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 B1LD, 4.7 to 35.0 kW
Gas condensing storage combi boiler
Natural gas and LPG version
Gas Council Number: 47-819-43, 47-819-44
For applicability, see the last page
VITODENS 111-W
Please keep safe.
5697 789 GB
4/2016

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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 B1LD, 4.7 to 35.0 kW Gas condensing storage combi boiler Natural gas and LPG version Gas Council Number: 47-819-43, 47-819-44 For applicability, see the last page VITODENS 111-W Please keep safe.
  • Page 2 ■ installer or a qualified person authorised by the For replacements, use only original spare parts installer. supplied or approved by Viessmann. Regulations to be observed Safety instructions for operating the system National installation regulations If you smell gas ■...
  • Page 3 Safety instructions Safety instructions (cont.) What to do if water escapes from the appliance Danger When water escapes from the appliance there is a risk of electrocution. Switch off the heating system at the external iso- lator (e.g. fuse box, domestic power distribu- tion).

  • Page 4: Table Of Contents

    Index Index 1. Information Disposal of packaging ................Symbols ....................Intended use ..................Product information ................Vitodens 111-W, type B1LD ..............■ Product description ................Connecting accessories ..............■ 2. Installation information Preparing for boiler installation .............. Dimensions and connections ..............
  • Page 5 Index Index (cont.) 9. Connection and wiring dia- ........................ 70 gram 10. Reports ........................ 71 Specification ........................ 72 12. Disposal Final decommissioning and disposal ............. 73 13. Certificates Declaration of conformity ............... 74 14. Keyword index ........................ 75...

  • Page 6: Disposal Of Packaging

    Please dispose of packaging waste in line with statu- DE: Use the disposal system organised by tory regulations. Viessmann. AT: Use the ARA statutory disposal system (Altstoff Recycling Austria AG, licence number 5766). CH: Packaging waste is disposed of by the HVAC contractor.

  • Page 7: Product Information

    The type plate is located behind the front panel (see page 49). Product description The Vitodens 111-W is equipped with a cylinder and an The following components are integrated into the integral plate heat exchanger as a cylinder loading hydraulic system: system for DHW heating.

  • Page 8: Preparing For Boiler Installation

    Installation information Preparing for boiler installation Dimensions and connections F GH K Fig. 1 Area for electrical connections Gas connection 22 mm Heating flow 22 mm Safety valve (DHW side) Condensate drain Cold water 15 mm Heating return 22 mm 15 mm Filling/draining Preparing the connections...
  • Page 9 Installation information Preparing for boiler installation (cont.) Safety assembly to DIN 1988 and EN 806 on the cold water connection GH D D H L D N K Fig. 2 Safety assembly (accessory for connection sets for Drain unfinished walls) Cold water Safety valve Drinking water filter...

  • Page 10: Fitting The Wall Mounting Bracket

    Installation sequence Fitting the wall mounting bracket Note The installation surface must be vertical and level. Ø10 Fig. 3 1. Mark out the rawl plug holes. 3. Fit the wall mounting bracket with the screws sup- plied. 2. Drill 10 mm holes and insert the rawl plugs sup- plied.

  • Page 11: Mounting The Boiler And Making Connections

    Installation sequence Mounting the boiler and making connections Removing the front panel and mounting the boiler Note When mounting on the wall, observe the following: Weight excl. packaging: approx. 65 kg. Fig. 4 1. Undo the screws on the underside of the boiler; do 3.
  • Page 12 Installation sequence Mounting the boiler and making connections (cont.) ¨ Fig. 5 Heating flow Cold water Heating return Gas connection Safety assembly Connection on the DHW side Install supplied safety assembly in the cold water connection. Permiss. cylinder operating pressure: 10 bar. No flow limiter is fitted in the cold water supply.

  • Page 13: Gas Connection

    Installation sequence Mounting the boiler and making connections (cont.) Gas connection 1. Connect the gas shut-off valve to connection 2. Carry out a tightness test. Note Only use suitable and approved leak detection agents (EN 14291) and devices for the tightness test.

