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Viessmann VITODENS 100-W Installation And Service Instructions Manual

For contractors. wall mounted gas condensing boiler natural gas and lpg version
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Download this manual See also: Instructions for Installation and Servicing, Installation and Service Instructions Manual
VIESMANN
Installation and service
instructions
for contractors
Vitodens 100-W
Type WB1C, 7.4 to 35.0 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 100-W
Please keep safe.
5603 938 GB
3/2011

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Summary of Contents for Viessmann VITODENS 100-W

  • Page 1 VIESMANN Installation and service instructions for contractors Vitodens 100-W Type WB1C, 7.4 to 35.0 kW Wall mounted gas condensing boiler Natural gas and LPG version For applicability, see the last page VITODENS 100-W Please keep safe. 5603 938 GB 3/2011...
  • Page 2 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 assembling connections............. 10 Opening the control unit..................14 Electrical connections................... 15 Service instructions Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance.......... 19 Further details regarding the individual steps............
  • Page 5 Index Index (cont.) Certificates Declaration of conformity..................71 Keyword index....................72...

  • Page 6: Preparing For Installation

    Preparing for installation Product information Vitodens 100-W, WB1C Preset for operation with natural gas. Preparing for installation Preparing for the boiler installation Dimensions and connections 58 58 A Heating flow C Gas connection B Gas condensing boiler: D Gas condensing boiler:...
  • Page 7 Preparing for installation Preparing for installation (cont.) E Heating return F Condensate drain/safety valve drain: Plastic hose 7 22 mm...
  • Page 8 Preparing for installation Preparing for installation (cont.) Fitting the wall mounting bracket Ø10 A Installation template Vitodens...
  • Page 9 Preparing for installation Preparing for installation (cont.) 1. Position the supplied installation tem- plate on the wall. 2. Mark out the rawl plug holes. 3. Drill 710 mm holes and insert the supplied rawl plugs. 4. Fit wall mounting bracket with screws supplied.

  • Page 10: Installation Sequence

    Installation sequence Fitting the boiler and assembling connections Removing the front panel and mounting the boiler 1. Release screws at the bottom of the 3. Hook the boiler into the wall mounting boiler; do not remove completely. bracket. 2. Remove front panel. Installing connections on the water side For fittings on the heating water side and DHW side, see separate installation instructions.
  • Page 11 Installation sequence Fitting the boiler and assembling connections (cont.) ¨ A Heating flow D Gas condensing boiler: Cylinder return B Gas condensing boiler: Gas condensing combi boiler: Cylinder flow Cold water Gas condensing combi boiler: E Heating return C Gas connection Gas connection 1.
  • Page 12 Installation sequence Fitting the boiler and assembling connections (cont.) 2. Carry out a tightness test. Note For the tightness test, use only suita- ble and approved leak detecting agents (EN 14291) and devices. Leak detecting agents with unsuita- ble contents (e.g. nitrites, sulphides) can lead to material damage.
  • Page 13 Installation sequence Fitting the boiler and assembling connections (cont.) Connection, safety valve and condensate drain Connect condensate drain pipe A with a constant fall and a pipe vent to the public sewage system. Observe the local waste water regula- tions. Note Fill the siphon with water before com- missioning.

  • Page 14: Opening The Control Unit

    Installation sequence Fitting the boiler and assembling connections (cont.) Balanced flue connection Connect the balanced flue. Flue system installation instruc- tions. Opening the control unit...

  • Page 15: Electrical Connections

    Installation sequence Opening the control unit (cont.) 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 about connecting accessories For this connection, observe the separate installation instructions provided with the accessories.
  • Page 16 Installation sequence Electrical connections (cont.) % Gas condensing boilers only: Outside temperature sensor (acces- Cylinder temperature sensor (plug sory) on the cable harness outside the B Open Therm device Remove jumper D when making control unit) or connect the control box (supplied with the system boiler) this connection.
  • Page 17 Installation sequence Electrical connections (cont.) Outside temperature sensor (accessory) 1. Plug the power cable supplied with 2. Connect the outside temperature the outside temperature sensor into sensor to terminals 3 and 4. slot "X21". Power supply Regulations and Directives We additionally recommend installing an AC/DC-sensitive RCD (RCD class B Danger ) for DC (fault) currents that can...
  • Page 18 Installation sequence Electrical connections (cont.) Routing connecting cables and closing control unit Please note Power cables will be damaged if they touch hot components. When routing and securing power cables on site, ensure that the maximum permissible temperatures for these cables are not exceeded.

  • Page 19: Commissioning, Inspection, Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page • • • 1. Filling the heating system..........20 • • • 2. Venting the boiler by flushing........22 •...

