Viessmann Vitodens 100-W WB1B 35 Installation And Service Instructions Manual

Installation and Service

Instructions

for use by heating contractor

Vitodens 100-W

WB1B Series

Wall-Mounted, gas-fired condensing boiler with optional on demand hot water Combi PLUS Kit

Heating input 37 to 118 MBH

10.8 to 34.5 kW

VITODENS

d

100-W

Vitodens 100-W, WB1B (with pre-installed coaxial vent pipe adaptor) and with Combi PLUS Kit installed.

IMPORTANT

Read and save these instructions for future reference.

5600 332 v1.3 08/2012 Please file in Service Binder

2

Safety

Safety, Installation and Warranty Requirements

Vitodens 100-W, WB1B Installation & Service

Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).

Product documentation

Read all applicable documentation before commencing installation. Store documentation near boiler in a

readily accessible location for reference in the future by service personnel.

u For a listing of applicable literature,

please see section entitled “Important

Regulatory and Safety Requirements”.

Carbon monoxide

Improper installation, adjustment, service and/or maintenance can cause flue products to flow into living space. Flue products contain poisonous carbon monoxide gas.

u For information pertaining to the proper installation, adjustment, service and maintenance of this equipment to avoid formation of carbon monoxide, please see instructions supplied with burner.

Warranty

Information contained in this and related product documentation must be read and followed. Failure to do so renders the warranty null and void.

Licensed professional heating contractor

The installation, adjustment, service and maintenance of this equipment must be performed by a licensed professional heating contractor.

u Please see section entitled

“Important Regulatory and Installation

Requirements”.

Fresh air

This equipment requires fresh air for safe operation and must be installed ensuring provisions for adequate combustion and ventilation air exist.

u For information pertaining to the fresh air requirements of this product, please see subsection entitled

“Combustion Air Supply”.

Contaminated air

Air contaminated by chemicals can cause by-products in the combustion process, which are poisonous to inhabitants and destructive to

Viessmann equipment.

u For a listing of chemicals which cannot be stored in or near the

boiler room, please see subsection entitled “Combustion Air Supply”.

Equipment venting

Never operate boiler without an installed venting system. An improper venting system can cause carbon monoxide poisoning.

u For information pertaining to venting and chimney requirements, please see section entitled “Venting

Connection”. All products of combustion must be safely vented to the outdoors.

Advice to owner

Once the installation work is complete, the heating contractor must familiarize the system operator/ ultimate owner with all equipment, as well as safety precautions/requirements, shutdown procedure, and the need for professional service annually before the

heating season begins.

WARNING

Installers must follow local regulations with respect to installation of carbon monoxide detectors. Follow manufacturer’s maintenance schedule of the boiler.


Safety

General Information

Dimensions

Connections

Table of Contents

Page

Safety, Installation and Warranty Requirements ..............2

Important Regulatory and Installation Requirements ........5

About these Installation Instructions ..............................6

Applicability . .............................................................7

Product Information .....................................................7

Mechanical Room . .....................................................8

Before Set-up .............................................................9

Minimum Clearances . ................................................10

CombiPLUS Installation Options ..................................10

Preparing the Connections ..........................................11

Connections overview............................................11

Dimensions overview without bottom piping connections..12

CombiPLUS connections and piping connections.......13

Piping connections for Vitodens 100W, WB1B-26

and -35 (factory supplied).......................................14

Wall Mounting ..........................................................15

Boiler and CombiPLUS installation............................15

Boiler mounting bracket and CombiPLUS installation..16

Mounting Vitodens 100-W boiler.............................17

Boiler Connections ....................................................17

Flue gas connection................................................17

Proper piping practice.............................................18

Gas connection and piping......................................18

Gas piping pressure test..........................................19

Heating water connections......................................20

Condensate connection...........................................21

Fill siphon with water.............................................21

Safety Connections and Pressure Testing .....................22

Installing safety devices on the boiler.......................22

Low water cut-off..................................................22

Performing pressure test on the boiler......................23

Hot water temperature and system pressure.............23

Preparing the CombiPLUS Connections ........................24

CombiPLUS Preparations for all Vitodens .....................25

Additional CombiPLUS Prearations for

Vitodens 100-W, WB1B-26 only .................................26

Mounting the CombiPLUS ..........................................27

CombiPLUS Installation Options .................................27

Connecting the CombiPLUS Piping ................................28

Connecting the CombiPLUS Wiring ..............................29

Accessing the Boiler Controls .....................................30

Preparing the Boiler Power Pump Module ...................31

Connecting the CombiPLUS Cables to the

Power Pump Module of the Boiler ...............................32

Re-installing Covers ...................................................33

Adding PRV and Label ...............................................34

Programming ............................................................35

3

4

Table of Contents

Connections

(continued)

Venting Connections

Control Connections

Start-up, Inspection and Maintenance

Troubleshooting

Additional Information


Page

Installation Examples .................................................36

General.................................................................36

Clearances...........................................................36

Pressure drop of Vitodens 100-W.............................36

Typical system flow rates........................................36

Heating circuit pumps.............................................36

CombiPLUS Built-in Pump.......................................37

System layout 1 to 4..............................................38

Vitodens and CombiPLUS Layout...............................44

Boiler in heating/cooling application..........................47

Boiler with low water cut-off (remote mounted, field supplied)..48

Low-loss header.....................................................49

Venting Connection ...................................................50

Electrical Connections ................................................50

Rotating the control unit and opening the power/pump module...50

Electrical connections to the power/pump module.....51

Optional operating control - OpenTherm...................51

Closing the power / pump module and reinstalling the control unit....................................................52

Reinstalling the front panel.....................................52

Necessary Tools .......................................................53

Testing/analysis equipment....................................53

Overview of Controls and Indicators ............................53

Control and display elements.................................53

Overview of Boiler Components ..................................54

Overview of CombiPLUS Components .........................55

Procedure (Overview) ................................................56

Steps .......................................................................57

Troubleshooting Steps ...............................................73

Changing Room Temperature ......................................73

Diagnosis ................................................................74

Sequence of operation and potential faults during each start-up cycle................................................74

Diagnostics table: Faults with fault display on control unit..75

How to reset faults...............................................76

Boiler Connection ....................................................77

Remove front panel...............................................77

Check boiler temperature sensor.............................77

Check outdoor temperature sensor..........................78

Determining the boiler set-point..............................79

Check fixed high limit............................................80

Check flue gas temperature sensor..........................80

Check fuses.........................................................81

CombiPLUS Connection ...........................................82

Check outlet temperature sensor.............................82

Replacing the flow limiter.......................................82

Checking or replacing the plate typeheat exchanger..83

Electrical connections to the Terminal Strip for

Accessories .............................................................84

Technical Data ........................................................85

Call for heat priority logic table...............................85

Burner Program Sequence of Operation ........................89

Wiring Diagram - Natural gas / Propane ........................91

Service Function Overview..................

.......................92

Parts List ................................................................93

Maintenance Record ..................................................98

Lighting and Operating Instructions .............................99


Important Regulatory and Installation Requirements

Safety

Codes

The installation of this unit shall be in accordance with local codes or, in the absence of local codes, use CAN/

CSA-B149.1 or .2 Installation Codes for Gas Burning

Appliances for Canada. For U.S. installations use the

National Fuel Gas Code ANSI Z223.1. Always use latest editions of codes.

In Canada all electrical wiring is to be done in accordance with the latest edition of CSA C22.1 Part 1 and/or local codes. In the U.S. use the National Electrical Code ANSI/

NFPA 70. The heating contractor must also comply with both the Standard for Controls and Safety Devices for

Automatically Fired Boilers, ANSI/ASME CSD-1, and the Installation Code for Hydronic Heating Systems,

CSA B214-01, where required by the authority having jurisdiction.

u Leave all literature at the installation site and advise the system operator/ultimate owner where the literature can be found. Contact Viessmann for additional copies.

u This product comes with several safety instruction labels attached. Do not remove!

Contact Viessmann immediately if replacement labels are required.

For installations on the Commonwealth of Massachusetts, the following modifications to NFPA-54 chapter 10 apply:

Excerpt from 248 CMR 5-08:

2(a) For all side-wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side-wall exhaust vent termination is less than (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side-wall horizontal

vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired carbon

monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment

is to be installed. In addition, the installing plumber or gas fitter shall observe that a battery operated or hard

wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or

structure served by the side-wall horizontal vented gas fueled equipment. It shall be the responsibility of

the property owner to secure the services of qualified licensed professional for the installation of hard-wired

carbon monoxide detectors.

a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or an

attic, the hard-wired carbon monoxide detector with alarm and battery back-up may be installed on the next

adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation,

the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however,

that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall

be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance

with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building

at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for

the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no

less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side-wall horizontally vented gas fueled equipment shall

not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and

signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current

edition of NFPA 54 as adopted by the Board; and

2. Product Approved side-wall horizontally vented gas fueled equipment installed in a room or structure separate

from the dwelling, building or structure used in whole or in part for residential purposes.

5

Safety/ General Information Vitodens 100-W, WB1B Installation & Service

Important Regulatory and Installation Requirements

(continued)

Working on the equipment

The installation, adjustment, service, and maintenance of this boiler must be performed by a licensed professional heating contractor who is qualified and experienced in the installation, service, and maintenance of hot water boilers.

There are no user serviceable parts on the boiler, burners, or control.

u The completeness and functionality of field supplied electrical controls and components must be verified by the heating contractor. This includes low water cut-offs, flow switches (if used), staging controls, pumps, motorized valves, air vents, thermostats, etc.

Ensure main power supply to equipment, the heating system, and all external controls has been deactivated.

