Viessmann VITODENS 100-W Installation And Service Instructions Manual
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Viessmann VITODENS 100-W Installation And Service Instructions Manual

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VIESMANN
Installation and service
instructions
for contractors
Vitodens 100-W
Type BPJA, 6.5 to 25.0 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
Gas Council no.: 47-819-26 P25; 47-819-27 P29
For applicability, see the last page
VITODENS 100-W
Please keep safe.
5609 913 GB
2/2013

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  • Page 1 VIESMANN Installation and service instructions for contractors Vitodens 100-W Type BPJA, 6.5 to 25.0 kW Wall mounted gas condensing boiler Natural gas and LPG version Gas Council no.: 47-819-26 P25; 47-819-27 P29 For applicability, see the last page VITODENS 100-W Please keep safe.

  • Page 2: Safety Instructions

    Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate- rial losses. Safety instructions explained ■ Codes of practice of the 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 If the boiler is operated at Defective components must be the same time, this can lead to reverse replaced with genuine flow of the flue gas. Viessmann spare parts.
  • Page 4 Installing non-author- ised components and making non-approved modifications or conversions can compromise safety and may invalidate our warranty. For replacements, use only orig- inal spare parts supplied or approved by Viessmann.

  • Page 5: Table Of Contents

    Index Index Installation instructions Preparing for installation................... Installation sequence Fitting the boiler and making connections............11 Opening the control unit casing................16 Electrical connections................... 17 Service instructions Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance.......... 20 Further details regarding the individual steps............21 Troubleshooting Function sequence and possible faults..............

  • Page 6: Preparing For Installation

    2 connections for DHW heating. accordance with the law of the country in If the Vitodens 100-W is installed in an S question. plan or Y plan system, the DHW primary connections are not used and must be...

  • Page 7: Preparing For Boiler Installation

    Preparing for installation Preparing for installation (cont.) The following components are integra- Accessory connection ted into the hydraulic system: ■ Circulation pump A time switch is connected with low volt- ■ 3-way diverter valve age to the control unit. ■ Safety valve ■...
  • Page 8 Preparing for installation Preparing for installation (cont.) E Heating return 7 22 mm F Condensate drain/safety valve drain: Plastic hose 7 22 mm...
  • Page 9 Preparing for installation Preparing for installation (cont.) Fitting the wall mounting bracket Ø10 A Vitodens installation template...
  • Page 10 Preparing for installation Preparing for installation (cont.) 1. Position the supplied installation tem- plate on the wall. 2. Mark out the rawl plug holes. 3. Drill 7 10 mm holes and insert the rawl plugs supplied. 4. Fit wall mounting bracket with screws supplied.

  • Page 11: Installation Sequence

    Installation sequence Fitting the boiler and making connections Removing the front panel and mounting the boiler 1. Undo screws at the bottom of the 3. Hook the boiler into the wall mounting boiler; do not remove completely. bracket. 2. Remove front panel.
  • Page 12 Installation sequence Fitting the boiler and making connections (cont.) Making the connections on the water side A B C ¨ A Heating flow 7 22 mm D Cold water 7 15 mm B DHW 7 15 mm E Heating return 7 22 mm C Gas connection 7 22 mm For installation of fittings on the heating water side and DHW...

  • Page 13: Gas Connection

    Installation sequence Fitting the boiler and making connections (cont.) Gas connection 1. Connect gas shut-off valve to con- nection A. 2. Carry out a tightness test. Note Only use suitable and approved leak detection agents (EN 14291) and devices for the tightness test. Leak detection agents with unsuitable con- stituents (e.g.
  • Page 14 Installation sequence Fitting the boiler and making connections (cont.) Connection, safety valve and condensate drain ■ 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 external pipe- lines.

  • Page 15: Filling The Siphon With Water

    Installation sequence Fitting the boiler and making connections (cont.) Filling the siphon with water Pour a minimum of 0.3 l of water into the flue outlet. Please note During commissioning, flue gas may escape from the condensate drain. Always fill the siphon with water before commissioning.

  • Page 16: Opening The Control Unit Casing

    Installation sequence Opening the control unit casing 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.

