Viessmann Vitodens 100 Installation And Service Instructions Manual
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Viessmann Vitodens 100 Installation And Service Instructions Manual

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VIESMANN
Installation and service
instructions
for heating engineers
Vitodens 100
Type WB1A
Gas fired wall mounted condensing boiler
Natural gas version
For applicability, see the last page
VITODENS 100
Please keep safe
5862 757 GB
7/2005

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  • Page 1 VIESMANN Installation and service instructions for heating engineers Vitodens 100 Type WB1A Gas fired wall mounted condensing boiler Natural gas version For applicability, see the last page VITODENS 100 Please keep safe 5862 757 GB 7/2005...

  • Page 2: Safety Instructions

    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.
  • Page 3 Please note For replacements, use only ori- Repairing components which ginal spare parts from fulfil a safety function can com- Viessmann or those which are promise the safe operation of approved by Viessmann. your heating system. Replace faulty components only with original Viessmann...

  • Page 4: Table Of Contents

    Index Index Installation instructions Preparing the installation Product information ..................General Information ..................Technical Specification ................Installation Requirements ................14 Preparations for boiler installation ............... 25 Installation steps Installing the boiler and making all connections ........... 29 Flue outlet ....................34 Electrical connections .................

  • Page 5: Product Information

    Vitodens 100, Type WB1A Set up for operation with natural gas. General Information Appliance description The Vitodens 100 is a fully automatic, Internal frost protection and an elec- wall hung, fan assisted balanced flue tronic control unit is fitted as standard condensing boiler for use with Natural equipment.

  • Page 6: Technical Specification

    Preparing the installation Technical Specification General Specifications and Performance Data Rated output range 50/30 °C 8 to 18 8 to 24 80/60 °C 7.3 to 16.4 7.3 to 21.8 Rated heat load range 7.4 to 16.7 7.4 to 22.3 Maximum gas rate 1.77 2.36 Minimum CH system pressure (static...
  • Page 7 Preparing the installation Technical Specification (cont.) Overall Appliance Dimensions A Heating return: 722 mm C Condensate drain: Plastic pipe B Heating flow: 722 mm 722 mm D Gas connection: R ½ FBSP Minimum installation clearances The following minimum clearances (mm) must be maintained for installing and servicing the appliance.

  • Page 8: Flue System Specifications

    Preparing the installation Technical Specification (cont.) 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 is supplied complete with a stan- increase the straight flue length up to dard concentric horizontal balanced 6 m and include one 87°...
  • Page 9 Preparing the installation Technical Specification (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.
  • Page 10 Preparing the installation Technical Specification (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)
  • Page 11 Preparing the installation Technical Specification (cont.) Elbows and extensions Extension Elbow 45° Elbow 87°...
  • Page 12 Preparing the installation Technical Specification (cont.) Hydraulic circuit Y-Plan System A DHW cylinder E Three-way diverter valve B Boiler F Heating circuit C heat exchanger G Feed & expansion tank D circulation pump...
  • Page 13 Preparing the installation Technical Specification (cont.) S-Plan System A DHW cylinder E Zone 2 Port Valve B Boiler F Heating circuit C heat exchanger G Feed & expansion tank D circulation pump...

  • Page 14: Installation Requirements

    Preparing the installation Technical Specification (cont.) Sectional Diagram Installation Requirements Statutory Requirements Gas safety (installation and use) regulations (current issue) This appliance must be installed in accordance with the gas safety regu- lations.

  • Page 15: Boiler Position

    Preparing the installation Installation Requirements (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...
  • Page 16 Preparing the installation Installation Requirements (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- &...
  • Page 17 Preparing the installation Installation Requirements (cont.) Flue terminal position B Car space Horizontal flue systems A Walkway or patio Position Minimum spacing Directly below an 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...
  • Page 18 Preparing the installation Installation Requirements (cont.) Position Minimum spacing Vertically from a terminal on same wall 1500 Horizontally from a terminal on same wall Adjacent to opening Vertical flue systems Position Minimum spacing From adjacent wall From adjacent opening window 1000 From another terminal Minimum height...