  • Page 14: Balanced Flue Connection

    Connecting several Vitodens 111-W to a shared Ensure the flue system functions correctly. Aper- flue system tures for combustion air supply must not be able to be closed off.

  • Page 15: Opening The Control Unit Enclosure

    Installation sequence Opening the control unit enclosure Fig. 11 Please note Electronic assemblies can be damaged by elec- trostatic discharge. Prior to commencing any work, touch earthed objects such as heating or water pipes to dis- charge static loads. Electrical connections Information on connecting accessories When connecting accessories observe the sep- arate installation instructions provided with...

  • Page 16: Connecting Accessories

    Installation sequence Electrical connections (cont.) Connecting accessories Accessory installation instructions 2. Connect the outside temperature sensor to termi- nals 3 and 4 of the power cable (see page 15). When connecting a Vitotrol 100 or an OpenTherm remote control, remove the jumper across L and 1. Outside temperature sensor (accessories) 1.

  • Page 17: Routing Connecting Cables And Closing The Control Unit Enclosure

    Installation sequence Electrical connections (cont.) Routing connecting cables and closing the control unit enclosure Please note Connecting cables/leads will be damaged if they touch hot components. When routing and securing cables/leads on site, ensure that the maximum permissible tempera- ture for these is not exceeded. Fig.

  • Page 18: Steps - Commissioning, Inspection And Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • • • 1. Filling the heating system....................19 • 2. Filling the loading cylinder on the DHW side..............20 • • • 3. Venting the boiler by flushing................... 20 •...

  • Page 19: Filling The Heating System

    Commissioning, inspection, maintenance Filling the heating system Please note Unsuitable fill water increases the level of deposits and corrosion and may lead to appli- ance damage. ■ Flush the heating system thoroughly before filling. Only fill with water of potable quality. ■...

  • Page 20: Filling The Loading Cylinder On The Dhw Side

    Commissioning, inspection, maintenance Filling the loading cylinder on the DHW side Fig. 15 1. Valves 3. Once air stops coming out of the DHW draw-off must be in the "top" position. point, the loading cylinder is completely filled. 2. Open the cold water supply and a DHW draw-off point.

  • Page 21: Converting The Gas Type

    Commissioning, inspection, maintenance Venting the boiler by flushing (cont.) Fig. 16 1. Close the shut-off valves on the heating water side. 5. First close valve 2. Remove cover panel 6. When the required operating pressure has built up, close valve .

  • Page 22: Checking The Static Pressure And Supply Pressure

    Commissioning, inspection, maintenance Converting the gas type (cont.) Selected gas type Date content in content in % CO content in type Factory setting G 20 7.5 - 10.5 < 1000 Changed to < 1000 Changed to < 1000 Checking the static pressure and supply pressure Danger 5.

  • Page 23: Reducing The Maximum Heating Output

    Commissioning, inspection, maintenance Checking the static pressure and supply pressure (cont.) Supply pressure (flow pressure) Steps For natural gas For LPG Below 10 mbar (1.0 kPa) Below 25 mbar (2.5 kPa) Do not commission the boiler. Notify the gas supply util- ity or LPG supplier.

  • Page 24: Matching The Burner Output To The Flue System

    Commissioning, inspection, maintenance Matching the circulation pump rate to the… (cont.) 15 20 Outside temperature in °C Fig. 18 Max. speed 26 kW Max. speed 35 kW Min. speed Changing the maximum speed Only when operating with an outside temperature sen- 6.

