Viessmann WB1A007 Installation And Service Instructions Manual
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Viessmann WB1A007 Installation And Service Instructions Manual

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Installation and Service
Instructions
for use by heating contractor
Vitodens 100-W
WB1A Series
Wall-mounted, natural gas-fired condensing boiler
For natural gas
Heating input
29 to 100 MBH
8.5 to
VITODENS 100-W
5581 775 v1.3 08/2009
29.3 kW
Vitodens 100-W, WB1A
(with preinstalled coaxial vent pipe
adaptor)
IMPORTANT
Read and save these instructions
for future reference.

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  • Page 1 Installation and Service Instructions for use by heating contractor Vitodens 100-W WB1A Series Wall-mounted, natural gas-fired condensing boiler For natural gas Heating input 29 to 100 MBH 8.5 to 29.3 kW VITODENS 100-W Vitodens 100-W, WB1A (with preinstalled coaxial vent pipe adaptor) IMPORTANT Read and save these instructions...

  • Page 2: Safety, Installation And Warranty Requirements

    Safety, Installation and Warranty Requirements Safety, Installation and Warranty Requirements Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life.
  • Page 3 Index Page Safety Important Regulatory and Installation Requirements ......General Information About these Installation Instructions .
  • Page 4 Initial Start-up, Necessary Tools ....................Overview of Controls and Indicators Inspection and Maintenance .

  • Page 5: Important Regulatory And Installation Requirements

    Contact CAN/CSA-B149.1 or .2 Installation Viessmann for additional copies. Codes for Gas Burning Appliances for Canada. For U.S. installations use the This product comes with several National Fuel Gas Code ANSI Z223.1.
  • Page 6 Safety Important Regulatory and Installation Requirements (continued) 2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified. 3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment.
  • Page 7 - Technical Data Manual operator/ultimate owner where the - Installation and Service Instructions literature can be found. Contact - Operating Instructions Viessmann for additional copies. and User’s Information Manual - Vitodens Venting System Installation This product comes with several Instructions safety instruction labels attached.

  • Page 8: About These Installation Instructions

    General Information About these Installation Instructions Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below. Warnings draw your attention to the WARNING presence of potential hazards or important product information.

  • Page 9: Product Information

    General Information Applicability Vitodens 100-W, WB1A 8-24, 8-30 IMPORTANT Serial No. Model No. WB1A 8-24 7246174 Boiler serial number must be provided when ordering replacement parts. WB1A 8-30 7246175 Both the 16-digit serial number bar code paper label and the 12-digit ASME/NB serial number correlate to each other.

  • Page 10: Mechanical Room

    General Information Mechanical Room During the early stages of new home design, we recommend that proper consideration be given to constructing a separate mechanical room dedicated to gas- or oil-fired equipment including domestic hot water storage tanks. The boiler must be located in a heated indoor space, near a floor drain, and as close as possible to the wall.
  • Page 11 General Information Mechanical Room (continued) Installation area conditions Sources of combustion and ventilation WARNING air contaminants If you notice fire coming from the WARNING Areas likely to contain contaminants: appliance, call the fire department immediately! Do not attempt to Incorrect ambient conditions can lead H New building construction extinguish the fire unless qualified to to damage to the heating system and...

  • Page 12: Before Set-Up

    General Information/Set-up Before Set-up Before placing boiler in its installation CAUTION location, ensure all necessary accessories are installed. The boiler must be installed in such a way that gas ignition system components are protected from water (spraying, splashing, etc.) during boiler operation and service. Minimum Clearances Recommended minimum service clearances Side...

  • Page 13: Preparing The Connections

    Boiler Connections Preparing the Connections Use an approved pipe sealant or teflon tape when connecting the following installation fittings. Connections overview This section constitutes an overview only! Refer to subsequent sections for detailed information on individual piping connections. Piping connections for Vitodens 100-W, WB1A 8-24 and 8-30 (factory supplied) Legend...
  • Page 14 Boiler Connections Preparing the Connections (continued) Dimensions overview without bottom connections When preparing gas, water and electrical connections in the field, see section entitled “Wall Mounting” on page 16 of this manual for information regarding the installation of the wall mounting bracket. IMPORTANT The maximum ambient temperature must not exceed 104 ºF/40 ºC.
  • Page 15 Boiler Connections Preparing the Connections (continued) Dimensions overview with connections This section constitutes an overview only! Refer to subsequent sections for detailed information on individual piping connections. Piping connections for Vitodens 100-W, WB1A 8-24 and 8-30 (factory 2¼” supplied) 14” / 15¾”...