  • Page 19: Flue Terminal Location

    Preparing the installation Installation Requirements (cont.) Flue Terminal Location & Detailed recommendations for flue If the terminal discharges into a installation are given in BS 5440:1. pathway or passageway check that The following notes are for general combustion products will not cause guidance.
  • Page 20 Preparing the installation Installation Requirements (cont.) & It is not necessary to have a pur- pose provided air vent in the room or internal space in which the appli- ance is installed. & If the boiler is to be installed in a cupboard or compartment, no per- manent air vents are required for cooling purposes in the cupboard or...
  • Page 21 Preparing the installation Installation Requirements (cont.) Central Heating System Y-Plan System A DHW-Cylinder B Boiler...
  • Page 22 G Drain cock at lowest point in the fÖ Power supply gH Mains connection accessories/ system H Control unit room temperature control K Room temperature control (on LR Connection of room temperature site) control Connection of Viessmann Vitotrol 100 see page 38...
  • Page 23 Preparing the installation Installation Requirements (cont.) S-Plan System A DHW-Cylinder D Feed & expansion tank B Boiler E Zone 2 Port Valve C Circulation pump F Radiators...

  • Page 24: Control Unit

    H Control unit sÖ Circulation pump K Room temperature control (on fÖ Power supply gH Mains connection accessories/ site) Connection of Viessmann room temperature control Vitotrol 100 see page 38 LR Connection of room temperature L Fuse 3 A control Gas Supply &...

  • Page 25: Preparations For Boiler Installation

    (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 certified room ther- mostat or time clock room thermostat.

  • Page 26: Wall Mounting Bracket Installation

    Preparing the installation Preparations for boiler installation (cont.) Wall mounting bracket installation Important: Before installing the appliance, check that the chosen position is sui- table, adequate installation clearances are available and that the requirements for flue terminal position are satisfied.
  • Page 27 Preparing the installation Preparations for boiler installation (cont.) A Installation template 1. Position the installation template 2. Mark wall plug holes and balanced on the wall. flue pipe opening.

  • Page 28: Preparing The Connections

    Preparing the installation Preparations for boiler installation (cont.) 3. Drill 710 mm holes and insert the 5. Fit wall mounting bracket with rawl plugs. enclosed screws. 4. Cut flue pipe opening. Preparing the connections Note For dimensions for on-site preparations of the gas and water side connections see "Overall Appliance Dimensions"...

  • Page 29: Installation Steps

    Installation steps 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. Remove the front panel. boiler.
  • Page 30 Installation steps Installing the boiler and making all connections (cont.) 2. Connect the gas supply to the gas inlet connection on the gas cock A. Upon completion, tighten the union connection. 3. Carry out a gas soundness test. A Gas connection: R ½ FBSP Heating connection A Heating return: 722 mm B Heating flow: 722 mm...

  • Page 31: Condensate Connection

    Installation steps Installing the boiler and making all connections (cont.) Condensate connection Vitodens 100 has an internal 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.
  • Page 32 Installation steps Installing the boiler and making all connections (cont.) Terminating into an external waste system Terminating into an internal waste A 722 mm plastic condensate pipe system 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.
  • Page 33 Installation steps Installing the boiler and making all connections (cont.) Terminating into the rainwater system A 722 mm plastic condensate pipe B Internal soil and vent stack Terminating into an external purpose made soakaway A 722 mm plastic condensate pipe B External length of pipe 3 m max.

  • Page 34: Flue Outlet

    Installation steps 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°...
  • Page 35 Installation steps 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.

  • Page 36: Electrical Connections

    Installation steps Electrical connections Opening the control unit housing...
  • Page 37 Installation steps 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.
  • Page 38 Installation steps Electrical connections (cont.) sÖ Circulation pump...
  • Page 39 Installation steps 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 LR Connection of room temperature conductor N.

  • Page 40: Routing Connecting Cables

    Installation steps Electrical connections (cont.) 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. 1. Remove 2 screws on the underside 2.

