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

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See also: Instructions for Installation and Servicing , Installation and Service Instructions Manual
VIESMANN
Installation and service
instructions
for contractors
Vitodens 100-W
Type WB1B, 7.9 to 35.0 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
Gas Council no.: 41-819-21; 41-819-22; 41-819-23; 41-819-24;
41-819-25
For applicability, see the last page
VITODENS 100-W
Please keep safe.
5368 662 GB
1/2012

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  • Page 1 VIESMANN Installation and service instructions for contractors Vitodens 100-W Type WB1B, 7.9 to 35.0 kW Wall mounted gas condensing boiler Natural gas and LPG version Gas Council no.: 41-819-21; 41-819-22; 41-819-23; 41-819-24; 41-819-25 For applicability, see the last page VITODENS 100-W Please keep safe.

  • Page 2: Safety Instructions

    Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate- rial losses. Safety instructions explained ■ all current safety regulations as defined by DIN, EN, DVGW, TRGI, Danger TRF, VDE and all locally applicable This symbol warns against the standards, risk of injury.
  • Page 3 ■ When using gas as fuel, also close the For replacements, use only orig- main gas shut-off valve and safeguard inal spare parts from Viessmann against unauthorised reopening. or those which are approved by ■ Isolate the system from the power sup- Viessmann.

  • Page 4: Table Of Contents

    Index Index Installation instructions Preparing for installation Product information....................Preparing for installation..................Installation sequence Fitting the boiler and making connections............Opening the control unit casing................14 Electrical connections................... 14 Service instructions Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance.......... 18 Further details regarding the individual steps............

  • Page 5: Preparing For Installation

    Preset for operation with natural gas. Conversion to LPG P requires a gas conversion kit. In principle, the Vitodens 100-W may only be supplied to the countries listed on the type plate. For deliveries to alternative countries, an approved contractor, on his own initiative, must arrange individual approval in accordance with the law of the country in question.

  • Page 6: Preparing For Installation

    Preparing for installation Preparing for installation Preparing for the boiler installation Dimensions and connections A Heating flow 7 22 mm D Gas connection R ½ B Heating return 7 22 mm C Condensate drain: Plastic hose 7 22 mm Rated heating output 7.9 - 13 7.9 - 16 7.9 - 19...
  • Page 7 Preparing for installation Preparing for installation (cont.) Fitting the wall mounting bracket Ø 1 A Vitodens installation template B Opening for the balanced flue...
  • Page 8 Preparing for installation Preparing for installation (cont.) 1. Align the supplied installation tem- plate on the wall. 2. Drill 7 10 mm holes and insert the rawl plugs supplied. 3. Fit wall mounting bracket with screws supplied. Preparing the connections Please note To prevent equipment damage, install all pipework free of load...

  • Page 9: Installation Sequence

    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. Note Align the boiler vertically or horizon- tally on all three axes.
  • Page 10 Note Install a shut-off valve and drain & fill valve on site in the heating water return. A Heating water flow B Heating water return Y-plan system A Cylinder C Circulation pump B Vitodens 100-W D Feed and expansion tank...

  • Page 11: Gas Connection

    Installation sequence Fitting the boiler and making connections (cont.) E 3-way diverter valve F Radiators Gas connection 1. Connect gas shut-off valve to con- nection A. 2. Carry out a tightness test. Note Only use suitable and approved leak detection agents (EN 14291) and devices for the tightness test.

  • Page 12: Condensate Connection

    Installation sequence Fitting the boiler and making connections (cont.) Condensate connection 1. Pull condensate pipe A so far out of the appliance that no unnecessary bends are created inside the appli- ance. Ensure that the siphon is prop- erly connected. 2.
  • Page 13 Installation sequence Fitting the boiler and making connections (cont.) Filling the condensate connection siphon with water Please note At commissioning, flue gas may be emitted from the condensate drain. Therefore fill the siphon with water before commissioning. Pour a minimum of 0.3 l of water into the flue outlet.