Close main gas supply valve. Take precautions in all instances to avoid accidental activation of power during service work.

Technical literature

Literature for the Vitodens boiler:

- Technical Data Manual

- Installation and Service Instructions

- Operating Instructions and User's Information Manual

- Vitodens Venting System Installation Instructions

- Instructions of other products utilized and installed

- Installation codes mentioned

in this manual and as locally applicable u Leave all literature at the installation site and advise the system operator/ultimate owner where the literature can be found. Contact Viessmann for additional copies.

u This product comes with several safety instruction labels attached. Do not remove!

Contact Viessmann immediately if replacement labels are required.

6

About these Installation Instructions

Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below.

u Warnings draw your attention to the presence of

potential hazards or important product information.

WARNING

Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury or substantial product/property damage.

u

Cautions draw your attention to the presence of

potential hazards or important product information.

CAUTION

Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or product/ property damage.

u

IMPORTANT u Helpful hints for installation, operation or maintenance

which pertain to the product.

u

This symbol indicates that additional, pertinent

information is to be found.

u

This symbol indicates that other instructions must

be referenced.


Applicability

General Information

IMPORTANT

The boiler serial number must be provided when ordering replacement parts. Both the 16-digit serial number bar code label and the 12-digit ASME/NB serial number correlate to each other. Providing either serial number is sufficient.

Model No.

WB1B 26 and

WB1B 35

Serial No.

7457960 £££££££££

7457961 £££££££££

Note: Check the boiler rating plate on the Vitodens 100-W, models WB1B-26 or WB1B-35 to ensure it states compatibility with the CombiPLUS kit.

ASME/NB stamp 12-digit serial number location

(metallic plate riveted on the heat exchanger) H

Stainless steel Inox-Radial heat exchanger

Serial No. location (16-digit bar code white label located on the boiler as shown in this drawing)

Product Information

Natural / propane gas-fired wall-mounted hot water heating boiler for space heating.

For operation with constant (set-point) and outdoor temperature responsive control in closed loop, forced circulation hot water heating circuits. An external controller is required for indirect storage tank DHW production (an optional

CombiPLUS kit providing reliable on demand hot water without a DHW tank is available).

The Vitodens 100-W comes factory set for operation with natural gas. Propane conversion kit is included with each boiler.

Boiler model must be selected based on an accurate heat loss calculation of the building. Ensure boiler model is compatible with connected radiation.

Vitodens 100-W boilers are factory tested and calibrated. Further gas valve adjustments are typically not required during field start-up.

Follow the Vitodens Venting System Installation Instructions to vent this boiler.

7

8

General Information

Mechanical Room


During the early stages of new home design, we recommend that proper consideration be given to constructing a separate mechanical room dedicated to gas- or oil-fired equipment including domestic hot water storage tanks.

The boiler must be located in a heated indoor space, near a floor drain, and as close as possible to the wall.

Whenever possible, install boiler near an outside wall so that it is easy to duct the venting system to the boiler.

Locate boiler on walls capable of supporting the weight of the boiler filled with water (see section entitled

“Technical Data" on page 86 for information required for total boiler weight calculation). Ensure that boiler location does not interfere with proper circulation of combustion and ventilation air of other fuel burning equipment (if applicable) within the mechanical room.

The maximum room temperature of the mechanical room where the boiler is located must not exceed 104° F (40° C).

WARNING

If you notice fire coming from the appliance, call the fire department immediately! Do not attempt to extinguish the fire unless qualified to do so.

WARNING

Fire causes a risk of burns and explosion!

n Shut down the boiler n Close fuel shut-off valves n Use a tested fire extinguisher, class ABC.

IMPORTANT

Boiler operation in marine environments (damp, salty coastal areas):

The service life of the boiler’s exposed metallic surfaces, such as the casing and fan housing, is directly influenced by proximity to damp and salty marine environments. In such areas, higher concentration levels of chlorides from sea spray, coupled with relative humidity, can lead to degradation of the exposed metallic surfaces mentioned above. Therefore, it is imperative that boilers installed in such environments not be installed using direct vent systems which draw outdoor air for combustion. Such boilers must be installed using room air dependent vent systems; i.e. using room air for combustion. The indoor air will have a much lower relative humidity and, hence, potential corrosion will be minimized.


Mechanical Room

(continued)

General Information

Installation area conditions

WARNING

Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk.

g Ensure ambient temperatures are higher than 32° F

(0° C) and lower than 104° F (40° C).

g Prevent the air from becoming contaminated by halogenated hydrocarbons (e.g. as contained in paint solvents or cleaning fluids) and excessive dust

(e.g. through grinding or polishing work).

Combustion air for the heating process, and ventilation of the boiler room must be free of corrosive contaminants. To that end, any boiler must be installed in an area that has no chemical exposure. The list to the right indicates the main, currently known sources.

g

Avoid continuously high levels of humidity

(e.g. through frequent drying of laundry).

g

Never close existing ventilation openings.

Sources of combustion and ventilation air contaminants.

Areas likely to contain contaminants:

- New building construction

- Swimming pools

- Remodelling areas, hobby rooms

- Garages with workshops

- Furniture refinishing areas

- Dry cleaning/laundry areas and establishments

- Auto body shops

- Refrigeration repair shops

- Metal fabrication plants

- Plastic manufacturing plants

- Photo processing plants

- Beauty salons

Products containing contaminants:

- Chlorine-type bleaches, detergents and cleaning

solvents found in household laundry rooms

- Paint and varnish removers

- Hydrochloric acid, muriatic acid

- Chlorine-based swimming pool chemicals

- Spray cans containing chlorofluorocarbons

- Chlorinated waxes and cleaners

- Cements and glues

- Refrigerant leaks

- Calcium chloride used for thawing

- Sodium chloride used for water softening salt

- Permanent wave solutions

- Adhesives used to fasten building products and other

similar items

- Antistatic fabric softeners used in clothes dryers

Before Set-up

Before placing boiler in its installation location, ensure all necessary accessories are installed.

CAUTION

The boiler must be installed in such a way that gas ignition system components are protected from water (spraying, splashing, etc.) during boiler operation and service.

9

Dimensions

Minimum Clearances


Front

Side

Top *

5

Side

Back

Recommended minimum service clearances

Note: The Vitodens 100-W boiler has passed the zero

inches vent clearance to combustibles testing

requirements dictated by the boiler Harmonized

Standard ANSI Z21.13. CSA 4.9.2007 and

therefore is listed for zero clearance to combustibles

when vented with a single-wall special venting

system (AL-29-4C material) or UL/ULC-listed CPVC

gas vent material. The zero inches vent clearance

to combustibles for the Vitodens 100-W boiler

supercedes the clearance to combustibles listing

that appears on the special venting system label.

Top clearance - 12” (30 cm).

See the Vitodens Venting System

Installation Instructions.

* 1 Refer to the Installation Instructions of the Vitodens

Venting System for details.

Clearance to combustibles

Top Front Rear Left

0 0 AL,

CL

0 0

Right

0

AL = Alcove

CL = Closet

Vent pipe *1

0

CombiPLUS Installation Options

Shown is the distance between the boiler and CombiPLUS with Viessmann supplied 7” flex piping connection fittings.

10

Note: The maximum distance between the boiler and the CombiPLUS is restricted by the communication cable to 36” (915 mm).

Shown is the maximum distance between the boiler and CombiPLUS using field supplied fittings and pipes.


Preparing the Connections

Note: Use an approved pipe sealant or teflon tape when connecting the following installation fittings.

Connections overview

Dimensions

This section is an overview only!

Refer to subsequent sections for detailed information on individual piping connections.

Piping connections for Vitodens 100-W, WB1B 26 and 35

(factory supplied)

Legend

BWR Boiler water return, ¾”

BWS Boiler water supply, ¾”

BD

BF

GC

Boiler drain

Boiler fill

Gas connection, ¾” NPTM (male thread)

PRV Pressure relief valve

NPT National Pipe Thread

VC

CAI

Vent connection

Combustion air inlet connection (optional)

11

Dimensions


(continued)

Dimensions overview without bottom piping connections


12

Front view Side view Top view

Connections Vitodens 100-W, WB1B 26, 35

Legend

Connections

A Condensate drain, plastic hose Ø 0.87” (22 mm)

B Boiler water supply, NPT ¾” (male thread)

C Gas connection, NPT ¾” (male thread)

D Boiler water return, NPT ¾” (male thread)

E Combustion air opening for double pipe system

F Combustion air opening for coaxial system

Dimensions a 14” (355 mm) b 15¾” (400 mm) c 2 f ” (68 mm) d 28½” (725 mm) e 4 7 /

8

” (123 mm) f 6 d ” (156 mm) g 14 d ” (360 mm) h 5” (125 mm) j 9 7 /

8

” (250 mm) k 1 a ” (31 mm) m 7 7 /

8

” (200 mm) n 3 d ” (80 mm)

When preparing gas, water and electrical connections in the field, see section entitled

“Wall Mounting” on page 15 of this manual for information regarding the installation of the wall mounting bracket.

IMPORTANT

The maximum ambient temperature must not exceed

104º F (40º C).

g

Heating water connections and gas connection to be made in the field. See connection-specific section for details.

g

See subsection entitled “Power supply connection" for details regarding power supply to the Vitodens

100-W boiler.



(continued)

CombiPLUS connections and piping connections

Dimensions

Front view Side view

Top view

Legend

A Boiler water supply, NPTM ¾” (male thread)

B Boiler water return, NPTM ¾” (male thread)

C System water supply, NPTM ¾” (male thread)

D System water return, NPTM ¾” (male thread)

E DHW, NPTM ½” (male thread)

F DCW, NPTM ½” (male thread)

A B

C E F D

Front view

Shown is the distance between the boiler and CombiPLUS with Viessmann supplied 7” flex piping connection fittings.

