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VIESMANN Installation and service instructions for contractors Vitodens 100-W Type WB1A Gas fired wall mounted condensing boiler Natural gas version For applicability, see the last page VITODENS 100-W Please keep safe. 5592 827 GB 4/2007...
Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained If you notice the smell of gas Danger Danger This symbol warns against the Escaping gas can cause explo- risk of injury. sions which may lead to ser- ious injury.
Repairing components which For replacements, use only ori- fulfil a safety function can com- ginal spare parts from promise the safe operation of Viessmann or those which are your heating system. approved by Viessmann. Replace faulty components only with original Viessmann...
Index Index Installation instructions Preparing for installation Product information ..................Preparing for installation ................Installation sequence Installing the boiler and making all connections ........... 32 Flue outlet ....................39 Electrical connections................. 41 Commissioning and testing ................. 46 Service instructions Commissioning, inspection, maintenance..........55 Service Instructions Routine Servicing Instructions ..............
Set up for operation with natural gas. Preparing for installation General Information Appliance description The Vitodens 100-W is a fully auto- The appliance is designed for use matic, wall hung, fan assisted with sealed primary water systems balanced flue condensing boiler for (only) and incorporates a circulation use with Natural Gas (G20).
Preparing for installation Preparing for installation (cont.) Technical Specification General Specifications and Performance Data Rated output range 50/30 °C 8 to 24 8 to 30 80/60 °C 7.3 to 21.8 7.3 to 27.3 Rated output range 7.4 to 22.3 7.4 to 28.0 Maximum gas rate 2.36 2.96...
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Preparing for installation Preparing for installation (cont.) Overall Appliance Dimensions Combi boiler A Condensate drain: Plastic pipe E Cold water: 715 mm 722 mm F Heating return: 722 mm B Heating flow: 722 mm G Safety valve drain: 718 mm/ C DHW: 715 mm 22 mm D Gas connection: Rp ½...
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Preparing for installation Preparing for installation (cont.) System boiler A Condensate drain: Plastic pipe E DHW return: 722 mm 722 mm F Heating return: 722 mm B Heating flow: 722 mm G Safety valve drain: 718 mm/ C DHW cylinder flow: 722 mm 22 mm D Gas connection: Rp ½...
Preparing for installation Preparing for installation (cont.) Minimum installation clearances The following minimum clearances (mm) must be maintained for installing and servicing the appliance. A Front (behind removable panel) B Front (for service) Flue System Specifications Concentric Horizontal Flue System Standard horizontal flue kit: The appli- Extension ducts can be used to ance can be supplied complete with a...
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Preparing for installation Preparing for installation (cont.) An extra 87° elbow can be used but this reduces the maximum permissi- ble length by 1 m . An extra 45° elbow can be used but this reduces the max- imum permissible length by 0.5 m . A Combined length of flue outlet/ B Flue outlet/ventilation pipe (can ventilation pipe max 6m.
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Preparing for installation Preparing for installation (cont.) Before commencing the installation refer to diagram below to determine which optional extension kits are required, if any. A Combined length of flue outlet/ B Flue outlet/ventilation pipe (can ventilation pipe max. 10 m. be shortened as necessary)
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Preparing for installation Preparing for installation (cont.) Elbows and extensions Extension Elbow 45° Elbow 87°...
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Preparing for installation Preparing for installation (cont.) Hydraulic circuit Combi boiler A Boiler E Plate heat exchanger B heat exchanger F DHW outlet C circulation pump G Cold water inlet D Three-way diverter valve H Heating circuit...
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Preparing for installation Preparing for installation (cont.) System boiler A DHW cylinder D circulation pump B Boiler E Three-way diverter valve C heat exchanger F Heating circuit...
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Preparing for installation Preparing for installation (cont.) Sectional Diagram Combi boiler illustrated Installation Requirements Statutory Requirements Gas safety (installation and use) regulations (current issue) It is in your own interest and safety, to ensure that the law is complied with.
Preparing for installation Preparing for installation (cont.) In addition to the above regulations, CORGI will then issue either a Build- this appliance must be installed in ing Compliance Certificate (for Eng- accordance with the current IEE Wir- land and Wales) or a Declaration of ing Regulations for electrical installa- Safety (for Scotland, Northern Ireland, tion (BS 7671), local building...
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Preparing for installation Preparing for installation (cont.) Due consideration should be given A compartment used to enclose the to the routing of the condensate appliance must be designed and drain from the chosen position. constructed specifically for this pur- If the boiler is to be fitted in a timber pose.
