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

Gas fired wall mounted condensing boiler
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VIESMANN
Installation and service
instructions
for contractors
Vitodens 100
Type WB1A
Gas fired wall mounted condensing boiler
Natural gas version
For applicability, see the last page
VITODENS 100
Please keep safe.
5862 881 GB
10/2006

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Summary of Contents for Viessmann VITODENS 100

  • Page 1 VIESMANN Installation and service instructions for contractors Vitodens 100 Type WB1A Gas fired wall mounted condensing boiler Natural gas version For applicability, see the last page VITODENS 100 Please keep safe. 5862 881 GB 10/2006...
  • Page 2 Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained If you notice the smell of gas Danger Danger This symbol warns against the Escaping gas can cause explo- risk of injury. sions which may lead to ser- ious injury.
  • Page 3 Repairing components which For replacements, use only ori- fulfil a safety function can com- ginal spare parts from promise the safe operation of Viessmann or those which are your heating system. approved by Viessmann. Replace faulty components only with original Viessmann...

  • Page 4: Table Of Contents

    Index Index Installation instructions Preparing for installation Product information ..................Preparing for installation ................Installation sequence Installing the boiler and making all connections ........... 31 Flue outlet ....................38 Electrical connections................. 40 Commissioning and testing ................. 45 Service instructions Commissioning, inspection, maintenance..........55 Service Instructions Routine Servicing Instructions ..............