13

Dimensions


(continued)


This section is an overview only! Refer to subsequent sections for detailed information on individual piping connections.

Piping connections for Vitodens 100-W, WB1B 26 and 35 (factory supplied)

14

Note: If using the optional CombiPLUS see page 10 and 24.

Legend



BD

BF

GC

Boiler drain

Boiler fill

Gas connection, ¾” NPTM (male thread)


PG Pressure gage

VC

CAI

Venting connection

Combustion air inlet connection (optional)


Wall Mounting

Dimensions

Boiler and CombiPLUS installation

The Vitodens 100-W boiler and CombiPLUScan be wall-mounted on:

- a brick/concrete wall

- wood studs

- metal studs

CAUTION

Whichever mounting method is used, ensure that the boiler bracket and CombiPLUS is tightly and securely fastened to wall. Failure to secure boiler or CombiPLUS properly could cause loosening, posing a severe safety hazard.

Following are the installation instructions for the mounting bracket on each material. Skip to the installation instructions applicable to your installation requirements.

Installation of mounting bracket on brick/concrete wall:

1.

Drill holes [Ø e ”(10 mm)], using mounting templates supplied with the boiler and the CombiPLUS.

2.

Align wall mounting boiler bracket and attach to wall with the screws and plastic anchors supplied. The

CombiPLUS is mounted directly to the wall with the screws and plastic anchors supplied.

1.

1.

mm mm

2.

1.

Legend

A Mounting template

B CombiPLUS mounting template

2.

15

16

Dimensions

Wall Mounting

(continued)

Boiler mounting bracket and CombiPLUS installation

Installation on wood studs


Install mounting bracket and CombiPLUS on wood studs as per illustration. Drill 3 /

16

” pilot holes to insert mounting bolts. Ensure that holes are located in the center of each wood stud. Secure with bolts to wooden studs as shown.

Boiler bracket

CombiPLUS

Installation on metal studs

Boiler bracket

Install mounting bracket and CombiPLUS on metal studs as per illustration. Drill f ” pilot holes to insert anchors.

Ensure that holes are located in the center of each metal stud. Use appropriate fasteners to mount CombiPLUS to metal studs (not supplied). Secure with bolts to metal studs as shown.

CombiPLUS


Wall Mounting

(continued)

Mounting Vitodens 100-W boiler

Dimensions/Connections

Note: Prior to installing the boiler, if a CombiPLUS kit is also required, verify that the minimum mounting clearances are met.

1.

Loosen the screws at the bottom of the boiler; do not remove completely.

2.

Remove the front panel.

3.

Mount boiler onto the mounting bracket.

For installation of the mounting bracket, see subsection entitled “Wall mounting installation” on page 16 of this manual.

Boiler Connections

Flue gas connection

The Vitodens 100-W boiler comes with a preinstalled vent pipe adaptor (as shown).

Run venting system, single-pipe, double-pipe or coaxial, through the side wall, roof or chimney, taking the shortest possible route and at a rising angle (min. 3º).

Installation Instructions Vitodens Venting System.

For double pipe installation, the combustion air inlet cover C must be in place. Also refer to the Venting Manual.

Remove and discard combustion air inlet cover C when installing coaxial vent pipe system.

17

Connections


(continued)


Proper piping practice

2 imperfect threads Use moderate amount of dope Support piping by proper suspension method.

Piping must not rest on or be supported by boiler.

Leave 2 threads bare

Gas connection and piping

1.

Make gas connection in accordance with codes

CAN/CSA B149.1 or 2 in Canada. In the United

States, use the National Fuel Gas Code ANSI Z223.1/

NFPA 54, as well as local codes where applicable.

2.

Close gas shutoff valve on boiler.

3.

Perform leak test.

4 . Bleed air from gas supply pipe.

See following page for details on gas connection and piping.

18

Legend

A Water supply connection

B Condensate drain connection

C Gas connection

D Water return connection



(continued)

Gas connection and piping (continued)

Legend

A Gas connection

B Accessible manual gas shutoff (factory supplied)

C Drip leg

IMPORTANT

Max. gas supply pressure: 14 “w.c.

Connections

1.

Refer to current CAN/CSA B149.1 or 2 in Canada.

In the United States, use the National Fuel Gas Code

ANSI Z223.1/NFPA 54, as well as local codes for gas piping requirements and sizing. Pipe size to the boiler must be determined based on:

- pipe length

- number of fittings

- maximum input requirements of all gas appliances in

the residence.

IMPORTANT

Design piping layout in such a way that piping does not interfere with serviceable components.

2.

Before connecting boiler to gas line, install ground joint union, capped drip leg and a manual equipment shutoff valve. Valves must be listed by a nationally recognized testing agency. Make boiler gas connection as shown on the left.

Gas connection (NPT)..........

∅ ¾”

3.

Perform gas piping pressure test as described in the following subsection.

4.

Identify shutoff valves as such with a tab and familiarize operator / ultimate owner of boiler with these valves.

WARNING

The gas supply piping must be leak tested before placing the boiler in operation.

CAUTION

Ensure that gas piping is large enough for all appliances in the residence. No noticeable gas pressure drop in the gas line must occur when any unit (or combination of units) lights or runs.

Gas piping pressure test

1.

Isolate the boiler from the gas supply piping system

using the individual manual shutoff valve during pressure tests equal to or less than ½ psig (14 “w.c.)

2.

The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of ½ psig (14 “w.c.)

3.

Perform leak test. Use approved liquid spray solution for bubble test. Ensure that no liquid is sprayed on any electrical components, wires or connectors. Do not allow leak detection fluid to contact gas valve regulator or regulator vent opening.

4.

Correct any and all deficiencies.

5.

Remove air from gas line.

When performing the gas piping pressure test, ensure the following requirements are met.

WARNING

Never check for gas leaks with an open flame.

WARNING

Exposing boiler gas pressure regulator and gas valve to extreme pressures renders warranty null and void.

IMPORTANT

½ psig = 14 “w.c.

19

20

Connections


(continued)

Heating water connections

Legend



BD Boiler drain

BF

GC

Boiler fill

Gas connection, ¾” NPTM


NPT National Pipe Thread

PG Pressure gage


1. Thoroughly flush heating system (particularly before connecting the boiler to an existing system).

2. Connect boiler to the heating system.

Max. operating pressure.......................3 bar (45 psig)

Test pressure......................................4 bar (60 psig)

IMPORTANT

Damage resulting from pressure exceeding those values stated is not covered by Viessmann warranty.

g

Use a two-hand wrench method when tightening fittings or piping onto the boiler connectors. Use one wrench to prevent the boiler pipes from twisting and the second wrench to tighten the fitting or piping. Failure to support the boiler connection could damage the boiler and its internal piping.

WARNING

The pressure gage is a sensitive component and may be damaged if the boiler connections are not supported by using a second wrench when tightening fittings and/or piping.

g

All plumbing must meet or exceed all local state and national plumbing codes.

IMPORTANT

SUPPORT ALL PIPING USING HANGERS. DO NOT support piping by the unit or its components.

g

Use isolation valves to isolate system components.



(continued)

Condensate connection

Legend

A Flexible discharge tubing

B Discharge tubing

Fill siphon with water

Connections

The Vitodens 100-W boiler comes with a built-in condensate trap. An external trap is not required when connecting the field drain to flexible discharge tubing.

Discharge tubing (field supplied) must be of 1” diameter.

Use CPVC, PVC or other material approved by codes listed below.

In the U.S. the drain pipe and fittings must conform to

ANSI standards and ASTM D1785 or D2846. CPVC or

PVC cement and primer must conform to ASTM D2564 or F493. In Canada use CSA or ULC listed schedule 40

CPVC or PVC drain pipe, fittings and cement.

If the condensate outlet of the Vitodens 100-W boiler is lower than the drain, a condensate pump must be installed. Select a pump which is approved for condensing boiler applications. To avoid condensate spillage, select a pump with an overflow switch. The drain connection must terminate into an open or vented drain as close to the boiler as possible to prevent siphoning of the boiler drain.

1.

Install the condensate drain pipe with a suitable gradient.

2.

Discharge condensate from the boiler into the drainage system, either directly or (if required) via a neutralization unit (accessory).

Installation Instructions of Neutralization Unit

(if applicable)

IMPORTANT

Pipe ventilation must take place between the siphon trap and the neutralization unit (if applicable).

IMPORTANT

Do not connect the drain pipe from any other appliance, such as water softener backwash pipe, to Vitodens condensate drain pipe.

Fill a minimum of 10 fl. oz. (0.3 liters) of water into the boiler adaptor.

WARNING

At initial start-up, flue gases may be emitted from the condensate drain. Fill the siphon with water before start-up.

21

22

Connections

Safety Connections and Pressure Testing


Installing safety devices on the boiler

1.

Remove loosely pre-assembled combination pressure relief valve and drain valve assembly.

2.

Apply sufficient amount of pipe sealant to both ends of all pipe fittings B , C , and E , and install onto tees D , F .

3.

Install pressure relief valve A and tighten.

4.

Install discharge pipe on pressure relief valve in such a way that...

- the end of the pipe is not threaded.

- the pressure relief discharge pipe extends to a

floor drain and ends approximately 6” (150 mm)

above the drain.

Ensure that...

- there is no shutoff valve installed in the discharge pipe.

- discharge pipe diameter is not reduced.

- discharge is not piped to outdoors.

