Table of Contents
Troubleshooting
Related Manuals for Viessmann Vitodens 100 WB1A
Summary of Contents for Viessmann Vitodens 100 WB1A
- Page 1 VIESMANN Installation and service instructions for heating engineers Vitodens 100 Type WB1A Gas fired wall mounted condensing boiler Natural gas version See applicability on the last page VITODENS 100 Please keep safe 5862 670 GB 2/2005...
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Page 2: Safety Instructions
Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained If you notice the smell of gas Danger Danger This symbol warns against the Escaping gas can cause explo- risk of injury. sions which may lead to ser- ious injury. - Page 3 Repairing components which For replacements, use only ori- fulfil a safety function can com- ginal spare parts from promise the safe operation of Viessmann or those which are your heating system. approved by Viessmann. Replace faulty components only with original Viessmann...
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Page 4: Table Of Contents
Index Index Installation instructions Preparing for installation Product information ..................General Information ..................Technical Specification ................Installation Requirements ................15 Preparations for boiler installation ............... 29 Installation Installing the boiler and making all connections ........... 32 Flue outlet ....................39 Electrical connections ................. -
Page 5: Preparing For Installation
The appliance always gives priority to / or time clock in addition to the domestic hot water supply. optional controls available from Viessmann. Certification details The Vitodens 100 is certified to com- The appliance classification is either ply with the requirements of prEN 483... -
Page 6: Technical Specification
Preparing for installation Technical Specification General Specifications and Performance Data Rated output range 50/30 °C 8 to 24 8 to 30 80/60 °C 7.3 to 21.8 7.3 to 27.3 Rated output range 7.4 to 22.3 7.4 to 28.0 Maximum gas rate 2.50 3.14 Combi boiler:... - Page 7 Preparing for installation Technical Specification (cont.) Overall Appliance Dimensions Combi boiler A Condensate drain: Plastic pipe D Gas connection: Rp ½ 722 mm E Cold water: 715 mm B Heating flow: 722 mm F Heating return: 722 mm C DHW: 715 mm G Safety valve drain: 715 mm...
- Page 8 Preparing for installation Technical Specification (cont.) System boiler A Condensate drain: Plastic pipe D Gas connection: Rp ½ 722 mm E DHW return: 722 mm B Heating flow: 722 mm F Heating return: 722 mm C DHW cylinder flow: 722 mm G Safety valve drain: 715 mm...
- Page 9 Preparing for installation Technical Specification (cont.) Minimum installation clearances The following minimum clearances (mm) must be maintained for installing and servicing the appliance. A Front (behind removable panel) B Front (for service) Flue System Specifications Concentric Horizontal Flue System Standard horizontal flue kit: The appli- Extension ducts can be used to ance is supplied complete with a stan- increase the straight flue length up to...
- Page 10 Preparing for installation Technical Specification (cont.) An extra 87° elbow can be used but this reduces the maximum permissi- ble length by 1 m . An extra 45° elbow can be used but this reduces the max- imum permissible length by 0.5 m . A Combined length of flue outlet/ B Flue outlet/ventilation pipe (can ventilation pipe max 6m.
- Page 11 Preparing for installation Technical Specification (cont.) Before commencing the installation refer to diagram below to determine which optional extension kits are required, if any. A Combined length of flue outlet/ B Flue outlet/ventilation pipe (can ventilation pipe max. 10 m. be shortened as necessary)
- Page 12 Preparing for installation Technical Specification (cont.) Elbows and extensions Extension Elbow 45° Elbow 87°...
- Page 13 Preparing for installation Technical Specification (cont.) Hydraulic circuit Combi boiler A Boiler E Plate heat exchanger B heat exchanger F DHW outlet C circulation pump G Cold water inlet D Three-way diverter valve H Heating circuit...
- Page 14 Preparing for installation Technical Specification (cont.) System boiler A DHW cylinder D circulation pump B Boiler E Three-way diverter valve C heat exchanger F Heating circuit...