  • Page 25: Burner Adjustment When Connecting Multiple Flues To A Shared Flue System

    60/100 mm — — coaxial — Burner adjustment when connecting multiple flues to a shared flue system When connecting several Vitodens 111-W to a shared ■ Minimum shaft cross-section flue system: – Square: 175 x 175 mm Adjust the burner setting of each connected boiler by a –...
  • Page 26 Commissioning, inspection, maintenance Burner adjustment when connecting multiple… (cont.) One boiler per floor Fig. 19 Rated heating output 26 kW operation with natural gas – Number of boilers Correction factor (setting value) Flue length a (m) ≤ ≤ > 18 >...
  • Page 27 Commissioning, inspection, maintenance Burner adjustment when connecting multiple… (cont.) Rated heating output 26 kW operation with LPG – Number of boilers Correction factor (setting value) Flue length a (m) ≤ ≤ ≤ > 12 > 10 – ≤ ≤ ≤ >...
  • Page 28 Commissioning, inspection, maintenance Burner adjustment when connecting multiple… (cont.) Two boilers per floor Fig. 20 Rated heating output 26 kW operation with natural gas – Number of boilers Correction factor (setting value) Flue length a (m) ≤ ≤ > 16 >...

  • Page 29: Checking The Co 2 Content

    Note The correction factor changes the boiler modulation range. Checking the CO content The Vitodens 111-W is factory-set for natural gas. Dur- If the actual CO or O and CO values deviate from the ing commissioning or maintenance, the CO...
  • Page 30 Commissioning, inspection, maintenance Checking the CO content (cont.) Fig. 21 1. Connect a flue gas analyser at flue gas port 4. Check the CO content for the upper heating out- the boiler flue connection. put (100 %). For CO content limits, see page 22. 2.

  • Page 31: Removing The Burner

    Commissioning, inspection, maintenance Removing the burner F 4x Fig. 22 1. Switch off the power supply. 5. Undo gas supply pipe fitting 2. Shut off the gas supply. 6. Undo 4 screws and remove the burner. 3. Pull the power cables from fan motor , gas train Please note and electrodes...

  • Page 32: Checking The Burner Gasket And Burner Gauze Assembly

    Commissioning, inspection, maintenance Checking the burner gasket and burner gauze assembly Check burner gasket and burner gauze assembly for possible damage and replace if necessary. Fig. 23 1. Remove electrode 5. Mount thermal insulation ring 2. Undo 2 Torx screws and remove thermal insulation Please note ring Tighten screws just enough...

  • Page 33: Cleaning The Heat Exchanger

    Commissioning, inspection, maintenance Checking and adjusting the electrode (cont.) 3. Check the electrode gaps. If the gaps are not as specified or the electrode is damaged: Replace the electrode and gasket and realign the electrode. Please note Tighten screws just enough to ensure the components do not suffer damage and will function correctly.

  • Page 34: Checking The Condensate Drain And Cleaning The Trap

    Commissioning, inspection, maintenance Checking the condensate drain and cleaning the trap 1. Release hook and remove trap with sealing piece Pull trap upwards away from the drain connec- tion. 2. Remove supply hose from trap 3. Clean trap 4. Insert trap with sealing piece Refit trap to the drain connection.

  • Page 35: Checking The Diaphragm Expansion Vessel And System Pressure

    Commissioning, inspection, maintenance Installing the burner (cont.) 3. Tighten 4 screws 6. Check the gas connections for tightness. diagonally. Please note Danger Tighten screws just enough Escaping gas leads to a risk of explosion. to ensure the components do not suffer Check the fitting for gas tightness.

  • Page 36: Checking All Connections On The Heating Water And Dhw Sides For Leaks

    Commissioning, inspection, maintenance Checking all connections on the heating water and DHW sides for leaks Checking the flue system for unrestricted flow and tightness Checking the firm seating of electrical connections Checking all gas equipment for tightness at operating pressure Danger Please note Escaping gas leads to a risk of explosion.

  • Page 37: Setting The Display Contrast

    Commissioning, inspection, maintenance Setting display backlighting for standby (cont.) 04. OK to confirm. 08. OK to confirm. "P" appears in the l.h. display area. The r.h. dis- "0" flashes in the r.h. display area. play area flashes. 09. Use / to select the display backlight. 05.

  • Page 38: Converting From Operation With Lpg To Operation With Natural Gas

    Gas type conversion Converting from operation with LPG to operation with natural gas Fig. 30 1. To remove the burner, see page 31. Changing the gas type at the control unit 2. Undo 2 screws and remove gas train 01. Turn the ON/OFF switch ON. 3.