  • Page 20: Further Details Regarding The Individual Steps

    Commissioning, inspection, maintenance Further details regarding the individual steps Filling the heating system Please note Unsuitable fill water increases the level of deposits and corrosion and may lead to boiler damage. ■ Thoroughly flush the entire heating system prior to filling it with water. ■...
  • Page 21 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Open shut-off valves A and (if instal- led) B. 5. Connect fill hose to valve C and open valve C. 6. Fill heating system. (Minimum sys- tem pressure > 0.8 bar). 7.

  • Page 22: Venting The Boiler By Flushing

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Venting the boiler by flushing 1. Connect the drain hose on shut-off valve A to a drain. 2. Close shut-off valve B. 3. Open valves A and C and flush at mains pressure, until no sound of escaping air can be heard.
  • Page 23 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Simultaneously turn rotary selectors "tw" and "tr" to their central posi- tions. "SERV" appears on the display. 3. Refer to the following table for the correction factor required for the con- nected flue system.

  • Page 24: Reducing The Max. Heating Output

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Observe max. flue pipe lengths in the pricelist. If the max. flue pipe lengths in the pricelist are exceeded, calculated function verification is required. Reducing the max. heating output The max. heating output can be reduced according to the system requirements. 1.

  • Page 25: Matching The Circulation Pump To The Heating System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Test selected heating output by measuring the gas throughput. 5. Transfer selected heating output: Turn rotary selector "tw" fully clock- wise for less than 2 s and then back to the control range on the right.

  • Page 26: Checking The Co 2 Content

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Within 2 s, turn rotary selector "tr" to the top right range. "r" appears on the display and the set value flashes. 4. Adjust the control unit to stage 1 or 2 by turning rotary selector "tw".
  • Page 27 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 02. Start the boiler and check for leaks. Danger Escaping gas leads to a risk of explosion. Check gas equipment for tightness. 03. Turn rotary selector "tr" fully clockwise for less than 2 s and then back to the control range on the right.
  • Page 28 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 06. Adjust the lower output: Turn rotary selector "tr" to the control range on the left until the dis- play shows 1 bar for the lower out- put. 07. Test the CO content for lower out- put.

  • Page 29: Burner Removal

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Burner removal F 4x 5. Release gas supply pipe fitting E. 1. Switch the power OFF. 2. Shut off the gas supply. 6. Undo four screws F and remove the burner.

  • Page 30: 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 for damage and replace if required. Replace the burner gauze assembly if it is damaged. 1. Remove electrode B. 4.

  • Page 31: Checking And Adjusting Electrodes

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Refit the electrode B. Fixing screw torque: 4.5 Nm. Checking and adjusting electrodes 1. Check the electrode for wear and contamination. 2. Clean the electrode with a small brush (not with a wire brush) or emery paper.

  • Page 32: Checking The Condensate Drain And Cleaning The Siphon

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Use a vacuum cleaner to remove res- idues from heat exchanger A inside the combustion chamber. 2. If required, spray slightly acidic, chloride-free cleaning agents based on phosphoric acid (e.g. Antox 75 E) onto heat exchanger A and let the solution soak in for approx.

  • Page 33: Burner Installation

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Burner installation A 4x 1. Install the burner and torque screws 4. Replace electrical cables from fan A diagonally with 8.5 Nm. motor D, gas valve E and ignition unit F. 2.

  • Page 34: Checking The Diaphragm Expansion Vessel And System Pressure

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

  • Page 35: Fitting The Front Panel

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

  • Page 36: Troubleshooting

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

  • Page 37: Fault Messages On The Display

    Troubleshooting Function sequence and possible faults (cont.) Burner in opera- Stops below the set Check the flue sys- tion boiler water tem- tem for tightness perature and (flue gas recircula- restarts immedi- tion), check the ately gas flow pressure Fault messages on the display Faults are indicated by a flashing fault code with fault symbol "U"...
  • Page 38 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics No DHW heating Short circuit, outlet Check the sensor (see temperature sen- page 47). Burner blocked Short circuit, flow Check connections and sensor lead; replace sensor if required.
  • Page 39 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics Burner in a fault The temperature Check heating system fill state limiter has respon- level. Check circulation pump. Vent the system. Check the temperature limiter and connecting leads (see page 45).
  • Page 40 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics Burner blocked Fault, combustion Check ignition electrodes controller and connecting cables. Check whether a strong interference (EMC) field exists near the appliance. Press "Reset" (see page 40).

