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

Wall mounted gas condensing boiler
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VIESMANN
Installation and service instructions
for contractors
Vitodens 100-W
Type B1GA, 3.2 to 25 kW
Wall mounted gas condensing boiler
Natural gas version
Gas Council No.
B1GA: 41-819-52, 41-819-53, 41-819-54, 41-819-55
VITODENS 100-W
Please keep safe.
6174240 GB
6/2021

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  • Page 1 VIESMANN Installation and service instructions for contractors Vitodens 100-W Type B1GA, 3.2 to 25 kW Wall mounted gas condensing boiler Natural gas version Gas Council No. B1GA: 41-819-52, 41-819-53, 41-819-54, 41-819-55 VITODENS 100-W Please keep safe. 6174240 GB 6/2021...
  • Page 2 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.
  • Page 3 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.
  • Page 4 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.
  • Page 5 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.

  • Page 6: Table Of Contents

    Disposal of packaging ................Gas Council No..................Symbols ....................10 Intended use ..................10 Product information ................11 Vitodens 100-W, type B1GA ............... 11 ■ System examples .................. 11 Spare parts lists ..................12 3. Preparing for installation Dimensions and connections ..............13 Removing the boiler from the packaging ..........
  • Page 7 Index Index (cont.) 9. Function description Appliance functions ................66 Heating mode ..................66 ■ Heating curve ..................66 ■ External heating circuit hook-up (if installed) ......... 67 10. Connection and wiring dia- HBMU heat management unit ............... 68 gram Commissioning/service ........................

  • Page 8: Warnings Warning Notices According To Gb25034-2010

    Warnings Warning notices according to GB25034-2010 Warning against incorrect use: Do not remove any sealed parts from the appliance. ■ ■ A faulty installation can lead to injury and material ■ Do not use caustic cleaning agents to clean the losses.

  • Page 9: Information Key To Date Of Manufacture

    Disposal of packaging Please dispose of packaging waste in line with statu- tory regulations. Gas Council No. Type Gas Council Number: Vitodens 100-W, B1GA, 11 kW 41-819-52 Vitodens 100-W, B1GA, 16 kW 41-819-53 Vitodens 100-W, B1GA, 19 kW 41-819-54 Vitodens 100-W, B1GA, 25 kW...

  • Page 10: Symbols

    Information Symbols The steps in connection with commissioning, inspec- Symbol Meaning tion and maintenance are found in the "Commission- Reference to other document containing ing, inspection and maintenance" section and identified further information as follows: Step in a diagram: Symbol Meaning The numbers correspond to the order in Steps required during commissioning...

  • Page 11: Product Information

    Information Product information Vitodens 100-W, type B1GA Wall mounted gas condensing boiler with Inox-Radial The selected gas category in the delivered condition heat exchanger and the following integrated compo- and the associated nominal gas pressure are given on nents: the boiler type plate. The type plate also shows the ■...

  • Page 12: Spare Parts Lists

    Information Spare parts lists Information about spare parts can be found at www.viessmann.com/etapp or in the Viessmann spare part app.

  • Page 13: Preparing For Installation Dimensions And Connections

    Preparing for installation Dimensions and connections Ø 95 -0,5 Ø 66 +0,8 Fig. 3 Condensate drain Heating flow Gas connection Heating return Dimension for siting with DHW cylinder below the boiler...
  • Page 14 Preparing for installation Dimensions and connections (cont.) Note This boiler (IP rating: IP X4) is approved for installation in wet rooms inside safety zone 1, to DIN VDE 0100. Exposure to jets of water must be prevented. For open flue operation, the boiler may only be oper- ated with a splash cover.

  • Page 15: Removing The Boiler From The Packaging

    Preparing for installation Removing the boiler from the packaging Fig. 4 Fitting the wall mounting bracket Installation template 1. Position the supplied installation template on the wall.
  • Page 16 Preparing for installation Fitting the wall mounting bracket (cont.) 2. Mark out the rawl plug holes. 4. Fit the wall mounting bracket with the screws sup- plied. 3. Drill 10 mm holes and insert the rawl plugs sup- plied. The rawl plugs are suitable for the following materi- als: Concrete ■...

  • Page 17: Installation Sequence Removing The Front Panel

    Installation sequence Removing the front panel 1. Unlock the front panel on the underside (push in), using a screwdriver or similar tool. 2. Swivel the front panel forwards slightly and lift away upwards. Fig. 5 Preparing the connections Please note 3.

  • Page 18: Fitting The Boiler To The Wall Mounting Bracket

    Installation sequence Fitting the boiler to the wall mounting bracket Note Various installation components can be found in a sep- arate pack. Keep the installation components safe, as they will be required for later installation. Fig. 6 1. Replace gaskets. 2.