Legend

A Pressure relief valve (30 psig),¾” NPT

B Brass nipple, length 2” x ¾”

C Drain valve connection, ¾”

D Tee, ¾”x¾”x¾”

E Brass nipple, length 3” x ¾”

F Tee, ¾”x¾”x¾”

L Boiler supply connection

Minimum connection diameters:

Pressure relief valve..........................¾”

Discharge pipe .................................¾”

Piping to pre-charged expansion tank...¾”

WARNING

Do not install an isolation valve between boiler and pressure relief valve.

The discharge pipe for the pressure relief valve must be oriented to prevent scalding of attendants.

Pipe pressure relief valve discharge pipe close to floor drain. Never pipe discharge pipe to the outdoors.

IMPORTANT

Install the (approved) factory supplied pressure relief valve.

Removal of air from the system must occur via use of air vent(s) in the system supply. To ensure the boiler can be purged of all air, ensure supply/return water lines do not contain restrictive piping where air could be trapped.

Low water cut-off

A low water cut-off may be required by local codes. If boiler is installed above radiation level, a low water cut-off device of approved type (field supplied) must be installed in all instances. Do not install an isolation valve between boiler and low water cut-off (see subsection entitled

“Boiler with low water cut-off” on page 48 in these instructions).


Safety Connections and Pressure Testing

(continued)

Connections

Performing pressure test on the boiler

The boiler must be leak tested before being placed in operation. Before boiler is connected to piping or electrical power supply, it must be hydrostatically pressure tested.

Hot water temperature and system pressure

1.

Cap supply and return connections (¾” NPT Male).

2.

Connect a ½” garden hose to boiler drain valve at the bottom of the boiler and fill boiler slowly until pressure gage indicates max. 4 bar (60 psig).

3.

Maintain pressure for 15 minutes. During time of pressure testing, do not leave boiler unattended.

4.

Inspect all pipe joint connections and safety devices with a flashlight for leaks. A lower manometer reading than 4 bar (60 psig) usually indicates loss of water due to leakage. All leaks must be repaired.

The hot water reading is constantly displayed during operation.

5.

After 15 minutes, release water pressure from boiler by opening boiler drain valve slowly, remove caps from supply and return connections as well as ¾” cap from 2” nipple, and install pressure relief valve immediately instead of ¾” cap.

After boiler has passed the pressure test, proceed with the installation.

WARNING

Exposing the boiler to pressures and temperatures in excess of those listed will result in damage, and will render warranty null and void.

See page 57 for fill procedure.

The boiler water pressure reading is displayed on an analog gage.

23

24

Connections

Preparing the CombiPLUS Connections

15 c ”

(400)


13 15 /

16

”

(355)

8 c ” (223)

16” (406)

17” (431)

50 7/16 ” (1280) when using 7” flex pipe.

54 7 /

16

” (1382) when using 12” flex pipe.

11 7/16 ” (291) when using 7” flex pipe.

15 7 /

16

” (393) when using 12” flex pipe.

10 15 /

16

”

(265)

9 13/16 ”

(249)

Note: The flex pipes must be bent due to the offset in the fittings between the boiler and the CombiPLUS.

The nominal length of the 7” flex pipe after bending is 6 b ” ! a ”.



CombiPLUS Preparations for all Vitodens

2.

4.

D

E

C

A

F

G

F

G

6.

B

C

D

E

A

B

1.

Connections

Installing the extension fitttings B and system connections D , E , F and G to the CombiPLUS A .

1. Using a Phillips screw driver, remove all four screws holding the CombiPLUS A cover and set aside.

2. Remove the cover by pulling straight out from the

CombiPLUS A and set aside.

3. Lubricate both extension fitting B O-rings with supplied lubricant and install each O-ring to the lower portion of the extension fittings B . Insert each of the extension fittings B on a slight angle through the rubber grommets and into the main supply/return connections of the CombiPLUS A . Ensure that the extension fittings B are fully seated.

4. Insert a locking clip C into the lower portion of each extension fitting B .

Note: Pull up on each extension fitting B to ensure that they are locked in place.

See page 34 for water flow directions in piping and fittings.

Note: Use a two-hand wrench method when tightening fittings or piping onto the boiler and CombiPLUS connectors. Use one wrench to prevent the boiler and CombiPLUS pipes from twisting and the second wrench to tighten the fitting or piping. Failure to support the boiler or CombiPLUS connections could damage the boiler and/or the CombiPLUS internal piping.

5. Insert both heating circuit gaskets D into the female end of each heating circuit adaptor E . Install the assembled heating circuit adaptors E to the system water supply/return connections on the CombiPLUS A .

6. Insert both DHW gaskets F into the female end of each DHW adaptor G .

Install the assembled DHW adaptors G to the DHW/

DCW connections on the CombiPLUS A .

IMPORTANT

DO NOT overtighten the adaptor fittings.

Legend

A CombiPLUS

B Extension fitting (x2)

C Locking clip (x2)

D Heat circuit gasket c ” (x2)

E DHW gasket b ” (x2)

F c ” Heating circuit adaptor (x2)

G b ” DHW adaptor (x2)

5.

25

26

Connections Vitodens 100-W, WB1B Installation & Service

Additional CombiPLUS Preparations for Vitodens 100-W, WB1B-26 only

A

2.

1.

H

Gasket

The CombiPLUS A flow restrictor must be exchanged when used with the Vitodens 100-W, WB1B-26.

1. Remove the two 4 mm hex head cap screws from the flow tube cap and set aside.

Gently remove the flow tube cap by pulling straight up (ensure not to damage the gasket) and set aside.

Remove the factory installed (14L/min) flow restrictor

(a small flat screw driver maybe required to unseat the restrictor) and discard.

2. Install the new flow restrictor H (for the WB1B-26 model only) supplied with the installation fittings.

Color Specification:

WB1B-26, black on white, 10L/min.

WB1B-35, brown on white, 14L/min.

3. Reinstall the flow tube cap (ensure not to pinch or damage the gasket).

4. Reinstall the two 4 mm hex head cap screws securing the flow tube cap. Torque screws to

4.5 Nm (40 lb/in)

Legend

A CombiPLUS

H 26kW flow restrictor

3.

4.

A


Mounting the CombiPLUS

Connections

I

J

4.

3.

I

J

K

A

K

1.

T

2.

CombiPLUS Installation Options

Shown is the maximum distance between the boiler and CombiPLUS using field supplied fittings and pipes.

Note: The maximum distance between the boiler and the

CombiPLUS is restricted by the communication cable to 36” (915 mm).

Prepare the wall and mount the CombiPLUS A using the supplied template and mounting hardware.

1. Pull the bottom of the boiler away from the wall approximately 1/2” (12 mm) and slide the top of the

CombiPLUS mounting template T between the wall and the boiler. Release the boiler and allow the weight of the boiler to hold the template in place.

The top outline on the template shows the lower imprint of the boiler (shown in dotted lines). Adjust the template to the boiler in this position when connecting the 12” flex piping.

The second outline on the template shows the lower imprint of the boiler (shown in solid lines). Adjust the template to the boiler in this position when connecting the 7” flex piping.

2. Drill a hole through the top mounting hole as shown on the template (x2). Drill a hole in the centre of the slot as shown on the template (x2).

Remove the template.

3. Install the supplied anchors K into the wall (if required).

4. Install the supplied washers J on to the lag bolts I .

Install the lag bolts/washers into the wall anchors

(if used) and through the slots of the CombiPLUS A .

Note: Leave the lag bolts loose enough to allow

up and down adjustments in the slot.

Note: Refer to the installation Instructions for

additional mounting options.

Legend

A CombiPLUS

I Lag bolt (x4)

J 1/4” plain washer (x4)

K Anchor (x4)

T Template

27

28

Connections

Connecting the CombiPLUS Piping

N

1.

L or M

A


N

L or M

Connecting the CombiPLUS A using the supplied piping, adaptors and mounting hardware.

1. Install the adaptors N to the tees at the bottom of the boiler. Install the flex pipes L or M to the adaptors N .

Carefully form the flex pipes L or M to align with the extension fittings on the top of the

CombiPLUS A .

Note: The flex pipes L or M must be bent due to the offset in the fittings between the boiler and the CombiPLUS.



Slide the CombiPLUS A up and install the flex pipes L or M to the extension fittings of the

CombiPLUS A .

Note:

L is a 7” pipe and M is a 12” pipe.

IMPORTANT

DO NOT overtighten the flex pipe fittings.

When connecting the flexible pipes do not overtighten the hex nuts. This is a gasketed design and should be hand tightened plus b turn with a wrench.

2. Tighten the two lag bolts located in the CombiPLUS

A mounting bracket slots.

Install the supplied washers J on to the lag bolts I .

Install the lag bolts/washers through the upper mounting holes of the CombiPLUS A mounting bracket and into the wall anchors (if used) and tighten.

Legend

A CombiPLUS

L 7” flex pipe (x2)

M 12” flex pipe (x2)

N c ” Adaptor (x2)

2.

I

J

A

I

J


Connecting the CombiPLUS Wiring

Diverting valve motor connection

Connections

A

1.

Pump connection

Q

R

Connecting the CombiPLUS A wiring using the supplied control and pump cables.

1. Remove both standard knock-outs from the rear right side of the CombiPLUS A .

Route the control cable Q through one knock-out and the pump cable R through the other.

Note: There are optional knock-outs on the front left side of the CombiPLUS A

(if required).

Secure the cables inside the CombiPLUS A using the locknuts provided.

2. Connect the electrical connectors in the

CombiPLUS A as shown.

Legend

A CombiPLUS

Q Control cable

R Pump cable

A

To remove, push to unlock

A

Water Temperature sensor connection

Flow sensor connection

2.

29

Connections

Accessing the Boiler Controls


Removing the boiler and power pump module covers to provide access to the power pump module.