  • Page 39: Function Sequence And Possible Faults

    Troubleshooting Function sequence and possible faults Display Action Control unit issues a heat Increase set value and demand ensure heat is drawn off Fan starts After approx. 1 min, fault Check the fan, fan con- necting cables, power at the fan and fan control Ignition Fault F4 Check the ignition module...
  • Page 40 Troubleshooting Fault display (cont.) Fault code dis- System characteristics Cause Measures played Burner blocked CO limiter (if installed) has Check the heating system. Re- responded. CO concentra- move the cause of escaping CO. tion too high. Burner blocked Gas pressure switch (if in- Check the gas supply.
  • Page 41 Troubleshooting Fault display (cont.) Fault code dis- System characteristics Cause Measures played Burner in a fault state Flame signal is already Check ionisation electrode and present at burner start connecting cable. Press "Reset" (see page 41). Burner in a fault state There is no flame signal Check the ignition/ionisation elec- trode and connecting cable, gas...

  • Page 42: Repairs

    Troubleshooting Repairs Please note Residual water will escape when the boiler or one of the following components is fitted or removed: ■ Water-filled pipework Circulation pumps ■ Plate heat exchanger ■ Components fitted in the heating water or ■ DHW circuit Water ingress can result in damage to other components.

  • Page 43: Outside Temperature Sensor

    Troubleshooting Repairs (cont.) Outside temperature sensor 1. Open the control unit enclosure. See page 15. 2. Disconnect leads from outside temperature sensor. 4 3 2 1 Fig. 33 3. Check sensor resistance and compare it to the curve. 4. In the event of severe deviation replace the sensor. -20 -10 0 10 20 Temperature in °C...

  • Page 44: Boiler Water Temperature Sensor

    Troubleshooting Repairs (cont.) Boiler water temperature sensor 1. Pull leads from boiler water temperature sensor and check resistance. Fig. 35 2. Check sensor resistance and compare it to the curve. 3. In the case of severe deviation, drain the boiler on the heating water side and replace the sensor.

  • Page 45: Checking The Cylinder Temperature Sensor

    Troubleshooting Repairs (cont.) Checking the cylinder temperature sensor 1. Pull plug from the cable harness. Fig. 37 2. Check sensor resistance and compare it to the curve. 3. In the event of severe deviation replace the sensor. 10 30 50 70 90 110 Temperature in °C Fig.

  • Page 46: Checking The Temperature Limiter

    Troubleshooting Repairs (cont.) 1. Pull leads from outlet temperature sensor 2. Check sensor resistance and compare it to the curve. 3. In the event of severe deviation replace the sensor. Danger The outlet temperature sensor is directly immersed in the DHW (risk of scalding). 10 30 50 70 90 110 Drain the DHW side of the boiler before Temperature in °C...

  • Page 47: Checking The Flue Gas Temperature Sensor

    Troubleshooting Repairs (cont.) Checking the flue gas temperature sensor 1. Pull leads from flue gas temperature sensor Fig. 42 2. Check sensor resistance and compare it to the curve. 3. In the event of severe deviation replace the sensor. 10 30 50 70 90 110 Temperature in °C Fig.

  • Page 48: Checking The Fuse

    Troubleshooting Repairs (cont.) Fig. 44 1. Undo plate heat exchanger (screws ) and 3. Install in reverse order using new gaskets. pull out forwards. 2. Check the connections on the heating water and DHW side for contamination and scaling; if required, replace the plate heat exchanger.

  • Page 49: Overview Of Assemblies

    Parts lists Overview of assemblies The following details are required when ordering parts: ■ Serial no. (see type plate ■ Assembly (from this parts list) Position number of the individual part within the ■ assembly (from this parts list) Fig. 46 Type plate (on the cover panel) Control unit assembly Casing assembly...

  • Page 50: Casing Assembly

    Parts lists Casing assembly 0013 0004 0008 0009 0010 0003 0012 0004 0011 0007 0005 0006 0002 0001 0002 Fig. 47...
  • Page 51 Parts lists Casing assembly (cont.) Pos. Part 0001 Front panel 0002 Viessmann logo 0003 Cover panel with gasket 0004 Profiled seal 0005 Control unit support 0006 Safety guard 600 mm 0007 Toggle fastener (4 pce) 0008 Pipe clip Ø 18...

