Viessmann Vitodens 050-W Installation And Service Instructions Manual
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Viessmann Vitodens 050-W Installation And Service Instructions Manual

Wall mounted gas condensing boiler
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VIESMANN
Installation and service
instructions
for contractors
Vitodens 050-W
Type BPJC, 6.5 to 35.0 kW
Wall mounted gas condensing boiler
For natural gas and LPG
Gas Council no.: 47 819 31, 47 819 32
For applicability, see the last page
VITODENS 050-W
Please keep safe.
5513 085 GB
9/2014

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Summary of Contents for Viessmann Vitodens 050-W

  • Page 1 VIESMANN Installation and service instructions for contractors Vitodens 050-W Type BPJC, 6.5 to 35.0 kW Wall mounted gas condensing boiler For natural gas and LPG Gas Council no.: 47 819 31, 47 819 32 For applicability, see the last page VITODENS 050-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 Safety instructions Safety instructions (cont.) If you smell flue gas Danger The simultaneous operation of Danger the boiler and appliances that Flue gas can lead to life threat- extract air to the outside can ening poisoning. result in life threatening poison- ■...
  • Page 4 Please note Repairing components that fulfil a safety function can compromise the safe operation of the sys- tem. Faulty components must be replaced with original Viessmann spare parts. Auxiliary components, spare and wearing parts Please note Spare and wearing parts that...

  • Page 5: Table Of Contents

    Index Index Installation instructions Preparing for installation................... Installation sequence Mounting the boiler and making the connections..........13 Opening the programming unit................18 Electrical connections................... 19 Service instructions Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance.......... 22 Further details regarding the individual steps............23 Troubleshooting Function sequence and possible faults..............
  • Page 6 Index Index (cont.) Keyword index....................83...

  • Page 7: Preparing For Installation

    Gas Council no. and DHW line, see page 12 onwards. ■ 29 kW combi: 47 819 31 The Vitodens 050-W is set up for opera- ■ 35 kW combi: 47 819 32 tion with a constant boiler water temper- ature.
  • Page 8 The installation area must be safe from ■ Ancillary rooms without own ventila- the risk of frost. tion Operation of the Vitodens 050-W in wet rooms Area 2 The Vitodens is approved for installation When installing the Vitodens in wet in wet rooms (e.g.

  • Page 9: Preparing For Boiler Installation

    Preparing for installation Preparing for installation (cont.) Electrical equipment in rooms containing VDE 0100 specifies that cables supply- a bathtub or a shower must be installed ing permanently installed consumers in in such a way that users cannot be zones 1 and 2 should only be run verti- exposed to dangerous body currents.
  • Page 10 Preparing for installation Preparing for installation (cont.) Minimum clearances Maintain a clearance of 700 mm in front of the Vitodens for maintenance purpo- ses. Maintenance clearances to the l.h. or r.h. side of the Vitodens are not required.
  • Page 11 Preparing for installation Preparing for installation (cont.) Fitting the wall mounting bracket Ø10 A Vitodens installation template...
  • Page 12 Preparing for installation Preparing for installation (cont.) 1. Position the supplied installation tem- Installation in a cupboard plate on the wall. Any cupboard enclosing the appliance 2. Mark out the rawl plug holes. must be designed and constructed spe- cifically for this purpose. An existing cup- 3.

  • Page 13: Installation Sequence

    Installation sequence Mounting the boiler and making the connections Removing the front panel and mounting the boiler 1. Undo the screws at the bottom of the 3. Hook the boiler onto the wall mount- boiler; do not remove completely. ing bracket. 2.
  • Page 14 Installation sequence Mounting the boiler and making the connections (cont.) Making the connections on the water side ¨ A Heating flow G ¾ C Cold water G ½ B DHW G ½ D Heating return G ¾ 1. Mount fittings with gaskets. 2.

  • Page 15: Gas Connection

    Installation sequence Mounting the boiler and making the connections (cont.) Gas connection ¨ 1. Fit the the gas shut-off valve with 3. Carry out a tightness test. bend to connection A. Note Only use suitable and approved leak 2. Connect the gas supply to connection detection agents (EN 14291) and devices for the tightness test.
  • Page 16 Installation sequence Mounting the boiler and making the connections (cont.) Please note 4. Purge the gas line. Excessive test pressure will damage the boiler and the gas train. Max. test pressure 150 mbar (15 kPa). If a higher pressure is required for tightness tests, disconnect the boiler and the gas train from the main supply pipe (undo the fitting).