  • Page 16: Wall Mounting

    Boiler Connections Wall Mounting Wall mounting bracket installation The Vitodens 100-W can be wall-mounted on H a brick/concrete wall H wood studs H metal studs Following are the installation instructions for the mounting bracket on each material. Skip to the installation instructions applicable to your installation requirements.
  • Page 17 Boiler Connections Wall Mounting (continued) Mounting bracket installation (continued) Installation of mounting bracket on wood and metal studs To mount the Vitodens 100-W boiler on wood or metal studs, install mounting bracket on wall as shown on previous page. Refer to drawings on the left and a = 16”/407 mm below for more detailed installation information.
  • Page 18 Boiler Connections Boiler Connections Wall Mounting (continued) Mounting Vitodens 100-W boiler 1. Remove the screw at the top of boiler. 2. Press down on springs at bottom of boiler and remove the front enclosure panel. 3. Remove front enclosure panel. 4.
  • Page 19 Boiler Connections Connections (continued) Proper piping practice 2 imperfect threads Use moderate amount of dope Support piping by proper suspension method. Piping must not rest on or be supported by boiler. Thread pipe right length Leave 2 end threads bare Gas connection and piping 1.
  • Page 20 Boiler Connections Connections (continued) Gas connection and piping (continued) 1. Refer to current CAN/CSA B149.1 or National Fuel Gas Code ANSI Z223.1/NFPA 54, as well as local codes for gas piping requirements and sizing. Pipe size to the boiler must be determined based on: –...
  • Page 21 Boiler Connections Connections (continued) Gas piping pressure test When performing the gas piping pressure test, ensure the following requirements are met. 1. Isolate the boiler from the gas supply WARNING piping system using the individual manual shutoff valve during pressure Never check for gas leaks with an tests equal to or less than ½...
  • Page 22 ............IMPORTANT Damage resulting from pressure exceeding those values stated is not covered by Viessmann warranty. H Use a two-hand wrench method when tightening fittings or piping onto the boiler connectors. Use one...
  • Page 23 Boiler Connections Connections (continued) Condensate connection The Vitodens 100-W boiler comes with 1. Install the condensate drain pipe a built-in condensate trap. An external with a suitable gradient. trap is not required when connecting the field drain to flexible discharge 2.

  • Page 24: Safety Connections And Pressure Testing

    Boiler Connections Safety Connections and Pressure Testing Installing safety devices on the boiler 1. Remove loosely preassembled Minimum connection diameters: combination pressure relief valve and Pressure relief valve ¾“ ......drain valve assembly.
  • Page 25 Boiler Connections Safety Connections and Pressure Testing (continued) Performing pressure test on the boiler The boiler must be leak tested before 5. After 15 minutes, release water being placed in operation. Before boiler pressure from boiler by opening is connected to piping or electrical boiler drain valve slowly, remove power supply, it must be caps from supply and return...

  • Page 26: Installation Examples

    Specific system layouts may maintained. In cases where the pipes be further discussed with the local are insulated with pipe insulation of Viessmann sales representative office. appropriate and sufficient thickness and insulation values, the above clearance may be reduced to 0” (refer to local gas codes).
  • Page 27 Observe boiler maximum and minimum flow rate limitations. If system flow rate exceeds boiler maximum flow rate (as stated on page 68) or if system flow rate is unknown, Viessmann strongly recommends the installation of a low-loss header. See page 36 for low-loss header information or refer to the Vitodens Venting System Installation Instructions.
  • Page 28 Boiler Connections Installation Examples (continued) System Layout 1 Vitodens 100-W, WB1A 8-24, 8-30 with... – one heating circuit Legend T- - T AV Air vent PRV Pressure relief valve Vitodens 100-W Room thermostat Heating circuit Heating circuit pump (field supplied) Expansion tank IMPORTANT Ensure that a pressure activated...
  • Page 29 IMPORTANT DHW supply and return piping between boiler DHW connections and the Viessmann DHW tank connections, shall be a minimum of 1” nominal pipe diameter (irrespective of the ¾” DHW connection outlet sizes provided on the boiler and the DHW tank).
  • Page 30 IMPORTANT DHW supply and return piping between boiler DHW connections and the Viessmann DHW tank connections, shall be a minimum of 1” nominal pipe diameter (irrespective of the ¾” DHW connection outlet sizes provided on the boiler and the DHW tank).
  • Page 31 Boiler Connections Installation Examples (continued) Wiring diagram for system layout 4...
  • Page 32 – DHW storage tank – Low-loss header – one high-temperature heating circuit – one low-temperature heating circuit – Viessmann Vitotronic 050, HK1M controller Legend See next page for notes and explanation of this drawing. Legend A Boiler power pump module...
  • Page 33 IMPORTANT DHW supply and return piping between boiler DHW connections and the Viessmann DHW tank connections, shall be a minimum of 1” nominal pipe diameter (irrespective of the ¾” DHW connection outlet sizes provided on the boiler and the DHW tank).
  • Page 34 Spring-loaded flow check valve chiller manufacturer carefully for Circulation pump additional requirements. Expansion tank Viessmann strongly suggests that the Water chiller valves pictured above be labelled “v1” Cooling season starts: Boiler circuit pump (field supplied) Close valve v1 and open valve v2.
  • Page 35 Boiler Connections Installation Examples (continued) Boiler with low water cut-off (remote-mounted, field supplied) A low water cut-off may be required by Hi-Vent Hi-Vent local codes. If boiler is installed above radiation level, a low water cut-off device of approved type (field supplied) must be installed in all instances at the highest point of the piping system.
  • Page 36 T2 = T4 primary bypass secondary page 27 in this manual. primary secondary Viessmann strongly recommends the use of a low-loss header in cases where the T1 ± 176°F / 80°C system head and flow rates are unknown. secondary primary+ bypass...