1. Loosen the boiler housing captive screws (located at the bottom front of the boiler). Remove the cover by pulling straight out from the boiler and set aside.

2. Release and hold the boiler control locks (located on both sides of the boiler) and rotate forward and down.

3. Release the four captive screws on the power pump module cover by rotating them 90 degrees with a

Phillips screw driver. Set the cover aside.

1.

2.

30

3.


Preparing the Boiler Power Pump Module

Jumper pin

Connections

Preparing the power pump module for connection to the

CombiPLUS wiring.

When handling static sensitive components, avoid damage caused by static discharge by following Electro-Static Discharge safety procedures.

1. Remove the jumper pin from terminal X8 (CombiPLUS) of the power pump module and discard.

2. Remove the jumper cable from terminal block X4

(terminals 3 & 4, room thermostat connection) of the power pump module and discard (for room thermostat connection only).

3. Remove the second and fourth hole plug from the base of the power pump module and discard.

Note: Once the CombiPLUS is installed and the jumper pin is removed, if not programmed for use with the CombiPLUS, the boiler will provide DHW heating based on the built-in resistors (DHW input connections of the power pump module). If the jumper pin is not removed the boiler will not provide on demand hot water via the CombiPLUS.

For programming see page 35.

Jumper pin

1.

Hole plug

2.

Hole plug

3.

Jumper cable

31

32

Connections Vitodens 100-W, WB1B Installation & Service

Connecting the CombiPLUS Cables to the Power Pump Module of the Boiler

1.

2.

Ground

BK1

Neutral

(green/yellow)

R

BK2

Line

Q

W

W

U

4.

U

V

DHW

Temperature

Sensor /

Flow Sensor

3.

Diverter Valve

Cable

Legend

BK1 - Black 1 (Neutral)

(BK1 with blue shrink sleeve on pump side)

BK2 - Black 2 (Line)

Note: See page 29 for CombiPLUS connections.

V

Connecting the CombiPLUS cables to the power pump module.

1. Route the control cable Q through the fourth hole of the power pump module base and route the pump cable R through the second hole of the power pump module base.

Secure the cables inside the power pump module using the locknuts provided.

2. There are three wires to connect on the power pump cable R .

Connect wire BK1 to the power pump neutral of terminal block X3 (as shown).

Connect wire BK2 to the power pump line of terminal block X3 (as shown).

Connect the green/yellow ground wire to terminal block X2 (any open terminal).

3. The control cable Q has two connectors.

Connect the DHW temperature sensor / flow sensor

(five pin connector) to terminal plugin X7.

Connect the diverter valve (six pin connector) to terminal plugin X10.

Note: For additional wiring details see the wiring

diagram.

4. Install the supplied anchors V into the wall behind the cables. Install the conduit clip U with the supplied screw W into the wall anchor V . Press cables Q and R into the conduit clip U .

Legend

Q Control cable

R Pump cable

U Conduit clip

V #10 Anchor

W #10 Screw


Re-installing Covers

1.

Connections

Reinstalling the covers for the boiler, power pump module and the CombiPLUS A .

1. Align and install the cover of the power pump module and lock into place by rotating the four captive screws

90 degrees with a Phillips screw driver.

2. Rotate the boiler controls up and in.

Ensure that the locking clips are engaged.

3. Install the boiler cover by inserting it straight on from the front.

4. Tighten the boiler housing captive screws (located at the bottom front of the boiler).

5. Install the CombiPLUS A cover by inserting it straight on from the front.

6. Using a Phillips screw driver, install and tighten all four screws holding the CombiPLUS A cover.

Legend

A CombiPLUS

2.

3.

4.

5.

A

6.

33

34

Connections

Adding PRV and Label

P

O

1.

Boiler

Supply

Boiler

Return

A

Heating

Circuit

Supply DHW DCW

Heating

Circuit

Return


Installing the PRV P and tee O to the CombiPLUS A and label S to the boiler.

Note: The system must be leak tested.

Refer to the boiler Installation Instructions.

The DHW pressure relief valve is designed to relieve excessive pressure in the system, produced during domestic hot water heating.

Model: Watts No. 3L

Size: ¾” NPT

Max. Operating Pressure: 150 psig

Input Rating: 200 MBH

The installation of the DHW pressure relief valve must be in accordance with local codes. The DHW pressure relief valve must be installed in the domestic hot water supply by a heating contractor. If local codes require a different relief valve, substitute the valve supplied by the manufacturer. The heat exchanger is approved for a max. operating pressure of 150 psig.

The DHW pressure relief valve must be installed in vertical position in the domestic hot water supply as close to the

CombiPLUS heat exchanger as possible. Drain pipe (of same diameter as valve outlet) must be routed to safe place of disposal, and must be installed with a downward slope from the valve.

Do not install a shutoff valve between the DHW pressure relief valve and the heat exchanger, or in the drain pipe.

1. Install the 150 psi PRV P and tee O to the installed field supplied piping from the CombiPLUS A .

2. Apply the scald danger label S as shown.

Note: This label must be installed as required by national code.

Legend

A CombiPLUS

O ¾” Tee

P ¾” PRV, 150 psi

S Danger label

S

2.


Programming

2.

1.

Connections

Programming the boiler control for operation with or without the CombiPLUS.

Note: If an optional CombiPLUS is used, the boiler control

must be programmed.

Note: For additional programming refer to the boiler

Operating, Installation and Service Instructions.

1. Lift flap and pull control unit cover down. All boiler controls are located behind the control unit cover.

2. Simultaneously turn rotary selectors “ “ and “ tr “ to their central position. “ and SERV “ will appear on the screen.

Note: If one (or both) of the rotary selector dials are already in the central position, take it (or them) out of the central position and then simultaneously turn both rotary selectors back to the central position.

3. Turn the rotary selector “ “ to the control range on the right. “ “ will appear on the display.

4. Adjust the control by turning the rotary selector “ tr “.

The display shows: “ 0 ” or “ 1 ” flashing

“ 1 ” boiler with the optional CombiPLUS

(right control range).

“ 0 ” boiler without optional CombiPLUS

(left control range) (factory default setting).

Note: After programming the boiler control to

accept the CombiPLUS, wait until the boiler

temperature is displayed, then switch the

control OFF then ON. ECO will be displayed

on the screen.

3.

4.

35

Connections

Installation Examples


General

The schematics on the following pages are to be seen as guidelines only. They further do not display all system varieties, safety devices, or concepts possible. Specific system layouts may be further discussed with the local

Viessmann sales representative office.

Clearances

A minimum of 2” (51 mm) circumferential clearance from non-insulated hot water pipes to combustible construction must be maintained. In cases where the pipes are insulated with pipe insulation of appropriate and sufficient thickness and insulation values, the above clearance may be reduced to 0” (refer to local gas codes).

g

Grundfos 15-58 (3-speed) g

Taco 00R or equivalent

Refer to the graph above for the proper waterside boiler friction loss calculations.

CAUTION

For underfloor heating applications, an additional immersion or strap-on aquastat must be installed in the low temperature underfloor loop (downstream of the mixing valve) to de-energize the pump and/or boiler to prevent overheating. High water temperatures can damage concrete slabs.

Pressure drop (primary circuit) of Vitodens 100-W

The Vitodens 100-W is designed only for closed loop, forced circulation hot water heating systems. ft. m

Heating circuit pumps

Recommended heating pumps with Vitodens 100-W,

WB1B 26, 35.

A low-loss header must be used when the system flow rate exceeds the maximum (or minimum) flow rate of the Vitodens 100-W boiler. An alternative method may be used, such as primary secondary piping using closely spaced tees.

A low-loss header offers additional benefits not provided by a pair of closely spaced tees. Viessmann strongly recommends and prefers the use of a low-loss header over closely spaced tees.

Use standard friction loss method for pipe sizing. Observe boiler maximum and minimum flow rate limitations.

If system flow rate exceeds boiler maximum flow rate

(as stated on page 86) or if system flow rate is unknown,

Viessmann strongly recommends the installation of a lowloss header. See page 49 for low-loss header information or refer to the Vitodens Venting System Installation

Instructions.

IMPORTANT

Pump selection must be based on accurate system flow and pressure drop calculations (incl. DHW sizing).

36

USGPM

L/h

Flow rate

Typical system flow rates

Model WB1B

∆ t

Output Btu/h

30º F rise (GPM)

35º F rise (GPM)

40º F rise (GPM)

26

83,000

5.5

4.7

4.2

35

108,000

----

6.2

5.4



(continued)

Connections

CombiPLUS built-in pump

Grundfos UPS15-78 three speed heating circuit/DHW production pump for Vitodens 100 WB1B 26, 35 boilers

(in the factory setting, the pump speed is preset to ‘speed three’)

Speed Three

Speed Two

Speed One

Flow Q (gpm)

Performance chart courtesy of Grundfos

Pump Model Grundfos UPS15-78

Rated voltage VAC 115

Rated current A max.

A min.

1.15

0.8

Capacitor

Power consumption l F

W max.

W min.

8

130

80

CombiPLUS built-in pump, Grundfos UPS15-78, residual head pressure

Residual head of built-in three speed pump used with Vitodens 100 WB1B 26, 35

Flow Q (gpm)

37

Connections


(continued)

System Layout 1

Vitodens 100-W, WB1B 26, 35 with...

- one heating circuit

PVR

AV

System Layout 1 - Alternate Option


Legend

AV Air vent


A Vitodens 100-W

B Room thermostat

C Heating circuit

D Heating circuit pump (field supplied)

E Expansion tank

F Pressure Activated By-Pass

Note: Heating circuit C in the examples should be designed

to 30º F to 40º F (16.7º C to 22.2º C). For a lesser

∆ t design, the system layout designer must use

one of the examples (3 or 4) on the following pages.

