Viessmann VITODENS 111-W Installation And Service Instructions Manual
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Viessmann VITODENS 111-W Installation And Service Instructions Manual

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VIESMANN
Installation and service
instructions
for contractors
Vitodens 111-W
Type B1LA, 6.5 to 35.0 kW
Gas condensing storage combi boiler
Natural gas and LPG version
Gas Council no.: 47-819-23; 47-819-24; 47-819-25
For applicability, see the last page
VITODENS 111-W
Please keep safe.
5618 648 GB
3/2012

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  • Page 1 VIESMANN Installation and service instructions for contractors Vitodens 111-W Type B1LA, 6.5 to 35.0 kW Gas condensing storage combi boiler Natural gas and LPG version Gas Council no.: 47-819-23; 47-819-24; 47-819-25 For applicability, see the last page VITODENS 111-W Please keep safe.

  • Page 2: Checking The Co 2 Content

    Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate- rial losses. Safety instructions explained ■ all current safety regulations as defined by DIN, EN, DVGW, TRGI, Danger TRF, VDE and all locally applicable This symbol warns against the standards, risk of injury.
  • Page 3 ■ When using gas as fuel, also close the For replacements, use only orig- main gas shut-off valve and safeguard inal spare parts from Viessmann against unauthorised reopening. or those which are approved by ■ Isolate the system from the power sup- Viessmann.

  • Page 4: Table Of Contents

    Index Index Service instructions Product information Product information....................Preparing for the boiler installation............... Installation instructions Installation sequence Fitting the wall mounting bracket................Fitting the boiler and making connections............10 Opening the control unit enclosure............... 16 Electrical connections................... 16 Service instructions Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance..........
  • Page 5 Index Index (cont.) Specification....................... 76 Certificates Declaration of conformity..................77 Keyword index....................78...

  • Page 6: Product Information

    ■ Cylinder and plate heat exchanger for DHW heating Product description Accessory connection The Vitodens 111-W is equipped with a cylinder and an integral plate heat Outside temperature sensor and time exchanger as primary store system for switch are connected with low voltage to DHW heating.

  • Page 7: Preparing For The Boiler Installation

    Product information Preparing for the boiler installation Dimensions and connections A Area for electrical connections F Gas connection 7 22 mm B Heating flow 7 22 mm G Cold water 7 15 mm C Condensate drain H DHW 7 15 mm D Heating return 7 22 mm E Filling loop...
  • Page 8 Product information Preparing for the boiler installation (cont.) Preparing the connections Note This boiler (IP rating: IP X4 D) is approved for installation in wet rooms inside safety zone 1 in accordance with IEEE Wiring Regulations, providing the occurrence of hosed water can be ruled out.

  • Page 9: Installation Sequence

    Installation sequence Fitting the wall mounting bracket Ø10...

  • Page 10: Fitting The Boiler And Making Connections

    Installation sequence Fitting the boiler and making connections Removing the front panel and mounting the boiler Note When mounting on the wall, observe the following: Weight excl. packaging: approx. 65 kg. 1. Undo screws at the bottom of the 3. Hook the boiler into the wall mounting boiler;...
  • Page 11 Installation sequence Fitting the boiler and making connections (cont.) Making the connections on the water side For fittings on the heating water C Gas connection side and DHW side, see separate D Cold water installation instructions. E DHW Please note DHW connection To prevent equipment damage, install all pipework free of load...

  • Page 12: Gas Connection

    Installation sequence Fitting the boiler and making connections (cont.) Fitting the connection set Gas connection 1. Connect gas shut-off valve to con- nection A.
  • Page 13 Installation sequence Fitting the boiler and making connections (cont.) 2. Carry out a tightness test. Note For tightness tests, use only approved leak detection agents (EN 14291) and devices. Leak detec- tion agents with unsuitable constitu- ents (e.g. nitrites, sulphides) can cause material damage.
  • Page 14 Installation sequence Fitting the boiler and making connections (cont.) Condensate drain connection ■ If the condensate pipe is routed out- side the building, use a pipe with at least 7 30 mm and protect this pipe from frost. Avoid long outdoor pipe- work.
  • Page 15 Installation sequence Fitting the boiler and making connections (cont.) Fill the flue outlet with at least 0.3 l of water. Please note Water in the ventilation air supply can be detrimental to the com- bustion quality. Never pour water into the exter- nal vent.