  • Page 5: Preparing For Installation

    Set up for operation with natural gas. Preparing for installation General Information Appliance description The Vitodens 100 is a fully automatic, The appliance is designed for use wall hung, fan assisted balanced flue with sealed primary water systems condensing boiler for use with natural (only) and incorporates a circulation gas (G20).
  • Page 6 Preparing for installation Preparing for installation (cont.) Technical Specification General Specifications and Performance Data Rated output range 50/30 °C 8 to 24 8 to 30 80/60 °C 7.3 to 21.8 7.3 to 27.3 Rated output range 7.4 to 22.3 7.4 to 28.0 Maximum gas rate 2.36 2.96...
  • Page 7 Preparing for installation Preparing for installation (cont.) Overall Appliance Dimensions Combi boiler A Condensate drain: Plastic pipe D Gas connection: Rp ½" 722 mm E Cold water: 715 mm B Heating flow: 722 mm F Heating return: 722 mm C DHW: 715 mm G Safety valve drain: 715 mm...
  • Page 8 Preparing for installation Preparing for installation (cont.) System boiler A Condensate drain: Plastic pipe D Gas connection: Rp ½" 722 mm E DHW return: 722 mm B Heating flow: 722 mm F Heating return: 722 mm C DHW cylinder flow: 722 mm G Safety valve drain: 715 mm...
  • Page 9 Preparing for installation Preparing for installation (cont.) Minimum installation clearances The following minimum clearances (mm) must be maintained for installing and servicing the appliance. A Front (behind removable panel) B Front (for service) Flue System Specifications Concentric Horizontal Flue System Standard horizontal flue kit: The appli- Extension ducts can be used to ance can be supplied complete with a...
  • Page 10 Preparing for installation Preparing for installation (cont.) An extra 87° elbow can be used but this reduces the maximum permissi- ble length by 1 m . An extra 45° elbow can be used but this reduces the max- imum permissible length by 0.5 m . A Combined length of flue outlet/ B Flue outlet/ventilation pipe (can ventilation pipe max 6m.
  • Page 11 Preparing for installation Preparing for installation (cont.) Before commencing the installation refer to diagram below to determine which optional extension kits are required, if any. A Combined length of flue outlet/ B Flue outlet/ventilation pipe (can ventilation pipe max. 10 m. be shortened as necessary)
  • Page 12 Preparing for installation Preparing for installation (cont.) Elbows and extensions Extension Elbow 45° Elbow 87°...
  • Page 13 Preparing for installation Preparing for installation (cont.) Hydraulic circuit Combi boiler A Boiler E Plate-type heat exchanger B heat exchanger F DHW outlet C circulation pump G Cold water inlet D Three-way diverter valve H Heating circuit...
  • Page 14 Preparing for installation Preparing for installation (cont.) System boiler A DHW cylinder D circulation pump B Boiler E Three-way diverter valve C heat exchanger F Heating circuit...
  • Page 15 Preparing for installation Preparing for installation (cont.) Sectional Diagram Combi boiler illustrated Installation Requirements Statutory Requirements Gas safety (installation and use) regulations (current issue) It is in your own interest and safety, to ensure that the law is complied with.
  • Page 16 Preparing for installation Preparing for installation (cont.) In addition to the above regulations, CORGI will then issue either a Build- this appliance must be installed in ing Compliance Certificate (for Eng- accordance with the current IEE Wir- land and Wales) or a Declaration of ing Regulations for electrical installa- Safety (for Scotland, Northern Ireland, tion (BS 7671), local building...
  • Page 17 Preparing for installation Preparing for installation (cont.) If the appliance is to be installed in a A compartment used to enclose the room containing a bath or shower, appliance must be designed and any electrical switch or control utilis- constructed specifically for this pur- ing mains electricity, it must be so pose.
  • Page 18 Preparing for installation Preparing for installation (cont.) Position Minimum spacing Below eaves Below a balcony From vertical drain or soil pipes From internal and external corners Above adjacent ground or balcony level/roof From a surface facing the terminal Facing terminals 1200 From opening door/window in carport into 1200...
  • Page 19 Preparing for installation Preparing for installation (cont.) Position Minimum spacing From adjacent wall From adjacent opening window 1000 From another terminal Minimum height Flue Terminal Location Detailed recommendations for flue If the terminal discharges into a installation are given in BS 5440:1. pathway or passageway check that The following notes are for general combustion products will not cause...
  • Page 20 9 are maintained. Central Heating System (typical system designs) The Vitodens 100 is designed for connection to sealed central heating water systems. A sealed system must only be filled by a competent person. Filling the heating system see page 47.
  • Page 21 Preparing for installation Preparing for installation (cont.) A Radiators F Drain cock at lowest point in the B Boiler system C Lockshield valve G Hot water taps D CH flow H Water main E CH return K BS stop valve...
  • Page 22 Connection see page 41 LS Connection of DHW cylinder con- S Connection box (not supplied) trol The following Viessmann control configurations are available: Constant temperature Timer with constant temperature Vitotrol 100 UTD The boiler requires a permanent live feed via plug 40.
  • Page 23 Preparing for installation Preparing for installation (cont.) A Radiators F CH return B Boiler G Drain cock at lowest point in the C DHW-Cylinder system D Lockshield valve H Control unit E CH flow K Cylinder thermostat...
  • Page 24 The following Viessmann control The DHW cylinder must have an configurations are available: integrated temperature control con- Constant temperature nected to the Vitodens 100 Timer with constant temperature The DHW will always take priority Vitotrol 100 UTD over the central heating when timed The boiler requires a permanent live demand is selected.
  • Page 25 Preparing for installation Preparing for installation (cont.) Expansion vessel Further details are available in the The table shows the maximum system current issues of BS 5449 and BS volume that the integral expansion 6798. vessel can sustain under different If the pressure gauge rises by 1.5 bar charge pressure conditions.
  • Page 26 Preparing for installation Preparing for installation (cont.) Pressure relief valve A pressure relief valve set at 3 bar (43.5 psi) is supplied with the appli- ance. Domestic Hot Water System (Combi boiler only) Check that the mains water pres- If the appliance is installed in an sure is sufficient to produce the area where the temporary hardness required DHW flow rate of 9.0 l/min...
  • Page 27 (and its external con- trols) may be used. External Controls To ensure optimum performance, Viessmann offer a range of external controls however the appliance may be used with any certificated room thermostat or time clock room thermo-...
  • Page 28 Preparing for installation Preparing for installation (cont.) Preparations for boiler installation Unpacking the appliance The appliance is supplied in 2 sepa- rate packages plus any optional flue packages. Check the availability and contents of each package before commencing the installation. Boiler package Combi boiler System boiler...
  • Page 29 Preparing for installation Preparing for installation (cont.) A Installation template B Observe the minimum slope of 3° (5mm/m) towards the boiler 1. Position the installation template 2. Mark wall plug holes and balanced on the wall. flue pipe opening.
  • Page 30 Preparing for installation Preparing for installation (cont.) 3. Drill 710 mm holes and insert the 5. Fit wall mounting frame with rawl plugs. enclosed screws. 4. Cut flue pipe opening to 100 mm Preparing the connections Note For dimensions for on-site preparations of the gas and water side connections see "Overall Appliance Dimensions"...

