Installation and service instructions VIESMANN for contractors Vitodens 100-W Type WB1B, 9.0 to 35.0 kW Wall mounted gas fired condensing boiler Natural gas and LPG version VITODENS 100-W 5354 802 GB 2/2008 Please keep safe.
Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained Danger This symbol warns against the risk of injury. ! Please note This symbol warns against the risk of material losses and environmental pollution. Note Details identified by the word "Note" contain additional information. Target group These instructions are exclusively designed for qualified personnel.
Safety instructions Safety instructions (cont.) Working on the system When using gas as fuel, also close the main gas shut-off valve and safeguard against unauthorised reopening. & Isolate the system from the power supply and check that it is no longer 'live', e.g. by removing a separate fuse or by means of a main isolator. & Safeguard the system against unauthorised reconnection. & Please note Electronic modules can be damaged by electro-static discharges.
Index Index Installation instructions Preparing for installation Product information .................................................................................... Preparing for installation ............................................................................. 5 5 Installation sequence Installing the boiler and making all connections ........................................... 9 Opening the control unit ..............................................................................
Preparing for installation Product information Vitodens 100-W, WB1B Set up for operation with natural gas.
Preparing for installation Preparing for installation (cont.
Preparing for installation Preparing for installation (cont.
Preparing for installation Preparing for installation (cont.) 1. Position the supplied installation template on the wall. 3. Drill 710 mm holes and insert the supplied rawl plugs. 2. Mark out the rawl plug holes. 4. Fit wall retainer with screws supplied. Preparing the connections 1. Prepare the water connections. Flush the heating system. 5354 802 GB 2. Prepare gas connection. 3. Prepare the electrical connections. Observe valid IEEE standards. & A 1.5 m long power cable is fitted as standard.
Installation sequence Installing the boiler and making all connections Installation Removing the front panel and mounting the boiler 1. Release screws at the bottom of the boiler; do not remove completely. 3. Hook the boiler into the wall retainer. 5354 802 GB 2. Remove front panel.
Installation sequence Installing the boiler and making all connections (cont.) Installing connections on the water side For fittings on the heating water side and DHW side, see separate installation instructions.
Installation sequence Installing the boiler and making all connections (cont.) Safety valve connection Installation Connect safety valve drain A (7 15 mm) with visible outlet B to the dewatering system or route with visible outlet through the external wall. Gas connection 1. Connect gas shut-off valve to connection A. 2. Carry out a leak/tightness test. ! Please note Excessive test pressure may damage the boiler and the gas valve. Max. test pressure 150 mbar.
Installation sequence Installing the boiler and making all connections (cont.) Condensate connection Connect condensate drain A with a slope and a pipe vent to the public sewer. Observe the local waste water regulations. Note Fill the siphon with water before startup. Filling the siphon with water Fill a minimum of 0.3 l of water into the flue gas connection. Please note At commissioning, flue gas may be emitted from the condensate drain. Fill the siphon with water before start-up.
Installation sequence Installing the boiler and making all connections (cont.) Balanced flue connection Connect the balanced flue. During installation and positioning of the flue gas system, observe building regulations part L and BS 5440. Installation Flue gas system installation instructions.
Installation sequence Opening the control unit (cont.) ! Please note Electronic modules can be damaged by electrostatic discharges. Touch earthed objects, such as heating or water pipes, to discharge static loads. Electrical connections 5354 802 GB Information regarding the connection of accessories For details of accessories, also observe their separate installation instructions provided.
Installation sequence Electrical connections (cont.) Note Gas fired condensing boiler without DHW cylinder: For operation without a DHW cylinder, set rotary selector "tw" to "0". A Only for weather-compensated mode: Outside temperature sensor (accessory) B Open room thermostat Remove jumper D when making this connection. C Connection line (accessory) D Jumper E Power supply (230 V, 50 Hz). Danger Incorrect core termination can cause severe injuries and damage to the equipment.