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Preparing for installation Preparing for installation (cont.) Flue terminal position Horizontal flue system Position Minimum spacing Directly below a window that can be opened, air vent or any other ventilation opening Below gutter drain or soil pipe Below eaves Below a balcony From vertical drain or soil pipes From internal and external corners Above adjacent ground or balcony level/roof...
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Preparing for installation Preparing for installation (cont.) Vertical flue systems Position Minimum spacing From adjacent wall From adjacent opening window 1000 From another terminal Minimum height Flue Terminal Location Detailed recommendations for flue The boiler must be installed so that installation are given in BS 5440:1.
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Preparing for installation Preparing for installation (cont.) It is essential to ensure that pro- Where the lowest part of the term- ducts of combustion discharging inal is fitted less than 2 m above from the terminal cannot re-enter ground, above a balcony or above a the building or any other adjacent flat roof to which people have building, through ventilators, win-...
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Preparing for installation (cont.) Central Heating System (typical system designs) The Vitodens 100-W is designed for connection to sealed central heating water systems. A sealed system must only be filled by a competent person. Filling the heating system see page 48.
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Preparing for installation Preparing for installation (cont.) A Radiators F Drain cock at lowest point in the B Boiler system C Lockshield valve G Hot water taps D CH flow H Water main E CH return K BS stop valve...
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Connection see page 42 LS Connection of DHW cylinder con- S Connection box (not supplied) trol The following Viessmann control configurations are available: Constant temperature Timer with constant temperature Vitotrol 100 UTD The boiler requires a permanent live feed via plug 40.
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Preparing for installation Preparing for installation (cont.) A Radiators F CH return B Boiler G Drain cock at lowest point in the C DHW-Cylinder system D Lockshield valve H Control unit E CH flow K Cylinder thermostat...
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P Connection box (not supplied) LS Connection of DHW cylinder con- R Fuse 3 A trol S Mains ON/OFF switch The following Viessmann control The DHW cylinder must have an configurations are available: integrated temperature control con- Constant temperature nected to the Vitodens...
Preparing for installation Preparing for installation (cont.) Expansion vessel Further details are available in the The table shows the maximum system current issues of BS 5449 and BS volume that the integral expansion 6798. vessel can sustain under different If the pressure gauge rises by 1.5 bar charge pressure conditions.
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Preparing for installation Preparing for installation (cont.) Pressure relief valve A pressure relief valve set at 3 bar (43.5 psi) is supplied with the appli- ance. Domestic Hot Water System (Combi boiler only) Check that the mains water pres- If the appliance is installed in an sure is sufficient to produce the area where the temporary hardness required DHW flow rate of 8.0 l/min...
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(and its external con- trols) may be used. External Controls To ensure optimum performance, Viessmann offer a range of external controls however the appliance may be used with any certificated room thermostat or time clock room thermo-...
Preparing for installation Preparing for installation (cont.) Preparations for boiler installation Unpacking the appliance The appliance is supplied in 2 sepa- rate packages plus any optional flue packages. Check the availability and contents of each package before commencing the installation. Boiler package Combi boiler System boiler...
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Preparing for installation Preparing for installation (cont.) A Installation template B Observe the minimum slope of 3° (5mm/m) towards the boiler 1. Position the installation template 2. Mark wall plug holes and balanced on the wall. flue pipe opening.
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Preparing for installation Preparing for installation (cont.) 3. Drill 710 mm holes and insert the 5. Fit wall mounting frame with rawl plugs. enclosed screws. 4. Cut flue pipe opening to 100 mm Preparing the connections Note For dimensions for on-site preparations of the gas and water side connections see "Overall Appliance Dimensions"...
Installation sequence Installing the boiler and making all connections Remove front panel and mount boiler Note The front panel must be removed before mounting the boiler. 1. Remove the screw at the top of the 3. Hook the boiler on to the wall boiler.
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Installation sequence Installing the boiler and making all connections (cont.) Gas connection 1. Connect the gas supply to the gas inlet connection on the gas cock A. Upon completion, tighten the union connection. 2. Carry out a gas soundness test. 3.
Installation sequence Installing the boiler and making all connections (cont.) C Gas connection: ½" BSP D Cold water: 715 mm E Heating return: 722 mm System boiler Note For operation without a DHW cylinder, shut-off connections C Gas connection: ½" BSP A Heating flow: 722 mm D DHW return: 722 mm B DHW cylinder flow: 722 mm...