  • Page 31: Installation Sequence

    Installation sequence Installing the boiler and making all connections Remove front panel and mount boiler Note The front panel must be removed before mounting the boiler. 1. Remove the screw at the top of the 3. Hook the boiler on to the wall boiler.
  • Page 32 Installation sequence Installing the boiler and making all connections (cont.) Gas connection 1. Connect the gas supply to the gas inlet connection on the gas cock A. Upon completion, tighten the union connection. 2. Carry out a gas soundness test. 3.
  • Page 33 Installation sequence Installing the boiler and making all connections (cont.) A Heating flow: 722 mm (red tog- D Cold water: 715 mm gle) E Heating return: 722 mm (blue B DHW: 715 mm toggle) C Gas connection: ½" BSP System boiler Note For operation without a DHW cylinder, shut-off connections C Gas connection: ½"...
  • Page 34 Installation sequence Installing the boiler and making all connections (cont.) Connect safety valve drain Connect a suitable discharge pipe to the pressure relief valve outlet. The pipe discharging to a safe place must be a minimum of 15 mm copper and run continually downwards.
  • Page 35 Installation sequence Installing the boiler and making all connections (cont.) Condensate connection Vitodens 100 has within a syphonic condensate trap. A 722 mm plastic condensate pipe Routing The condensate pipe can terminate into any one of the following areas. It is always the best practice to terminate the condensate pipe via an internal waste system.
  • Page 36 Installation sequence Installing the boiler and making all connections (cont.) Terminating into an external waste system Terminating into an internal waste system A 722 mm plastic condensate pipe B External length of pipe 3 m max. A 722 mm plastic condensate pipe C Open end direct into gully, below B External length of pipe 3 m max.
  • Page 37 Installation sequence Installing the boiler and making all connections (cont.) Terminating into the rainwater system Terminating into an external purpose A 722 mm plastic condensate pipe made soakaway B Internal soil and vent stack A 722 mm plastic condensate pipe B External length of pipe 3 m max.

  • Page 38: Flue Outlet

    Installation sequence Flue outlet External wall terminal C 1. Insert pipe bend into the boiler flue 4. Connect external flue terminal to outlet. pipe bend. Install flue and supply pipes 2. Insert external flue terminal into the accordingly, wall outlet. with a minimum of 3°...
  • Page 39 Installation sequence Flue outlet (cont.) Vertical roof terminal C 1. Install the universal roof tile. 3. Push roof terminal through roof and insert into flue/supply pipe. 2. Install flue and supply pipes accordingly. 4. Seal roof terminal.

  • Page 40: Electrical Connections

    Installation sequence Electrical connections Opening the control unit housing...
  • Page 41 Installation sequence Electrical connections (cont.) Making connections Notes regarding the connection of accessories For details of accessories, also observe the separate installation instruc- tions provided. Notes regarding the connection of room temperature and DHW cylinder temperature control For more information about the connection of on site temperature controls see page 20.
  • Page 42 Installation sequence Electrical connections (cont.) fÖ Mains power connection 230 V ~ gH Mains connection accessories/ 50 Hz (green plug) room temperature control/DHW Do not interchange the supply cylinder control (black plug) conductors L1 and the neutral A If making the connection between, conductor N.
  • Page 43 Installation sequence Electrical connections (cont.) Connect DHW cylinder temperature control Connect Vitotrol 100 A Vitotrol 100 UTD C Vitotrol 100 RT B Vitotrol 100 UTA D When connecting, remove jumper Routing connecting cables Please note Connecting cables can be damaged if they touch hot components. When routing and securing connecting cables on site, ensure that the maximum permissible cable temperatures are not exceeded.
  • Page 44 Installation sequence Electrical connections (cont.) A Low voltage connections B 230 V connections 1. Connect strain relief to the external 2. Fit cover. cable and clip into the mounting plate aperture. 3. Pivot the control unit upwards.