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Page 15: Installation Requirements
Preparing for installation Technical Specification (cont.) Sectional Diagram Combi boiler illustrated Installation Requirements Statutory Requirements Gas safety (installation and use) regulations (current issue) It is in your own interest and safety, to ensure that the law is complied with. -
Page 16: Boiler Position
Preparing for installation Installation Requirements (cont.) In addition to the above regulations, CORGI will then issue either a Build- this appliance must be installed in ing Compliance Certificate (for Eng- accordance with the current IEE Wir- land and Wales) or a Declaration of ing Regulations for electrical installa- Safety (for Scotland, Northern Ireland, tion (BS 7671), local building... - Page 17 Preparing for installation Installation Requirements (cont.) & & Due consideration should be given A compartment used to enclose the to the routing of the condensate appliance must be designed and drain from the chosen position. constructed specifically for this pur- &...
- Page 18 Preparing for installation Installation Requirements (cont.) Flue terminal position Horizontal flue systems Position Minimum spacing Directly below an window that can be opened, air vent or any other ventilation opening Below gutter drain or soil pipe Below eaves Below a balcony From vertical drain or soil pipes From internal and external corners Above adjacent ground or balcony level/roof...
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Page 19: Flue Terminal Location
Preparing for installation Installation Requirements (cont.) Vertical flue systems Position Minimum spacing From adjacent wall From adjacent opening window 1000 From another terminal Minimum height Flue Terminal Location & Detailed recommendations for flue The boiler must be installed so that installation are given in BS 5440:1. -
Page 20: Ventilation Requirements
Preparing for installation Installation Requirements (cont.) & & It is essential to ensure that pro- Where the lowest part of the term- ducts of combustion discharging inal is fitted less than 2 m above from the terminal cannot re-enter ground, above a balcony or above a the building or any other adjacent flat roof to which people have building, through ventilators, win-... - Page 21 Preparing for installation Installation Requirements (cont.) Central Heating System (typical system designs) & The Vitodens 100 is designed for connection to sealed central heating water systems. & A sealed system must only be filled by a competent person. Filling the heating system see page 48. Do not fill up the whole system using the internal filling loop (the internal filling loop is only for topping-up).
- Page 22 Preparing for installation Installation Requirements (cont.) A Radiators E CH return B Boiler F Drain cock at lowest point in the C Lockshield valve system D CH flow G Hot water taps...
- Page 23 R Open therm-connection(alterna- control tive) LS Connection of DHW cylinder con- Connection see page 42 trol & The following Viessmann control configurations are available: Constant temperature Timer with constant temperature Vitotrol 100 UTD & The boiler requires a permanent live feed via plug 40.
- Page 24 Preparing for installation Installation Requirements (cont.) A Radiators E CH flow B Boiler F CH return C DHW-Cylinder G Drain cock at lowest point in the D Lockshield valve system...
- Page 25 LS Connection of DHW cylinder con- P Connection box (not supplied) trol R Fuse 3 A & & The following Viessmann control The DHW cylinder must have an configurations are available: integrated temperature control con- Constant temperature nected to the Vitodens 100 &...
- Page 26 Preparing for installation Installation Requirements (cont.) Expansion vessel The table shows the maximum system Further details are available in the volume that the integral expansion current issues of BS 5449 and BS vessel can sustain under different 6798. charge pressure conditions. If the sys- tem volume exceeds that shown, an Note additional expansion vessel must be...
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Page 27: Gas Supply
Preparing for installation Installation Requirements (cont.) Pressure relief valve A pressure relief valve set at 3 bar (43.5 psi) is supplied with the appli- ance. Domestic Hot Water System (Combi boiler only) & & Check that the mains water pres- If the appliance is installed in an sure is sufficient to produce the area where the temporary hardness... -
Page 28: Electricity Supply
(and its external con- trols) may be used. External Controls To ensure optimum performance, Viessmann offer a range of external controls however the appliance may be used with any certificated room thermostat or time clock room thermo-... -
Page 29: Preparations For Boiler Installation
Preparing for installation Preparations for boiler installation Unpacking the appliance The appliance is supplied in 2 sepa- rate packages plus any optional flue packages. Check the availability and contents of each package before commencing the installation. Boiler package Combi boiler System boiler &... - Page 30 Preparing for installation Preparations for boiler installation (cont.) A Installation template B Observe the minimum slope of 3° (5mm/m) towards the boiler 1. Position the installation template 2. Mark wall plug holes and balanced on the wall. flue pipe opening.