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Installation sequence Installing the boiler and making all connections (cont.) Connect safety valve drain Connect a suitable discharge pipe to the pressure relief valve outlet. The pipe discharging to a safe place must be a minimum of 15 mm copper and run continually downwards.
Installation sequence Installing the boiler and making all connections (cont.) Condensate connection Vitodens 100-W has within a syphonic condensate trap. A 722 mm plastic condensate pipe Routing The condensate pipe can terminate into any one of the following areas. It is always the best practice to terminate the condensate pipe via an internal waste system.
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Installation sequence Installing the boiler and making all connections (cont.) Terminating into an external waste system Terminating into an internal waste system A 722 mm plastic condensate pipe B External length of pipe 3 m max. A 722 mm plastic condensate pipe C Open end direct into gully, below B External length of pipe 3 m max.
Installation sequence Installing the boiler and making all connections (cont.) Terminating into the rainwater system Terminating into an external purpose A 722 mm plastic condensate pipe made soakaway B Internal soil and vent stack A 722 mm plastic condensate pipe B External length of pipe 3 m max.
Installation sequence Flue outlet External wall terminal C 1. Insert pipe bend into the boiler flue 4. Connect external flue terminal to outlet. pipe bend. Install flue and supply pipes 2. Insert external flue terminal into the accordingly, wall outlet. with a minimum of 3°...
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Installation sequence Flue outlet (cont.) Vertical roof terminal C 1. Install the universal roof tile. 3. Push roof terminal through roof and insert into flue/supply pipe. 2. Install flue and supply pipes accordingly. 4. Seal roof terminal.
Installation sequence Electrical connections Opening the control unit housing 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.
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Installation sequence Electrical connections (cont.) Making connections Notes regarding the connection of accessories For details of accessories, also observe the separate installation instruc- tions provided. Notes regarding the connection of room temperature and DHW cylinder temperature control For more information about the connection of on site temperature controls see page 21.
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Installation sequence Electrical connections (cont.) fÖ Mains power connection 230 V ~ gH Mains connection accessories/ 50 Hz (green plug) room temperature control/DHW Do not interchange the supply cylinder control (black plug) conductors L1 and the neutral A If making the connection between, conductor N.
Installation sequence Electrical connections (cont.) Connect DHW cylinder temperature control Connect Vitotrol 100 A Vitotrol 100 UTD C Vitotrol 100 RT B Vitotrol 100 UTA D When connecting, remove jumper Routing connecting cables Please note Connecting cables can be damaged if they touch hot components. When routing and securing connecting cables on site, ensure that the maximum permissible cable temperatures are not exceeded.
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Installation sequence Electrical connections (cont.) A Low voltage connections B 230 V connections 1. Connect strain relief to the external 2. Fit cover. cable and clip into the mounting plate aperture. 3. Pivot the control unit upwards.
Installation sequence Electrical connections (cont.) Front panel installation 1. Hang the front panel to the wall 3. Insert the screw at the top of the mounting frame by the appropriate boiler. hook. Note 2. Press down the front panel at the The outer case forms a seal with bottom.
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Installation sequence Commissioning and testing (cont.) Danger Open all doors and windows; extinguish naked lights and do not smoke whilst purging the gas line. Before commencing the commissioning procedure, ensure that the gas service cock is turned on, the electricity supply is isolated and that the DHW and CH pipework is complete.
Installation sequence Commissioning and testing (cont.) Note Additive combinations are permitted only if approved additive suppliers recom- mend it and always according to supplier´s dosage recommendation. It is essential that the procedure below is followed to ensure that all the air in the boiler heat exchanger and the system is completely vented prior to firing the appliance.
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Installation sequence Commissioning and testing (cont.) 4. Open shut-off valves A and B. 5. Connect filling hose to valve C and open valve C. 6. Fill heating system. (minimum sys- tem pressure > 1.0 bar). The actual system pressure is dis- played electronically on the boiler display.
Installation sequence Commissioning and testing (cont.) 9. Turn rotary selectors "tr" and "tw" into control range again (turn selector "tr" only for system boil- er). Note Be aware that the boiler may still need to be vented as air pockets are drawn into the heat exchanger.
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Installation sequence Commissioning and testing (cont.) 1. Close the gas shut-off valve. 2. Release the screw inside test nip- ple "IN" A on the gas combination valve , but do not remove, and con- nect the pressure gauge. 3. Open the gas shut-off valve. 4.