Installation sequence Electrical connections (cont.) Routing connecting cables and closing control unit Please note Power cables will be damaged if they contact hot parts. When routing and securing power cables on site, ensure that the maximum permissible temperatures for these cables are not exceeded.
Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps ! ! ! • • • • • • 01. Filling the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 02. Venting the boiler by flushing out (after venting system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning, inspection, maintenance Further details regarding the individual steps Filling the heating system ! Please note Unsuitable fill water increases the level of deposits and corrosion and may lead to boiler damage. & Thoroughly flush the entire heating system prior to filling it with water. & Only use fill water of potable quality. & Soften fill water harder than 150 ppm. & An antifreeze additive suitable for heating systems can be mixed with the fill water. 1. Close the gas shut-off valve. 2.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Open shut-off valves A and (if installed) B. 5. Connect filling hose to valve C and open valve C. 6. Fill heating system. (Minimum system pressure > 0.8 bar). 7. Close valve C . 5354 802 GB Service Note If external filling equipment is installed, it must meet the requirements of the Water Fittings Regulations 1999 Section G 24.1 and G 24.2.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Venting the boiler by flushing out (after venting system) 1. Connect the drain hose on shut-off valve A to a drain. 2. Close shut-off valve B. 3. Open valves A and C and flush at mains pressure, until no sound of escaping air can be heard. 4. First shut off valve A then valve C. 5. Operating pressure ≥ 0.8 bar; adjust with valve C. 6. Open shut-off valve B.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Simultaneously turn rotary selectors "tw" and "tr" to their central position. "SERV" appears on the display. 3. Within 2 s turn rotary selector "rt" to the top right area. "r" and the set value flash on the display. 5. Do not adjust the rotary selectors for 15 s. The set operating mode is then saved and the control unit returns to standard mode.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the CO 2 content 1. Connect a flue gas analyser at flue gas port A on the boiler flue connection. 2. Start up the boiler and check for tightness. Installation and service instructions Danger Escaping gas leads to a risk of explosion. Check gas equipment for tightness. 3. Turn rotary selector "tr" clockwise for less than 2 s and then anticlockwise back to the control range on the right.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Adjust the lower output: Turn rotary selector "tr" to the left control range. The display shows 1 bar for lower output. 7. Test the CO 2 content for lower output. The CO 2 content must be between 7.5 and 10.5 %. 8. If the CO 2 content is within the given range, continue with point 15. & If the CO 2 content is not within the given range, check the flue gas/ventilation air system for tightness.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 15. Shut the boiler down, remove flue gas analyser and close flue gas port A. 16. Return rotary selectors "tw" and "rt" to their original positions. Burner removal 2. Shut off the gas supply. 3. Pull power cables from fan motor A, gas valve B and electrodes E. 4. Pull the venturi extension D from the fan. 24 5354 802 GB 1. Switch OFF the power.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 5. Release gas supply pipe E fitting. 6. Undo four screws F and remove the burner. ! Please note To prevent damage, never rest the burner on the gauze assembly. Checking the burner gasket and the burner gauze assembly Check burner gasket A for damage and replace if required. 5354 802 GB Service Replace the burner gauze assembly if it is damaged.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Remove electrode B. 2. Undo the three cheese-head screws and remove thermal insulating ring C. 3. Undo the four Torx screws and remove burner gauze assembly D with its gasket E. 4. Insert and secure a new burner gauze assembly D with a new gasket E. Fixing screw torque: 3.5 Nm. 5. Refit thermal insulation ring C. Fixing screw torque: 3.5 Nm. 6. Refit the electrode B. Fixing screw torque: 3.5 Nm.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the heat exchanger ! Please note Scratches on parts that are in contact with flue gas can lead to corrosion. Never use brushes to clean the heat exchanger. 