  • Page 17: Filling The Siphon With Water

    Part J of building regulations and BS 5440. Flue system installation instruc- tions Connecting several Vitodens 050-W to a shared flue system Adjust the burner setting of each con- nected boiler to match the flue system. See page 29.

  • Page 18: Opening The Programming Unit

    Installation sequence Mounting the boiler and making the connections (cont.) Danger Ensure the flue system functions Leaking or blocked flue systems correctly. Apertures for combus- or an insufficient supply of com- tion air supply must not be able to bustion air cause life threatening be closed off.

  • Page 19: Electrical Connections

    Installation sequence Electrical connections 4 3 2 1 A Terminals on underside of appli- Information on connecting ance accessories B Outside temperature sensor When connecting accessories C Vitotrol 100 or on-site room temper- observe the separate installation ature controller with LV switching instructions provided with them.

  • Page 20: Power Supply

    Installation sequence Electrical connections (cont.) Outside temperature sensor (accessories) 1. Fit outside temperature sensor. 2. Connect the outside temperature sensor across terminals 3 and 4 Installation site: (underside of appliance). ■ North or north-westerly wall, 2 to 2.5 m above ground level; in multi storey buildings, in the upper half of the 2nd floor ■...

  • Page 21: Routing The Connecting Cables

    Installation sequence Electrical connections (cont.) Danger Connect the appliance and pipe- If system components are not work to the equipotential bonding earthed, serious injury from elec- of the building in question. tric current can result if an elec- trical fault occurs. Routing the connecting cables Please note Connecting cables will be dam-...

  • Page 22: 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..........23 • • • 2. Converting to operation with LPG........ 25 •...

  • Page 23: Further Details Regarding The Individual Steps

    Commissioning, inspection, maintenance Further details regarding the individual steps Filling the heating system Please note ■ Fill water with a hardness Unsuitable fill water increases above 300 ppm must be soft- the level of deposits and corro- ened. sion and may lead to boiler dam- ■...
  • Page 24 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Open shut-off valves B and C.

  • Page 25: Converting To Operation With Lpg

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 5. Fill and vent the heating system using the on-site valve. System pressure 0.8 to 1.2 bar (0.08 to 0.1 MPa). The system can be filled using a sep- arate filling point fitted at a convenient position on the heating circuit.
  • Page 26 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Gas train viewed from behind 1. Close the gas shut-off valve. 5. Start the boiler. 2. Undo screw A inside test connector Note During commissioning, the boiler can "IN" on the gas train, but do not remove it.

  • Page 27: Reducing The Max. Heating Output

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Check the supply (flow) pressure. 8. Shut down the boiler, close the gas shut-off valve, remove the pressure gauge and close test nipple A with Set value: ■ Natural gas: 20 mbar (2.0 kPa) the screw.

  • Page 28: Matching The Burner Output To The Flue System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Press MODE and simultaneously 5. Start the boiler. for 3 s. Service mode is terminated. Service 6. Check the selected burner output by mode also terminates automatically measuring the gas throughput at a after 30 min.

  • Page 29: Burner Adjustment When Connecting Multiple Flues To A Flue System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Room sealed operation 7 60 mm coaxial Correction fac- Rated heating Flue length (m) output (kW) ≤ 4 > 4 ≤ 8 > 8 ≤ > 12 ≤ Do not adjust ≤...
  • Page 30 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) One boiler per floor Rated heating output 24 kW Number of boilers Correction factor (setting value) Flue length a (m) ≤ 21 > 21 ≤ 25 ≤ 19 ≤ 13 –...
  • Page 31 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3 m...
  • Page 32 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Two boilers per floor Rated heating output 24 kW Number of boilers Correction factor (setting value) Flue length a (m) ≤15 ≤5 – > 5 ≤ 9 – > 9 ≤ 14 –...

