.) Condensate drain connection 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.
  • Page 14 Installation sequence Fitting the boiler and making connections (cont.) Fill in at least 0.3 l of water into the flue outlet. Please note Water in the ventilation air supply can be detrimental to the com- bustion quality. Never pour water into the exter- nal vent.

  • Page 15: Opening The Control Unit Casing

    Installation sequence Opening the control unit casing 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.
  • Page 16 Installation sequence Electrical connections (cont.) L N 1 L N 4 3 2 1 A Only for weather-compensated E Power supply (230 V, 50 Hz). mode: See page 17. Outside temperature sensor (acces- F Vitotrol 100 sory) Remove jumper D when making B OpenTherm device this connection.

  • Page 17: Power Supply

    Installation sequence Electrical connections (cont.) ■ Not immediately below balconies 3. Connect the outside temperature or gutters sensor to terminals 3 and 4 (see ■ Never render over page 16). ■ Connection: 2-core lead, length max. 35 m with a cross-section of 1.5 mm 2.
  • Page 18 Installation sequence Electrical connections (cont.) Routing connecting cables and closing the control unit casing Please note When routing and securing Connecting cables will be dam- cables/leads on site, ensure that aged if they touch hot compo- the maximum permissible tem- nents.

  • Page 19: Commissioning, Inspection, 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 the heating system..........20 • • • 2. Venting the boiler by flushing........22 •...

  • Page 20: Further Details Regarding The Individual Steps

    Commissioning, inspection, maintenance Further details regarding the individual steps Filling the heating system Please note ■ Soften fill water harder than Unsuitable fill water increases 16.8 °dH (3.0 mmol/l). the level of deposits and corro- ■ An antifreeze additive suitable sion and may lead to boiler dam- for heating systems can be age.
  • Page 21 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Open shut-off valves A and (if instal- led) B. 5. Connect fill hose to tap C and open tap C. 6. Fill heating system. (Minimum sys- tem pressure > 0.8 bar). 7.

  • Page 22: Venting The Boiler By Flushing

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Venting the boiler by flushing 1. Close the shut-off valves on the heat- 4. Close taps A and B, open the shut- ing water side. off valves on the heating water side. 2.

  • Page 23: Changing To Operation With Lpg

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Changing to operation with LPG In the delivered condition, the boiler is Separate installation instruc- set up for operation with natural gas. For tions. operation with LPG, change the gas noz- zle and convert the gas type in the con- Changing from LPG to natural gas - see trol unit.

  • Page 24: Reducing The Max. Heating Output

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Correction factor Flue system Rated Max. run length (m) heating output (kW) Open flue operation 7 60 mm — — 8 13.5 18.5 — — Balanced flue operation 7 60/100 mm coaxial 13.5 Balanced flue operation 7 60/60 mm parallel...
  • Page 25 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Turn rotary selector "tr" fully clock- wise, until the display shows "SERV". Within 2 s return the rotary selector to the r.h. control range. The display shows "A". 3. Select the required max. heating out- put with rotary selector "tr".

  • Page 26: Checking The Co 2 Content

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 5. Transfer selected heating output: Turn rotary selector "tw" fully clock- wise for less than 2 s and then back into the r.h. control range. During the transfer, "-.-.-". will be dis- played.
  • Page 27 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 03. Turn rotary selector "tr" fully clockwise, until the display shows "SERV". Within 2 s return the rotary selector to the r.h. control range. The display shows "A". 04. Set to upper heating output: Turn rotary selector "tr"...
  • Page 28 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 08. ■ If the CO content is within the given range, continue with point ■ If the CO content is outside the given range, check the flue gas/ ventilation air system for tight- ness;...

  • Page 29: Burner Removal

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Burner removal F 4x 4. Push grommet D down. 1. Switch off the power. 2. Shut off the gas supply. 5. Undo gas supply pipe fitting E. 3. Pull power cables from fan motor A, gas valve B and electrodes...

  • Page 30: Checking The Burner Gasket And Burner Gauze Assembly

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Undo four screws F and remove the Please note To prevent any damage, burner. never rest the burner on the burner gauze assembly. Checking the burner gasket and burner gauze assembly Check burner gasket A and burner gauze assembly D for possible damage and replace, if required.

  • Page 31: Checking And Adjusting Electrode

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Undo two Torx screws and remove 5. Mount thermal insulation ring C. burner gauze assembly D with its Fixing screw torque: 3.5 Nm. gasket E. 6. Fit electrode B. 4.