  • Page 16: Opening The Control Unit Enclosure

    Installation sequence Opening the control unit enclosure Please note Electronic assemblies can be damaged by electrostatic dis- charge. Before beginning work, touch earthed objects, such as heating or water pipes, to discharge static loads. Electrical connections Information on connecting accessories When connecting accessories observe the separate installation instructions provided with them.
  • Page 17 Installation sequence Electrical connections (cont.) L N 1 L N 4 3 2 1 A Only for weather-compensated E Power supply (230 V, 50 Hz). mode: See page 18. Outside temperature sensor (acces- F Vitotrol 100 or on-site room temper- sory) ature controller (switched 230 V B OpenTherm device...

  • Page 18: Power Supply

    Installation sequence Electrical connections (cont.) Installation site: 2. Plug the power cable supplied with ■ North or north-westerly wall, 2 to the outside temperature sensor into 2.5 m above ground level; in multi slot "X21". storey buildings, in the upper half of the second floor 3.
  • Page 19 Installation sequence Electrical connections (cont.) Routing connecting cables and closing the control unit enclo- sure Please note When routing and securing Connecting cables will be dam- cables/leads on site, ensure that aged if they touch hot compo- the maximum permissible tem- nents.

  • Page 20: 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..........22 • • • 2. Venting the boiler by flushing........24 •...

  • Page 21: Commissioning Steps

    Commissioning, inspection, maintenance Steps - commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • 22. Instructing the system user........... 41...

  • Page 22: Further Details Regarding The Individual Steps

    Commissioning, inspection, maintenance Further details regarding the individual steps Filling the heating system Please note ■ Soften fill water harder than Unsuitable fill water increases 300 ppm. the level of deposits and corro- ■ An antifreeze additive suitable sion and may lead to boiler dam- for heating systems can be age.
  • Page 23 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Open shut-off valves A and B. 5. Open taps C and fill the heating sys- tem. (Minimum system pressure > 0.8 bar). 6. Close taps C.

  • Page 24: Venting The Boiler By Flushing

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Venting the boiler by flushing 1. Close the shut-off valves on the heat- 4. Close taps A and B, open the shut- ing water side. off valves on the heating water side. 2.

  • Page 25: Changing To Operation With Lpg

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Changing to operation with LPG In the delivered condition, the boiler is Separate installation instruc- set up for operation with natural gas. For tions. operation with LPG, change the gas noz- zle and convert the gas type in the con- Changing from LPG to natural gas - see trol unit.

  • Page 26: Matching The Burner Output To The Flue System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 8. Shut down the boiler, close the gas Note shut-off valve, remove the pressure The maximum pressure drop between gauge and close test nipple A with the gas shut-off valve and test nipple A at the gas train is 0.5 mbar.

  • Page 27: Reducing The Max. Heating Output

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Refer to the following table for the correction factor required for the con- nected flue system. 4. Within 2 s, turn rotary selector "tw" to the top left range. The display then shows "r", "w", "A"...
  • Page 28 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Turn on the ON/OFF switch. Note The heating output can only be changed with the burner in opera- tion. 2. Turn rotary selector "tr" fully clock- wise, until the display shows "SERV".

  • Page 29: Adjusting The Circulation Pump To The Heating System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 5. Transfer selected heating output: Turn rotary selector "tw" for less than 2 s fully clockwise and then back into the r.h. control range. During the transfer, "– . – . –" will be displayed.
  • Page 30 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Turn both rotary selectors "tw" and "tr" simultaneously into their respective central positions. "SERV" appears on the display. 3. Within 2 s, turn rotary selector "tr" to the top right range. "r"...
  • Page 31 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the CO content The Vitodens 111-W is factory-set for If the actual CO or O and CO values natural gas. During commissioning or deviate from the stated range, check the...
  • Page 32 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 04. Adjust the upper heating output: Turn rotary selector "tr" fully clockwise, until the display shows 5 bars for the upper heating output. 05. Check the CO content for the upper heating output.

  • Page 33: Burner Removal

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Burner removal F 4x 4. Push U-bend D down. 1. Switch the power OFF. 2. Shut off the gas supply. 5. Undo gas supply pipe fitting E. 3. Pull electrical cables from fan motor A, gas valve B and electrodes...

  • Page 34: Checking The Burner Gasket And Burner Gauze Assembly

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Undo four screws F and remove the Please note To prevent any damage, burner. never rest the burner on the burner gauze assembly. Checking the burner gasket and burner gauze assembly Check burner gasket A and burner gauze assembly D for possible damage and replace if required.