  • Page 33: Checking The Co 2 Content

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3 m Checking the CO content The Vitodens 050-W is factory-set for We recommend measuring O as the natural gas. During commissioning or value is unmistakable regarding lambda maintenance, the CO and CO have to (air/gas).
  • Page 34 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Note Operate the appliance with uncontami- nated combustion air to prevent operat- ing faults and damage. 1. Connect a flue gas analyser at flue gas port A on the boiler flue con- nection.
  • Page 35 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Set the higher heating output and check the CO content. Subject to gas type, the CO content must be within the following range. See table. Gas type content in % E or H (G20) 7.5 –...

  • Page 36: Burner Removal

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Burner removal 1. Switch ON/OFF switch to OFF. 5. Undo gas supply pipe fitting F. 2. Shut off the gas supply. 6. Undo 4 screws G and remove the burner. 3.
  • Page 37 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Remove electrode B. 4. Insert and secure a new burner gauze assembly D with new gasket 2. Undo the 2 Torx screws and remove thermal insulation ring C. Please note 3.

  • Page 38: Checking And Adjusting The Electrode

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 5. Refit thermal insulation ring C. 6. Refit electrode B. Please note Please note Tighten screws just enough Tighten screws just enough to ensure the components do to ensure the components do not suffer damage and will not suffer damage and will function correctly.

  • Page 39: Cleaning The Heat Exchanger

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the heat exchanger Please note Note Do not damage the surfaces of Discolouration on the heat exchanger the heat exchanger that come surface is a normal sign of use. It has no into contact with hot gas.

  • Page 40: 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. Unclip burner control unit A and 6. Refit siphon B to the drain connec- remove. Protect against escaping tion. condensate. 7. Install burner control unit A. Check 2.

  • Page 41: Installing The Burner

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Installing the burner 1. Fit burner and tighten 4 screws A 4. Fit the power cables for fan motor diagonally. D, gas train E, ignition unit F and electrodes G. Please note Tighten screws just enough 5.

  • Page 42: Checking The Diaphragm Expansion Vessel And System Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Check the gas connections for Please note leaks. The use of leak detection spray can result in faulty oper- Danger ation. Escaping gas leads to a risk of Leak detection spray must not explosion.

  • Page 43: Fitting The Front Panel

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Leak detection spray must not come into contact with electrical contacts or seal the diaphragm opening on the gas valve. Fitting the front panel 1. Hook the front panel into place. 2.

  • Page 44: Instructing The System User

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Instructing the system user The system installer should hand the operating instructions to the system user and instruct the user in operating the system.

  • Page 45: Troubleshooting

    Troubleshooting Function sequence and possible faults Display Action 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 46: Fault 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 re- (flue gas recircula- starts immediately tion); check the gas flow pressure Fault display Display ■...
  • Page 47 Troubleshooting Fault display (cont.) Displayed System characteris- Cause Measures fault code tics Burner blocked Short circuit, flow Check connections and sensor lead; replace sensor if re- quired. No DHW heating Lead break, outlet Check sensor (see temperature sen- page 54). Burner blocked Lead break, flow Check connections and...
  • Page 48 Troubleshooting Fault display (cont.) Displayed System characteris- Cause Measures fault code tics Burner in a fault Flame signal is al- Check ionisation elec- state ready present at trode and connecting ca- burner start ble. Press "Reset" (see page 49). Burner in a fault No flame signal de- Check the ignition/ionisa- state...
  • Page 49 Troubleshooting Fault 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 49). Replace control unit if fault persists.

  • Page 50: 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 51: Outside Temperature Sensor

    Troubleshooting Repairs (cont.) Outside temperature sensor 4 3 2 1 1. Disconnect the leads of outside tem- perature sensor A. 2. Check the sensor resistance and compare it with the curve. 3. In the event of severe deviation replace the sensor. -20 -10 10 20 30 Temperature in °C...

  • Page 52: Boiler Water Temperature Sensor

    Troubleshooting Repairs (cont.) Boiler water temperature sensor 1. Pull out the leads on 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 53 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 out the leads of temperature lim- iter A.
  • Page 54 Troubleshooting Repairs (cont.) Checking the outlet temperature sensor 1. Pull out the leads on outlet tempera- ture sensor A. 2. Check the sensor resistance and compare it with the curve. 3. In the event of severe deviation replace the sensor. Note Water may leak out when replacing the outlet temperature sensor.
  • Page 55 Troubleshooting Repairs (cont.) Checking the flue gas temperature sensor 1. Pull out the leads on flue gas temper- ature sensor A. 2. Check the sensor resistance and compare it with the curve. 3. In the event of severe deviation replace the sensor. 10 30 50 70 90 110 Temperature in °C Sensor type: NTC 10 kΩ...