  • Page 41: Repairs

    Troubleshooting Repairs Removing the front panel 1. Release screws at the bottom of the 2. Remove front panel. boiler; do not remove completely. Outside temperature sensor 1. Open the control unit casing. See page 14.
  • Page 42 Troubleshooting Repairs (cont.) 2. Disconnect cables 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. 10 20 30 Temperature in °C...
  • Page 43 Troubleshooting Repairs (cont.) Boiler water temperature sensor 1. Pull the leads from boiler water tem- perature sensor A and check the resistance.
  • Page 44 Troubleshooting Repairs (cont.) 2. Check the sensor resistance and compare it with the curve. 3. In case of severe deviation, drain 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- 10 30 50 70 90 110 ing).
  • Page 45 Troubleshooting Repairs (cont.) 2. Compare the sensor resistance with the curve. 3. Replace the sensor in the case of severe deviation. 10 30 50 70 90 110 Temperature in °C Checking the temperature limiter If the burner control unit cannot be reset after a fault shutdown, although the boiler water temperature is below approx.
  • Page 46 Troubleshooting Repairs (cont.) 1. Pull the leads from temperature lim- iter A. 2. Check the continuity of the tempera- ture limiter with a multimeter. 3. Remove the faulty temperature lim- iter. 4. Install a new temperature limiter. 5. Press "Reset" at the control unit (see page 40).
  • Page 47 Troubleshooting Repairs (cont.) Checking the outlet temperature sensor (gas condensing combi boiler) 1. Pull out the leads from outlet temper- ature sensor.A 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in the case of severe deviation.
  • Page 48 Troubleshooting Repairs (cont.) Check flue gas temperature sensor 1. Pull out the leads from flue gas tem- perature sensor A. 2. Check the sensor resistance and compare it with the curve.
  • Page 49 Troubleshooting Repairs (cont.) 3. Replace the sensor in the case of severe deviation. 10 30 50 70 90 110 Temperature in °C Replacing flow limiter (gas condensing combi boiler) 1. Drain the boiler from the DHW side. 2. Pivot the control unit downwards. 3.
  • Page 50 Troubleshooting Repairs (cont.) Checking or replacing the plate heat exchanger (gas condensing combi boiler) E Heating water flow G Cold water F Heating water return H DHW 1. Shut off and drain the boiler on the 4. Turn the three-way valve B with heating water and the DHW side.
  • Page 51 Troubleshooting Repairs (cont.) 5. Remove two screws C from the 7. Check the heating water side for con- plate heat exchanger and remove tamination and if required clean or plate heat exchanger D with gas- replace the plate heat exchanger. kets.

  • Page 52: Gas Type Conversion

    Gas type conversion Converting from LPG to natural gas Removing gas restrictor 1. Pull out power cable from gas train 6. Remove or void gas type sticker on the top of the boiler (next to the type plate). 2. Undo union nut B. 7.
  • Page 53 Gas type conversion Converting from LPG to natural gas (cont.) Converting the gas type at the control unit 1. Turn ON/OFF switch ON. 2. Simultaneously turn rotary selectors "tw" and "tr" to their central posi- tions. "SERV" appears on the display. 3.

  • Page 54: Control Unit

    Control unit Functions and operating conditions in weather-compensated mode In weather-compensated mode, the boiler water temperature is regulated subject to the outside temperature. Heating curve of weather-compensated control unit -5 -10 -15 -20 Outside temperature in °C Rotary selector setting "tr" Frost protection function is enabled at outside temperatures of <...

  • Page 55: Designs

    Designs Connection and wiring diagram Stepper motor diverter valve Vitotrol 100, type RT Ignition/ionisation Vitotrol 100, type UTDB Vitotrol 100, type UTA Mains input 230V/50Hz...
  • Page 56 Designs Connection and wiring diagram (cont.) Remote control (accessory) Cylinder temperature sensor (gas condensing boiler) Outside temperature sensor (accessory) Flue gas temperature sensor Time switch (accessory) sÖ Circulation pump 230V~ Gas pressure limiter (accessory) Gas solenoid valve PCB inside the control unit Temperature limiter a-Ö...

  • Page 57: Parts Lists

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

  • Page 58: Overview Of The Assemblies

    Parts lists Overview of the assemblies A Type plate D VBC LCV control unit assembly B Sheet metal parts assembly E Heat cell assembly C Vitodens hydraulic assembly F Miscellaneous assembly...

  • Page 59: Sheet Metal Parts Assembly

    Parts lists Sheet metal parts assembly 0001 Front panel 0005 Air box floor 0002 Profiled seal 0006 Diaphragm grommets (set) 0003 Logo 0007 Wall mounting bracket 0004 Strain relief upper part 0007 0002 0003 0002 0001 0005 0003 0006 0004...