1. Use a vacuum cleaner to remove residues from the heat exchanger A inside the combustion chamber. 2. If required, spray slightly acidic, chloride-free cleaning agents based on phosphoric acid (e.g.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the condensate drain and cleaning the siphon 1. Check that the condensate can drain freely at the siphon. 2. Remove all hoses from siphon A. 3. Release locking tabs at opening B from underneath and remove siphon A upwards. 4. Clean siphon A and reinstall. 5. Refit all hoses. Secure drain hose with cable ties. 5354 802 GB 6. Fill siphon A with water by pouring about 0.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Install the burner and torque screws A diagonally with 4.0 Nm. 5. Reopen gas supply and switch on power supply. 2. Insert new gasket and tighten the fittings on gas supply pipe B 6. Check the gas connections for tightness. 5354 802 GB 3. Plug the venturi extension C into the fan. 4. Replace electrical cables from fan motor D, gas valve E and ignition unit E.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking all gas equipment for tightness at operating pressure Danger Escaping gas leads to a risk of explosion. Check gas equipment for tightness. 1. Push front panel into place on the guide rails. 30 2. Tighten screws at the bottom.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Instructing the system user 5354 802 GB Service The system installer must hand the operating instructions to the system user and instruct him/her in the operation of the system.
Troubleshooting Function sequence and possible faults Display screen Control unit issues a heat demand No Measures Increase set value and ensure heat is drawn off Yes Fan starts No after approx.
Troubleshooting Fault messages on the display 5354 802 GB Fault code System characteron the dis- istics play 10 Constant mode 18 Constant mode 30 Burner blocked 38 Burner blocked 50 No DHW heating 51 No DHW heating 52 Burner blocked 58 No DHW heating 59 No DHW heating Cause Measures Outside temperature sensor shorted out Outside temperature sensor lead broken Boiler water temperature sensor shorted out Boiler water temperature sensor lead broken Cylinder temperature sensor shorted out
Troubleshooting Fault messages on the display (cont.) Cause Measures Flow sensor lead broken Check connections and lead; replace sensor if required. Check connections and lead; replace Open Therm device if required. Check the sensor (see page 43). A9 Regulated operation Communication without Open Therm fault Open Therm device device b0 Burner blocked b8 Burner blocked E5 Burner blocked E6 Burner blocked F0 F1 Burner blocked.
Troubleshooting Fault messages on the display (cont.) 5354 802 GB F8 Burner in a fault state F9 Burner in a fault state FA Burner in a fault state FC Burner blocked Fd Burner blocked Cause Measures No flame signal is present Check the ionisation electrode and leads, measure the ionisation current, check the gas pressure, check the gas train, ignition, ignition module and condensate drain. Press "Reset" (see page 36). The fuel valve Check the gas train.
Troubleshooting Fault messages on the display (cont.) Press reset 5354 802 GB Turn rotary selector "rt" less than 2 s to "URESET", then back to the control range.
Troubleshooting Repairs Removing front panel 2. Remove front panel. Service 1. Release screws at the bottom of the boiler; do not remove completely. Outside temperature sensor 5354 802 GB 1. Open the control unit casing. See page 13.
Troubleshooting Repairs (cont.) 2. Disconnect cables from outside temperature sensor. 3. Check the sensor resistance and compare it with the curve. 5354 802 GB 4. Replace the sensor in case of severe deviation.
Troubleshooting Repairs (cont.) Boiler water temperature sensor 2. Check the sensor resistance and compare it with the curve. 5354 802 GB 3. In case of severe deviation, drain boiler on the heating water side and replace the sensor. Danger The boiler water temperature sensor is immersed in the heating water (risk of scalding). Drain the boiler before replacing the sensor. 39 Service 1. Pull the leads from boiler water temperature sensor A and check the resistance.
Troubleshooting Repairs (cont.) Checking cylinder temperature sensor (gas fired condensing boiler) 1. Remove plugs % from the cable harness and check the resistance. 2. Compare the sensor resistance with the curve. 5354 802 GB 3. Replace the sensor in case of severe deviation.
