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VIESMANN Installation and service instructions for contractors Vitodens 050-W Type B0KA, BPKA, 3.2 to 25 kW Type B0KA-M (for multiple connection), 7.0 to 25 kW Wall mounted gas condensing boiler Natural gas version Gas Council No. ■ B0KA: 47-819-55, 47-819-57 ■...
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Safety instructions Safety instructions Please follow these safety instruc- tions closely to prevent accidents and material losses. Safety instructions explained Danger Note This symbol warns against the risk Details identified by the word "Note" of injury. contain additional information. Please note This symbol warns against the risk of material losses and environmen- tal pollution.
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Viessmann. water pipes to discharge static loads. Repair work Please note Repairing components that fulfil a safety function can compromise the safe operation of the system. Replace faulty components only with genuine Viessmann spare parts.
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Safety instructions Safety instructions (cont.) Safety instructions for operating the system If you smell gas Condensate Danger Danger Escaping gas can lead to explo- Contact with condensate can be sions which may result in serious harmful to health. injury. Never let condensate touch your Do not smoke.
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Safety instructions Safety instructions (cont.) Danger The simultaneous operation of the boiler and appliances that exhausts air to the outside can result in life threatening poisoning due to a reverse flow of flue gas. Fit an interlock circuit or take suita- ble steps to ensure an adequate supply of combustion air.
Index Index 1. Information Disposal of packaging ................Gas Council No..................Symbols ....................Intended use ..................Product information ................Type plate ................... ■ System examples .................. 10 Spare parts lists ..................10 2. Preparing for installation ........................ 11 3. Installation sequence Removing the boiler from the packaging ..........
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Index Index (cont.) Checking the fuse ................79 ■ 8. Function description Appliance functions ................80 Heating mode ..................80 ■ OpenTherm controller ................. 80 ■ Venting program ................. 80 ■ Filling program ..................80 ■ Heating curve ..................80 ■...
Disposal of packaging Please dispose of packaging waste in line with statu- tory regulations. Gas Council No. Type Gas Council Number: Vitodens 050-W, B0KA, 25 kW 47-819-55 Vitodens 050-W, B0KA, 30 kW 47-819-57 Vitodens 050-W, B0KA-M, 25 kW 47-819-56 Symbols...
The type plate also shows the ■ Type BPKA, B0KA: Plate heat exchanger for DHW other gas types and pressures with which the boiler heating can be operated. A conversion within the stated natu- ral gas groups is not required.
Detailed information on system examples can be found tion diagrams and function descriptions are available at: www.viessmann-schemes.com to help setting up the heating system. Spare parts lists Information about spare parts can be found at www.viessmann.com/etapp or in the Viessmann spare part app.
Preparing for installation Preparing for installation Ø 96 -0.5 Ø 60.5 +0.8 Fig. 2 Illustration shows a gas condensing combi boiler Condensate drain Heating return Heating flow Filling/draining DHW (gas condensing combi boiler) Dimension for siting with DHW cylinder below the Cylinder flow (gas condensing system boiler) boiler Gas connection...
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Install this expansion vessel in the cylinder return, as the 3-way diverter valve is located in the heating flow. Not possible with type B0KA, BPKA Connection on the DHW side for gas condensing combi boiler Cold water installation Visible discharge pipe outlet point...
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Preparing for installation Preparing for installation (cont.) Shock arrestor If draw-off points likely to cause water hammer are connected to the boiler's DHW network (e.g. flush valves, washing machines, dishwashers): Shock arrestors should be installed close to the cause of the water hammer.
Installation sequence Mounting the boiler and making connections Removing the front panel Fig. 5 1. Unlock the front panel on the underside (push in), 2. Swivel the front panel forwards slightly and lift using a screwdriver or similar tool. away upwards. Mounting the boiler on the pre-plumbing jig or mounting frame Note Various installation components can be found in a sep-...