  • Page 52: Heat Cell Assembly

    Parts lists Heat cell assembly 0005 0001 0024 0016 0002 0023 0003 0025 0001 0025 0023 0003 0004 0006 0004 0008 0007 0023 0012 0025 0012 0007 0023 0009 0019 0010 0011 0016 0013 0023 0015 0016 0020 0021 Fig. 48...
  • Page 53 Parts lists Heat cell assembly (cont.) Pos. Part 0001 Gasket DN 60 0002 Boiler flue connection 0003 Plug for boiler flue connection 0004 Flue gasket 0005 Flue gas temperature sensor 0006 Heat exchanger 0007 Thermal insulation block 0008 Profile hose HR 0009 Condensate hose 0010...

  • Page 54: Burner Assembly

    Parts lists Burner assembly 0005 0004 0003 0002 0009 0001 0004 0009 0001 0004 0006 0008 0015 0007 0006 0006 0009 0012 0014 0008 0010 0008 0015 0011 0015 0015 0014 Fig. 49...
  • Page 55 Parts lists Burner assembly (cont.) Pos. Part 0001 Burner gasket Ø 187 (wearing part) 0002 Thermal insulation ring 0003 Cylinder burner gauze assembly (wearing part) 0004 Burner gauze assembly gasket 0005 Burner door 0006 Gasket, ionisation electrode (5 pce) 0007 Ignition/ionisation electrode 0008 Gasket, burner door flange (wearing part)

  • Page 56: Hydraulic Assembly

    Parts lists Hydraulic assembly 0042 0037 0039 0012 0004 0041 0043 0044 0043 0012 0005 0001 0005 0038 0003 0044 0034 0012 0005 0039 0007 0041 0007 0002 0041 0040 0005 0006 0039 0007 0041 0009 0007 0028 0008 0010 0027 0010 0014...
  • Page 57 Parts lists Hydraulic assembly (cont.) Pos. Part 0001 Temperature sensor 0002 Thermal circuit breaker 0003 Air vent valve G 3/8 0004 Hose 10 x 1.5 x 1500 0005 Clip Ø 8 (5 pce) 0006 Profile hose HF 0007 Spring clip DN 25 (5 pce) 0008 Connection pipe HF 0009...

  • Page 58: Aqua-Plate Assembly

    Parts lists Aqua-plate assembly 0006 0007 0011 0002 0007 0011 0011 0007 0009 0010 0008 0013 0001 0011 0012 0013 0005 0012 0004 0012 0013 0003 Fig. 51...
  • Page 59 Parts lists Aqua-plate assembly (cont.) Pos. Part 0001 Valve insert 0002 Flow unit 0003 Return unit 0004 Overflow valve 0005 Overflow line 0006 Plate heat exchanger 0007 Profile gasket (4 pce) 0008 Temperature sensor 0009 Clip Ø 8 (5 pce) 0010 Clip Ø...

  • Page 60: Control Unit Assembly

    Parts lists Control unit assembly 0002 0009 0010 0008 0003 0001 0004 0006 0007 0011 0005 Fig. 52...
  • Page 61 Parts lists Control unit assembly (cont.) Pos. Part 0001 VBC113-D10 control unit 0002 Cover, wiring chamber 0003 Fuse, 2.5 A (slow), 250 V (10 pce) 0004 Cable harness X20 0005 Cable harness 100/35 0006 Cable harness, Molex stepper motor 0007 Ignition cable with angled plug 5 kOhm 0008 Cable ties (10 pce)

  • Page 62: Cylinder Module Assembly

    Parts lists Cylinder module assembly 0009 0008 0011 0009 0008 0001 0002 0002 0010 0003 0001 0007 0007 0005 0001 0006 0001 0007 0007 0004 Fig. 53...
  • Page 63 Parts lists Cylinder module assembly (cont.) Pos. Part 0001 O-ring 14.3 x 2.4 (5 pce) 0002 Clip Ø 15 (5 pce) 0003 Connection pipe WW (DHW) 0004 RV cartridge (non-return valve) DN 15 0005 Right-angle shut-off valve, cylinder 0006 Connection pipe WW (DHW) 0007 Gasket A 18.5 x 24 x 2 (3 pce) 0008...