Troubleshooting Repairs (cont.) Checking the temperature limiter If the burner control unit cannot be reset after a fault shutdown, although the boiler water temperature is below approx. 95 °C, check the temperature limiter. 1. Pull the leads from temperature limiter A. 2. Check the continuity of the temperature limiter with a multimeter. If it is open circuit, it is faulty. 3. Remove the faulty temperature limiter. 4. Install a new temperature limiter. 5354 802 GB Service 5.
Troubleshooting Repairs (cont.) Checking the outlet temperature sensor (gas fired condensing combi boiler) 1. Pull the leads from outlet temperature sensor A 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in case of severe deviation. 5354 802 GB Note Water can leak when replacing the outlet temperature sensor. Shut off the cold water supply. Drain the DHW line and the plate-type heat exchanger (DHW side).
Troubleshooting Repairs (cont.) Checking the flue gas temperature sensor 1. Pull the leads from flue gas temperature sensor A. 2. Check the sensor resistance and compare it with the curve. 5354 802 GB Service 3. Replace the sensor in case of severe deviation.
Troubleshooting Repairs (cont.) Replacing flow limiter (gas fired condensing combi boiler) 1. Drain the boiler from the DHW side. 2. Pivot the control unit downwards. 3. Undo screws A. 4. Remove the cap B. 5. Remove faulty flow limiter C. 6. Select new flow limiter C corresponding to boiler serial no. (see type plate) and the following table. 7. Insert new flow limiter C. 8. Fit new cap B provided.
Troubleshooting Repairs (cont.) E Heating water flow F Heating water return G Cold water H DHW 1. Shut off and drain the boiler on the heating water and the DHW side. 4. Turn the three-way valve B with drive A 1/8 anticlockwise and remove. Service Checking or replacing the plate-type heat exchanger (gas fired condensing combi boiler) 2. Flip down control unit. 5354 802 GB 3. Push the three-way valve drive A slightly upwards.
Troubleshooting Repairs (cont.) 5. Remove two screws C from the plate-type heat exchanger and remove plate-type heat exchanger D with gaskets. Note During removal, small amounts of water may trickle out and escape from the removed plate-type heat exchanger. 6. Check the DHW side for scaling and, if required, clean or replace the plate-type heat exchanger. 7. Check the heating water side for contamination and, if required, clean or replace the plate-type heat exchanger. 8.
Gas type conversion Converting from LPG to natural gas 5354 802 GB Service Removing gas restrictor 1. Pull power cable from gas train A. 3. Undo three screws C and remove gas train A. 2. Remove union nut B.
Gas type conversion Converting from LPG to natural gas (cont.) 4. Remove gas restrictor D from gas train. 6. Remove or void gas type sticker on the top of the boiler (next to the type plate). 5. Fit gas train A with new gaskets E and F. Fixing screw torque C: 3 Nm. Union nut torque B: 22 Nm. Converting gas type on the control unit 1. Turn ON/OFF switch ON. 2. Simultaneously turn rotary selectors "tw" and "tr" to their central position. "SERV" appears on the display. 5354 802 GB 3.
Gas type conversion Converting from LPG to natural gas (cont.) 4. Adjust the control unit to natural gas or LPG by turning the rotary selector "tw". The display shows: & "0" for operation with natural gas & or & "1" for operation with LPG. 5. Do not adjust the rotary selectors for 15 s. The set operating mode is then saved and the control unit returns to standard mode. Adjusting the burner 5354 802 GB Service See "Checking the CO 2 content" on page 22.
Control unit Functions and operating conditions in weather-compensated mode In weather-compensated mode, the boiler water temperature is regulated subject to the outside temperature. Heating curve of weather-compensated control unit A Rotary selector "tr" setting: 6 B Delivered condition C Rotary selector "tr" setting: 1 Frost protection function Frost protection function is active at outside temperatures of < 5°C. The burner is switched ON and the boiler water temperature is held at 20 °C.