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Installation sequence Mounting the boiler and making connections (cont.) Fig. 6 Note 1. Replace gaskets. The diagram shows installation on a pre-plumbing jig for a gas condensing combi boiler. Internal gasket diameter: Gas connection Ø 18.5 mm ■ The boiler can be installed on the following accesso- Heating water side connections Ø...
Installation sequence Mounting the boiler and making connections (cont.) 3. Note 5. Tighten locking ring fittings so that they form a tight Only remove the locking clip under the gas pipe seal: union nut once the appliance has been installed. One turn beyond finger-tight.
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Installation sequence Mounting the boiler and making connections (cont.) Fig. 7 1. Replace gaskets. Fit valves and gas shut-off valve. 3. Note Only remove the locking clip under the gas pipe Internal gasket diameter: union nut once the appliance has been installed. Gas connection Ø...
Installation sequence Mounting the boiler and making connections (cont.) 4. Tighten union nuts so that they form a tight seal. Tighten the union nuts as tightly as necessary and ensure that the components are undamaged and are functioning correctly throughout service life. Observe torque settings if a torque wrench is avail- able.
Installation sequence Condensate connection 1. Push the supplied drain hose on to the drain con- nector. 2. Connect the drain hose with a constant fall and a pipe vent to the drain network or a neutralising sys- tem. Note Route the onward drain line inside the building as far as possible.
Unrestricted flow in the flue gas routes. documentation may only be used in conjunction with ■ Positive pressure flue system is gas-tight. the Viessmann flue system made by Skoberne or ■ Inspection port covers checked for secure and tight Groppalli.
Installation sequence Gas connection Fig. 12 1. If the gas connection has not been fitted previ- 3. Purge the gas line. ously, seal gas shut-off valve to the gas con- nection. When carrying out any work on gas connection fit- tings, hold with a suitable tool.
Installation sequence Electrical connections Opening the wiring chamber Please note Electronic assemblies can be damaged by elec- trostatic discharge. Prior to commencing any work, touch earthed objects, such as heating or water pipes to dis- charge static loads. Fig. 13 Layout of the electrical connections Note For further information on the connections, see the fol-...
Installation sequence Electrical connections (cont.) Connections to 230 V~ plugs Gas solenoid valve Power supply fÖ Ignition unit/ionisation Configurable floating input , 230 V, No function assigned 230 V output Equipotential bonding (earth conductor) sÖ Room thermostat connection 230 V Cylinder temperature sensor (system boiler) Note on connecting accessories Remote control (OpenTherm controller)
Installation sequence Electrical connections (cont.) Power supply fÖ Danger If the power supply to the appliance is connected ■ Incorrectly executed electrical installations can with a flexible power cable, ensure that the live con- result in injuries from electrical current and dam- ductors are pulled taut before the earth conductor in age to the appliance.
Installation sequence WiFi operational reliability and system requirements WiFi router system requirement Dynamic IP addressing (DHCP, delivered condition) ■ ■ WiFi router with activated WiFi: in the network (WiFi): The WiFi router must be protected by a sufficiently Have this checked on site, and if required set up, by secure WPA2 password.
Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • 1. Commissioning the system....................30 • • 2. Filling the heating system....................32 • • • 3. Checking all connections on the heating water and DHW sides for leaks....34 •...
Commissioning, inspection, maintenance Commissioning the system Please note 3. For further steps, see commissioning assistant in Only commission the appliance with a fully filled the following overview. trap. Check that the trap has been filled with water. Commissioning via software tool Commissioning via commissioning assistant Note Apps for commissioning and service are available for...
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Commissioning, inspection, maintenance Commissioning the system (cont.) Commissioning assistant Explanations and references sequence Commissioning "C.1" ON = on Filling program OF = off Note It is possible to interrupt or end the process while a rotating rectangle alternat- ing with the current system pressure is displayed; to do so, press for 3 s.