  • Page 64: Cylinder Assembly

    Parts lists Cylinder assembly 0002 0001 0003 0002 0003 Fig. 54...
  • Page 65 Parts lists Cylinder assembly (cont.) Pos. Part 0001 Cylinder with thermal insulation 0002 Thermal insulation EPS, front 0003 Thermal insulation EPS, back...

  • Page 66: Miscellaneous Assembly

    Parts lists Miscellaneous assembly 0001 0002 0003 0004 0005 Fig. 55...
  • Page 67 Parts lists Miscellaneous assembly (cont.) Pos. Part 0001 Touch-up spray paint, white, 150 ml can 0002 Touch-up paint stick, white 0003 Special grease 0004 Installation and service instructions 0005 Operating instructions...

  • Page 68: Functions And Operating Conditions In Weather-Compensated Mode

    Control unit Functions and operating conditions in weather-compensated mode Heating mode In weather-compensated mode, the boiler water tem- perature is regulated subject to the outside tempera- ture. Heating curve for weather-compensated control Outside temperature in °C Fig. 56 Code for selected heating curve The setting can be made in increments of - - to 35.
  • Page 69 Control unit Functions and operating conditions in… (cont.) The heating circuit pump is switched ON and the 3- way diverter valve is changed over, if the cylinder tem- perature sensor captures a temperature lower than the defaulted set value. ■ The cylinder loading pump is switched ON if the boiler water temperature set cylinder temperature.

  • Page 70: Connection And Wiring Diagram

    Connection and wiring diagram Connection and wiring diagram Fig. 57 Diverter valve, stepper motor Gas pressure switch (accessories) Ignition/ionisation X ... Electrical interface Vitotrol 100 Boiler water temperature sensor § Type RT Outlet temperature sensor ■ ■ Type UTA Cylinder temperature sensor ■...

  • Page 71: Reports

    Reports (cont.) Settings and test values Commis- Mainte- Mainte- Mainte- Mainte- sioning nance/ nance/ nance/ nance/serv- service service service Date Signature Gas type Static pressure mbar Supply pressure (flow pres- mbar sure) Carbon dioxide content CO Upper heating output % by ■...

  • Page 72: Specification

    Specification Specification Rated heating output range in heating mode 50/30 °C 4.7 (6.5) 5.9 (8.8) – – 80/60 °C 4.3 (5.9) 23.8 5.3 (8.0) 32.1 – – Rated heating output range 4.3 (5.9) 29.3 5.4 (8.0) 35.0 – – for DHW heating Rated heating input range 4.4 (6.1) 30.5...

  • Page 73: Disposal Final Decommissioning And Disposal

    Disposal Final decommissioning and disposal Viessmann products can be recycled. Components and substances from the system are not part of ordi- nary household waste. For decommissioning the system, isolate the system from the power supply and allow components to cool down where appropriate.

  • Page 74: Certificates Declaration Of Conformity

    Certificates Declaration of conformity Vitodens 111-W, type B1LD We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, declare as sole responsible body that the named product complies with the provisions of the following directives and regulations: 2009/142/EC Gas Appliances Directive...

  • Page 75: Keyword Index

    Keyword index Keyword index Boiler water temperature sensor ....... 44 Limits Burner gasket.............32 – Flue gas values............22 Burner gauze assembly..........32 Loading cylinder, filling..........20 Burner installation............34 LPG................21 Burner removal............31 Max. heating output............23 CO2 content check.............29 Cold water connection..........8 Combustion chamber cleaning........33 Outlet temperature sensor.........
  • Page 76 Applicability Serial No.: 7570732 7570733 Viessmann Werke GmbH & Co. KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040 E-mail: info-uk@viessmann.com...

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