  • Page 37: Venting Connection

    Boiler Connections Venting Connection For detailed installation information and specific venting requirements, reference the Vitodens Venting System Installation Instructions supplied with the boiler. Installation Instructions Vitodens Venting System CAUTION Under certain climatic conditions some building materials may be affected by flue products expelled in close proximity to unprotected surfaces.
  • Page 38 Control Connections Electrical Connections (continued) Electrical connections to the power pump module Note: Boilers are factory shipped with a wiring diagram (11”x17” page inside a pouch) attached to the inside of the front cover. The X3 L N N L X4 1 2 3 4 wiring diagram shipped with the 120V...
  • Page 39 3. Screw in screw at top part of boiler. IMPORTANT Read and follow, where applicable, the safety instructions of all labels and stickers attached to boiler surfaces. Do not remove any of these instructions. Contact Viessmann if any replacement labels are required.

  • Page 40: Necessary Tools

    Start-up, Inspection and Maintenance Necessary Tools Special items H Approved leak detection fluid for natural gas H Pipe joint sealant H Garden hose for pressure testing Use only calibrated equipment. Testing/analysis equipment H Multimeter to measure 0 - 12 A AC H Flue gas analyzer to measure % CO or O (i.e.

  • Page 41: Overview Of Controls And Indicators

    Start-up, Inspection and Maintenance Overview of Controls and Indicators Opening the control unit Controls and indicators are located behind the hinged front cover. Control and display elements The control unit is preset at the factory for standard operation. Your heating system is ready for use.
  • Page 42 Start-up, Inspection and Maintenance Overview of Controls and Indicators (continued) Legend Display value or fault code Heating mode Burner in operation Current burner firing rate Boiler water temperature in °F (combined with display value) Fault System pressure (combined with display value) SERV Emissions test activated (only for licensed professional heating...

  • Page 43: Overview Of Components

    Start-up, Inspection and Maintenance Overview of Components Legend Fixed high limit, 210°F/99°C Vent pipe adaptor Power pump module Ignition transformer module Test port cap Control console ZIG 2/12 Burner mounting flange assembly Flow switch, VK315M Boiler temperature sensor P-trap Radial fan RG130, 120/1/60 Air pressure switch Air + gas inlet venturi Condensate hose, 400mm...