Designs 5354 802 GB Service Connection and wiring diagram A B C Stepper motor diverter valve Ignition/Ionisation Vitotrol 100, type UTA D E F Vitotrol 100, type RT Vitotrol 100, type UTD Mains input 230V/50Hz 51
Designs Connection and wiring diagram (cont.) G H K L $ Outlet temperature sensor (gas fired condensing combi boiler) % Cylinder temperature sensor (gas fired condensing boiler) aG Flue gas temperature sensor sÖ Circulation pump 230V~ dG Gas solenoid valve fJ Temperature limiter a-Ö Fan motor 230V~ a-ÖA Fan control aVL Throughput sensor 5354 802 GB M X ...
Parts lists Parts lists 5354 802 GB 001 Heat exchanger 002 Moulded hose heating water flow 003 Moulded hose heating water return 004 Hose connector adapter 005 Heating water return connection elbow 006 Heating water flow connection elbow 007 Gas supply pipe 009 Pressure gauge 010 Boiler flue connection 011 Drain valve 012 Siphon 013 Flue gas gasket 014 Diaphragm expansion vessel 015 Connection line; diaphragm expansion vessel 016 Boiler flue connection plug 017 Thermal insulation block 018 Condensate hos
Parts lists Parts lists (cont.) Cable harness stepper motor Fuse 2.5 A (slow) (10 pce.
Parts lists 5354 802 GB Service Parts lists (cont.
Parts lists 5354 802 GB Parts lists (cont.
Parts lists 5354 802 GB Service Parts lists (cont.
Parts lists 5354 802 GB Parts lists (cont.
Specification Specification Permissible ambient temperature & during operation: 0 to +40 °C & during storage and transport: -20 to +65 °C 230 V~ 50 Hz 2.0 A~ I IP X4 to EN 60529 Temperature limiter setting: Line fuse (mains): Gas fired condensing boiler, class II 2H3P Rated output range in heating mode T V/T R 50/30 °C kW T V/T R 80/60 °C kW 41-819-12 11 to 30 10.0 to 27.3 10.0 to 27.3 10.3 to 28.0 41-819-13 11 to 35 10.0 to 31.9 10.0 to 31.9 10.3 to 32.7 41-819-14 2.6 3.0 3.5 1.9 107 2.
Specification Specification (cont.) Rated output range in heating mode T V/T R 50/30 °C T V/T R 80/60 °C kW kW 9 to 26 8.2 to 23.7 Rated thermal load range kW 8.4 to 27.1 LPG P Power consumption (max.) Gas fired condensing combi boiler (DHW heating) Permissible operating pressure Rated water volume at ΔT = 35 K Set flow rate (max.) Weight without front panel (installation) Product ID *1 The m3/ h kg/h W 47-819-18 11 to 26 10.0 to 23.7 10.3 to 36.5 47-819-20 2.9 3.3 3.9 2.1 111 2.4 144 2.
Certificates Declaration of conformity Declaration of conformity for the Vitodens 100-W We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm as sole responsible body that the product Vitodens 100-W complies with the following standards: DIN 4702–6 EN 483 EN 625 EN 677 EN 50 165 EN 55 014 EN 60 335 EN 61 000-3-2 EN 61 000-3-3 In accordance with the following Directives, this product is designated _-0085: 90/396/EEC 92/ 42/EEC 2004/108/EC 2006/95/EC This product complies with the requirements of th
Keyword index Keyword index 39 25 25 29 24 C Cleaning the combustion chamber Cleaning the heat exchanger . . . . . . . . Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condensate connection . . . . . . . . . . . . . . . . Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . Connection diagram . . . . . . . . . . . . . . . . . . . . . Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connections on the water side . . . . . .
5354 802 GB
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