  • Page 41: Commissioning And Testing

    Installation steps Electrical connections (cont.) 4. Fit cover. 5. Pivot the control unit upwards. Commissioning and testing Before commissioning the appliance, the whole gas installation including the meter must be purged and tested for gas soundness in accordance with BS 6891: 1988.

  • Page 42: Filling The Heating System

    Installation steps Commissioning and testing (cont.) & Fuel, Oil, Grease, Washing powder/liquid & pipe jointing compound (like boss white and boss green, Sentinel) & Anti-blockage Filling the heating system Please note Unsuitable fill water increases the level of deposits and corrosion and may lead to boiler damage.
  • Page 43 Installation steps Commissioning and testing (cont.) 2. Pivot down control unit A. 3. Remove 2 screws and remove cover panel B. 4. Release the screw inside test nip- ple "IN" C on the gas combina- tion valve , but do not remove, and connect the pressure gauge.
  • Page 44 Installation steps Commissioning and testing (cont.) 8. Check the inlet working pressure = 20 mbar. & Minimum working pressure = 12 mbar & Maximum working pressure = 20 mbar Note Use suitable test equipment, with a resolution of at least 0.5 mbar, to measure the supply pressure.
  • Page 45 Installation steps Commissioning and testing (cont.) 3. Start up the boiler and at the poten- tiometer A select the maximum boiler output. Check the adjustment for the corresponding gas through- put. 4. Flip up the control unit front and snap into position. Front panel installation...

  • Page 46: Adjusting The Boiler Water Temperature

    Installation steps Commissioning and testing (cont.) 1. Fasten the cover panel onto the 5. Insert the screw at the top of the boiler boiler. 2. Pivot the control unit upwards. Note The outer case forms a seal with 3. Hang the front panel to the wall the combustion box.
  • Page 47 Installation steps 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.

  • Page 48: Service Instructions

    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.
  • Page 49 Service Instructions Routine Servicing Instructions (cont.) 3. Lift the front panel from the wall 5. Remove 2 screws and remove mounting bracket. cover panel. 4. Flip down the control unit. Burner removal 1. Close the gas shut-off valve and 2. Pull electrical cables from fan motor A, gas valve B, and igni- safeguard against reopening.
  • Page 50 Service Instructions Routine Servicing Instructions (cont.) 5. Release four screws F and 3. Remove connection hose from air pressure switch D. remove the burner. 4. Release gas connection pipe E. Please note To prevent damage, never rest the burner on the gauze assembly.
  • Page 51 Service Instructions Routine Servicing Instructions (cont.) 2. Release the three Torx screws, and 4. Insert and secure a new burner remove thermal insulating ring C. gauze assembly D with a new gasket E. 3. Release the four Torx screws, and remove burner gauze assembly D 5.

  • Page 52: Cleaning The Heating Surfaces

    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.
  • Page 53 Service Instructions Routine Servicing Instructions (cont.) Checking the condensate drain and cleaning the siphon 4. Replace the locking cap B. 1. Check at the siphon, that the con- densate can freely drain. 5. Fill the siphon A with water by 2.

  • Page 54: Burner Installation

    Service Instructions Routine Servicing Instructions (cont.) Burner installation 1. Install the burner and torque 4. Replace electrical cables from fan screws A diagonally. motor D, gas valve E, and igni- tion unit F. 2. Tighten the fittings on the gas con- nection pipe B.
  • Page 55 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.
  • Page 56 Service Instructions Routine Servicing Instructions (cont.) Check primary and secondary connections for leaks Check function of all safety valves Check tightness of electrical connections Check static and supply pressure see page 42. Front panel installation 1. Fasten cover panel on the boiler. 3.
  • Page 57 Service Instructions Routine Servicing Instructions (cont.) 4. Press down the front panel at the 5. Insert the screw at the top of the bottom. boiler. Note The outer case forms a seal with the combustion box. It must there- fore be securely fitted with the screw provided.
  • Page 58 Troubleshooting Fault finding Note It is the law that any service work must be carried out by a competent CORGI registered engineer. General Before looking for a fault condition, Before attempting any electrical fault check that: finding, always conduct the prelimin- &...
  • Page 59 Troubleshooting Fault finding (cont.) Ignition Fault Check the con- nection to the igni- tion module 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...