  • Page 44: Procedure Overview

    Initial Start-up, Inspection and Maintenance Procedure Overview Start-up steps Inspection steps Maintenance steps Page 1. Fill and vent the heating system ............................2.
  • Page 45 Initial Start-up, Inspection and Maintenance Steps Start-up 1. Fill and vent heating system ervice 1. Open system isolation valves (if Please note: installed). Before filling the heating system with water, check that all necessary flow check valves are installed. 2. Check inlet pressure of the If the nitrogen pressure of the diaphragm expansion tank.
  • Page 46 Initial Start-up, Inspection and Maintenance Initial Start-up, Inspection and Maintenance Steps (continued) Start-up 1. Fill and vent heating system (continued) ervice 5. Check system pressure. 6. Ensure proper/adequate fuel supply exists. Open gas shutoff valve. Max. boiler operating pressure ..45 psig Min.
  • Page 47 Initial Start-up, Inspection and Maintenance Steps (continued) Start-up and Maintenance 3. Select appropriate gas type ervice 1. Ensure that the fuel type listed on the boiler rating plate is the correct type for the installation being attempted. 2. Record fuel type in Maintenance Record on page 74.
  • Page 48 Initial Start-up, Inspection and Maintenance Steps (continued) Start-up and Maintenance 4. Measure static pressure and running pressure (continued) ervice Running pressure 8. All measurements must be made Use suitable measuring instruments under high fire conditions. calibrated with a minimum resolution Measure the running pressure;...
  • Page 49 Initial Start-up, Inspection and Maintenance Steps (continued) Start-up and Maintenance 5. How the Vitodens 100-W boiler operates... ervice The Vitodens 100-W boiler uses a premix combustion system, which is designed to deliver a measured air-gas mixture to the burner for complete combustion. The gas is injected upstream of the blower.
  • Page 50 Initial Start-up, Inspection and Maintenance Steps (continued) Start-up and Maintenance 6. Relais tests ervice The Vitodens 100-W boiler is factory The CO value lies within the range of If the CO value measured lies more H 6.6 to 10.0% for natural gas preset for operation with natural gas.
  • Page 51 Initial Start-up, Inspection and Maintenance Steps (continued) Start-up and Maintenance 7. Clock natural gas meter ervice Clock natural gas meter to verify input Ensure all other gas equipment For example: IMPORTANT served by the meter is turned off A Vitodens 100-W, WB1A 8-30 boiler during timing of gas input to the (100 000 Btu/h input) requires 360 Vitodens 100-W boiler.
  • Page 52 Initial Start-up, Inspection and Maintenance Steps (continued) Start-up and Maintenance 9. Check all primary and secondary circuit connections for leaks ervice Check heating system and domestic hot water connections (if applicable). Ensure all connections are pressure tight. Correct any leaks found on fittings, pumps, valves, etc.
  • Page 53 (continued) 11. Check venting system for leaks (circular air gap measurement) Start-up and Maintenance ervice For sealed combustion, coaxial vent only Viessmann strongly recommends that If higher CO values or lower O values the heating contractor perform a are measured, check venting system simplified leak test during boiler thoroughly.
  • Page 54 Initial Start-up, Inspection and Maintenance Steps (continued) 12. Remove burner (continued) Maintenance ervice 6. Disconnect electrical cables from gas valve , and ignition transformer unit 7. Remove connection hose from air pressure switch. 8. Loosen the fitting on the gas connection pipe.
  • Page 55 Initial Start-up, Inspection and Maintenance Steps (continued) 13. Check burner gasket and cylinder assembly for damage Maintenance ervice Check the burner gasket and burner cylinder assembly for damage and replace if necessay. Replace the burner cylinder assembly if damaged. 1. Remove electrode block 2.
  • Page 56 Initial Start-up, Inspection and Maintenance Steps (continued) 15. Check condensate drain and clean siphon (P-trap) Maintenance ervice 1. Check the siphon to ensure IMPORTANT unimpeded drainage of condensate. If the condensate does not drain freely, 2. Place appropriate container condensate will accumulate in bottom underneath siphon part of boiler resulting in a burner shut-down (fault message F4).
  • Page 57 Initial Start-up, Inspection and Maintenance Steps (continued) 17. Clean combustion chamber/heat exchanger surfaces Maintenance ervice 1. Remove burner cover panel (if still installed) as per the removal and reinstallation instructions on page 53 in this manual, and reinstall panel upon completion of service work. 2.
  • Page 58 Initial Start-up, Inspection and Maintenance Steps (continued) Start-up and Maintenance 18. Check diaphragm expansion tank and system pressure ervice Perform check on the system when cold. 1. Drain boiler/system and reduce pressure until the manometer reading is ”0”. 2. If the nitrogen pressure of the Example precharged expansion tank is less Static head of 33 ft./10 m...
  • Page 59 Initial Start-up, Inspection and Maintenance Steps (continued) Start-up and Maintenance 20. Check gas pipes and fittings for leaks ervice WARNING CAUTION The gas supply piping must be leak Ensure all joints of gas line are tested before placing the boiler in pressure tight and that gas valves do operation.

  • Page 60: Troubleshooting Steps

    Troubleshooting Troubleshooting Steps Diagnosis 1. Establish fault message or diagnose behavior of system. 2. Look for corresponding cause of fault in the diagnostics table. Diagnosis H for faults with fault display on control unit (see below). Please note: 3. Find corrective action in the table. Correction 4.