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Installation sequence Commissioning and testing (cont.) 8. Open the gas shut-off valve and start the boiler. Danger Gas escaping from the test nipple leads to a risk of explosion. Check test nipple A for soundness. Domestic hot water flow rate and temperature (Combi boiler only) A flow regulator is fitted to ensure that no adjustment of maximum flow is neces- sary.
Installation sequence Commissioning and testing (cont.) Disabling the comfort function Turn the rotary selector tw briefly and fully anti-clockwise (shorter than 3 s), and then turn it clockwise. The display will then show "ECO". Adjusting the boiler water temperature The boiler water temperature must be set at an adequate level to satisfy the requirements of the heating system.
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Installation sequence Commissioning and testing (cont.) User´s instructions Upon completion of commissioning Advise the user of the precautions and testing, hand the appliance over necessary to prevent damage to the to the user, with reference to the fol- system and to the building in the lowing.
Service Instructions Routine Servicing Instructions To ensure continued efficient operation of the appliance, it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage but in general once a year should be adequate.
Service Instructions Routine Servicing Instructions (cont.) 1. Remove the screw at the top of the 3. Lift the front panel from the wall boiler. mounting frame. 2. Press down the springs on the underside of the boiler and remove the front panel. Burner removal 1.
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Service Instructions Routine Servicing Instructions (cont.) 5. Release gas connection pipe E. 6. Release four screws F and remove the burner. Please note To prevent damage, never rest the burner on the gauze assembly. Check the burner gasket and burner gauze assembly for damage.
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Service Instructions Routine Servicing Instructions (cont.) 1. Remove electrode B. 4. Insert and secure a new burner gauze assembly D with a new 2. Release the three Torx screws, and gasket E. remove thermal insulating ring C. Torque: 3.5 Nm.approx. 3.
Service Instructions Routine Servicing Instructions (cont.) 3. Check all clearances. If the gaps are not as specified or the elec- trode is damaged, replace and align the electrode together with new gaskets. Tighten the electrode fixing screws. (2.5 Nm approx.). Cleaning the heating surfaces If required, clean heating surfaces A with a brush or flush with water.
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Service Instructions Routine Servicing Instructions (cont.) Checking the condensate drain and cleaning the siphon 1. Check at the siphon, that the con- densate can freely drain. 2. Place an appropriate container under the siphon A. 3. Remove the locking cap B and drain the siphon content.
Service Instructions Routine Servicing Instructions (cont.) Burner installation 1. Install the burner and torque 4. Replace electrical cables from fan screws A diagonally. (4 Nm. motor D, gas valve E, and igni- approx.) tion unit F. 2. Insert new gasket and tighten the 5.
Service Instructions Routine Servicing Instructions (cont.) 6. Check the gas connections for soundness. Danger Escaping gas leads to a risk of explosion. Check all fittings for sound- ness. Check primary and secondary connections for leaks Checking diaphragm expansion vessel and system pressure Note 1.
Service Instructions Routine Servicing Instructions (cont.) 2. Check the inlet pressure of the dia- 4. Top up your heating system with phragm expansion vessel at the water and vent until the filling pres- test nipple A. sure of a cool system is 0.2 bar higher than the inlet pressure of the 3.
Service Instructions Routine Servicing Instructions (cont.) Front panel installation 1. Hang the front panel to the wall 3. Insert the screw at the top of the mounting frame by the appropriate boiler. hook. Note 2. Press down the front panel at the The outer case forms a seal with bottom.
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Service Instructions Routine Servicing Instructions (cont.) Checking all gas equipment for soundness at operating pres- sure Danger Escaping gas leads to a risk of explosion. Check gas equipment for soundness. Final checks 1. Check that the flue terminal in is 2.
Troubleshooting Fault finding General Note The gas service cock is open. It is the law that any service work The DHW (Combi only) and CH iso- must be carried out by a competent lation cocks are open. CORGI registered engineer. The system is at design pressure.
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Troubleshooting Fault finding (cont.) Gas combina- Fault Check the gas tion valve opens train (control vol- tage 230 V) and gas supply pres- sure Fault Ionisation cur- Check the ionisa- rent builds tion current, check (higher than the electrode ad- 2 µA) justment and the gas pipe for air-...