  • Page 32: Cleaning The Heat Exchanger

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the heat exchanger Please note Scratches on parts that are in contact with flue gas can lead to corrosion. Never use brushes to clean the heat exchanger. Use a vacuum cleaner to remove res- idues from heat exchanger A inside the combustion chamber.

  • Page 33: Checking The Condensate Drain And Cleaning The Siphon

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the condensate drain and cleaning the siphon 1. Release hook and remove siphon A with sealing piece B. Pull siphon A upwards away from the drain connection. 2. Remove supply hose C from siphon 3.

  • Page 34: Burner Installation

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Burner installation A 4x 4. Fit electrical cables to fan motor D, 1. Mount burner and secure with four screws A. gas valve E and ignition unit F. 2. Insert new gasket and tighten the fit- 5.
  • Page 35 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Check the gas connections for tight- 7. Push grommet C up again. ness. Danger Escaping gas leads to a risk of explosion. Check all fittings for gas tight- ness. Please note The use of leak detection spray can result in incorrect...

  • Page 36: 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 Carry out this check with a cold system. 1. Drain the system, until the pressure gauge indicates "0". 2. If the pre-charge pressure of the dia- phragm expansion vessel is lower than the static system pressure, top up with nitrogen until the pre-charge...

  • Page 37: Fitting The Front Panel

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Fitting the front panel 1. Hook the front panel into place. 2. Tighten screws at the bottom. Instructing the system user The system installer must hand the oper- ating instructions to the system user and instruct the user in operating the sys- tem.

  • Page 38: Troubleshooting

    Troubleshooting Function sequence and possible faults Display Measure Control unit issues Increase set value a heat demand and ensure heat is drawn off Fan starts After approx. 1 min Check the fan, fan fault F9 connecting cables, power at the fan and fan control Ignition Fault F4...

  • Page 39: Fault Messages On The Display

    Troubleshooting Function sequence and possible faults (cont.) Burner in opera- Stops below the set Check the flue sys- tion boiler water tem- tem for tightness perature and (flue gas recircula- restarts immedi- tion), check the ately gas flow pressure Fault messages on the display Faults are indicated by a flashing fault code with fault symbol "U"...
  • Page 40 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics No DHW heating Short circuit, outlet Check the sensor (see temperature sen- page 47). No DHW heating Lead break, cylin- Check the sensor (see der temperature page 46).
  • Page 41 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics Burner in a fault The temperature Check heating system fill state limiter has respon- level. Check circulation pump. Vent the system. Check the temperature limiter and connecting leads (see page 48).
  • Page 42 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics Burner blocked Fault, burner con- Check ignition electrodes trol unit and connecting cables. Check whether a strong interference (EMC) field exists near the appliance. Press "Reset" (see page 42).

  • Page 43: Repairs

    Troubleshooting Repairs Removing the front panel 1. Undo screws at the bottom of the 2. Remove front panel. boiler; do not remove completely.

  • Page 44: Outside Temperature Sensor

    Troubleshooting Repairs (cont.) Outside temperature sensor 1. Open the control unit casing. See page 15. 2. Disconnect leads from outside tem- perature sensor. 4 3 2 1 3. Check the sensor resistance and compare it with the curve. 4. Replace the sensor in the case of severe deviation.

  • Page 45: Boiler Water Temperature Sensor

    Troubleshooting Repairs (cont.) Boiler water temperature sensor 1. Pull the leads from boiler water tem- perature sensor A and check the resistance. 2. Check the sensor resistance and compare it with the curve. 3. In the case of severe deviation, drain the boiler on the heating water side and replace the sensor.
  • Page 46 Troubleshooting Repairs (cont.) Checking cylinder temperature sensor 1. Pull plug % from the cable harness. 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in the case of severe deviation. 10 30 50 70 90 110 Temperature in °C...
  • Page 47 Troubleshooting Repairs (cont.) Checking the outlet temperature sensor 1. Pull leads from outlet temperature sensor A. 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in the case of severe deviation. Danger The outlet temperature sen- 10 30 50 70 90 110 sor is immersed in the DHW Temperature in °C...
  • Page 48 Troubleshooting Repairs (cont.) Checking the temperature limiter If the burner control unit cannot be reset after a fault shutdown, although the boiler water temperature is below approx. 95 °C, check the temperature limiter. 1. Pull the leads from temperature lim- iter A.
  • Page 49 Troubleshooting Repairs (cont.) Checking the flue gas temperature sensor 1. Pull leads from flue gas temperature sensor A. 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in the case of severe deviation. 10 30 50 70 90 110 Temperature in °C...
  • Page 50 Troubleshooting Repairs (cont.) Checking and cleaning the plate heat exchanger Note Drain the boiler on its heating water and DHW side. 1. Undo plate heat exchanger A 3. Install in reverse order with new gas- kets. (screws B) and pull away from the front.
  • Page 51 Troubleshooting Repairs (cont.) Checking the fuse 1. Switch off the power. 2. Open control unit casing (see page 15). 3. Check fuse F4.