  • Page 45: Commissioning And Testing

    Installation sequence Electrical connections (cont.) Front panel installation 1. Hang the front panel to the wall 3. Insert the screw at the top of the mounting frame by the appropriate boiler. hook. Note 2. Press down the front panel at the The outer case forms a seal with bottom.
  • Page 46 Installation sequence Commissioning and testing (cont.) Danger Open all doors and windows; extinguish naked lights and do not smoke whilst purging the gas line. Before commencing the commissioning procedure, ensure that the gas service cock is turned on, the electricity supply is isolated and that the DHW and CH pipework is complete.
  • Page 47 Installation sequence Commissioning and testing (cont.) 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 with water. Only use fill water of potable quality. Soften fill water harder than 150 ppm temporary hardness.
  • Page 48 Installation sequence Commissioning and testing (cont.) 4. Close the shut off valves A and C to prevent water leaving the boiler (toggle at 90° to the pipe). Connect a hose pipe to outlet D ready to vent the boiler later. 5.
  • Page 49 Installation sequence Commissioning and testing (cont.) Venting the boiler by flushing out (after venting system) 1. Leaving the hose connections from filling the system continue to fill the boiler from the external filling loop and draining the water to a drain from connection D.
  • Page 50 Installation sequence Commissioning and testing (cont.) 6. Ensure both isolation valves A and B to operating position (toggle to the rear), seal with the caps pro- vided. 7. Turn temperature gauge controls to the desired operating position. Note Be aware that the boiler may still need to be vented as air pockets are drawn into the heat exchanger.
  • Page 51 Installation sequence Commissioning and testing (cont.) Checking static and supply pressure Danger CO formation, as a result of incorrect burner adjustment,can lead to severe health problems. Carry out a CO test prior to, and after, work on gas equipment. 1. Close the gas shut-off valve. 2.
  • Page 52 Installation sequence Commissioning and testing (cont.) 7. Shut down the boiler, close the gas shut-off valve, remove the pressure gauge, and close test nipple A with the screw. 8. Open the gas shut-off valve and start the boiler. Danger Gas escaping from the test nipple leads to a risk of explosion.
  • Page 53 Installation sequence Commissioning and testing (cont.) Enabling the comfort function Turn the rotary selector tw briefly and fully clockwise (shorter than 3 s), and then turn it anti-clockwise. The Display will then show "COMFORT". Disabling the comfort function Turn the rotary selector tw briefly and fully anti-clockwise (shorter than 3 s), and then turn it clockwise.
  • Page 54 Installation sequence Commissioning and testing (cont.) Final checks 1. If a time switch has been built into 2. Fill in the relevant details for the the control unit: installation in the benchmark log- Set required activation periods as book supplied in the instructions per the time switch operating pack and affix the self adhesive bar instructions.