Commissioning, inspection, maintenance Commissioning the system (cont.) Automatic flue gas temperature sensor check The display shows: "Er" Note If the flue gas temperature sensor is not positioned The burner remains locked out until the test has been correctly, fault message 416 appears. passed.
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Commissioning, inspection, maintenance Filling the heating system (cont.) E DC Fig. 22 ON/OFF switch 1. Check the pre-charge pressure of the expansion 5. Fit hose to air vent valve . Route the hose into a vessel. suitable container or drain outlet. 2.
Commissioning, inspection, maintenance Filling the heating system (cont.) 8. OK The filling function is activated. The display shows a rotating rectangle. The filling function ends automatically after 20 min or press for 4 s. Checking all connections on the heating water and DHW sides for leaks Danger Risk of electric shock from escaping heating water or DHW.
Commissioning, inspection, maintenance Removing the front panel Danger Contact with live components can lead to seri- ous injury from electric current. Some compo- nents on PCBs remain live even after the power supply has been switched off. Never touch the wiring chambers (control unit ■...
Commissioning, inspection, maintenance Checking the static pressure and supply pressure Danger CO formation as a result of incorrect burner adjustment can have serious health implications. Always carry out a CO test before and after work on gas appliances. 01. Turn off the ON/OFF switch. 02.
Commissioning, inspection, maintenance Checking the static pressure and supply pressure (cont.) Supply pressure (flow pressure) Measures For natural gas < 20 mbar (2.0 kPa) Do not start the boiler. Notify the gas supply utility. 20 - 25 mbar (2.0 - 2.5 kPa) Start the boiler.
Commissioning, inspection, maintenance Function sequence and possible faults (cont.) Automatic calibration of Fault 62, 373 Ensure adequate heat trans- the combustion controller fer. Reset the appliance. Fault 346, 377 Check gap between ionisa- tion electrode and burner gauze assembly. Check flue system. Remove flue gas recirculation if re- quired.
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Commissioning, inspection, maintenance Adjusting pump rate of integral circulation pump (cont.) In the delivered condition, the minimum pump rate ■ and the maximum pump rate are set to the following values: Rated heating output Speed settings in the de- in kW livered condition in % Min.
Commissioning, inspection, maintenance Burner adjustment when connecting multiple… (cont.) For multiple connection, in the commissioning assis- Minimum shaft cross-section ■ tant use "C.5" and "C.6" to match the burner setting – Square: 175 x 175 mm to the flue system. See page 30. –...
Commissioning, inspection, maintenance Checking the burner gasket and burner gauze assembly Fig. 29 Check burner gauze assembly , electrodes , ther- 7. Align the hole in burner gauze assembly with the burner door pin. mal insulation ring and gasket for damage. Only remove and replace components if they are damaged Secure burner gauze assembly and gasket...
Commissioning, inspection, maintenance Checking and adjusting the ignition and ionisation electrodes ±0.5 Fig. 30 Ignition electrodes Ionisation electrode 1. Check the electrodes for wear and contamination. 3. Check the electrode gaps. If the gaps are not as specified or the electrodes are damaged, replace 2.
Commissioning, inspection, maintenance Checking the back draught safety devices (cont.) Back draught safety device in the flue gas connec- 1. Remove the balanced flue system. tion Note If the balanced flue system cannot be removed, clean and check the back draught safety device via the inspection cover.
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Commissioning, inspection, maintenance Checking the condensate drain and cleaning the… (cont.) 4. Pull trap upwards out of the drain hose. 5. Hold trap as straight as possible and remove. Ensure that no condensate runs out. 6. Clean the trap. 7. Fill the trap with water and refit it on the drain hose. Please note If the trap is not filled with water, flue gas can escape.
Commissioning, inspection, maintenance Installing the burner Fig. 35 1. Insert the burner. Tighten screws diagonally. 3. Check the gas connections for leaks. Tighten screws as tightly as necessary and ensure that the components are undamaged and are func- Danger tioning correctly throughout service life. Escaping gas leads to a risk of explosion.