  • Page 52: Gas Type Conversion

    Gas type conversion Converting from LPG to natural gas Removing gas restrictor 2. Pull cable from gas train A. 3. Undo two screws B and remove gas train A. 4. Remove gas restrictor C from gas train A. 5. Mount gas train A with new gasket Torque for fixing screws B: 3 Nm.
  • Page 53 Gas type conversion Converting from LPG to natural gas (cont.) 2. Turn both rotary selectors "tw" and "tr" simultaneously to their respec- tive central positions. "SERV" appears on the display. 3. Turn rotary selector "tr" within 2 s fully anticlockwise. The display shows "A"...

  • Page 54: Control Unit

    Control unit Functions and operating conditions in weather-compensated mode Heating mode In weather-compensated mode, the boiler water temperature is regulated subject to the outside temperature. Heating curve of weather-compensated control unit -5 -10 -15 -20 Outside temperature in °C Setting of rotary selector "tr" Frost protection function A = 1 Frost protection function is only possible...

  • Page 55: Dhw Heating

    Control unit Functions and operating conditions in… (cont.) DHW heating Heating the DHW primary store from ■ The cylinder primary pump is switched on if the boiler water temperature ≥ set cold DHW temperature. The heating circuit pump is switched on ■...

  • Page 56: Designs

    Designs Connection and wiring diagram Stepper motor diverter valve Ignition/ionisation...
  • Page 57 Designs Connection and wiring diagram (cont.) Vitotrol 100 X ... Electrical interface ■ Type RT § Boiler water temperature sensor ■ Type UTA Outlet temperature sensor (gas ■ type UTDB condensing combi boiler) ■ Type UTDB-RF Cylinder temperature sensor Power input 230 V/50 Hz (gas condensing boiler) Remote control (Open Therm Flue gas temperature sensor...

  • Page 58: Parts Lists

    Parts lists Ordering parts The following information is required: Standard parts are available from your ■ Serial no. (see type plate A) local supplier. ■ Assembly (from this parts list) ■ Position number of the individual part within the assembly (from this parts list)

  • Page 59: Overview Of The Assemblies

    Parts lists Overview of the assemblies A Type plate (on the cover panel) D Hydraulic assembly B Casing assembly E Control unit assembly C Heat cell assembly F Miscellaneous assembly...

  • Page 60: Casing Assembly

    Parts lists Overview of the assemblies (cont.) G Cylinder assembly Casing assembly 0001 Front panel 0007 Toggle fastener (set) 0002 Logo 0008 Pipe clip Ø 18 0003 Cover panel with gasket 0012 Air box gasket, gas pipe 0004 Profiled seal 0013 Wall mounting bracket 0005 Control unit support 0014 Diaphragm grommets (5 pce)

  • Page 61: Heat Cell Assembly

    Parts lists Heat cell assembly 0001 Gasket DN 60 0009 Condensate hose 0002 Boiler flue connection 0010 Splash siphon 0003 Boiler flue connection plug 0013 Condensate hose 0004 Flue gas gasket 0015 Gas supply pipe 0005 Flue gas temperature sensor 0016 Gasket 17 x 24 x 2 (set) 0006 Heat exchanger 0019 Burner...
  • Page 62 Parts lists Heat cell assembly (cont.) 0005 0001 0002 0001 0003 0003 0023 0004 0008 0006 0023 0007 0009 0019 0010 0013 0016 0020 0015 0016 0023 0021...