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Page 31: Preparing The Connections
Preparing for installation Preparations for boiler installation (cont.) 3. Drill 710 mm holes and insert the 5. Fit wall mounting frame with rawl plugs. enclosed screws. 4. Cut flue pipe opening to 100 mm Preparing the connections Note For dimensions for on-site preparations of the gas and water side connections see "Overall Appliance Dimensions"... -
Page 32: Installation
Installation Installing the boiler and making all connections Remove front panel and mount boiler Note The front panel must be removed before mounting the boiler. 1. Remove the screw at the top of the 3. Hook the boiler on to the wall boiler. -
Page 33: Gas Connection
Installation Installing the boiler and making all connections (cont.) Gas connection 1. Connect the gas supply to the gas inlet connection on the gas cock A. Upon completion, tighten the union connection. 2. Carry out a gas soundness test. 3. Purge the gas supply pipe. A Gas connection: ½... - Page 34 Installation Installing the boiler and making all connections (cont.) A Heating flow: 722 mm D Cold water: 715 mm B DHW: 715 mm E Heating return: 722 mm C Gas connection: ½ BSP System boiler For operation without a DHW cylinder, shut-off connections B and D. C Gas connection: ½...
- Page 35 Installation Installing the boiler and making all connections (cont.) Connect safety valve drain Connect a suitable discharge pipe to the pressure relief valve outlet. The pipe discharging to a safe place must be a minimum of 15 mm copper and run continually downwards.
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Page 36: Condensate Connection
Installation Installing the boiler and making all connections (cont.) Condensate connection Vitodens 100 has within a syphonic condensate trap. A 722 mm plastic condensate pipe Routing The condensate pipe can terminate into any one of the following areas. It is always the best practice to terminate the condensate pipe via an internal waste system. - Page 37 Installation Installing the boiler and making all connections (cont.) Terminating into an external waste system Terminating into an internal waste A 722 mm plastic condensate pipe system B External length of pipe 3 m max. A 722 mm plastic condensate pipe C Open end direct into gully, below B External length of pipe 3 m max.
- Page 38 Installation Installing the boiler and making all connections (cont.) Terminating into the rainwater system A 722 mm plastic condensate pipe Terminating into an external purpose B Internal soil and vent stack made soakaway A 722 mm plastic condensate pipe B External length of pipe 3 m max. C Open end direct into gully, below ground but above water level Filling the siphon with water...
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Page 39: Flue Outlet
Installation Flue outlet External wall terminal C 1. Insert pipe bend into the boiler flue 4. Connect external flue terminal to outlet. pipe bend. Install flue and supply pipes 2. Insert external flue terminal into the accordingly, wall outlet. with a minimum of 3° slope (ca. 50 mm/m) towards the boiler. - Page 40 Installation Flue outlet (cont.) Vertical roof terminal C 1. Install the universal roof tile. 3. Push roof terminal through roof and insert into flue/supply pipe. 2. Install flue and supply pipes accordingly. 4. Seal roof terminal.
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Page 41: Electrical Connections
Installation Electrical connections Opening the control unit housing... - Page 42 Installation Electrical connections (cont.) Making connections Notes regarding the connection of accessories For details of accessories, also observe the separate installation instruc- tions provided. Notes regarding the connection of room temperature and DHW cylinder temperature control For more information about the connection of on site temperature controls see page 21.
- Page 43 Installation Electrical connections (cont.) fÖ Mains power connection 230 V ~ A Room temperature control with 50 Hz (green plug) zero volt contact e.g. Vitotrol 100 Do not interchange the supply conductors L1 and the neutral If making the connection between, conductor N.
- Page 44 Installation Electrical connections (cont.) Connect DHW cylinder temperature control Connect Vitotrol 100 A Vitotrol 100 UTD B Vitotrol 100 UTA C When connecting, remove link...
- Page 45 Installation Electrical connections (cont.) Routing connecting cables Important information Connecting cables can be damaged if they touch hot components. When routing and securing connecting cables on site, ensure that the maximum permissible cable temperatures are not exceeded. A Low voltage connections B 230 V connections...