  • Page 35: Checking And Adjusting The Electrode

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Undo two Torx screws and remove 6. Fit electrode B. burner gauze assembly D with its gasket E. Please note Tighten screws far enough 4. Insert a new gasket E into the new that the components are not burner gauze assembly D and damaged and to ensure their...

  • Page 36: Cleaning The Heat Exchanger

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Check the electrode gaps. If the gaps are not as specified or the electrode is damaged, replace and align the electrode together with a new gas- ket. Please note Tighten screws far enough that the components are not damaged and to ensure their...

  • Page 37: 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. Release hook and remove siphon A with sealing piece B. Pull siphon A upwards away from the drain connection. 2. Remove supply hose C from siphon 3.

  • Page 38: Burner Installation

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Burner installation A 4x 3. Tighten four screws A diagonally. 1. Mount burner and secure with four screws A. Please note 2. Insert new gasket and tighten the fit- Tighten screws far enough tings on gas supply pipe B.

  • Page 39: Checking The Diaphragm Expansion Vessel And System Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Fit electrical cables to fan motor D, 7. Push U-bend C up again. gas valve E and ignition unit F. 5. Reopen gas supply and switch on power supply. 6.

  • Page 40: Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Drain the system until the pressure gauge indicates "0". 2. If the pre-charge pressure of the dia- phragm expansion vessel is lower than the static system pressure, top up with nitrogen until the pre-charge pressure is raised by 0.1 to 0.2 bar.

  • Page 41: Fitting The Front Panel

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Fitting the front panel 1. Hook the front panel into place. 2. Tighten screws at the bottom. Instructing the system user The system installer must hand the oper- ating instructions to the system user and instruct the user in the operation of the system.

  • Page 42: Troubleshooting

    Troubleshooting Function sequence and possible faults Display Measure Control unit issues Increase set value a heat demand and ensure heat is drawn off Fan starts After approx. 1 min Check the fan, fan fault F9 connecting cables, power at the fan and fan control Ignition Fault F4...

  • Page 43: Fault Messages On The Display

    Troubleshooting Function sequence and possible faults (cont.) Burner in opera- Stops below the set Check the flue sys- tion boiler water tem- tem for tightness perature and (flue gas recircula- restarts immedi- tion); check the ately gas flow pressure Fault messages on the display Faults are indicated by a flashing fault code with fault symbol "U"...
  • Page 44 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics No DHW heating Short circuit, outlet Check the sensor (see temperature sen- page 51). No DHW heating Lead break, cylin- Check the sensor (see der temperature page 50).
  • Page 45 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics Burner in a fault The temperature Check heating system fill state limiter has respon- level. Check circulation pump. Vent the system. Check the temperature limiter and connecting leads (see page 52).
  • Page 46 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics Burner blocked Fault, burner con- Check ignition electrodes trol unit and connecting cables. Check whether a strong interference (EMC) field exists near the appliance. Press "RESET" (see page 46).

  • Page 47: Repairs

    Troubleshooting Repairs Removing the front panel 1. Undo screws at the bottom of the 2. Remove front panel. boiler; do not remove completely. Outside temperature sensor 1. Open the control unit enclosure. See page 16.
  • Page 48 Troubleshooting Repairs (cont.) 2. Disconnect leads from outside tem- perature sensor. 4 3 2 1 3. Check the sensor resistance and compare it with the curve. 4. Replace the sensor in the case of severe deviation. 10 20 30 Temperature in °C...
  • Page 49 Troubleshooting Repairs (cont.) Boiler water temperature sensor 1. Pull the leads off boiler water temper- ature sensor A and check the resist- ance. 2. Check the sensor resistance and compare it with the curve. 3. In the case of severe deviation, drain boiler on the heating water side and replace the sensor.
  • Page 50 Troubleshooting Repairs (cont.) Checking cylinder temperature sensor 1. Pull plug % from the cable harness. 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in the case of severe deviation. 10 30 50 70 90 110 Temperature in °C...
  • Page 51 Troubleshooting Repairs (cont.) Checking the outlet temperature sensor 1. Pull leads from outlet temperature sensor A. 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in the case of severe deviation. Danger The outlet temperature sen- 10 30 50 70 90 110 sor is immersed in the DHW Temperature in °C...
  • Page 52 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 53 Troubleshooting Repairs (cont.) Checking the flue gas temperature sensor 1. Pull leads from flue gas temperature sensor A. 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in the case of severe deviation. 10 30 50 70 90 110 Temperature in °C...
  • Page 54 Troubleshooting Repairs (cont.) Checking and cleaning the plate heat exchanger Note Drain the boiler on its heating water and DHW side. 1. Undo plate heat exchanger A 3. Install in reverse order with new gas- kets. (screws B) and pull out of the front. 2.
  • Page 55 Troubleshooting Repairs (cont.) Checking the fuse 1. Switch the power OFF. 2. Open control unit enclosure (see page 16). 3. Check fuse F4.