  • Page 56: Replacing The Flow Limiter

    Troubleshooting Repairs (cont.) Replacing the flow limiter 1. Drain the boiler on the DHW side. 2. Pull off spring clip B. 3. Remove flow sensor A. 4. Remove faulty flow limiter C. 5. Check fitted strainer for dirt/contami- nation. Clean strainer if required. 6.
  • Page 57 Troubleshooting Repairs (cont.) Replacing the flow sensor 01. Drain the boiler on the DHW side. 02. Pull the leads off faulty flow sensor 03. Pull off spring clip B. 04. Remove enclosure C with flow sensor A. 05. Pull off spring clip D and remove faulty flow sensor A.
  • Page 58 Troubleshooting Repairs (cont.) Checking or replacing the plate heat exchanger C Heating water return E DHW D Heating water flow F Cold water 1. Shut off and drain the boiler on the 2. Undo screw A on the plate heat heating water and the DHW side.
  • Page 59 Troubleshooting Repairs (cont.) 3. Check the connections on the DHW 5. Install in reverse order using new side for scaling; clean or replace the gaskets. plate heat exchanger if required. Note 4. Check the connections on the heat- During installation, ensure the fixing ing water side for contamination;...

  • Page 60: Gas Type Conversion

    Gas type conversion Converting from LPG to natural gas Removing the gas restrictor 1. Pull out power cable from gas train 7. Fit gas train A with new gas gasket 2. Undo union nut B and remove gas Please note gasket.
  • Page 61 Gas type conversion Converting from LPG to natural gas (cont.) 9. Start the boiler and check for leaks. Please note The use of leak detection Danger spray can result in faulty oper- Escaping gas leads to a risk of ation. explosion.

  • Page 62: Control Unit

    Control unit Functions and operating conditions in weather-compensated mode If an outside temperature sensor is con- The heating curve is set at the control nected to the control unit, the boiler unit as a code. In the delivered condition, water temperature is regulated subject to the heating curve with code 20 is set.

  • Page 63: Designs

    Designs Connection and wiring diagrams Overview Power supply Programming unit Main PCB in control unit enclosure ON/OFF switch X ... Electrical interface on side panel...
  • Page 64 Designs Connection and wiring diagrams (cont.) Programming unit Power supply...
  • Page 65 Designs Connection and wiring diagrams (cont.) Gas pressure switch (accesso- Jumper, remove when connecting ries) room temperature controller Outside temperature sensor Main PCB (accessories) Programming unit Room temperature controller ON/OFF switch (accessories) X ... Electrical interface Time switch or wireless receiver (accessories)
  • Page 66 Designs Connection and wiring diagrams (cont.) Control unit Programming unit connection Flow sensor...
  • Page 67 Designs Connection and wiring diagrams (cont.) Diverter valve stepper motor Flue gas temperature sensor Ionisation electrode sÖ Circulation pump 230 V~ Main PCB Gas solenoid valve Power supply unit fÖ Power supply Programming unit Temperature limiter PWM Circulation pump switching Ignition X ...

  • Page 68: 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 69: Overview Of Assemblies

    Parts lists Overview of assemblies A Type plate D Hydraulic assembly B Casing assembly E Control unit assembly C Heat cell assembly F Miscellaneous...

  • Page 70: Casing Assembly

    Parts lists Casing assembly Pos. Component 0001 Front panel 0002 Profiled seal 0003 Viessmann logo 0004 Wall mounting bracket 0004 0002 0003 0001 0002 0003...

  • Page 71: Heat Cell Assembly

    Parts lists Heat cell assembly Pos. Component 0001 Gasket DN 60 0002 Boiler flue connection 0003 Boiler flue connection plug 0004 Flue gasket 0005 Flue gas temperature sensor 0006 Heat exchanger 0007 Condensate hose 0008 Splash siphon 0009 Tee connector 7 19 0010 Gas connection 0011...
  • Page 72 Parts lists Heat cell assembly (cont.) 0005 0001 0001 0003 0002 0003 0014 0004 0014 0015 0014 0006 0004 0013 0013 0014 0012 0015 0018 0011 0007 0010 0011 0008 0009 0016 0017...