  • Page 17: Electrical Connections

    Installation sequence Electrical connections 4 3 2 1 A Outside temperature sensor (acces- Information on connecting sories) accessories B Connecting cable (accessories) When connecting accessories C Jumper observe the separate installation D Power supply (230 V, 50 Hz). instructions provided with them. See page.

  • Page 18: Power Supply

    Installation sequence Electrical connections (cont.) Cable entry A Power cable, remote control con- necting cable B LV leads (sensor leads) Power supply Regulations and Directives Install an isolator in the power cable that simultaneously isolates all non-earthed Danger conductors from the power supply with at Incorrectly executed electrical least 3 mm contact separation.
  • Page 19 Installation sequence Electrical connections (cont.) Danger Connect the appliance and pipe- The absence of component work to the equipotential bonding earthing can lead to serious injury of the building in question. from electric current if an electri- cal fault occurs. Routing connecting cables and closing the control unit enclo- sure Please note...

  • 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..........21 • • • 2. Changing to operation with LPG........22 •...

  • Page 21: 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 22: 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 switch to the correct gas type in Changing from LPG to natural gas - see the control unit.

  • Page 23: Checking The Static And Supply Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Correction factor Flue system Rated Max. run length (m) heating output (kW) Open flue operation 7 60 mm — — 8 13.5 18.5 Balanced flue operation 7 60/100 mm coaxial 13.5 Observe max.
  • Page 24 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Open the gas shut-off valve. 7. Record the actual value in the report on page. 4. Check the static pressure. Take the action shown in the follow- Set value: max. 57.5 mbar ing table.

  • Page 25: Checking The Co Content

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the CO content During commissioning or maintenance, If flue installation is OK, change the gas the CO and CO have to be measured at valve. the boiler flue adaptor test point to check Note the flue integrity.
  • Page 26 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 04. Adjust the upper heating output: Turn rotary selector "tr" to the control range on the right until the display shows 5 bars for the upper heating output. 05. Check the CO content for the upper heating output.

  • Page 27: Burner Removal

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 11. Turn both rotary selectors "tw" and "tr" to their respective original positions. Burner removal F 4x 1. Switch OFF the power. 4. Pull venturi extension D from the fan. 2.

  • Page 28: 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 Prevent damage. burner. Never rest the burner on the burner gauze assembly. Checking the burner gasket and burner gauze assembly Check burner gasket A for damage and Replace the burner gauze assembly if it replace if required.

  • Page 29: Checking And Adjusting Electrode

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Insert and secure new burner gauze 6. Fit electrode B. assembly D with new gasket E. Please note Please note Fasten screws tightly enough Fasten screws tightly enough to ensure the components are to ensure the components are not being damaged and are not being damaged and are...

  • Page 30: Cleaning The Heat Exchanger

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the heat exchanger Please note Note There should be no scratches or Discolouration of the heat exchanger other damage on the heat surface is a normal sign of usage. It has exchanger surface that comes no impact on the function and service life into contact with hot gases.

  • Page 31: 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. Pull siphon A upwards out of the drain connection. 2. Pull supply hose B off siphon A. 3. Clean siphon A. 4.

  • Page 32: Burner Installation

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Burner installation A 4x 1. Fit burner and tighten four screws 2. Insert new gasket and tighten the fit- A diagonally. tings on gas supply pipe B. Please note 3. Plug venturi extension C into the Fasten screws tightly enough fan.

  • Page 33: Checking The Diaphragm Expansion Vessel And System Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Check the gas connections for tight- Please note ness. The use of leak detection spray can result in incorrect Danger functions. Escaping gas leads to a risk of Leak detection spray must not explosion.

  • Page 34: 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 should hand the operating instructions to the system user and instruct the user in operating the system.