  • Page 56: Gas Type Conversion

    Gas type conversion Converting from LPG to natural gas Removing gas restrictor 2. Pull cable from gas train A. 3. Undo two screws B and remove gas train A. 4. Remove gas restrictor C from gas train A. 5. Mount gas train A with new gasket Torque for fixing screw B: 3 Nm.
  • Page 57 Gas type conversion Converting from LPG to natural gas (cont.) 2. Turn both rotary selectors "tw" and "tr" simultaneously into their respective central positions. "SERV" appears on the display. 3. Turn rotary selector "tr" within 2 s fully anti-clockwise. The display shows "A" and the set value flashes.

  • Page 58: Control Unit

    Control unit Functions and operating conditions in weather-compensated mode Heating mode In weather-compensated mode, the boiler water temperature is regulated subject to the outside temperature. Heating curve of weather-compensated control unit -5 -10 -15 -20 Outside temperature in °C Setting of rotary selector "tr" Frost protection function A = 1 Frost protection function is only possible...
  • Page 59 Control unit Functions and operating conditions in… (cont.) DHW heating Heating the DHW primary store from ■ The cylinder primary pump is switched on if the boiler water temperature ≥ set cold DHW temperature. The heating circulation pump is switched ■...

  • Page 60: Designs

    Designs Connection and wiring diagram Stepper motor diverter valve Ignition/ionisation...
  • Page 61 Designs Connection and wiring diagram (cont.) Vitotrol 100 X ... Electrical interface ■ Type RT § Boiler water temperature sensor ■ Type UTA Outlet temperature sensor (gas ■ Type UTDB condensing combi boiler) ■ Type UTDB-RF Cylinder temperature sensor Power input 230 V/50 Hz (gas condensing boiler) Remote control (OpenTherm Flue gas temperature sensor...

  • Page 62: Parts Lists

    Parts lists Ordering parts The following information is required: Standard parts are available from your ■ Serial no. (see type plate A) local supplier. ■ Assembly (from this parts list) ■ Position number of the individual part within the assembly (from this parts list)

  • Page 63: Overview Of The Assemblies

    Parts lists Overview of the assemblies A Type plate (on the cover panel) D Hydraulic assembly B Casing assembly E Control unit assembly C Heat cell assembly F Miscellaneous assembly...

  • Page 64: Casing Assembly

    Parts lists Overview of the assemblies (cont.) G Cylinder assembly Casing assembly 0001 Front panel 0007 Toggle fastener (set) 0002 Logo 0008 Pipe clip Ø 18 0003 Cover panel with gasket 0012 Air box gasket, gas pipe 0004 Profiled seal 0013 Wall mounting bracket 0005 Control unit support 0014 Diaphragm grommets (5 pce)

  • Page 65: Heat Cell Assembly

    Parts lists Heat cell assembly 0001 Gasket DN 60 0009 Condensate hose 0002 Boiler flue connection 0010 Splash siphon 0003 Boiler flue connection plug 0013 Condensate hose 0004 Flue gas gasket 0015 Gas supply pipe 0005 Flue gas temperature sensor 0016 Gasket 17 x 24 x 2 (set) 0006 Heat exchanger 0019 Burner...

  • Page 66: Burner Assembly

    Parts lists Heat cell assembly (cont.) 0001 0005 0002 0001 0003 0003 0004 0014 0015 0006 0013 0004 0013 0014 0015 0007 0012 0008 0009 0011 0010 0011 0016 Burner assembly 0001 Burner gasket 0005 Burner door 0002 Thermal insulation ring 0006 Ionisation electrode gasket 0003 Cylinder burner gauze assembly 0007 Ignition and ionisation electrode...
  • Page 67 Parts lists Burner assembly (cont.) 0009 Radial fan 0013 Gaskets (set) 0010 Gas valve 0014 Conversion kit G31 0012 Venturi extension 0003 0001 0002 0006 0003 0005 0007 0006 0004 0012 0008 0009 0013 0014 0013 0010 0013...