  • Page 14: Opening The Control Unit Casing

    Installation sequence Opening the control unit casing Please note Before beginning work, touch Electronic assemblies can be earthed objects, such as heating damaged by electrostatic dis- or water pipes, to discharge static charge. loads. Electrical connections Information on connecting accessories For this connection, observe the separate installation instructions provided with the accessories.
  • Page 15 Installation sequence Electrical connections (cont.) PUMP L N 1 L N 4 3 2 1 A Only for weather-compensated F Power supply (230 V, 50 Hz). mode: Outside temperature sensor (acces- Danger sory). Incorrect core allocation can B Connecting cable (accessory). result in serious injury and C Terminal box cylinder demand damage to the appliance.
  • Page 16 Installation sequence Electrical connections (cont.) Separate installation Take power for external controls instructions from "L" and "N". The switched live to start the boiler goes into "1". Please note that if there are two cir- ■ On-site room temperature con- cuits connected, e.g.
  • Page 17 Installation sequence Electrical connections (cont.) Routing connecting cables and closing the control unit casing Please note Connecting cables will be dam- aged if they touch hot compo- nents. When routing and securing cables/leads on site, ensure that the maximum permissible tem- peratures for these cables/leads are not exceeded.

  • Page 18: 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..........19 • 2. Venting the boiler............20 •...

  • Page 19: Further Details Regarding The Individual Steps

    Commissioning, inspection, maintenance Further details regarding the individual steps Filling the heating system Please note Fill and vent the heating system. Unsuitable fill water increases the level of deposits and corro- sion and may lead to boiler dam- age. ■ Thoroughly flush the entire heating system prior to filling it with water.

  • Page 20: Venting The Boiler

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Venting the boiler 1. Close shut-off valve in heating water return. 2. Remove cover panel. 3. Connect drain hose to air vent valve A with a drain connection. 4. Open air vent valve A and on-site fill valve in heating water return B.

  • Page 21: 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 22 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Undo the screw inside the test nipple 7. Record the actual value in the report A on the gas train, but do not on page. remove it; then connect the pressure Take the action shown in the follow- ing table.

  • Page 23: Checking The Co Or O Content

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the CO or O content The Vitodens100-W is factory-set for If the actual CO or O and CO values natural gas. During commissioning or deviate from the stated range, check the maintenance, the CO and CO have to balanced flue systems for leaks.

  • Page 24: Burner Removal

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Burner removal 1. Switch off the power. 6. Release gas supply pipe fitting D. 2. Shut off the gas supply. 7. Undo four screws E and remove the burner. 3. Disconnect power cables from fan motor A and gas valve B.

  • Page 25: Checking The Burner Gasket And Burner Gauze Assembly

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the burner gasket and burner gauze assembly Check burner gasket A and burner gauze assembly D for damage and replace if necessary. 1. Remove electrode B. 4. Insert new burner gauze assembly D with new gasket E and secure.

  • Page 26: Checking And Adjusting Electrodes

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Fit electrode B. Please note Tighten screws far enough to prevent the components being damaged and to ensure they function correctly. Checking and adjusting electrodes 1. Check the electrode for wear and contamination.

  • Page 27: 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 deposits from heat exchangers A in the combustion chamber.

  • Page 28: Burner Installation

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Burner installation 1. Fit burner and tighten four screws 5. Plug ignition electrode cable E into A crosswise. the control unit and close the control unit casing. Please note Tighten screws far enough 6.

  • Page 29: Checking All Gas Equipment For Tightness At Operating

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking all gas equipment for tightness at operating pressure Danger Note Escaping gas leads to a risk of Only use suitable and approved leak explosion. detection agents (EN 14291) and devi- Check gas equipment for tight- ces for the tightness test.

  • Page 30: Instructing The System User

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Instructing the system user The system installer must hand the oper- ating instructions to the system user and instruct the user in operating the sys- tem.

  • Page 31: 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 No fault display Heating water flow rate too low. In- crease flow rate and ensure heat is drawn off.

  • Page 32: Fault Messages On The Display

    Troubleshooting Function sequence and possible faults (cont.) Ionisation current Fault F4 Check the ionisa- builds (higher than tion current, check 2 µA) the electrode ad- Symbol A justment, check the condensate drain and the gas line for airlocks Burner in opera- Stops below the set Check the flue sys- tion...
  • Page 33 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics Constant mode Short circuit, out- Check the outside tem- side temperature perature sensor and lead sensor (see page 38). Constant mode Lead break, out- Check the outside tem- side temperature perature sensor and lead sensor...
  • Page 34 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics Burner in a fault Max. flue gas tem- Check heating system fill state perature exceeded level. Check circulation pump. Vent the system. Press "Reset" (see page 36).
  • Page 35 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics Burner blocked Electrical fan con- Check fan connecting ca- trol (control unit) ble; if required, replace or faulty replace control unit. Burner blocked Fault, burner con- Check ignition electrodes trol unit and connecting cables.
  • Page 36 Troubleshooting Fault messages on the display (cont.) Press reset Note Only press RESET if fault symbol " U " flashes. Turn rotary selector "rt" between 1 s and 2 s to position "U RESET" and then back to the control range.