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Page 46: Front Panel Installation
Installation Electrical connections (cont.) 1. Connect strain relief to the external 2. Fit cover. cable and clip into the mounting plate aperture. 3. Pivot the control unit upwards. Front panel installation 1. Hang the front panel to the wall 3. Insert the screw at the top of the mounting frame by the appropriate boiler. -
Page 47: Commissioning And Testing
Installation Commissioning and testing Before commissioning the appliance, the whole gas installation including the meter must be purged and tested for gas soundness in accordance with BS 6891: 1988. Danger Open all doors and windows; extinguish naked lights and do not smoke whilst purging the gas line. -
Page 48: Filling The Heating System
Installation Commissioning and testing (cont.) Note Additive combinations are permitted only if approsed additive suppliers recom- mend it and always according to supplier´s dosage recommendation. Filling the heating system Important information Unsuitable fill water increases the level of deposits and corrosion and may lead to boiler damage. - Page 49 Installation Commissioning and testing (cont.) 4. Close the shut off valves A to pre- vent water leaving the boiler (toggle at 90 to the pipe). Connect a hose- pipe to outlet D ready to vent the boiler later. 5. Turn valve B to the draining posi- tion (toggle to the front).
- Page 50 Installation Commissioning and testing (cont.) Venting the boiler by flushing out (after venting system) 1. Leaving the hose connections from filling the system continue to fil the biler from the external filling loop and draininig the ewater to a drain from connection D.
- Page 51 Installation Commissioning and testing (cont.) 8. Turn temperature gauge controls to the desired operating position. Note: Be aware thath the boiler may still need to be vented as air pockets are drawn into the heat exchanger. 9. Turn rotary knobs "tr" and "tw" into control range again.
- Page 52 Installation Commissioning and testing (cont.) 1. Close the gas shut-off valve. 2. Release the screw inside test nip- ple "IN" A on the gas combination valve , but do not remove, and con- nect the pressure gauge. 3. Open the gas shut-off valve. 4.
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Page 53: Checking The Co
Installation Commissioning and testing (cont.) 8. Open the gas shut-off valve and start the boiler. Danger Gas escaping from the test nipple leads to a risk of explosion. Check test nipple A for soundness. Checking the CO settings Vitodens100 is factory-set for natural gas. During commissioning or maintenance, the CO setting can be measured at the boiler flue adaptor testpoint. - Page 54 Installation Commissioning and testing (cont.) 3. Set the upper rated output. Turn rotary selector "tr" less than 3 seconds clockwise to the end stop, then back again into the cor- rect control range. 4. Check the CO content. Should the actual value deviate by more than 1% from the above range, check the seals in the balanced flue sys-...
- Page 55 Installation Commissioning and testing (cont.) Setting the max. output Note The gas control is fully modulating and will normally facilitate a rapid heat up at maximum output followed by a continually controlled heat output. If the system has a particularly low heating load it is possible to restrict the maximum heating output to prevent short cycling.
- Page 56 Installation Commissioning and testing (cont.) Setting DHW temperature: Set rotary selector tw to the desired DHW temperature. The display shows w the set tem- perature is shown. Adjusting the boiler water temperature The boiler water temperature must be set at an adequate level to satisfy the requirements of the heating system.
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Page 57: User´s Instructions
Installation Commissioning and testing (cont.) User´s instructions & Upon completion of commissioning Advise the user of the precautions and testing, hand the appliance over necessary to prevent damage to the to the user, with reference to the fol- system and to the building in the lowing. -
Page 58: Service Instructions
Service Instructions Routine Servicing Instructions To ensure continued efficient operation of the appliance, it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage but in general once a year should be adequate. -
Page 59: Burner Removal
Service Instructions Routine Servicing Instructions (cont.) 1. Remove the screw at the top of the 3. Lift the front panel from the wall boiler. mounting frame. 2. Press down the springs on the underside of the boiler and remove the front panel. Burner removal 1. - Page 60 Service Instructions Routine Servicing Instructions (cont.) 5. Release gas connection pipe E. 6. Release four screws F and remove the burner. Important information To prevent damage, never rest the burner on the gauze assembly. Check the burner gasket and burner gauze assembly for damage.
- Page 61 Service Instructions Routine Servicing Instructions (cont.) 1. Remove electrode B. 4. Insert and secure a new burner gauze assembly D with a new gasket E. 2. Release the three Torx screws, and remove thermal insulating ring C. Torque: 3.5 Nm.approx. 5.