  • Page 35: Troubleshooting

    Troubleshooting Function sequence and possible faults Display Action 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 36: 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 re- (flue gas recircula- starts immediately tion); check the gas flow pressure Fault messages on the display Faults are indicated by a flashing fault code with fault symbol "U"...
  • Page 37 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics Burner blocked Short circuit, flue Check the sensor (see gas temperature page 44). sensor Burner blocked Lead break, flue Check the sensor (see gas temperature page 44).
  • Page 38 Troubleshooting Fault messages on the display (cont.) Displayed System characteris- Cause Measures fault code tics Burner in a fault No flame signal de- Check the ionisation elec- state tected trode and connecting ca- bles, check the gas pres- sure, check the gas train, ignition, ignition module and condensate drain.
  • Page 39 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. Initiate "Reset" (see page 39).

  • Page 40: Repairs

    Troubleshooting Repairs Removing the front panel 1. Undo screws at the bottom of the 2. Remove front panel. boiler; do not remove completely.

  • Page 41: Boiler Water Temperature Sensor

    Troubleshooting Repairs (cont.) Boiler water temperature sensor 1. Pull the leads from boiler water tem- perature sensor A and check the resistance.
  • Page 42 Troubleshooting Repairs (cont.) 2. Check the sensor resistance and compare it with the curve. 3. In the case of severe deviation, drain the boiler on the heating water side and replace the sensor. Danger The boiler water temperature sensor is immersed in the heating water (risk of scald- 10 30 50 70 90 110 ing).
  • Page 43 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. Note Water can leak when replacing the outlet temperature sensor.

  • Page 44: Check Flue Gas Temperature Sensor

    Troubleshooting Repairs (cont.) Check flue gas temperature sensor 1. Pull leads from flue gas temperature sensor A. 2. Check the sensor resistance and compare it with the curve.
  • Page 45 Troubleshooting Repairs (cont.) 3. Replace the sensor in the case of severe deviation. 10 30 50 70 90 110 Temperature in °C Replacing flow limiter 1. Drain the boiler from the DHW side. 2. Pivot the control unit downwards. 3. Undo screws A. 4.
  • Page 46 Troubleshooting Repairs (cont.) Checking or replacing the plate heat exchanger E Heating water flow G Cold water F Heating water return H DHW 5. Remove two screws C from the 1. Shut off and drain the boiler on the heating water and the DHW side. plate heat exchanger and remove plate heat exchanger D with gas- 2.
  • Page 47 Troubleshooting Repairs (cont.) 6. Check the connections on the DHW 8. Install in reverse order using new side for scaling, and if required clean gaskets. or replace the plate heat exchanger. Note Ensure that fixing holes and gaskets 7. Check the connections on the heat- are aligned.

  • Page 48: Gas Type Conversion

    Gas type conversion Converting from LPG to natural gas Removing gas restrictor 1. Pull cable from gas train A. 6. Remove or void gas type sticker on the top of the boiler (next to the type 2. Remove union nut B. plate).
  • Page 49 Gas type conversion Converting from LPG to natural gas (cont.) Changing the gas type at the control unit 1. Turn on the ON/OFF switch. 2. Turn both rotary selectors "tw" and "tr" simultaneously into their respective central positions. The display shows "SERV". 3.

  • Page 50: Designs

    Designs Connection and wiring diagram Stepper motor diverter valve Vitotrol 100 type UTA or on-site room temperature controller Ignition/ionisation (switched 230 V input)
  • Page 51 Designs Connection and wiring diagram (cont.) Vitotrol 100, type RT or on-site § Boiler water temperature sensor room temperature controller Outlet temperature sensor (switched input 230 V) No function Vitotrol 100, type UTDB or on-site Flue gas temperature sensor room temperature controller sÖ...

  • Page 52: 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 53: Overview Of The Assemblies

    Parts lists Overview of the assemblies A Type plate D Control unit assembly B Sheet metal parts assembly E Miscellaneous assembly C Heat cell assembly F Hydraulic assembly...

  • Page 54: Sheet Metal Parts Assembly

    Parts lists Sheet metal parts assembly 0001 Front panel 0005 Air box floor 0002 Profiled seal 0006 Diaphragm grommets (set) 0003 Logo 0007 Wall mounting bracket 0004 Strain relief upper part 0007 0002 0003 0002 0001 0005 0003 0006 0004...