  • Page 73: Burner Assembly

    Parts lists Burner assembly Pos. Component 0001 Burner gasket 7 187 0002 Thermal insulation ring 0003 Cylinder burner gauze assembly 0004 Burner gauze assembly gasket 0005 Burner door 0006 Gasket, ionisation electrode (5 pce) 0007 Ignition/ionisation electrode 0008 Burner door flange gasket 0009 Radial fan NRG 118 0010...
  • Page 74 Parts lists Burner assembly (cont.) 0004 0003 0002 0001 0001 0004 0006 0006 0008 0007 0006 0005 0004 0012 0008 0010 0008 0012 0009 0012 0012 0011 0013 0011...

  • Page 75: Hydraulic Assembly

    Parts lists Hydraulic assembly Pos. Component 0001 Diaphragm expansion vessel CRI 8 0002 DEV pad 0003 Gasket A 10 x 15 x 1.5 (5 pce) 0004 DEV connection line G 3/8 0005 Connection elbow HR brass 0006 Profile hose HR 0007 Spring clip DN 25 (5 pce) 0008...
  • Page 76 Parts lists Hydraulic assembly (cont.) 0002 0001 0003 0003 0009 0012 0004 0007 0010 0012 0005 0009 0007 0009 0010 0011 0010 0016 0007 0006 0013 0010 0007 0007 0007 0015 0018 0018 0015 0018 0018 0017 0008 0008 0014...

  • Page 77: Grundfos Hydraulic Assembly

    Parts lists Grundfos hydraulic assembly Pos. Component 0001 Flow casing EU1 0002 Temperature sensor 0003 Expansion tank 0004 O-ring 19.8 x 3.6 (5 pce) 0005 O-ring 16 x 3 (5 pce) 0006 Clip 7 8 narrow (5 pce) 0008 Plate heat exchanger 0009 Circulation pump motor 0010...
  • Page 78 Parts lists Grundfos hydraulic assembly (cont.) 0006 0002 0004 0005 0004 0030 0002 0006 0005 0028 0011 0019 0012 0001 0015 0003 0018 0020 0028 0010 0004 0005 0011 0015 0011 0018 0015 0020 0012 0010 0028 0005 0022 0008 0028 0022 0028...

  • Page 79: Control Unit Assembly

    Parts lists Control unit assembly Pos. Component 0001 Programming unit 0002 Burner control unit 0003 Cable harness X1/X17/stepper motor 0004 Cable harness 100/35/54/ion 0005 Cable harness, connecting cable X21/GFA/programming unit 0006 Outside temperature sensor lead 0007 Connecting cable, heating circuit pump 20 0008 PWM BUS 0009...

  • Page 80: Miscellaneous

    Parts lists Miscellaneous Pos. Component 0001 Touch-up spray paint, Vitowhite, 150 ml can 0002 Touch-up paint stick, Vitowhite 0003 Special grease 0004 Operating instructions 0005 Installation and service instructions 0001 0004 0002 0005 0003...

  • Page 81: 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): IP rating: IP X4D to EN 60529 Permissible ambient temperature ■ During operation: -5 to +40 °C ■...

  • Page 82: Certificates

    Certificates Declaration of conformity Declaration of Conformity for the Vitodens 050-W We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, confirm as sole respon- sible body that the product Vitodens 050-W complies with the following standards: EN 297 EN 55 014-2 EN 483 EN 60 335–1...

  • Page 83: Keyword Index

    Keyword index Keyword index Gas train ...........26 Boiler water temperature sensor ..52 Gas type conversion......60 Burner gasket........36 – LPG..........25 Burner gauze assembly.....36 – Natural gas........60 Burner removal........36 Heating curve........62 Cleaning the combustion chamber..39 Cleaning the heat exchanger.....39 Commissioning........23 Ignition..........38 Condensate........16 Ignition electrode........38 Condensate drain......16, 40 Installing the burner......41...
  • Page 84 Ventilation air pipe......17 Applicability These service instructions relate to appliances with the following serial num- bers (see type plate): 7537906 7537947 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB...

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