Viessmann Vitodens 100-W WB1B Installation And Service Instructions Manual
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Viessmann Vitodens 100-W WB1B Installation And Service Instructions Manual

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VIESMANN
Installation and service
instructions
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
Please keep safe.
5354 802 GB
2/2008

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  • Page 1 VIESMANN Installation and service instructions 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 Please keep safe. 5354 802 GB 2/2008...

  • Page 2: Safety Instructions

    Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained the Code of Practice of relevant trade associations, Danger all current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury.
  • Page 3 Instal- charge static loads. ling non-authorised compo- nents and non-approved modifications/conversion can compromise safety and may invalidate our warranty. For replacements, use only ori- ginal spare parts from Viessmann or those which are approved by 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 ........... Opening the control unit ................13 Electrical connections................. 14 Service instructions Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance ........17 Further details regarding the individual steps ..........

  • Page 5: Preparing For Installation

    Preparing for installation Product information Vitodens 100-W, WB1B Set up for operation with natural gas. Preparing for installation Preparing the boiler installation Dimensions and connections A Condensate drain: Plastic pipe 7 22 mm B Heating flow...
  • Page 6 Preparing for installation Preparing for installation (cont.) C Gas fired condensing boiler: E Gas fired condensing boiler: Cylinder flow Cylinder return Gas fired condensing combi boil- Gas fired condensing combi boil- Cold water D Gas connection F Heating return G Drain safety valve Rated output range 9 - 26 11 - 30...
  • Page 7 Preparing for installation Preparing for installation (cont.) Fitting the wall retainer A Installation template Vitodens...
  • Page 8 Preparing for installation Preparing for installation (cont.) 1. Position the supplied installation 3. Drill 710 mm holes and insert the template on the wall. supplied rawl plugs. 2. Mark out the rawl plug holes. 4. Fit wall retainer with screws sup- plied.

  • Page 9: Installation Sequence

    Installation sequence Installing the boiler and making all connections Removing the front panel and mounting the boiler 1. Release screws at the bottom of 3. Hook the boiler into the wall retai- the boiler; do not remove comple- ner. tely. 2.
  • Page 10 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 instal- lation instructions. A Heating flow D Gas fired condensing boiler: B Gas fired condensing boiler: Cylinder return Cylinder flow Gas fired condensing combi boil-...

  • Page 11: Gas Connection

    Installation sequence Installing the boiler and making all connections (cont.) Safety valve connection 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.
  • Page 12 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 regula- tions. Note Fill the siphon with water before start- Filling the siphon with water Fill a minimum of 0.3 l of water into the flue gas connection.

  • Page 13: Opening The Control Unit

    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. Flue gas system installation instructions. Opening the control unit...

  • Page 14: Electrical Connections

    Installation sequence Opening the control unit (cont.) Please note Electronic modules can be damaged by electrostatic dis- charges. Touch earthed objects, such as heating or water pipes, to dis- charge static loads. Electrical connections Information regarding the connection of accessories For details of accessories, also observe their separate installation instructions provided.
  • Page 15 Installation sequence Electrical connections (cont.) % Gas fired condensing boilers only: D Jumper Cylinder temperature sensor (plug E Power supply (230 V, 50 Hz). on the cable harness outside the control unit) Danger Incorrect core termination Note can cause severe injuries Gas fired condensing boiler with- and damage to the equip- out DHW cylinder:...
  • Page 16 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 maxi- mum permissible temperatures for these cables are not exceeded.

  • Page 17: Commissioning, Inspection, Maintenance

    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 Page 1. Filling the heating system ..........2.

  • Page 18: Further Details Regarding The Individual Steps

    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.
  • Page 19 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 sys- tem pressure > 0.8 bar). 7.

  • Page 20: Venting The Boiler By Flushing Out (After Venting System)

    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.

  • Page 21: Changing To Operation With Lpg

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Simultaneously turn rotary selec- tors "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"...

  • Page 22: Checking The Co Content

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the CO 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...
  • Page 23 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 content for lower out- put.

  • Page 24: Burner Removal

    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 1. Switch OFF the power. 3.

  • Page 25: Checking The Burner Gasket And The Burner Gauze Assembly

    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.

  • Page 26: Checking And Adjusting Electrodes

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Remove electrode B. 4. Insert and secure a new burner gauze assembly D with a new 2. Undo the three cheese-head gasket E. screws and remove thermal insu- Fixing screw torque: 3.5 Nm. lating ring C.

  • Page 27: Cleaning The Heat Exchanger

    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 combus- tion chamber.

  • Page 28: Checking The Condensate Drain And Cleaning The Siphon

    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.

  • Page 29: Burner Installation

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Burner installation 1. Install the burner and torque 5. Reopen gas supply and switch on screws A diagonally with 4.0 Nm. power supply. 2. Insert new gasket and tighten the 6.

  • Page 30: Checking All Gas Equipment For Tightness At Operating Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking all gas equipment for tightness at operating pres- sure Danger Escaping gas leads to a risk of explosion. Check gas equipment for tight- ness. Fitting the front panel 1. Push front panel into place on the 2.

  • Page 31: Instructing The System User

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Instructing the system user The system installer must hand the operating instructions to the system user and instruct him/her in the operation of the system.

  • Page 32: Troubleshooting

    Troubleshooting Function sequence and possible faults Display screen Measures Control unit is- Increase set sues a heat de- value and ensure mand heat is drawn off Fan starts after approx. 51 s Check the fan, fault F9 fan connecting cables, power at the fan and fan control Ignition...