  • Page 61: Changing Room Temperature

    Troubleshooting Overview of Controls and Indicators (continued) Legend Display value or fault code Heating mode Burner in operation Current burner firing rate Boiler water temperature in °F (combined with display value) Fault System pressure (combined with display value) SERV Emissions test activated (only for licensed professional heating contractor) Changing Room Temperature...
  • Page 62 Check water flow switch. Replace Water flow switch activates if necessary. plug 33. Display message Fault F5/F9 Check cabling and plug-in connectors of the blower , as well as blower itself. Check after approx. 51 seconds proper power supply to the blower. Differential air pressure switch enables Check flue gas system and differential air Fault F5/F9...
  • Page 63 Troubleshooting Diagnosis (continued) Faults are indicated by a flashing fault code with fault code sysmbol “ ” and the reset button is illuminated. For fault code explanations see the following table. Diagnostics table: Faults with fault display on control unit Fault mes- System behavior Cause...
  • Page 64 Troubleshooting Diagnosis (continued) Diagnostics table: Faults with fault display on control unit (continued) Fault mes- System behavior Cause Corrective measures sage in dis- play window Burner blocked Faulty water pressure sensor Check the water pressure sensor and the interconnecting cable. Burner in fault mode Combination gas valve closes too Check the gas combination valve.
  • Page 65 Troubleshooting Correction Remove front cover panel 1. Remove the screw at the top of the boiler. 2. Press down the springs on the underside of the boiler. 3. Remove the front cover panel. 4. Lift the front cover panel from the wall mounting frame.
  • Page 66 Troubleshooting Correction (continued) Check fixed high limit If the burner control unit cannot be reset after a fault shutdown (F2), even though the boiler water temperature is below approx. 203°F / 95°C, check the fixed high limit. 1. Pull the leads from fixed high limit 2.
  • Page 67 2. Flip down and remove control unit 3. Remove power pump module cover plate 4. Check fuse F1 T6.3A (slow blow). Replacements available form Viessmann - package of 10 (PN 7815 580). Fuse F1 T6.3A ¾”/20mm ¼”/5mm Control unit fuse 1.

  • Page 68: Technical Data

    Additional Information Technical Data Rated voltage: 120 VAC Max. ambient Setting of fixed high limit Rated frequency: 60 Hz temperature safety cut-out: 210 ºF Rated current: 6.0 A~ H at operation: 32 to 104 ºF (fixed setting) 99 ºC 0 to +40 ºC H when storing Main fuse: max.
  • Page 69 Based on typical boiler cycles, including partial load conditions. Requires 1”/25 mm tubing. See Vitodens 100-W Installation Instructions for details. For detailed information refer to the Vitodens Venting System Installation Instructions (PN 5285 268). "For information regarding other Viessmann System Technology componentry, please reference documentation of respective product.

  • Page 70: Burner Program Sequence Of Operation

    Additional Information Burner Program Sequence of Operation Flame safeguard program sequence of operation Call for heat Pre-ignition timing Flame signal (factory-set) if flame exists after gas Ignition valve closure Combination gas valve Actual fan Safety timing Post-purge speed time Fan required Ignition load Pre-purge signal...

  • Page 71: Wiring Diagram

    Additional Information Wiring Diagram...

  • Page 72: Parts List

    Ordering Replacement Parts: Please provide Model and Serial Number from rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor. Parts 003 Air pressure switch 013 Gas connection pipe 021 Gasket set for gas connection pipe, 17x24x2mm...
  • Page 73 Additional Information Parts List (continued) Parts 001 Fixed high limit, 210ºF/99ºC 002 Boiler temperature sensor 004 Test port cap (set of 2) 005 Vent pipe adaptor 006 Gasket set for flue gases (order glue, part 095 below) 007 Heat exchanger assembly, ASME 008 Combustion chamber refractory 009 Support bracket set for heat exchanger...
  • Page 74 Service Measurements Service Service Service Service Setpoint value Service date: date: date: date: date: date: max. Static pressure “w.c. 14 ”w.c. Running pressure (supply pressure) 4-14 ”w.c. j Natural gas “w.c. Carbon dioxide content CO H at lower end of rated input range vol.-% (low fire) H at upper end of rated input range...

  • Page 75: For Your Safety Read Before Operating

    Additional Information Lighting and Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING W A R N I N G: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
  • Page 76 Viessmann Manufacturing Company (U.S.) Inc. Viessmann Manufacturing Company Inc. 45 Access Road 750 McMurray Road Warwick, Rhode Island • 02886 • USA Waterloo, Ontario • N2V 2G5 • Canada Tel. (401) 732-0667 • Fax (401) 732-0590 Tel. (519) 885-6300 • Fax (519) 885-0887 www.viessmann-us.com •...

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