IMPORTANT

Ensure that a pressure activated by-pass is installed if there are system component(s) in

C

that may isolate the flow to the pump

D

.

Maximum Flow Rates

Model WB1B

∆ t

Output Btu/h

30º F rise (GPM)

35º F rise (GPM)

40º F rise (GPM)

26

83,000

5.5

4.7

4.2

35

108,000

----

6.2

5.4

AV

PVR

38

Note: The use of a low-loss header is recommended if the water flow rate is less than 1.7 GPM (400 L/h) or more than 6.2 GPM (1400 L/h).

The low-loss header is available as an accessory part .



(continued)

System Layout 2


- DHW storage tank

- low-loss header


PRV

AV

Connections

TPV

Legend

AV Air vent


TPV Temperature and pressure relief valve

A Vitodens 100-W gas-fired condensing boiler

B External boiler/DHW controller (field supplied)

C Heating circuit


E DHW storage tank

F DHW tank temperature aquastat or sensor

G DHW circulating pump field supplied)

H Low-loss header

K Expansion tank

L Primary pump (boiler circuit, field supplied) with low-loss header only


Model WB1B

∆ t

Output Btu/h

30º F rise (GPM)

35º F rise (GPM)

40º F rise (GPM)

26

83,000

5.5

4.7

4.2

35

108,000

----

6.2

5.4

IMPORTANT

Primary pump

L must pump into the boiler (as illustrated).


The low-loss header is available as an accessory part.

See page 49 in this manual for details on the low- loss header.

39

40

Connections


(continued)

System Layout 3


- DHW storage tank


PRV

AV

4xpipe Ø or 12” / 305 mm

TPV

IMPORTANT

Primary pump

L must pump into the boiler (as illustrated)


The low-loss header is available as accessory part.

See page 49 in this manual for details on the low- loss header.


Legend

AV Air vent


TPV Temperature and pressure relief valve


B External boiler/DHW controller (field supplied)

C Heating circuit


E DHW storage tank

F DHW tank temperature aquastat or sensor

G DHW circulating pump (field supplied)

H Closely spaced tees, 4x pipe Ø or 12” (305 mm)*

K Expansion tank

L Primary pump (boiler circuit, (field supplied)

*A low-loss header offers additional benefits not provided

by a pair of closely spaced tees. Viessmann strongly

recommends and prefers the use of a low-loss header

over closely spaced tees. Please see page 36 for details.


Model WB1B

∆ t

Output Btu/h

30º F rise (GPM)

35º F rise (GPM)

40º F rise (GPM)

26

83,000

5.5

4.7

4.2

35

108,000

----

6.2

5.4



(continued)

System Layout 4


- DHW storage tank

- Low-loss header

- one high-temperature heating circuit

- one low-temperature heating circuit

- Viessmann Vitotronic 050, HK1M controller

Connections

OPTIONAL ROOM

THERMOSTAT

SEE NOTE 2

120V POWER

SUPPLY

4-7 GPM

FLOW

GRUNDFOSS

UPS-15-58FC

3-SPEED

CIRCULATOR OR

EQUIVALENT

RECOMMENDED

RT

ST max. 17.5 GPM or

35 GPM (SEE LOW

LOSS HEADER)

OPTIONAL LIMIT

THERMOSTAT

SEE NOTE 1

ATS

HK1M PPM

SEE NOTE 3

120V

POWER

SUPPLY

120V POWER SUPPLY

LOW LOSS HEADER

ViPN 7134791 (for max. 17.5 GPM)

ViPN 7134792 (for max. 35 GPM)

SEE NOTE 1

See page 43 for notes and explanation of this drawing.

Legend

A Boiler power pump module

A1 Primary pump (boiler power / pump module control)

(field supplied)

B Honeywell switching relay for

B1 Heating circuit pump (field supplied)

C Honeywell switching relay for DHW H control

C1 DHW circulating pump (field supplied)

D Vitotronic 050, Model HK1M Digital indoor / outdoor heating circuit control unit & pump control

Vi. Part No. 7134 627

D1 Heating circuit pump (field supplied)

E Radiator heating circuit

F Underfloor heating circuit

G Low loss header

-Max. flow 17.5 USGPM

Vi. Part No. 7134 791

-Max. flow 35 USGPM

Vi. Part No. 7134 792

H DHW indirect storage tank

I Outdoor temperature sensor

J Limit thermostat (optional) See note 1

K DHW tank aquastat, Honeywell Part No.

L4008A1031, Vi. Part No. 9560 985

M Mixing valve motor / control

N Mixing valve supply temperature sensor

O Viessmann mixing valve

P Room thermostat (optional) See note 2.

Q Vitodens 100 boiler

R Expansion tank

41

42

Connections


(continued)

Wiring diagram for system layout 4


ROOM THERMOSTAT

RT

DHW

Power Pump Module

Honeywell Aquastat L4008A1031

Vi.PN. 9560985 for DHW Control

TANK AQUASTAT

HONEYWELL SWITCHING

RELAY RA889A-1001

(OPTIONAL)

120 VAC/

1PH

DOMESTIC HOT

WATER PUMP

protection as required

050 is used to energize the TT output of PPM.

Therefor using a room thermostat in series with RT

input of the boiler will reduce unnecessary calls

initiated by pump logic output of the Vitotronic to the

Vitodens 100 boiler

3 DHW has priority over heating circuit E (see also 4 )

and NO PRIORITY over Heating Circuit F (mixing

valve)

power to terminals L1, L2 of RA889A relay of heating

circuit E B

1PH

Vitotronic 050, Model HK1M

Digital Indoor/ Outdoor

Heating Circuit Control Unit

& Power Pump Module Vi.PN

7134627 See Installation

Instruction specific to each control

LOW TEMP HEATING CIRCUIT PUMP

USED WITH MIXING VALVE

1PH

(OPTIONAL)

Honeywell Switching

Relay RA889A-1001 for heating circuit E

HIGH TEMP HEATING CIRCUIT PUMP

24V Field Wiring

120V Field Wiring

Factory Wiring



(continued)

Connections

System Layout 4

Installation of heating circuits:

- radiator heating circuit (high temperature circuit)

- underfloor heating circuit with 3-way mixing valve (low

temperature circuit)

- DHW production with the following flow conditions:

The flow rate of the heating circuits is greater than the maximum possible water flow rate of the Vitodens 100 boiler.

The use of a low-loss header is therefore recommended.

A low-loss header is available as an accessory part.

The radiator heating circuit is supplied by a circulation pump (field supplied). The underfloor heating circuit is supplied by a circulation pump installed on site which is controlled by the extension kit. The DHW pump is field supplied.

Note 1

Optional high limit safety control of heating circuit the boiler supply temperature will be set automatically to 172º F (78º C)].

The heating system must be protected from excessive temperature if no automatic mixing valves are used or no DHW priority is required.

After the DHW call for heat is satisfied, there is a 20 second pump post-purge time.

E .

[During DHW production with DHW terminal activated,

Note 2

The heating circuit pump logic output of the Vitotronic

050 is used to energize the RT (room thermostat) output of power / pump module.

Therefore, using a room thermostat in series with

RT (room thermostat) input of the boiler will reduce unnecessary calls initiated by the pump logic output of the Vitotronic to the Vitodens 100 boiler (mixing valve heating circuit only).

Note: The use of a low-loss header is recommended if the

water flow rate is less than 1.7 GPM (400 L/h) or

more than 6.2 GPM (1400 L/h).


See page 49 in this manual for details on the low-

loss header.

Note 3

During DHW call for heat, there is no priority on mixing valve heating circuit.


Model WB1B

∆ t

Output Btu/h

30º F rise (GPM)

35º F rise (GPM)

40º F rise (GPM)

26

83,000

5.5

4.7

4.2

35

108,000

----

6.2

5.4

43

44

Connections


(continued)

Vitodens 100-W, WB1B 26, 35 with one heating circuit and the CombiPLUS



Model WB1B

∆ t

Output Btu/h

30° F rise (GPM)

35° F rise (GPM)

40° F rise (GPM)

26

83,000

5.5

4.7

4.2

35

108,000

---

6.2

5.4



Built-in pump residual head for the heating system side is 6.0 ft. of water column at the boiler maximum flow rate of 6.2 GPM.

Note: Heating circuit C in the examples should be designed to 30º F to 40º F (16.7º C to 22.2º C).

For lesser delta T design, system layout designer must use one of the examples (5 or 6) on the following pages.

Legend

AV Air vent

PRV Pressure relief valve (boiler)

PRV* Pressure relief valve (DHW 150 psi)

WSE Water softner equipment

A Vitodens 100-W

B Room thermostat

C Heating circuit

D CombiPLUS

E Expansion tank



(continued)

Vitodens 100-W, WB1B 10-26, 10-35 with...

- CombiPLUS Kit

- low-loss header


Connections




Model WB1B

∆ t

Output Btu/h

30° F rise (GPM)

35° F rise (GPM)

40° F rise (GPM)

26

83,000

5.5

4.7

4.2

35

108,000

---

6.2

5.4

Legend

AV Air vent





B External boiler / system controller (field supplied)

C Heating circuit


E CombiPLUS

F LLH

G Expansion tank

45

Connections


(continued)


Vitodens 100-W, WB1B 10-26, 10-35 with CombiPLUS and one heating circuit without LLH


The low-loss header is available as an accessory part.


Model WB1B

∆ t

Output Btu/h

30° F rise (GPM)

35° F rise (GPM)

40° F rise (GPM)

26

83,000

5.5

4.7

4.2

35

108,000

---

6.2

5.4

46

Legend

AV Air vent





B External system controller (field supplied)

C Heating circuit


E CombiPLUS

F Closely spaced tees, 4x pipe Ø or 12” (305 mm)*

G Expansion tank

* A low-loss header offers additional benefits not provided by a pair of closely spaced tees.