  • Page 63: Burner Assembly

    Parts lists Burner assembly 0001 Burner gasket 0009 Radial fan 0002 Thermal insulation ring 0010 Gas valve 0003 Cylinder burner gauze assembly 0012 Venturi extension 0004 Burner gauze assembly gasket 0013 Gaskets (set) 0005 Burner door 0014 Conversion kit G31 0006 Ionisation electrode gasket 0015 Gasket set G27 0007 Ignition and ionisation electrode...
  • Page 64 Parts lists Burner assembly (cont.) 0003 0001 0002 0006 0003 0005 0007 0006 0004 0012 0008 0009 0015 0015 0013 0014 0016 0013 0010 0015 0013...

  • Page 65: Hydraulic Assembly

    Parts lists Hydraulic assembly 0001 Temperature sensor 0028 Clip Ø 10 (5 pce) 0002 Thermal circuit breaker 0029 Return pipe 0003 Air vent valve G ⅜ 0030 Safety valve 0004 Hose Ø 10 x 1.5 x 750 0031 Condensate hose 0005 Clip Ø...
  • Page 66 Parts lists Hydraulic assembly (cont.) 0004 0003 0038 0005 0001 0039 0002 0027 0008 0005 0006 0040 0041 0012 0007 0029 0011 0010 0009 0030 0035 0008 0013 0031 0010 0020 0042 0015 0032 0015 0034 0028 0020 0015 0028 0043 0036 0012...

  • Page 67: Aqua Plate Assembly

    Parts lists Aqua plate assembly 0001 Valve insert 0008 Temperature sensor 0002 Flow unit 0009 Clip Ø 8 (5 pce) 0003 Return unit 0010 Clip Ø 10 (5 pce) 0004 Overflow valve 0011 Pipe clip Ø 18 (5 pce) 0005 Overflow pipe 0012 Gasket A 17 x 24 x 2 (set) 0006 Plate heat exchanger 0013 Gasket, O-ring 17.86 x 2.62 (set)

  • Page 68: Control Unit Assembly

    Parts lists Control unit assembly 0001 Control unit 0006 Cable harness stepper motor 0002 Cover, wiring chamber 0007 Ignition cable with angled plug 0003 Fuse 2.5 A (slow) 250 V 5 kΩ 0004 Cable harness X20 0008 Cable fixing 0005 Cable harness 100/35...
  • Page 69 Parts lists Control unit assembly (cont.) 0002 0008 0003 0001 0004 0005 0007 0006...

  • Page 70: Cylinder Assembly

    Parts lists Cylinder assembly 0001 O-ring 14.3 x 2.4 (set) 0008 Protective profile 0002 Clip Ø 15 (5 pce) 0009 Hose clip Ø 340 - 360 x 9 0003 DHW connection pipe 0010 Cylinder 0004 Non-return valve (cartridge) 0011 Thermal insulation EPS, front 0005 Shut-off elbow, cylinder 0012 Thermal insulation EPS, back 0006 DHW connection pipe...

  • Page 71: Miscellaneous Assembly

    Parts lists Cylinder assembly (cont.) 0012 0010 0011 0009 0002 0002 0014 0007 0003 0005 0001 0001 0007 0004 0001 0007 0007 0006 0015 0008 Miscellaneous assembly 0001 Special grease 0003 Touch-up paint stick, white 0002 Touch-up spray paint, white...
  • Page 72 Parts lists Miscellaneous assembly (cont.) 0004 Installation and service instruc- tions 0005 Operating instructions 0001 0002 0004 0005 0003...

  • Page 73: Specification

    Specification Specification Rated voltage: 230 V~ Temperature limiter Rated frequency: 50 Hz setting: 100 °C (fixed) Rated current: 2.0 A~ Backup fuse (power Safety category: supply): max. 16 A IP rating: IP X4D to EN 60529 Permissible ambient temperature ■ during operation: 0 to +40 °C ■...

  • Page 74: Declaration Of Conformity

    Declaration of conformity Declaration of Conformity for the Vitodens 111-W We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm as sole respon- sible body that the product Vitodens 111-W complies with the following standards: DIN 4753 EN 55 014-1 EN 297...

  • Page 75: Keyword Index

    Keyword index Keyword index Boiler water temperature sensor ..45 Gas connection......7, 11 Burner gasket........30 Gas type conversion Burner gauze assembly.....30 ■ LPG..........23 Burner installation......34 ■ Natural gas........52 Burner removal........29 Heating curve........54 Cleaning the combustion chamber..32 Heating flow.........7 Cleaning the heat exchanger.....32 Heating return........7 Cold water connection......7 Commissioning........20...
  • Page 76 7499472 7499473 7499474 7499475 7499476 7499477 7499478 7499479 7499480 7499481 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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