  • Page 19: Connections On The Heating Water Side

    Installation sequence Fitting the boiler to the wall mounting bracket (cont.) 4. Tighten union nuts so that they form a tight seal. 5. Tighten locking ring fittings so that they form a tight Tighten the union nuts as tightly as necessary and seal: ensure that the components are undamaged and 1 turn beyond finger-tight...

  • Page 20: Y-Plan System

    Installation sequence Connections on the heating water side (cont.) Y-plan system Fig. 8 Cylinder Feed and expansion tank Vitodens 100-W 3-way diverter valve Circulation pump Radiators Condensate connection 1. Push the supplied drain hose on to the drain con- nector.

  • Page 21: Filling The Trap With Water

    Flue system installation instructions or Groppalli flue system" enclosed with the technical documentation may only be used in conjunction with the Viessmann flue system made by Skoberne or Groppalli. Gas connection 1. If the gas connection has not been fitted previ-...

  • Page 22: Electrical Connections

    Installation sequence Gas connection (cont.) 2. Check for leaks. 3. Purge the gas line. Danger Escaping gas leads to a risk of explosion. Check all connections on the gas side (also inside the appliance) for tightness. Note Only use suitable and approved leak detection agents (EN 14291) and devices for the leak test.

  • Page 23: Layout Of The Electrical Connections

    Installation sequence Electrical connections (cont.) Layout of the electrical connections Note For further information on the connections, see the fol- lowing chapters. N 1 L N L L N N L N L N L 10 987654321 654321 654321 654321 35 54 X12 X5 Fig.

  • Page 24: On-Site Connections On The Hbmu Heat Management Unit

    Installation sequence Electrical connections (cont.) On-site connections on the HBMU heat management unit Open diaphragm grommets as required. Thread ■ through only one cable at a time without a plug. Ensure diaphragm grommets are airtight. If required, remove plug from cable. After threading the cable through, re-fit the plug to the wire ferrules.

  • Page 25: Routing Connecting Cables/Leads

    Installation sequence Electrical connections (cont.) Danger The absence of system component earthing can lead to serious injury from electric current if an electrical fault occurs. The appliance and pipework must be connected to the equipotential bonding of the building. Routing connecting cables/leads Please note Bundle cables using the supplied cable clips.

  • Page 26: Fitting The Front Panel

    Installation sequence Fitting the front panel Fig. 17...

  • Page 27: Commissioning, Inspec-Steps - Commissioning, Inspection And Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • 1. Commissioning the system....................28 • • 2. Filling the heating system....................29 • • • 3. Checking all connections on the heating water and DHW sides for leaks....29 •...

  • Page 28: Commissioning The System

    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...

  • Page 29: Filling The Heating System

    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.

  • Page 30: Checking The Gas Type

    Commissioning, inspection, maintenance Checking the gas type The boiler is equipped with an electronic combustion 1. Check with your gas supply utility regarding the controller that adjusts the burner for optimum combus- gas type and Wobbe index. tion in accordance with the prevailing gas quality. ■...
  • Page 31 Commissioning, inspection, maintenance Checking the static pressure and supply pressure (cont.) 01. Turn off the ON/OFF switch. 02. Close the gas shut-off valve. 03. Undo screw inside test connector on the gas solenoid valve, but do not remove it. Connect the pressure gauge.

  • Page 32: Function Sequence And Possible Faults

    Commissioning, inspection, maintenance Function sequence and possible faults Display Measure Control unit issues a heat Increase set value. Ensure demand heat transfer. Fan starts Fault 59, 457 Check the fan connecting ca- bles. Check the fan power supply. Ignition Fault 359 Check ignition module (con- trol voltage 230 V across plug "X1/54"...

  • Page 33: Setting The Maximum Heating Output

    Commissioning, inspection, maintenance Setting the maximum heating output Note 2. Use to select "b.2" for system configura- It is not possible to set the max. heating output for tion. type B1GA-11. 3. OK A limit can be set on the maximum heating output for heating mode.

  • Page 34: Removing The Burner

    Commissioning, inspection, maintenance Removing the burner 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 ■...

  • Page 35: Checking The Burner Gasket And Burner Gauze Assembly

    Commissioning, inspection, maintenance Checking the burner gasket and burner gauze assembly Fig. 22 7. Align the hole in burner gauze assembly Check burner gauze assembly , electrodes , ther- with mal insulation ring and gasket for damage. Only the burner door pin. remove and replace components if they are damaged Secure burner gauze assembly and gasket...