  • Page 55: Service Instructions

    Service Instructions Routine Servicing Instructions To ensure continued efficient operation of the appliance, it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage but in general once a year should be adequate.
  • Page 56 Service Instructions Routine Servicing Instructions (cont.) 1. Remove the screw at the top of the 3. Lift the front panel from the wall boiler. mounting frame. 2. Press down the springs on the underside of the boiler and remove the front panel. Burner removal 1.
  • Page 57 Service Instructions Routine Servicing Instructions (cont.) 5. Release gas connection pipe E. 6. Release four screws F and remove the burner. Please note To prevent damage, never rest the burner on the gauze assembly. Check the burner gasket and burner gauze assembly for damage.
  • Page 58 Service Instructions Routine Servicing Instructions (cont.) 1. Remove electrode B. 4. Insert and secure a new burner gauze assembly D with a new 2. Release the three Torx screws, and gasket E. remove thermal insulating ring C. Torque: 3.5 Nm.approx. 3.
  • Page 59 Service Instructions Routine Servicing Instructions (cont.) 3. Check all clearances. If the gaps are not as specified or the elec- trode is damaged, replace and align the electrode together with new gaskets. Tighten the electrode fixing screws. (2.5 Nm approx.). Cleaning the heating surfaces If required, clean heating surfaces A with a brush or flush with water.
  • Page 60 Service Instructions Routine Servicing Instructions (cont.) Checking the condensate drain and cleaning the siphon 1. Check at the siphon, that the con- densate can freely drain. 2. Place an appropriate container under the siphon A. 3. Remove the locking cap B and drain the siphon content.
  • Page 61 Service Instructions Routine Servicing Instructions (cont.) Burner installation 1. Install the burner and torque 4. Replace electrical cables from fan screws A diagonally. (4 Nm. motor D, gas valve E, and igni- approx.) tion unit E. 2. Insert new gasket and tighten the 5.
  • Page 62 Service Instructions Routine Servicing Instructions (cont.) 6. Check the gas connections for soundness. Danger Escaping gas leads to a risk of explosion. Check all fittings for sound- ness. Check primary and secondary connections for leaks Checking diaphragm expansion vessel and system pressure Note 1.
  • Page 63 Service Instructions Routine Servicing Instructions (cont.) 2. Check the inlet pressure of the dia- 4. Top up your heating system with phragm expansion vessel at the water and vent until the filling pres- test nipple A. sure of a cool system is 0.2 bar higher than the inlet pressure of the 3.
  • Page 64 Service Instructions Routine Servicing Instructions (cont.) Front panel installation 1. Hang the front panel to the wall 3. Insert the screw at the top of the mounting frame by the appropriate boiler. hook. Note 2. Press down the front panel at the The outer case forms a seal with bottom.
  • Page 65 Service Instructions Routine Servicing Instructions (cont.) Checking all gas equipment for soundness at operating pres- sure Danger Escaping gas leads to a risk of explosion. Check gas equipment for soundness. Final checks 1. Check that the flue terminal in is 2.

  • Page 66: Troubleshooting Fault Finding

    Troubleshooting Fault finding General Note The gas service cock is open. It is the law that any service work The DHW (Combi only) and CH iso- must be carried out by a competent lation cocks are open. CORGI registered fitter. The system is at design pressure.
  • Page 67 Troubleshooting Fault finding (cont.) Gas combina- Fault Check the gas tion valve opens train (control vol- tage 230 V) and gas supply pres- sure Fault Ionisation cur- Check the ionisa- rent builds tion current, check (higher than the electrode ad- 2 µA) justment and the gas pipe for air-...
  • Page 68 Troubleshooting Fault finding (cont.) Display System character- Cause Measures fault code istics Burner blocked Flow of water to Check the circulation low. pump. Air in heat ex- Vent the heating sys- changer. tem. Flow switch Check the interconnect- faulty. ing cable. Burner blocked Voltage to low.
  • Page 69 Troubleshooting Fault finding (cont.) Display System character- Cause Measures fault code istics Burner in fault state The flame signal Check the ionisation is already present electrode and leads. at burner start Press"Reset". Burner in fault state No flame signal is Check the ionisation present electrode and leads,...