  • Page 60: Troubleshooting Fault Finding

    Troubleshooting Fault finding (cont.) Fault messages in the display Faults are indicated by a flashing fault code with fault symbol "U" and the reset key is illuminated. For fault code explanations see the following table. Display fault System char- Cause Remedy code acteristics...
  • Page 61 Troubleshooting Fault finding (cont.) Display fault System char- Cause Remedy code acteristics Burner in fault Temperature limit- Check the heating sys- state er has responded. tem water level. Check the circulation pump. Vent the heating system. Check the temperature limiter and leads. Press "Reset".
  • Page 62 Troubleshooting Fault finding (cont.) Display fault System char- Cause Remedy code acteristics Burner Burner control unit Check the ignition elec- blocked fault trodes and leads. Check whether a strong interfer- ence (EMC) field exists near the equipment. Press"Reset". If the fault is not re- moved, replace the con- trol unit.

  • Page 63: Repairs

    Troubleshooting Repairs Removing front panel 1. Remove the screw at the top of the 3. Lift the front panel from the wall boiler. mounting bracket. 2. Press down the springs on the 4. Flip down control unit. underside of the boiler and remove the front panel.
  • Page 64 Troubleshooting Repairs (cont.) Boiler temperature sensor and return temperature sensor 1. Pull the leads from boiler tempera- ture sensor A or return tempera- ture sensor B and measure the resistance.
  • Page 65 Troubleshooting Repairs (cont.) 2. Check the sensor resistance and compare actual values with the curve. 3. In case of severe deviation, drain boiler and replace the sensor. Danger The sensor is immersed in the heating water(risk of scalding). Drain the boiler before repla- cing the sensor.
  • Page 66 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.
  • Page 67 Troubleshooting Repairs (cont.) Checking the fuse 3. Remove cover A. 1. Switch OFF the mains power. 2. Flip down control unit. 4. Check fuse F1.

  • Page 68: Designs

    Designs Connection and wiring diagram Main PCB Ionisation electrode Programming unit Return temperature sensor § sÖ Boiler temperature sensor Circulation pump 230V~...
  • Page 69 Designs Connection and wiring diagram (cont.) Flow switch Mains connection accessories/ Gas solenoid valve room temperature control fÖ a-ÖA Fan Mains input 230V~/50Hz Temperature limiter Air pressure switch Ignition unit...

  • Page 70: Parts Lists

    009 Flue gas gaskets (set) 010 Heat exchanger 200 Front panel 011 Insulating block 201 Spring tie 012 Heat exchanger mounting (set) 203 Viessmann logotype 013 Condensate hose 014 Siphon Wearing parts 015 Condensate pipe 054 Ignition and ionisation electrode...
  • Page 71 Parts lists Parts lists (cont.)
  • Page 72 Parts lists Parts lists (cont.)

  • Page 73: Commissioning/Service Reports

    Commissioning/service reports Commissioning/service reports...
  • Page 74 Commissioning/service reports Commissioning/service reports (cont.)
  • Page 75 Commissioning/service reports Commissioning/service reports (cont.)
  • Page 76 Commissioning/service reports Commissioning/service reports (cont.)

  • Page 77: Certificates

    Certificates Declaration of conformity Declaration of conformity for Vitodens 100 We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, declare as sole responsible body, that the product Vitodens 100 conforms to the following stan- This product is designated in accor-...

  • Page 78: Keyword Index

    Keyword index Keyword index Additives Heating connection ........
  • Page 80 Type WB1A 8 to 18 kW from serial no. 7179 920 5 00001 8 to 24 kW from serial no. 7179 919 5 00001 Viessmann Limited Hortonwood 30, Telford, TF1 7YP, GB Telephone: +44 1952 675000 Fax: +44 1952 675040 www.viessmann.com...

  • Page 81: Operating Instructions

    VIESMANN Operating instructions for system users Gas fired wall mounted condensing boiler with control unit for constant temperature operation VITODENS 100 Please keep safe 5592 498 GB 7/2005...