Risk of electric shock from escaping heating water or DHW Check all water side connections for tight- ness. Fig. 36 Flow limiter Device type Serial no. Flow rate Colour (type plate) l/min B0KA-19 7721280 7721282 7721284 7721286 BPKA-19 7721975 B0KA-25 7721281 Pink 7721283 Pink...
Commissioning, inspection, maintenance Checking the expansion vessel and system… (cont.) 3. Top up with water until the charge pressure of the cooled system is at least 1.0 bar (0.1 MPa), and is 0.1 to 0.2 bar (10 to 20 kPa) higher than the pre- charge pressure of the expansion vessel.
Commissioning, inspection, maintenance Checking the combustion quality The electronic combustion controller automatically Note ensures optimum combustion quality. During commis- To prevent operating faults and damage, operate the sioning/maintenance, only the combustion values need appliance with uncontaminated combustion air. to be checked. To do this, test the CO content and CO or O content, and record these in the report on page 86.
Commissioning, inspection, maintenance Checking the combustion quality (cont.) Regulating to the upper/lower heating output Note 3. OK Ensure adequate heat transfer. 4. Use to set the value. Tap the following buttons: "0" - OFF "1" - Min. heating output and OK simultaneously for approx. 4 s, then "2"...
System configuration (parameters) Calling up parameters Note 3. OK The display and setting of some parameters is dependent on: 4. Use to select the parameter for adjust- ■ Heat generator ment. See tables below. ■ Connected accessories and the functions associated with them 5.
System configuration (parameters) Parameters (cont.) 6 "Minimum heating output" Setting Explanations A limit can be set on the minimum heating output for heating mode. Delivered condition specified by settings specific to the appliance 0 to 100 Adjustable from 0 to 100 % 7 "Maximum heating output"...
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System configuration (parameters) Parameters (cont.) 1667.0 Pump activation, heating circuit pump in standby mode (via software tool) Setting Explanations Operating mode heating circuit pump (only for con- stant operation) In "Standby mode" = permanently switched off 1 - 24 In "Standby mode", started 1 to 24 times per day for 10 min each time...
Diagnosis and service checks Service menu Calling up the service menu Tap the following buttons: Note Tap " " to return to the service menu. and OK simultaneously for approx. 4 s, then release. 2. Select the required menu section (e.g. "b.1" Con- nect with software tool).
Diagnosis and service checks Diagnosis Checking operating data Operating data can be checked in various areas. See 2. Use to select "b.3" for diagnostics. "Diagnosis" in the service menu overview. Operating data on heating circuits with mixer can only 3. OK be called up if such components are installed in the system.
Troubleshooting Fault display on the programming unit A fault in the burner control unit causes the display to to select "Er". show " ". 3. OK Note If a central fault message facility is connected, this is to call up fault entry "E.1 to E.5". switched on.
Troubleshooting Overview of electronics modules Fig. 38 HBMU heat management unit Programming unit with TCU 100 communication module Fault messages Note For diagnosis and troubleshooting, see chapter "Repairs". Fault messages dependent on appliance equipment level...
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Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code No DHW heating Lead break, cylinder tem- Check DHW setting in the com- ■ perature sensor missioning assistant and correct if required. Check the cylinder temperature ■ sensor (terminal 2). Measure voltage at sensor input ■...
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Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state High limit safety cut-out Check heating system fill level. ■ has responded. Check pre-charge pressure in di- ■ aphragm expansion vessel. Ad- just to required system pressure. Check whether flow rate is suffi- ■...
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Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state Ionisation current lies out- Check ionisation electrode for the side the permissible range following: Check whether insulation block is ■ touching electrode ceramic. To check the gas solenoid valve: ■...
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Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Function of the relevant elec- ADIO electronics module Check setting in the commission- ■ tronics module in emergency communication error ing assistant and correct if re- mode quired. Check connections and leads to ■...