  • Page 55: Heat Cell Assembly

    Parts lists Heat cell assembly 0001 Gasket DN 60 0009 Tee 0002 Boiler flue connection 0010 Gas pipe 0003 Boiler flue connection plug 0011 Gasket 17 x 24 x 2 (set) 0004 Flue gasket 0012 Burner 0005 Flue gas temperature sensor 0013 Thermal insulation block 0006 Heat exchanger 0014 Heat exchanger mounting (set)

  • Page 56: Burner Assembly

    Parts lists Burner assembly 0001 Burner gasket 0008 Burner door flange gasket 0002 Thermal insulation ring 0009 Radial fan 0003 Cylinder burner gauze assembly 0010 Gas valve 0004 Burner gauze assembly gasket 0012 Venturi extension 0005 Burner door 0013 Gasket set 0006 Ionisation electrode gasket 0014 Conversion kit G2.350/G27 0007 Ignition and ionisation electrode...
  • Page 57 Parts lists Burner assembly (cont.) 0007 0006 0005 0004 0003 0002 0001 0006 0008 0012 0013 0010 0014 0009 0013...

  • Page 58: Hydraulic Assembly

    Parts lists Hydraulic assembly 0001 Diaphragm expansion vessel 0010 O-ring gasket set 20.6 x 2.6 0002 Support block, diaphragm expan- 0011 Temperature sensor sion vessel 0012 Round sealing ring 8 x 2 (5 pce) 0003 Gasket A 10 x 15 x 1.5 (set) 0013 Moulded hose heating water flow 0004 Connection line;...
  • Page 59 Parts lists Hydraulic assembly (cont.) 0002 0001 0005 0010 0007 0010 0007 0006 0007 0003 0017 0004 0003 0011 0019 0009 0010 0007 0020 0007 0010 0013 0017 0007 0009 0012 0007 0018 0007 0007 0018 0014 0007 0015 0014 0008 0014 0015...

  • Page 60: Combi Hydraulic Assembly

    Parts lists Combi hydraulic assembly 0001 Air vent valve 0013 Expansion tank 0002 O-ring 34 x 3 (5 pce) 0014 Stepper motor adaptor 0003 Plate heat exchanger 0015 Linear stepper motor 0004 Gasket set, plate heat exchanger 0016 Oval cap seal (5 pce) 0005 Safety valve 0017 Water volume controller 0006 Clip Ø...

  • Page 61: Control Unit Assembly

    Parts lists Control unit assembly 0001 Cover, wiring chamber 0007 Gas valve cable 0002 Clip hinge 0008 Fan connecting cable 0003 Profiled seal 0009 Cable harness stepper motor 0004 Control unit 0010 Fuse 2.5 A (slow) 250 V 0005 Cable harness X20 0006 Ignition cable with angled plug 5 kΩ...

  • Page 62: Miscellaneous Assembly

    Parts lists Miscellaneous assembly 0001 Touch-up spray paint, white 0004 Operating instructions 0002 Touch-up paint stick, white 0005 Installation and service instruc- 0003 Special grease tions 0001 0002 0003 0004 0005...

  • Page 63: 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): IP rating: IP X4 to EN 60529 Permissible ambient temperature ■ During operation: 0 to +40 °C ■...

  • Page 64: Certificates

    Declaration of conformity Declaration of Conformity for the Vitodens 100-W We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm as sole respon- sible body that the product Vitodens 100-W complies with the following standards: EN 297 EN 55 014-2 EN 483...

  • Page 65: Keyword Index

    Keyword index Keyword index Boiler water temperature sensor ..41 Ignition..........29 Burner gasket........28 Ignition electrode........29 Burner gauze assembly.....28 Ionisation electrode......29 Burner installation......32 Burner removal........27 Outlet temperature sensor....43 Output matching Combustion chamber, cleaning..30 ■ Flue pipe length......22 Commissioning........21 Condensate........14 Condensate drain......14, 31 Plate heat exchanger......46 Connection diagram......50 Power supply........18...
  • Page 68 These service instructions apply for appliances with the following serial num- bers (see type plate): 7501297 7501298 7501823 7501824 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...

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