  • Page 36: Checking And Adjusting The Ignition And Ionisation Electrodes

    Commissioning, inspection, maintenance Checking and adjusting the ignition and ionisation electrodes ±0.5 Fig. 23 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.

  • Page 37: Checking The Condensate Drain And Cleaning The Trap

    Commissioning, inspection, maintenance Checking the condensate drain and cleaning the trap Please note 3. Remove the black supply hose. Prevent damage due to condensate. Cover electronic components with suitable 4. Pull trap upwards out of the drain hose. watertight material. 5.

  • Page 38: Installing The Burner

    Commissioning, inspection, maintenance Installing the burner Fig. 26 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 Escaping gas leads to a risk of explosion. tioning correctly throughout service life.

  • Page 39: Checking The Electrical Connections For Firm Seating

    Commissioning, inspection, maintenance Checking the electrical connections for firm seating 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 ■...

  • Page 40: Checking The Flue System For Unrestricted Flow And Leaks

    Commissioning, inspection, maintenance Checking the combustion quality (cont.) If the actual CO, CO or O values lie outside their respective ranges, proceed as follows: ■ Check the balanced flue system for leaks; see page 33. ■ Check the ionisation electrode and connecting cable, see page 36.

  • Page 41: Adjusting The Heating Curves

    Commissioning, inspection, maintenance Adjusting the heating curves Tap the following buttons: 4. Use to set the slope. 5. OK 2. Use to select "P.3" for the heating curve. 6. Use to set the level. 3. OK 7. OK to confirm Instructing the system user The system installer should hand the operating instruc- This includes all components installed as accessories,...

  • Page 42: System Configuration Calling Up Parameters

    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.

  • Page 43: Energy Saving Functions (Setting Only Via Software Tool)

    System configuration (parameters) Parameter (cont.) 7 "Maximum heating output" Setting Explanations A limit can be set on the maximum heating output for heating mode. Heating output in the delivered condition 100 % 0 to 100 Adjustable from 0 to 100 % 9 "Maximum flow temperature limit, heating circuit 1"...

  • Page 44: Diagnosis And Service Service Menu

    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).
  • Page 45 Diagnosis and service checks Diagnosis (cont.) 4. Use to select the required entry. 5. OK Note "d.8" Use to view the heat generator serial number in sections.

  • Page 46: Troubleshooting Fault Display On The Programming Unit

    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.

  • Page 47: Overview Of Electronics Modules

    Troubleshooting Overview of electronics modules Fig. 28 HBMU heat management unit Programming unit Fault messages Note For diagnosis and troubleshooting, see chapter "Repairs". Fault messages dependent on appliance equipment level Displayed fault System characteristics Cause Measures code No DHW heating Lead break, cylinder tem- Check the DHW setting in the ■...
  • Page 48 Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Regulates as if the outside Lead break, outside tem- Check the operating mode set- ■ temperature were 0 °C. perature sensor ting in the commissioning assis- tant and remedy if necessary. Check outside temperature sen- ■...
  • Page 49 Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state Flue gas temperature lim- Check heating system fill level. ■ iter has responded. Check pre-charge pressure in di- ■ aphragm expansion vessel. Ad- just to required system pressure. Check whether flow rate is suffi- ■...
  • Page 50 Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state Fan speed too low Check fan for blockage. ■ Check setting for gas type and ■ flue system. Reset the appliance. Burner in a fault state Internal communication Reset the appliance.
  • Page 51 Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Normal operation Internal communication Check cables and plug-in connec- error, programming unit tions between heat management unit and HMI programming unit. Depending on configuration External fault message in- Check connected external device. of EM-EA1 extension (DIO put active electronics module)
  • Page 52 Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner locked out, automatic Temperature limiter has Ensure adequate heat transfer. ■ enabling after appliance cool- responded. Check heating system fill level. ■ down. Independent restart Check pre-charge pressure in di- ■...
  • Page 53 Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Shutdown with restart if de- Insufficient gas supply, Check the gas supply. mand exists burner output reduced Visually check the inlet strainer in the gas solenoid valve for dirt. Reset the appliance.
  • Page 54 Troubleshooting Fault messages (cont.) Displayed fault System characteristics Cause Measures code Burner in a fault state Flame signal is not Check ionisation electrode and present or insufficient at connecting cable. Check plug-in burner start. connections for loose contacts. Note Deposits on the electrodes indicate foreign bodies in the combustion air.
  • Page 55 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 ■...
  • Page 56 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.
  • Page 57 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.
  • Page 58 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.
  • Page 59 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 Check whether there is a lot of ■...
  • Page 60 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).