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Page 62: Cleaning The Heating Surfaces
Service Instructions Routine Servicing Instructions (cont.) 2. Clean the electrode with a small 3. Check all clearances. If the gaps brush (not with a wire brush) or are not as specified or the elec- emery paper. trode is damaged, replace and align the electrode together with new gaskets. - Page 63 Service Instructions Routine Servicing Instructions (cont.) Checking the condensate drain and cleaning the siphon 1. Check at the siphon, that the con- densate can freely drain. 2. Place an appropriate container under the siphon A. 3. Remove the locking cap B and drain the siphon content.
- Page 64 Service Instructions Routine Servicing Instructions (cont.) Burner installation 1. Install the burner and torque 4. Replace electrical cables from fan screws A diagonally. (4 Nm. motor D, gas valve E, and igni- tion unit E. approx.) 2. Insert new gasket and tighten the 5.
- Page 65 Service Instructions Routine Servicing Instructions (cont.) 6. Check the gas connections for soundness. Danger Escaping gas leads to a risk of explosion. Check all fittings for sound- ness. Check primary and secondary connections for leaks Checking diaphragm expansion vessel and system pressure Note 1.
- Page 66 Service Instructions Routine Servicing Instructions (cont.) 2. Check the inlet pressure of the dia- 4. Top up your heating system with phragm expansion vessel at the water and vent until the filling pres- test nipple A. sure of a cool system is 0.2 bar higher than the inlet pressure of the 3.
- Page 67 Service Instructions Routine Servicing Instructions (cont.) Checking function of all safety valves Checking tightness of electrical connections Checking static and supply pressure See page 51. Front panel installation 1. Hang the front panel to the wall 2. Press down the front panel at the mounting frame by the appropriate bottom.
- Page 68 Service Instructions Routine Servicing Instructions (cont.) 3. Insert the screw at the top of the boiler. Note The outer case forms a seal with the combustion box: It must there- fore be securely fitted with the screw provided. Start-up the boiler 1.
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Page 69: Troubleshooting
Troubleshooting Fault finding Note It is the law that any service work must be carried out by a competent CORGI registered engineer. General Before looking for a fault condition, Before attempting any electrical fault check that: finding, always conduct the prelimin- &... -
Page 70: Troubleshooting Fault Finding
Troubleshooting Fault finding (cont.) Ignition Fault Check the con- nection ignition module Gas combina- Fault Check the gas tion valve opens train (control vol- tage 230 V) and gas supply pres- sure Fault Ionisation cur- Check the ionisa- rent builds tion current, check (higher than the electrode ad-... - Page 71 Troubleshooting Fault finding (cont.) Fault messages in the display Faults are indicated by a flashing fault code with fault symbol "U" and the reset key is illuminated. For fault code explanations see the following table. Display fault System char- Cause Remedy code acteristics...
- Page 72 Troubleshooting Fault finding (cont.) Display fault System char- Cause Remedy code acteristics Burner in fault Temperature limit- Check the heating sys- state er has responded. tem water level. Check the circulation pump. Vent the heating system. Check the temperature limiter and leads. Press"Reset".
- Page 73 Troubleshooting Fault finding (cont.) Display fault System char- Cause Remedy code acteristics Burner Burner control unit Check the ignition elec- blocked fault trodes and leads. Check whether a strong interfer- ence (EMC) field exists near the equipment. Press"Reset". If the fault is not re- moved, replace the con- trol unit.
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Page 74: Repairs
Troubleshooting Repairs Removing front panel 1. Remove the screw at the top of the 3. Lift the front panel from the wall boiler. mounting frame. 2. Press down the springs on the underside of the boiler and remove the front panel. Drain boiler on the primary side Note For certain repairs the boiler must be... - Page 75 Troubleshooting Repairs (cont.) 1. Connect the drain hose to valve A and connect with a drain outlet. 2. Turn toggle on the shut-off valve B to the front. 3. Turn toggle on the shut-off valve C to the front. 4. Turn toggle on the valve A to the front and drain the boiler if neces- sary.