  • Page 70: Repairs

    Troubleshooting Fault finding (cont.) Display System character- Cause Measures fault code istics Burner blocked Faulty main PCB Switch OFF the control unit, if the equipment will not restart. Repairs Removing front panel 1. Remove the screw at the top of the 2.
  • Page 71 Troubleshooting Repairs (cont.) 3. Lift the front panel from the wall mounting frame. Drain boiler on the primary side Note For certain repairs the boiler must be drained on the primary side. 1. Connect the drain hose to valve A and connect with a drain outlet.
  • Page 72 Troubleshooting Repairs (cont.) Boiler temperature sensor 1. Pull the leads from boiler tempera- ture sensor A and measure the resistance. 2. Check the sensor resistance and compare actual values with the curve. 3. In case of severe deviation, drain boiler on the primary side (see page 71) and replace the sensor.
  • Page 73 Troubleshooting Repairs (cont.) Check the temperature limiter If the burner control unit cannot be reset after a fault shutdown, although the boiler water temperature is below approx. 75 °C, check the temperature limiter. 1. Pull the leads from temperature lim- iter A.
  • Page 74 Troubleshooting Repairs (cont.) Check the DHW temperature sensor (only for gas combina- tion devices) 1. Pull the leads from outlet tempera- ture sensor A 2. Check the sensor resistance and compare actual values with the curve. 3. Replace the sensor in case of severe deviation.
  • Page 75 Troubleshooting Repairs (cont.) Replacing flow limiter 1. Switch OFF the mains power. 2. Close the gas shut-off valve and safeguard against reopening. 3. Drain the boiler from the secondary side. 4. Pivot the control unit downwards. 5. Release the ties A and screwsB. 6.
  • Page 76 Troubleshooting Repairs (cont.) Checking plate-type heat exchanger C DHW outlet E Heating water return D Cold water F Heating water flow 1. Switch OFF the mains power. 5. Remove two screws A at the plate-type heat exchanger and B 2. Close the gas shut-off valve and remove.
  • Page 77 Troubleshooting Repairs (cont.) 6. Check the secondary side for con- 8. Install in reverse order using new tamination and, if necessary, clean gaskets. or replace the plate-type heat exchanger. Note Ensure that fixing holes and seals 7. Check the primary side for contami- are aligned.

  • Page 78: Designs

    Designs Connection and wiring diagrams combi boiler Main PCB Time switch Programming unit...
  • Page 79 Designs Connection and wiring diagrams combi boiler (cont.) Alternative (remove jumper fÖ Mains input 230V~/50Hz when connecting) Temperature limiter § Boiler temperature sensor Mains connection accessories/ DHW outlet sensor room temperature control sÖ Circulation pump 230V~ a-ÖA Fan dÖ Step motor diverter valve Air pressure switch Flow switch (Heating water) Flow switch (DHW)

  • Page 80: Connection And Wiring Diagram - System Boiler

    Designs Connection and wiring diagram - system boiler Main PCB Time switch Programming unit...
  • Page 81 Designs Connection and wiring diagram - system boiler (cont.) Alternative (remove jumper Temperature limiter when connecting) Mains connection accessories/ § Boiler temperature sensor room temperature control/DHW sÖ Circulation pump 230V~ cylinder control dÖ Step motor diverter valve a-ÖA Fan Flow switch (heating water) Air pressure switch Gas solenoid valve Water pressure sensor...

  • Page 82: Parts Lists

    Parts lists Parts lists Spare parts information 032 Bypass with overflow valve Quote the type and serial no. (see 033 Grommets data plate) and the item no. of the 034 Gaskets (set) required part (as per this parts list). 035 Spring clips (set) Obtain standard parts from your local 036 Flow limiter supplier.
  • Page 83 Parts lists Parts lists (cont.) 094 Mains power switch cable har- 300 Touch-up spray paint, Vitowhite ness 301 Touch-up paint stick, Vitowhite 095 Gas valve connecting cable 35 A Data plate 096 Ignition transformer/ionisation connecting cable...
  • Page 84 Parts lists Parts lists (cont.)
  • Page 85 Parts lists Parts lists (cont.)
  • Page 86 Parts lists Parts lists (cont.)
  • Page 87 Parts lists Parts lists (cont.)

  • Page 88: Commissioning/Service Reports

    Commissioning/service reports Commissioning/service reports...
  • Page 89 Commissioning/service reports Commissioning/service reports (cont.)
  • Page 90 Commissioning/service reports Commissioning/service reports (cont.)
  • Page 91 Commissioning/service reports Commissioning/service reports (cont.)

  • Page 92: Certificates

    Certificates Declaration of conformity Declaration of conformity for Vitodens 100 We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, declare as sole responsible body, that the product Vitodens 100 conforms to the following stan- This product is designated in accor-...

  • Page 93: Keyword Index

    Keyword index Keyword index additives Horizontal Flue System ........
  • Page 94 Keyword index...
  • Page 95 Keyword index...
  • Page 96 7247 428 6 00001 7247 426 6 00001 8 to 30 kW from serial no. 7247 427 6 00001 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB...

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