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Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state Checksum error, data Reset the appliance. memory access, HBMU If the fault occurs repeatedly, re- heat management unit place the HBMU heat management unit. See chapter "Replacing the HBMU heat management unit".
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Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state Air mass rate flow not de- Check for dust contamination in ■ tected correctly in fan unit. the ventilation air. Check burner gauze assembly ■...
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Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state No ignition spark Check whether the ignition elec- ■ trode insulation is damaged. Check for a voltage of 230 V∼ at ■ the ignition module during the ig- nition phase.
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Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state Repeated flame loss dur- Check ionisation electrode and ■ ing calibration connecting cable. Check plug-in connections for ■ loose contacts. Check flue system. Remove flue ■...
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Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state Flame is lost immediately Check gas supply (gas pressure after flame formation (dur- and gas flow switch). ing safety time) Check balanced flue system for flue gas recirculation.
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Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state HBMU heat management Replace the HBMU heat manage- unit faulty ment unit. See chapter "Replacing the HBMU heat management unit". Reset the appliance. Burner in a fault state IO electrode earth fault, Check IO electrode for earth fault.
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Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code System in control mode, cal- Time synchronisation Set the time. culation out of operation failed Calculation values can be viewed via software tool. Burner in a fault state Deviation, heat generator Check the flow temperature sen- flow temperature sensor/ sor/high limit safety cut-out.
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Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state Ionisation current too low Check ionisation electrode and ■ during calibration. Differ- connecting cable. Check plug-in ential compared to previ- connections for loose contacts. ous value not plausible.
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Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state Ionisation current too high Check gap between ionisation during calibration electrode and burner gauze as- sembly. Check whether there is a lot of dust in the ventilation air (e.g. from construction work).
Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state Condensate backup in the Check system for condensate ■ heat cell backup. Check the condensate drain and ■ trap. Replace insulation blocks, elec- ■ trodes and burner gauze assem- bly if required.
Troubleshooting Repairs (cont.) Shutting down the boiler 1. Turn off the power supply at the ON/OFF switch. 3. If the boiler needs to be removed: Isolate the system from the power supply, e.g. by ■ 2. Shut off the gas supply. removing the separate fuse or by means of a mains isolator, and check that it is no longer live.
Troubleshooting Repairs (cont.) Note Note Use new gaskets and, if required, new locking ring When carrying out any work on gas connection fittings, connections when assembling. hold with a suitable tool. Never transfer any forces to the internal components. Internal gasket diameter: Gas connection Ø...
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Troubleshooting Repairs (cont.) 3. Check the sensor resistance. Note position of 3. Check the sensor resistance. Compare the resist- guide lug ance with the value for the current temperature ■ Sensor 1: Connections 1 and 3 from the following diagram. ■...
If replacing the HBMU heat management unit, the See spare part installation instructions and inter- "Vitoguide app" must be used. net address: "www.vitoguide.info" Replacing the power cable When replacing the power cable, only use the power cable available as an individual part from Viessmann.
Troubleshooting Repairs (cont.) Replacing the HMI connecting cable Please note Incorrect routing of the cable can lead to heat damage and impairment of the EMC properties. For positioning and securing of the cable (fixing point of the cable tie) see connecting cable installation instructions.
Troubleshooting Repairs (cont.) 7. Install plate heat exchanger in reverse order using new gaskets. Tighten screws as tightly as necessary and ensure that the components are undamaged and are func- tioning correctly throughout service life. Observe torque settings if a torque wrench is avail- able.
Troubleshooting Repairs (cont.) Checking the fuse Fig. 43 1. Turn off the ON/OFF switch 5. Check fuse F1 (see connection and wiring dia- gram). 2. Remove the programming unit. Danger 3. Pivot the HBMU heat management unit down. Incorrect or improperly fitted fuses can lead to an increased risk of fire.