  • Page 68: Hydraulic Assembly

    Parts lists Hydraulic assembly 0001 Temperature sensor 0028 Clip Ø 10 (5 pce) 0002 Thermal circuit breaker 0029 Return pipe 0003 Air vent valve G ⅜ 0030 Safety valve 0004 Hose Ø 10 x 1.5 x 750 0031 Condensate hose 0005 Clip Ø...
  • Page 69 Parts lists Hydraulic assembly (cont.) 0047 0004 0003 0038 0048 0005 0001 0039 0012 0027 0008 0002 0005 0006 0040 0016 0041 0005 0027 0007 0012 0029 0011 0010 0009 0030 0008 0013 0031 0010 0033 0020 0042 0015 0032 0015 0034 0028...

  • Page 70: Aqua-Plate Assembly

    Parts lists Aqua-plate assembly 0001 Valve insert 0008 Temperature sensor 0002 Flow unit 0009 Clip Ø 8 (5 pce) 0003 Return unit 0010 Clip Ø 10 (5 pce) 0004 Overflow valve 0011 Pipe clip Ø 18 (5 pce) 0005 Overflow pipe 0012 Gasket A 17 x 24 x 2 (set) 0006 Plate heat exchanger 0013 Gasket, O-ring 17.86 x 2.62 (set)

  • Page 71: Control Unit Assembly

    Parts lists Control unit assembly 0001 Control unit 0006 Cable harness stepper motor 0002 Cover, wiring chamber 0007 Ignition cable with angled plug 0003 Fuse 2.5 A (slow) 250 V 5 kΩ 0004 Cable harness X20 0008 Cable fixing 0005 Cable harness 100/35...
  • Page 72 Parts lists Control unit assembly (cont.) 0002 0008 0003 0001 0004 0005 0007 0006...

  • Page 73: Cylinder Assembly

    Parts lists Cylinder assembly 0001 O-ring 14.3 x 2.4 (set) 0008 Protective profile 0002 Clip Ø 15 (5 pce) 0009 Hose clip Ø 340 - 360 x 9 0003 DHW connection pipe 0010 Cylinder 0004 Non-return valve (cartridge) 0011 Thermal insulation EPS, front 0005 Shut-off elbow, cylinder 0012 Thermal insulation EPS, back 0006 DHW connection pipe...

  • Page 74: Miscellaneous Assembly

    Parts lists Cylinder assembly (cont.) 0012 0010 0011 0009 0002 0002 0014 0007 0003 0005 0001 0001 0007 0004 0001 0007 0007 0006 0015 0008 Miscellaneous assembly 0001 Special grease 0003 Touch-up paint stick, white 0002 Touch-up spray paint, white...
  • Page 75 Parts lists Miscellaneous assembly (cont.) 0004 Installation and service instruc- tions 0005 Operating instructions 0001 0002 0004 0005 0003...

  • Page 76: Specification

    Specification Specification Rated voltage: 230 V~ Temperature limiter Rated frequency: 50 Hz setting: 100 °C (fixed) Rated current: 2.0 A~ Backup fuse (power Safety category: supply): max. 3 A IP rating: IP X4D to EN 60529 Permissible ambient temperature ■ during operation: 0 to +40 °C ■...

  • Page 77: Declaration Of Conformity

    Certificates Declaration of conformity Declaration of Conformity for the Vitodens 111-W We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, confirm as sole respon- sible body that the product Vitodens 111-W complies with the following standards: DIN 4753 EN 55 014-1...

  • Page 78: Keyword Index

    Keyword index Keyword index Gas train ...........25 Boiler water temperature sensor ..49 Gas type conversion Burner gasket........34 ■ LPG..........25 Burner gauze assembly.....34 ■ Natural gas........56 Burner installation......38 Burner removal........33 Heat exchanger cleaning....36 Heating curve........58 Cold water connection......7 Heating flow.........7 Combustion chamber cleaning..36 Heating return........7 Commissioning........22 Condensate........14...
  • Page 79 Keyword index Keyword index (cont.) Temperature limiter......52 Wall mounting........9 Troubleshooting.........47 Weather-compensated mode.....58 Ventilation air pipe......15 Venting..........24...
  • Page 80 Applicability Serial No.: 7499484 7499485 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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