Viessmann strongly recommends and prefers the use of a low-loss header over closely spaced tees.

See page 49 for details.



(continued)

Boiler in heating/cooling application

Connections

Legend

A Heating/Cooling unit

B Spring-loaded flow check valve

C Circulation pump

D Expansion tank

E Water chiller

F Boiler circuit pump (field supplied)

IMPORTANT

Viessmann strongly suggests that the valves pictured above be labelled “v1” and “v2”.

The boiler, when used in connection with a refrigeration system, must be installed ensuring the chilled medium is piped in parallel to the boiler with appropriate valves to prevent the chilled medium from entering the boiler.

The boiler piping system of a hot water heating boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

Check installation instructions of the chiller manufacturer carefully for additional requirements.

Cooling season starts:

Close valve v1 and open valve v2.

Heating season starts:

Close valve v2 and open valve v1.

47

48

Connections


(continued)


Boiler with low water cut-off (remote-mounted, field supplied) A low water cut-off may be required by local codes.

If boiler is installed above radiation level, a low water

Hi-Vent Hi-Vent cut-off device of approved type (field supplied) must be installed in all instances at the highest point of the piping system. Do not install an isolation valve between boiler and low water cut-off.

Follow the installation instructions of the low water cut-off manufacturer.

LWCO LWCO

For low water cut-off wiring information specific to your application, refer to applicable wiring diagram on the boiler front panel.

Note: The Vitodens 100-W boiler has a built-in flow

switch, which may be accepted by local codes

in lieu of a low water cut-off.

Boiler below radiation Boiler above radiation



(continued)

Accessories for the Vitodens 100-W

Neutralization Unit for Single-Boiler Applications with neutralizing granulate for Vitodens 100-W, WB1B 26, 35

Part No. 7134 231

Connections

V primary

V bypass

V secondary

Low-Loss Header

- Type 80/50, Part No. 7134 791

[max. flow rate 17.6 GPM (4 m 3 /h)]

- Type 120/80, Part No. 7134 792

[max. flow rate 35.2 GPM (8 m 3 /h)]

A low-loss header offers additional benefits not provided by a pair of closely spaced tees. Viessmann strongly recommends and prefers the use of a low-loss header over closely spaced tees. When used in conjunction with the Vitodens 100-W boiler, the low-loss header acts as hydraulic break, decoupling boiler and system circuits from each other (no sensor required). It is recommended to use the low-loss header in applications in which the total system flow rate exceeds the maximum or falls below the minimum flow rate of the Vitodens 100-W boiler.

For maximum boiler flow rates, see the table on page 87 in this manual.

Viessmann strongly recommends the use of a low-loss header in cases where the system head and flow rates are unknown.

In addition, the low-loss header helps eliminate air and debris [D] from the heating system. See illustrations for

Low-loss header design and the principle of operation.

Product may not look exactly as illustrated.

Principal of operation

The low-loss header is available in the following sizes.

Select the size based on the maximum system flow rate of your application.

Model No.

Type 80/50

Type 120/80

Max. system flow rate

17.6 GPM (4 m 3 /h)

35.2 GPM (8 m 3 /h)

Legend

AB Air Bleed

BR Boiler Return

BS Boiler Supply

BY Bypass

(with laminar flow)

D Debris and/or air

T1 Boiler supply temp.

T2 Boiler return temp.

DV

SR

SS

T3

T4

Drain Valve

System Return

System Supply

TS Viessmann Temp.

Sensor (not used)

SW Sensor Well

System supply temp.

System return temp.

V primary

V secondary

V bypass

Q primary

Q secondary

Boiler circuit flow rate

Heating circuit flow rate

Bypass flow rate

Heat supplied by boiler

Heat consumed by system

V primary < V secondary

T1 > T3

T2 = T4

Q primary = Q secondary

T1 176° F (80° C)

Vsecondary=Vprimary+Vbypass

IMPORTANT

When installing a low-loss header, system mixed supply temperature (T3) must be calculated as follows

Product may not look exactly as illustrated.

Low-loss header design

49

50

Venting / Control Connections

Venting Connection

CAUTION

Under certain climatic conditions some building materials may be affected by flue products expelled in close proximity to unprotected surfaces. Sealing or shielding of the exposed surfaces with a corrosion resistant material (e.g. aluminum sheeting) may be required to prevent staining or deterioration. The protective material should be attached and sealed (if necessary) to the building before attaching the vent termination. It is strongly recommended to install the vent termination on the leeward side of the building.


For detailed installation information and specific venting requirements, reference the Vitodens

Venting System Installation Instructions supplied with the boiler.

Electrical Connections

Rotating the control unit and opening the power/pump module

1.

Loosen the screws underneath the boiler but do not remove them. Remove the cover (as shown on page 17).

2.

Pull tabs outwards.

3.

Flip control unit down.

4.

Remove cover by releasing tabs if necessary.

5.

Unlock 4 spring-loaded lock screws B and remove cover plate of the power pump module.

IMPORTANT

Both the control unit and the power pump module have labels and stickers containing important information. Read and follow their respective instructions.

IMPORTANT

The ON / OFF switch located on the boiler does not disconnect power to power / pump module, therefore the main service switch or breaker must be turned off.

Note on connection of accessories

For other required installation steps, please reference the Installation Instructions for the accessory part.



(continued)

Electrical connections to the power pump module (room thermostat and DHW)

Control Connections

120V PUMP DHW RT

Legend

A Main power supply

(120V, 60Hz, 1 PH).

B Heating circuit pump

(or boiler pump for low-loss header application or

CombiPLUS pump).

C DHW tank temperature controller / external heat demand (field supplied)

(not used with the

CombiPLUS kit).

D Room temperature thermostat

(Anticipator setting 0.2A)

(field supplied).

Note: Boilers are factory shipped with a wiring diagram

(11”x17” sheet inside a pouch) attached to the

inside of the front cover. The wiring diagram

shipped with the boiler supercedes the wiring

information in this manual.

Provide a main power disconnect / service switch as per local code requirements. Also refer to wiring diagram on page 91.

IMPORTANT

Remove short factory test leads from terminal L, N and

Ground before connecting main power supply to boiler

A

.

IMPORTANT

Ensure that pressure activated by-pass is installed with system layout 1 on page 38.

Optional operating control - OpenTherm

Boiler control base

GAS PUMP FAN

Diverting valve

DHW / flow sensor

What is OpenTherm?

The OpenTherm (OT) protocol is a point-to-point communication system, which connects a boiler with a room controller or other devices. The room unit calculates a heating demand (water temperature request) and transmits it to the boiler. The boiler will adjust the heat input accordingly (low-high modulation).

Legend

A Viessmann outdoor temperature sensor (field wiring)

B OpenTherm (field wiring)

C Connection cable terminal

D Power pump module

Follow the installation instructions of the field supplied operating controls.

51

52

Control Connections


(continued)

Closing the power pump module and reinstalling the control unit


1.

Reinstall power pump module cover plate.

2.

Install control cover (if previously removed).

3.

Flip control upward and lock into position.

CAUTION

Electrical cables may become damaged if in contact with hot components.

When running and securing connecting cables on site, ensure that the maximum permissible temperatures of the cables are not exceeded.

Reinstalling the front panel

1.

Set front panel on the guide rails and push in place.

2.

Tighten screws at the bottom.

IMPORTANT

Read and follow, where applicable, the safety instructions of all labels and stickers attached to boiler surfaces.

Do not remove any of these instructions.

Contact Viessmann if any replacement labels are required.


Necessary Tools

Start-up, Inspection and Maintenance

Testing/analysis equipment (use only calibrated equipment) g Multimeter to measure 0 - 12A, 120V and W resistances g

Flue gas analyzer to measure % CO

2

or O

2

(i.e. Bacharach fluid samplers or suitable electronic flue gas analyzer) g Manometer to measure gas pressure 0 to 11 “w.c.

(accurately) and up to 28 “w.c. gas pressure (or a non-electric Magnehelic® manometer may also be utilized) g

Stack thermometer 0 to 500° F (0 to 260° C) g

Bacharach calculator or suitable tables to calculate standard (non-condensing) efficiency g

Carbon monoxide measuring equipment 0 to 400 ppm.

Special items g

Approved leak detection fluid for natural gas g

Pipe joint sealant g

Garden hose for bleeding boiler heat exchanger and pressure testing

Cleaning supplies g

Plastic hand brush g

Rags

Overview of Controls and Indicators

Lift flap and pull control unit cover down. All boiler controls are located behind the control unit cover.

Control and display elements

The control unit is preset at the factory for standard operation. Your heating system is ready for use. The factory presets may be individually adjusted to suit your specific requirements.