Function description Appliance functions Heating mode Weather-compensated operation: Constant operation without room thermostat: ■ ■ The rooms are heated in accordance with the room The rooms are heated according to the set flow tem- temperature settings. perature settings. The control unit determines a set flow temperature ■...
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Function description Appliance functions (cont.) Slope -5 -10 -15 -20 Outside temperature in °C Fig. 44 Slope setting ranges: Changing the set room temperature ■ Underfloor heating systems: 0.2 to 0.8 ■ Low temperature heating systems: 0.8 to 1.6 Operating instructions Set room temperature Changing the slope and level Standard room temperature...
Function description DHW heating The burner, the circulation pump and the 3-way Danger diverter valve are started or changed over if the cylin- Risk of injury due to increased DHW tempera- der temperature lies 2.5 K below the set cylinder tem- ture.
Connection and wiring diagram HBMU heat management unit Fig. 47 A1 HBMU heat management unit Fan motor control A2 Power supply unit Outlet temperature sensor (combi boiler only) X... Electrical interfaces Connection accessory 230 V Power supply 230 V/50 Hz Fan motor 230 V a-Ö...
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Connection and wiring diagram HBMU heat management unit (cont.) Mains input fÖ No function Fig. 48 A1 HBMU heat management unit X... Electrical interfaces A3 Programming unit with communication module Flow sensor (combi boiler only)
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Connection and wiring diagram (cont.) Water pressure sensor Stepper motor for diverter valve Flue gas temperature sensor Outside temperature sensor Boiler water temperature sensor Remote control (OpenTherm controller) Internal circulation pump (PWM) Cylinder temperature sensor (system boiler only)
Commissioning/service reports (cont.) Settings and test values Set value Commission- Maintenance/ Maintenance/ service service Date Signature Static pressure mbar 57.5 ≤ 5.75 ≤ Supply pressure (flow pres- sure) For natural gas ..mbar See table "Supply pressure" (Commis- sioning ...) Enter gas type Carbon dioxide content CO For natural gas...
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Commissioning/service reports (cont.) Settings and test values Set value Commission- Maintenance/ Maintenance/ service service At lower heating output % by See "Check- ■ vol. ing the com- bustion qual- At upper heating output % by ■ ity" (Com- vol. mission- ing ...) Oxygen content O At lower heating output...
■ During storage and transport °C -5 to +60 ■ Appliances for multiple connection of type B0KA-[kW]-M If the gas supply pressure is higher than the maximum permissible value, install a separate gas pressure governor up- stream of the system.
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Temperature (at a return temperature of 60 °C, for DHW °C heating) Mass flow rate (for DHW heating) Natural gas At rated heating output kg/h 31.7 41.6 – At partial load kg/h 5.6 (9.8) 5.6 (9.8) – Available draught mbar Appliances for multiple connection of type B0KA-[kW]-M...
ME, MT, NO, PT, RO, RS, RU, SE, SK, TR, UA, AM, AZ, BY, MD, KG, KZ, RU, UA, UZ 2N/2H - G 20 - (13) 20 mbar Appliances for multiple connection of type B0KA-[kW]-M Only for specifically marked appliances.
Specification Gas categories (cont.) Available in the following countries Gas categories BE, FR 2N - G 20/G 25 - 20/25 mbar 2N - G 20/G 25 - 20 mbar 2N/2H - G 20 - 20 mbar 2E - G 20 - 20 mbar 2K - G 25.3 - 25 mbar 2N/2E - G 20 - 20 mbar 2ELw...
Disposal Final decommissioning and disposal Viessmann products can be recycled. Components For decommissioning, isolate the system from the and substances from the system are not part of ordi- power supply and allow components to cool down nary domestic waste. where appropriate.
Certificates Declaration of conformity We, Viessmann Climate Solutions SE, D-35108 Allen- dorf, declare as sole responsible body that the named product complies with the European directives and supplementary national requirements in terms of its design and operational characteristics. Viessmann Cli-...
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