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Page 76: Boiler Temperature Sensor
Troubleshooting Repairs (cont.) Boiler temperature sensor 1. Pull the leads from boiler tempera- ture sensor A and measure the resistance. 2. Check the sensor resistance and compare actual values with the curve. 3. In case of severe deviation, drain boiler on the primary side (see page 74) and replace the sensor. - Page 77 Troubleshooting Repairs (cont.) Check the temperature limiter If the burner control unit cannot be reset after a fault shutdown, although the boiler water temperature is below approx. 75 °C, check the temperature limiter. 1. Pull the leads from temperature lim- iter A.
- Page 78 Troubleshooting Repairs (cont.) Check the DHW temperature sensor (only for gas combina- tion devices) 1. Pull the leads from outlet tempera- ture sensor A 2. Check the sensor resistance and compare actual values with the curve. 3. Replace the sensor in case of severe deviation.
- Page 79 Troubleshooting Repairs (cont.) Replacing flow limiter 1. Switch OFF the mains power. 2. Close the gas shut-off valve and safeguard against reopening. 3. Drain the boiler from the secondary side. 4. Pivot the control unit downwards. 5. Release the ties A and screwsB. 6.
- Page 80 Troubleshooting Repairs (cont.) Checking plate heat exchanger C DHW E Heating water return D Cold water F Heating water flow 5. Remove two screws A at the plate 1. Switch OFF the mains power. heat exchanger and B remove. 2. Close the gas shut-off valve and safeguard against reopening.
- Page 81 Troubleshooting Repairs (cont.) 8. Install in reverse order using new gaskets. Note Ensure that fixing holes and seals are aligned. Install the heat plate exchanger the correct way round. Checking the fuse 3. Remove cover A. 1. Switch OFF the mains power. 2.
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Page 82: Designs
Designs Connection and wiring diagrams – combi boiler Main PCB Programming unit... - Page 83 Designs Connection and wiring diagrams – combi boiler (cont.) Time switch Temperature limiter § Boiler temperature sensor Mains connection accessories/ DHW outlet sensor room temperature control sÖ a-ÖA Fan Circulation pump 230V~ dÖ Step motor diverter valve Air pressure switch Gas solenoid valve Flow switch fÖ...
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Page 84: Connection And Wiring Diagram - System Boiler
Designs Connection and wiring diagram - system boiler Main PCB Programming unit... - Page 85 Designs Connection and wiring diagram - system boiler (cont.) Time switch Mains connection accessories/ § Boiler temperature sensor room temperature control/DHW sÖ Circulation pump 230V~ cylinder control dÖ a-ÖA Fan Step motor diverter valve Gas solenoid valve Air pressure switch fÖ...
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Page 86: Parts Lists
Parts lists Parts lists Spare parts information Quote the type and serial no. (see data plate) and the item no. of the required part (as per this parts list). Obtain standard parts from your local supplier. 001 Thermocouple 031 Circulation pump 002 Temperature sensor 032 Bypass with overflow valve 003 Pressure switch... -
Page 87: Data Plate
Parts lists Parts lists (cont.) Parts not shown 094 Mains power switch cable har- 039 Installation and service instruc- ness tions 095 Gas valve connecting cable 35 090 Cable harness X8 096 Ignition transformer/ionisation 091 Cable harness X9 connecting cable 092 Cable harness 100/35/54 300 Touch-up spray paint, Vitowhite 093 Step motor connecting cable... - Page 88 Parts lists Parts lists (cont.)
- Page 89 Parts lists Parts lists (cont.)
- Page 90 Parts lists Parts lists (cont.)
- Page 91 Parts lists Parts lists (cont.)
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Page 92: Certificates
Certificates Declaration of conformity Declaration of conformity for Vitodens 100 We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, declare as sole responsible body, that the product Vitodens 100 conforms to the following stan- This product is designated in accor-... -
Page 93: Keyword Index
Keyword index Keyword index additives Gas combination valve ........ - Page 94 Keyword index Keyword index (cont.) Venting Wall mounting bracket installation ........Vertical Flue System .
- Page 96 7179 917 5 00001 7179 918 5 00001 8 to 30 kW from serial no. 7179 916 5 00001 Viessmann Limited Hortonwood 30, Telford, TF1 7YP, GB Telephone: +44 1952 675000 Fax: +44 1952 675040 www.viessmann.com...