  • Page 33: Fault Messages On The Display

    Troubleshooting Fault messages on the display Faults are indicated by a flashing fault code with fault symbol "U" on the dis- play. For fault code explanations see the following table. Fault code System character- Cause Measures on the dis- istics play Constant mode Outside tempera-...
  • Page 34 Troubleshooting Fault messages on the display (cont.) Fault code System character- Cause Measures on the dis- istics play Burner blocked Flow sensor lead Check connections and broken lead; replace sensor if required. Regulated operation Communication Check connections and without Open Therm fault Open Therm lead;...
  • Page 35 Troubleshooting Fault messages on the display (cont.) Fault code System character- Cause Measures on the dis- istics play Burner in a fault No flame signal is Check the ionisation state present electrode and leads, measure the ionisation current, check the gas pressure, check the gas train, ignition, ignition module and condensate...
  • Page 36 Troubleshooting Fault messages on the display (cont.) Press reset Turn rotary selector "rt" less than 2 s to "URESET", then back to the con- trol range.

  • Page 37: Repairs

    Troubleshooting Repairs Removing front panel 1. Release screws at the bottom of 2. Remove front panel. the boiler; do not remove comple- tely. Outside temperature sensor 1. Open the control unit casing. See page 13.
  • Page 38 Troubleshooting Repairs (cont.) 2. Disconnect cables from outside temperature sensor. 3. Check the sensor resistance and compare it with the curve. 4. Replace the sensor in case of severe deviation.

  • Page 39: Boiler Water Temperature Sensor

    Troubleshooting Repairs (cont.) Boiler water temperature sensor 1. Pull the leads from boiler water temperature sensor A and check the resistance. 2. Check the sensor resistance and compare it with the curve. 3. In case of severe deviation, drain boiler on the heating water side and replace the sensor.
  • Page 40 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. 3. Replace the sensor in case of severe deviation.
  • Page 41 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 lim- iter A.
  • Page 42 Troubleshooting Repairs (cont.) Checking the outlet temperature sensor (gas fired conden- sing combi boiler) 1. Pull the leads from outlet tempera- ture sensor A 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in case of severe deviation.
  • Page 43 Troubleshooting Repairs (cont.) Checking the flue gas temperature sensor 1. Pull the leads from flue gas tem- perature sensor A. 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in case of severe deviation.
  • Page 44 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.
  • Page 45 Troubleshooting Repairs (cont.) Checking or replacing the plate-type heat exchanger (gas fired condensing combi boiler) E Heating water flow G Cold water F Heating water return H DHW 1. Shut off and drain the boiler on the 4. Turn the three-way valve B with heating water and the DHW side.
  • Page 46 Troubleshooting Repairs (cont.) 5. Remove two screws C from the 7. Check the heating water side for plate-type heat exchanger and contamination and, if required, remove plate-type heat exchanger clean or replace the plate-type heat D with gaskets. exchanger. Note 8.

  • Page 47: Gas Type Conversion

    Gas type conversion Converting from LPG to natural gas 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.
  • Page 48 Gas type conversion Converting from LPG to natural gas (cont.) 4. Remove gas restrictor D from gas 6. Remove or void gas type sticker on train. the top of the boiler (next to the type plate). 5. Fit gas train A with new gaskets E and F.

  • Page 49: Adjusting The Burner

    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 "1" for operation with LPG. 5.

  • Page 50: Control Unit

    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 only possi- Frost protection function is active at...

  • Page 51: Designs

    Designs Connection and wiring diagram Stepper motor diverter valve Vitotrol 100, type RT Ignition/Ionisation Vitotrol 100, type UTD Vitotrol 100, type UTA Mains input 230V/50Hz...

  • Page 52: Designs Connection And Wiring Diagram

    Designs Connection and wiring diagram (cont.) Remote control (accessory) Outlet temperature sensor (gas Outside temperature sensor fired condensing combi boiler) (accessory) Cylinder temperature sensor Time switch (accessories) (gas fired condensing boiler) Gas pressure limiter (acces- Flue gas temperature sensor sory) sÖ...

  • Page 53: Parts Lists

    Parts lists Parts lists When ordering spare parts: 038 Check valve Quote the part and serial no. (see 039 Clip 7 8 type plate) and the item number of the 040 Clip 7 10 required part (as per this parts list). 041 Clip 7 13.5 Obtain standard parts from your local 042 Clip 7 16...
  • Page 54 Parts lists Parts lists (cont.) 080 Cable harness stepper motor 104 Special grease 081 Fuse 2.5 A (slow) (10 pce.) 110 Installation and service instruc- 082 Cable fixing tions 102 Spray paint, Vitowhite 111 Operating instructions 103 Touch-up paint stick, Vitowhite A Type plate...
  • Page 55 Parts lists Parts lists (cont.)
  • Page 56 Parts lists Parts lists (cont.)
  • Page 57 Parts lists Parts lists (cont.)
  • Page 58 Parts lists Parts lists (cont.)

  • Page 59: Specification

    Specification Specification Rated voltage: 230 V~ Permissible ambient temperature Rated frequency: 50 Hz during operation: 0 to +40 °C Rated current: 2.0 A~ during storage Safety class: and transport: -20 to +65 °C Protection: IP X4 to EN 60529 Temperature limiter setting: 100 °C (fixed) Line fuse (mains):...
  • Page 60 Specification Specification (cont.) Rated output range in heating mode 9 to 26 11 to 26 11 to 26 50/30 °C 8.2 to 10.0 to 10.0 to 80/60 °C 23.7 23.7 23.7 10.3 to 10.3 to Rated thermal load range 8.4 to 27.1 31.3 36.5 Gas council no.

  • Page 61: Certificates

    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 55 014 EN 483...

  • Page 62: Keyword Index

    Keyword index Keyword index Boiler water temperature sensor Heating curve ....... . . Burner gasket .
  • Page 64 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 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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