  • Page 37: Repairs

    Troubleshooting Repairs Remove front panel and pivot control unit downwards...

  • Page 38: Outside Temperature Sensor

    Troubleshooting Repairs (cont.) Outside temperature sensor 1. Open the control unit casing. See page 14. 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 39 Troubleshooting Repairs (cont.) Checking the boiler water temperature sensor and return tem- perature sensor 1. Remove the leads from the boiler water temperature sensor A or return temperature sensor B and check the resistance.
  • Page 40 Troubleshooting Repairs (cont.) 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. Danger The boiler water temperature sensor is immersed in the heating water (risk of scald- ing).
  • Page 41 Troubleshooting Repairs (cont.) Checking the flue gas temperature sensor 1. Remove the leads from the flue gas temperature sensor A and check the resistance. 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in the case of severe deviation.
  • Page 42 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. Disconnect the leads from tempera- ture limiter A. 2.
  • Page 43 Troubleshooting Repairs (cont.) Checking the fuse 1. Switch off the power. 2. Open control unit casing (see page 14). 3. Check fuse F4.

  • Page 44: Gas Type Conversion

    Gas type conversion Changing from LPG to natural gas Replacing the gas restrictor 1. Removing the burner (see page 24). 4. Fit gas train B with new gasket D. 2. Undo three screws A and remove Please note gas train B. Tighten screws far enough to prevent the components being damaged and to ensure...
  • Page 45 Gas type conversion Changing from LPG to natural gas (cont.) 5. Refit burner with new gasket E and Please note tighten the union nuts. Tighten union nuts far enough to prevent the components being damaged and to ensure they function correctly. Changing the gas type at the control unit 1.
  • Page 46 Gas type conversion Changing from LPG to natural gas (cont.) 5. Do not adjust the rotary selectors for 15 s. The set operating mode is then saved and the control unit returns to standard mode. 6. Switch ON/OFF switch OFF and ON again.

  • Page 47: Control Unit

    Control unit Functions and operating conditions in weather-compensated mode In weather-compensated mode, the Note boiler water temperature is regulated Y-plan and S-plan systems cannot be subject to the outside temperature. operated in weather-compensated mode. For further information, see separate ter- minal box cylinder demand (accessory) installation instructions.
  • Page 48 Control unit Functions and operating conditions in… (cont.) Note The frost protection function is only ena- bled if the circulation pump is connected to the boiler control unit. Otherwise install an external frost stat.

  • Page 49: Designs

    Designs Connection and wiring diagram Ignition/ionisation Vitotrol 100, type UTA or on-site room temperature controller (switched 230 V input)
  • Page 50 Designs Connection and wiring diagram (cont.) Vitotrol 100, type RT or on-site PCB inside the control unit room temperature controller X ... Electrical interface (switched 230 V input) § Boiler water temperature sensor Vitotrol 100, type UTD or on-site Terminal box cylinder demand room temperature controller (accessory) (switched 230 V input)

  • Page 51: Parts Lists

    Parts lists Parts lists When ordering spare parts: 024 Venturi extension Quote the part and serial no. (see type 025 Control unit plate) and the item number of the 026 Cover, wiring chamber required part (as per this parts list). 027 Thermal circuit breaker Standard parts are available from your 028 Boiler water temperature sensor...
  • Page 52 Parts lists Parts lists (cont.)
  • Page 53 Parts lists Parts lists (cont.)

  • Page 54: 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 X4 to EN 60529 Permissible ambient temperature ■ during operation: 0 to +40 °C ■...

  • Page 55: Certificates

    Declaration of conformity Declaration of conformity for the Vitodens 100-W We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm as sole respon- sible body that the product Vitodens 100-W complies with the following standards: DIN 4702–6 EN 55 014 EN 483...

  • Page 56: Keyword Index

    Keyword index Keyword index Boiler water temperature sensor..39 Heat exchanger cleaning....27 Burner gasket........25 Heating curve........47 Burner gauze assembly.....25 Burner installation......28 Burner removal........24 Ignition..........26 Ignition electrode........26 Ionisation electrode......26 Checking volumetric flow rate....40 Combustion chamber cleaning..27 Commissioning........19 Outside temperature sensor .....38 Condensate connection.....12 Condensate drain.......27 Connection diagram......49 Reset..........36...
  • Page 60 These service instructions apply for appliances with the following serial num- bers (see type plate): 7416302 7416303 7416304 7416307 7499606 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...

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