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Troubleshooting Fault finding (cont.) Display System character- Cause Measures fault code istics Burner blocked Flow of water to Check the circulation low. pump. Air in heat ex- Vent the heating sys- changer. tem. Flow switch Check the interconnect- faulty. ing cable. Burner blocked Voltage to low.
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Troubleshooting Fault finding (cont.) Display System character- Cause Measures fault code istics Burner in fault state The flame signal Check the ionisation is already present electrode and leads. at burner start Press"Reset". Burner in fault state No flame signal is Check the ionisation present electrode and leads,...
Troubleshooting Fault finding (cont.) Display System character- Cause Measures fault code istics Burner blocked Faulty main PCB Switch OFF the control unit, if the equipment will not restart. Repairs Removing front panel 1. Remove the screw at the top of the 2.
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Troubleshooting Repairs (cont.) 3. Lift the front panel from the wall mounting frame. Drain boiler on the primary side Note For certain repairs the boiler must be drained on the primary side. 1. Connect the drain hose to valve A and connect with a drain outlet.
Troubleshooting Repairs (cont.) Boiler temperature sensor 1. Pull the leads from boiler tempera- ture sensor A and measure the resistance. 2. Check the sensor resistance and compare actual values with the curve. 3. In case of severe deviation, drain boiler on the primary side (see page 71) and replace the sensor.
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Troubleshooting Repairs (cont.) Check the temperature limiter If the burner control unit cannot be reset after a fault shutdown, although the boiler water temperature is below approx. 75 °C, check the temperature limiter. 1. Pull the leads from temperature lim- iter A.
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Troubleshooting Repairs (cont.) Check the DHW temperature sensor (only for gas combina- tion devices) 1. Pull the leads from outlet tempera- ture sensor A 2. Check the sensor resistance and compare actual values with the curve. 3. Replace the sensor in case of severe deviation.
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Troubleshooting Repairs (cont.) Replacing flow limiter 1. Switch OFF the mains power. 2. Close the gas shut-off valve and safeguard against reopening. 3. Drain the boiler from the secondary side. 4. Pivot the control unit downwards. 5. Release the ties A and screwsB. 6.
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Troubleshooting Repairs (cont.) Checking plate heat exchanger C DHW E Heating water return D Cold water F Heating water flow 1. Switch OFF the mains power. 5. Remove two screws A at the plate heat exchanger and B remove. 2. Close the gas shut-off valve and safeguard against reopening.
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Troubleshooting Repairs (cont.) 7. Check the primary side for contami- 8. Install in reverse order using new nation and, if necessary, clean or gaskets. replace the plate heat exchanger. Note Ensure that fixing holes and seals are aligned. Install the heat plate exchanger the correct way round.
Designs Connection and wiring diagrams combi boiler Main PCB Time switch Programming unit...
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Designs Connection and wiring diagrams combi boiler (cont.) Alternative (remove jumper fÖ Mains input 230V~/50Hz when connecting) Temperature limiter § Boiler temperature sensor Mains connection accessories/ DHW outlet sensor room temperature control sÖ Circulation pump 230V~ a-ÖA Fan dÖ Step motor diverter valve Air pressure switch Flow switch (Heating water) Flow switch (DHW)
Designs Connection and wiring diagram - system boiler Main PCB Time switch Programming unit...
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Designs Connection and wiring diagram - system boiler (cont.) Alternative (remove jumper Temperature limiter when connecting) Mains connection accessories/ § Boiler temperature sensor room temperature control/DHW sÖ Circulation pump 230V~ cylinder control dÖ Step motor diverter valve a-ÖA Fan Flow switch (Heating water) Air pressure switch Gas solenoid valve Water pressure sensor...
Parts lists Parts lists Spare parts information 032 Bypass with overflow valve Quote the type and serial no. (see 033 Grommets data plate) and the item no. of the 034 Line retainer required part (as per this parts list). 037 Hydraulic Obtain standard parts from your local 038 Expansion pipe supplier.
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Parts lists Parts lists (cont.) 306 Corner gas tap 091 Cable harness X9 307 Dichtungen (Satz) 092 Cable harness 100 308 Heating water pipe bends (set) 093 Step motor connecting cable 309 Domestic water pipe bends (set) 094 Mains power switch cable har- ness 095 Gas valve connecting cable 35 Wearing parts...
Certificates Declaration of conformity Declaration of conformity for Vitodens 100-W We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, declare as sole responsible body, that the product Vitodens 100-W conforms to the following stan- This product is designated in accor-...
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