  • Page 61: Repairs

    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 necessary.

  • Page 62: Shutting Down The Boiler

    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.

  • Page 63: Checking The Temperature Sensors

    Troubleshooting Repairs (cont.) Checking the temperature sensors Fig. 30 Heat generator circuit flow temperature sensor 3. Check the sensor resistance. Note position of (dual sensor) guide lug ■ Sensor 1: Connections 1 and 3 1. Check the leads and plugs of flow temperature ■...
  • Page 64 Troubleshooting Repairs (cont.) 2. Disconnect wires 7 and 8 from terminal 4. 4. Check the sensor resistance. Compare the resist- ance with the value for the currently recorded tem- 3. Check the sensor resistance. Compare the resist- perature from the following diagram. ance with the value for the current temperature In the event of severe deviation (>...

  • Page 65: Information On Replacing The Hbmu Heat Management Unit

    "www.vitoguide.info" Replacing the power cable When replacing the power cable, only use the power cable available as an individual part from Viessmann. Replacing the HMI connecting cable Please note Incorrect routing of the cable can lead to heat damage and impairment of the EMC properties.

  • Page 66: Function Description Appliance Functions

    Function description Appliance functions Heating mode Weather-compensated operation: ■ The rooms are heated in accordance with the room temperature settings. The control unit determines a set flow temperature for the heat generator, subject to the outside temper- ature, the room temperature and the slope/level of the heating curve.

  • Page 67: External Heating Circuit Hook-Up (If Installed)

    Function description Appliance functions (cont.) The heating curve is offset along the set room temper- Changing the slope and level ature axis. The start and stop points of the heating cir- cuit pumps depend on the Heating limit, outside tem- Individually adjustable for each heating circuit perature for heating circuit...

  • Page 68: Connection And Wiring Dia-Hbmu Heat Management Unit

    Connection and wiring diagram HBMU heat management unit Fig. 35 A1 HBMU heat management unit Ignition/ionisation A2 Power supply unit Fan control X... Electrical interfaces Cylinder demand junction box Power supply 230 V/50 Hz Jumper; remove when making this connection. Vitotrol 100, type UTDB 230 V connection accessories for accessories Vitotrol 100, type UTA...
  • Page 69 Connection and wiring diagram HBMU heat management unit (cont.) Gas solenoid valve Mains input fÖ Heating circuit pump...
  • Page 70 Connection and wiring diagram (cont.) Fig. 36 A1 HBMU heat management unit Flue gas temperature sensor A3 Programming unit Boiler water temperature sensor X... Electrical interfaces Outside temperature sensor Flow switch...

  • Page 71: Commissioning/Service

    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...
  • Page 72 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...

  • Page 73: Specification Gas Condensing Boiler

    Specification Gas condensing boiler Gas boiler, type B and C, category I Type B1GA Rated heating output range (details to EN 15502) = 50/30 °C Natural gas 3.2 - 11 3.2 - 16 3.2 - 19 3.2 - 25 3.2 - 32 = 80/60 °C Natural gas 2.9 - 9.9...
  • Page 74 Specification Gas condensing boiler (cont.) Gas boiler, type B and C, category I Type B1GA Rated heating output range (details to EN 15502) = 50/30 °C Natural gas 3.2 - 11 3.2 - 16 3.2 - 19 3.2 - 25 3.2 - 32 = 80/60 °C Natural gas...

  • Page 75: Flue System Types

    Specification Flue system types Available in the following countries Flue system types GB, IE Gas categories Available in the following countries Gas categories GB, IE 2N/2H - G 20 - 20 mbar Electronic combustion control unit The electronic combustion controller utilises the physi- To achieve optimum combustion control, the system cal correlation between the level of the ionisation cur- regularly carries out an automatic self-calibration;...

  • Page 76: Disposal Final Decommissioning And Disposal

    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.

  • Page 77: Certificates Declaration Of Conformity

    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-...

  • Page 78: Keyword Index

    Keyword index Keyword index Boiler water temperature sensor........ 63 Ignition................36 Burner gasket.............35 Ignition electrodes............36 Burner gauze assembly..........35 Installation preparation..........13 Burner installation............38 Intended use.............. 10 Burner removal............34 Ionisation electrode............ 36 Combustion chamber, cleaning........36 Language selection............ 28 Combustion controller..........75 Leak test, balanced flue system.........33 Combustion quality, checking........39 Commissioning............29...
  • Page 80 Viessmann Climate Solutions SE Viessmann Limited 35108 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 Fax: +44 1952 675040 E-mail: info-uk@viessmann.com...

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B1ga

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