  • Page 82: For Your Safety

    Safety instructions For your safety Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained If you notice the smell of gas con- tact your heating installer or Danger TRANSCO immediately. This symbol warns against the risk of injury.
  • Page 83 Safety instructions For your safety (cont.) If you notice fire from the appliance Installation area conditions call the fire brigade. Do not attempt to extinguish the fire unless com- Please note petent to do so. Incorrect ambient conditions can lead to damage to the Danger heating system and put safe Fire causes a risk of burns and...
  • Page 84 Index Index Introduction Initial start-up ..................... Your system is preset at the factory ............. General Description ..................Where to find the controls Summary of controls and indicators ............& Control and display elements ..............& Display indication ..................Changing room temperature ............... Start-up and shutdown Starting the heating system.................

  • Page 85: Introduction

    Your system is preset at the factory Your boiler will provide both heating The Vitodens 100 is certified to com- and hot water providing a cylinder is ply with the requirements of the rele- installed.

  • Page 86: Where To Find The Controls

    Where to find the controls Summary of controls and indicators Control and display elements The control unit is preset at the factory for standard operation. Your heating system is ready for use. A tr Rotary selector "Boiler water B Display, fault and reset button. C LCD Display temperature"...

  • Page 87: Changing Room Temperature

    Where to find the controls Summary of controls and indicators (cont.) F Fault G Emissions test switch (only for qualified personnel) Changing room temperature In addition to the boiler control unit, a separate room temperature controller must be installed in one of the living rooms to comply with part L of the building regulations if the heating system is to be regulated in accordance with the required room temperature.

  • Page 88: Start-Up And Shutdown

    Start-up and shutdown Starting the heating system The initial start-up and matching of the control unit to local conditions and struc- tural characteristics of the building, must be carried out by your heating contrac- tor. Before you switch ON a heating system which has been switched OFF for longer periods, it would be advisable to contact your local heating contractor.

  • Page 89: Settings

    Settings Heating If the room temperature controller Vitotrol 100, or similar programmable room thermostat, is connected, then the room temperature is controlled from there. Observe the separate operating instructions. Should the room temperature controller not produce sufficient heat (e.g. when it's very cold), the boiler water temperature can be changed at the rotary selec- tor "tr".

  • Page 90: Displays

    Displays Heating water temperature and system pressure Boiler water temperature During operation, boiler water tem- perature is constantly displayed.

  • Page 91: Switch Off

    Switch OFF Switching OFF Vitodens with frost protection Switch OFF the equipment if you don't want to use the boiler for a few days. Turn rotary selector "tr" to "9". Boiler frost protection is active. Heating system shutdown Shut down your heating system completely, if it will not be needed for longer periods of time (several months).

  • Page 92: What Needs Doing

    What needs doing? System characteristics What to do if ... Cause Solution ... the heating system System switch switched Switch on doesn't come on System controls includ- Switch on System con- ing room thermostats trols to create demand. not calling for heat. Knob "tr"...

  • Page 93: Fault Messages On The Display

    What needs doing? System characteristics (cont.) What to do if ... Cause Solution ... the rooms are cold, Hot water priority Switch off hot water de- even though the burner is mand or wait until de- working mand is satisfied. Fault on Vitotrol 100 or Contact your heating en- similar programmable...

  • Page 94: Repairs

    Repairs Cleaning The appliance casing can be cleaned using a damp cloth and a mild deter- gent. Do not use abrasive cleaners. Inspection and maintenance To ensure continued efficient opera- tion of the appliance, it is recom- mended that it is checked and serviced at regular intervals.

  • Page 95: Energy Saving Tips

    Energy saving tips Energy saving tips Along with using a modern heating system, you can save additional energy by your own actions. For this, the following measures will help you: & Correct ventilation. If windows are left open A close thermostatic radiator valves B to prevent incorrect heat demand.

  • Page 96: Keyword Index

    Contact your local heating contractor if you have any questions regarding the maintenance and repair of your heating system. You may, for example, find local heating contractors on the internet under www.viessmann.com. Viessmann Limited Hortonwood 30, Telford, TF1 7YP, GB...

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