  • Page 60: Heat Cell Assembly

    Parts lists Heat cell assembly 0001 Gasket DN 60 0009 Tee 0002 Boiler flue connection 0010 Gas pipe 0003 Boiler flue connection plug 0011 Gasket 17 x 24 x 2 (set) 0004 Flue gas gasket 0012 Burner 0005 Flue gas temperature sensor 0013 Thermal insulation block 0006 Heat exchanger 0014 Heat exchanger mounting (set)

  • Page 61: Burner Assembly

    Parts lists Burner assembly 0001 Burner gasket 0008 Burner door flange gasket 0002 Insulation ring 0009 Radial fan 0003 Cylinder burner gauze assembly 0010 Gas valve 0004 Burner gauze assembly gasket 0012 Venturi extension 0005 Burner door 0013 Gasket A 17 x 24 x 2 (set) 0006 Ionisation electrode gasket 0014 Conversion kit G31 0007 Ignition and ionisation electrode...
  • Page 62 Parts lists Burner assembly (cont.) 0007 0006 0005 0004 0003 0002 0001 0006 0008 0012 0013 0010 0014 0009 0013...

  • Page 63: Vitodens Hydraulic Assembly

    Parts lists Vitodens hydraulic assembly 0011 Air vent valve G ⅜ 0001 Diaphragm expansion vessel 0002 Diaphragm expansion vessel cap 0012 Temperature sensor 0003 Gasket A 10 x 15 x 1.5 (set) 0013 Round sealing ring 8 x 2 0004 Connection pipe; diaphragm 0014 Moulded hose heating water flow expansion vessel 0015 Clip Ø...
  • Page 64 Parts lists Vitodens hydraulic assembly (cont.) 0002 0001 0003 0005 0007 0010 0003 0010 0007 0012 0018 0021 0010 0006 0007 0020 0007 0010 0004 0018 0003 0007 0009 0011 0009 0014 0013 0007 0007 0019 0007 0007 0016 0015 0019 0015 0016...

  • Page 65: System Boiler Hydraulic Assembly

    Parts lists System boiler hydraulic assembly 0001 Air vent valve 0009 O-ring 16 x 3 (5 pce) 0002 Gasket set PWT 0010 Check valve 0003 Safety valve 0011 Clip Ø 16 (5 pce) 0004 Safety valve clip (5 pce) 0013 Stepper motor adaptor 0005 Hydraulics 0014 Linear stepper motor 0006 Clip Ø...
  • Page 66 Parts lists Combi hydraulic assembly (cont.) 0009 Bypass cartridge 0019 Top-up tap key 0010 Flow sensor 0020 Hydraulics 0011 Clip Ø 10 (5 pce) 0021 Round sealing ring 8 x 2 (5 pce) 0012 Clip Ø 16 (5 pce) 0022 O-ring 16 x 3 (5 pce) 0013 Shut-off valve 0023 Check valve 0014 Stepper motor adaptor...
  • Page 67 Parts lists Combi hydraulic assembly (cont.) 0001 0002 0015 0003 0002 0014 0016 0017 0004 0018 0026 0006 0005 0007 0021 0023 0020 0022 0001 0004 0012 0009 0006 0026 0007 0012 0027 0009 0022 0011 0011 0023 0010 0024 0013 0014 0011...

  • Page 68: Vbc Lcv Control Unit Assembly

    Parts lists VBC LCV control unit assembly 0001 Cover, wiring chamber 0003 Profiled seal 0002 Clip hinge 0004 Control unit 0001 0002 0003 0004 0002 0003 Miscellaneous assembly 0001 Spray paint, Vitowhite 0004 Operating instructions 0002 Touch-up paint stick, Vitowhite 0005 Installation and service instruc- 0003 Special grease tions...
  • Page 69 Parts lists Miscellaneous assembly (cont.) 0001 0002 0003 0004 0005...

  • Page 70: 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 71 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: EN 297 EN 55 014-2...
  • Page 72 Keyword index Keyword index Boiler water temperature sensor ..43 Heating curve........54 Burner gasket........30 Burner gauze assembly.....30 Burner installation......33 Ignition..........31 Burner removal........29 Ignition electrodes......31 Ionisation electrode......31 Cleaning the combustion chamber..31 Cleaning the heat exchanger.....31 Max. Heating output......24 Commissioning........20 Condensate........13 Condensate drain......13, 32 Opening the control unit.....14 Connection diagram......55 Outlet temperature sensor...47, 48...
  • Page 73 Keyword index Keyword index (cont.) Wall mounting........8 Weather-compensated mode.....54...
  • Page 76 These service instructions apply for appliances with the following serial num- bers (see type plate): 7441736 7441737 7441739 7441745 7441748 7441749 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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