Legend

A Pressure gage

B LCD display

C “ ” Selector dial for DHW temperature

D “ tr ” Selector dial for boiler water temperature

E ON / OFF switch

F Gas shut-off valve

Legend

A Heating mode pump output “ON” (when RT is closed)

B DHW mode pump output “ON” (when DHW is closed)

C Boiler water temperature in °F or fault code

D Units for boiler water temperature measurement

E Service mode

F Current burner firing power rate

G Burner in operation indicator

H Fault indicator

I Comfort function started

J Comfort function stopped

53


Overview of Boiler Components


54

Fig. 45

Legend

A Fixed high limit, 210° F (99° C)

B Ignition / ionization electrode

C Flow switch, VK315M

D P-trap

F Condensate hose, 16” (400 mm)

G Water pressure gage

H Vent pipe adaptor

J Flue gas temperature sensor 230º F (110º C)

K Test port caps (x2)

L Burner mounting flange assembly

N Radial fan

O Air / gas inlet Venturi

L Burner mounting flange assembly

M Boiler temperature sensor

N Radial fan

O Air / gas inlet Venturi

T Heat exchanger / flue gas collector

U Control console flame safeguard (with ignition transformer unit)

V ASME / NB plate

W Inlet air Venturi extension

X Terminal strip (low voltage wiring)


Overview of CombiPLUS Components


Fig. 46

Legend

A Boiler water supply

B Diverting valve

C Expansion tank

D Outlet temperature sensor

E System water supply

F DHW

G Boiler water return

H Air vent valve

I Plate-type heat exchanger

J Flow sensor

K Circulation pump

L System water return

M DCW

55

56


Procedure Overview


Start-up steps

Inspection steps

Maintenance steps

6 6 6

S I M

S

S

I M

S I M

I

I

S M

S I M

I M

I M

I

1. Fill and vent the heating system ......................................................................................57

2. Check power supply connection . ......................................................................................58

3. Select appropriate gas type ..............................................................................................58

4. Measure static pressure and running pressure .....................................................................59

5. How the Vitodens 100-W boiler operates ...........................................................................61

6. Relay tests (burner tests).................................................................................................62

7. High altitude testing ........................................................................................................64

8. Set maximum input.......

..................................................................................................65

9. Clock natural gas meter ...................................................................................................66

10. Check all primary and secondary circuit connections for leaks ...............................................66

11. Perform combustion analysis ............................................................................................66

12. Check venting system for leaks (circular air gap measurement)

for sealed combustion, coaxial vent only ..........................................................................67

S I M

S I M

I M

I M

I M

I M

I M

M

I

I

I

13. Removing front panel ......................................................................................................67

14. Remove burner ...............................................................................................................68

15. Check burner gasket and cylinder assembly for damage ......................................................68

16. Check and adjust ignition and ionization electrodes .............................................................69

17. Check condensate drain and clean siphon (P-trap) ...............................................................69

18. Check neutralization unit (if applicable) ..............................................................................70

19. Clean combustion chamber/heat exchanger surfaces ...........................................................70

20. Check diaphragm expansion tank and system pressure ........................................................71

21. Check functioning of safety valves ....................................................................................71

22. Check gas pipes and fittings for leaks ................................................................................72

23. Reinstall burner ...............................................................................................................72


Steps

Start-up


1. Filling and bleeding heating system

B

CAUTION

Unsuitable fill water increases the level of deposits and corrosion, and may lead to damage to the equipment.

n Thoroughly flush the entire heating system prior to

filling with water.

n Only use fill water of potable quality.

n Soften fill water harder than 150 ppm temporary

hardness.

n Inhibitors or antifreeze additives suitable for heating

systems may be added manually.

1

2

A

During fill and removal of air, the boiler pump can be activated. To activate the pump, in less than 2 seconds turn selector dial to stand-by position 1 from a control range (counter-clockwise) and then right back into the control range 2 (clockwise). The pump will run for 30 minutes and cancel the request automatically or after the

ON/OFF switch is turned OFF.

1.

Open system isolation valves (if installed).

Note: Before filling the heating system with water, check

that all necessary flow check valves are installed.

2.

Check inlet pressure of the diaphragm expansion tank.

Note: If the nitrogen pressure of the precharged expansion

tank is less than the static pressure of the system,

inflate membrane pressure to slightly exceed pressure

of system. The static pressure required at the tank

is based upon the static height of the system. The

system fill pressure value must be equal to the

expansion tank pressure value at approx. 60º F

(15.6º C).

3.

To remove debris and/or sludge ensure that the system piping is flushed out. Failure to do so may cause sediment in the boiler causing overheating and damage not covered by warranty.

Note: System fill pressure must be approximately 3 psig

higher than the static head when the system is cold.

4.

Optional:

Fill the heating system with water at the boiler filling tap A and drain air completely from the drain tap B .

Note: Water treatment should be considered in areas where it is known that boiler feed water contains a high mineral content and hardness. In areas where freezing might occur, an antifreeze may be added to the system water to protect the system. Please adhere to the specifications given by the antifreeze manufacturer. Do not use automotive silicate- based antifreeze. Please observe that an antifreeze/ water mixture may require a backflow preventer within the automatic water feed and influence components such as diaphragm expansion tanks, radiation, etc. A 30% antifreeze content will provide freeze-up protection to -10° F (-23° C). Do not use antifreeze other than specifically made for hot water heating systems. System also may contain components which might be negatively affected by antifreeze.

Check total system frequently when filled with antifreeze.

To remove air from the heat exchanger: g

Connect a hose to the boiler filling tap A and connect

the other end to fresh water supply (or heating medium).

g

Open the fresh water supply valve and then open the

boiler filling tap A slowly to fill the boiler with water.

Isolation valves (not shown) to isolate system

components must be closed during fill/bleed process.

g

Flush the boiler heat exchanger via the boiler supply

and return (for at least 10 mins.) until all air has

been removed from the boiler.

g

When the drain tap B begins to bleed water, close

the boiler drain valve and open system isolation valves.

57


Steps

(continued)

Start-up


1. Fill and vent heating system (continued)

5.

Check system pressure.

6.

Ensure proper / adequate fuel supply exists.

Open gas shutoff valve.

Max. boiler operating pressure.......................45 psig

Min. boiler operating pressure...............14 to 23 psig

Pressure relief valve.....................................30 psig

Start-up 2. Check power supply connection

A power module is supplied with the Vitodens 100-W boiler, which requires a 120 VAC power supply.

The voltage at connector X3 must be 120 V (see wiring diagram).

Neutral conductor

The electrical power supply must have a neutral conductor.

58

IMPORTANT

In Canada all electrical wiring is to be done in accordance with the latest edition of CSA C22.1 Part 1 and/or local codes. In the U.S. use the National Electrical Code ANSI/

NFPA 70. The heating contractor must also comply with both the Standard for Controls and Safety Devices for

Automatically Fired Boilers, ANSI, ASME CSD-1.

Start-up and Maintenance

Note: The outer conductor “L“ and the neutral conductor

“N” must not be interchanged. See wiring diagram on page 91 entitled “Additional Information” in this manual.

3. Select appropriate gas type

Natural gas

Heating value (gross) Btu/ft 3 970 to 1100

Specific gravity 0.57 to 0.70

Ultimate carbon dioxide (CO2) % 11.7 to 12.2

The Vitodens 100-W boiler is for use with gases whose characteristics fall within the following ranges. Do not use any other types of gas.

Liquid Propane gas

2466 to 2542

1.522 to 1.574

13.73 to 13.82

1.

Verify that the fuel type listed on the boiler rating plate is the correct type for the installation being attempted.

2.

Once verified, record the fuel type in Maintenance

Record on page 98.


Steps

(continued)



3. Select appropriate gas type (continued)

To verify the fuel type

1. Simultaneously turn selector dial “ “ and “ tr “ to their center position as shown. “SERV" appears in the display. (To do the following step, “SERV" must still be shown in the display).

2. Turn selector dial “ tr ” counter clockwise to the

“O” position within 2 seconds as shown. “ A “ and the setpoint value will flash on the display.

3. Adjust the control unit to natural gas or LPG by turning the selector dial “ “ counter clockwise or clockwise. The display shows:

“ 0 ” for operation with natural gas or

“ 1 ” for operation with LPG.

4. Do not adjust the selector dials for 15 seconds. The set operating mode is then saved and the control unit returns to standard mode.

Start-up and Maintenance 4. Measure static pressure and running pressure

Static pressure

1.

To measure static and/or running pressure remove burner cover panel as per the removal instructions on page 67.

2.

Close gas shutoff valve.

3.

Loosen screw in test nipple A on the gas combination valve, do not remove completely . Connect calibrated manometer.

4.

Open the gas shutoff valve.

5.

Measure static pressure. Values must be:

- 14 “w.c. max. for NG

- 14 “w.c. max. for LPG

6.

Enter measured value into Maintenance Record on page 98 in this manual.

7.

Start up boiler, using the on/off service switch (field supplied).

Legend

A Inlet gas pressure measurement port

B Outlet pressure port

C Low-fire adjustment screw / cover

D Hi-fire adjustment screw

IMPORTANT

A CO

2

measurement (see page 62) must be taken before and after working on gas appliances to eliminate health risks and to guarantee the satisfactory condition of the system.

IMPORTANT

The burner is automatically ignited and starts operation after a safety time has elapsed. During initial start-up, the unit may indicate a fault F4 because of air in the gas supply pipe. After fault F4 is displayed, reset the burner

(see page 76). The ignition procedure is repeated. This boiler employs a direct spark ignition system with 3 trials for ignition.

59

60


Steps

(continued)



4. Measure static pressure and running pressure (continued)

Measuring running gas supply pressure, using test nipple

A

8.

All measurements must be made under high-fire conditions.

Note: Use suitable measuring instruments calibrated with a minimum resolution of 0.04 “w.c. for measuring the running pressure.

Measure the running pressure; value must be:

Running supply pressure with

Natural gas under 4

“w.c.

4 to 14

“w.c.

over 14

“w.c.

Running supply pressure with

Liquid propane gas

Corrective action under 10

“w.c.

Do not attempt adjustment. Call local gas utility to increase pressure.

Start up boiler.

10 to 14

“w.c.

over 14 “w.c.

Do not attempt adjustment. Call local gas utility to decrease pressure.

Boiler valve must not be exposed to pressure over

14 “w.c.

9.

Enter gas type into Maintenance Record on page 98 in this manual.

10.

Switch off the heating system ON/OFF service switch

(boiler is shut down), close the gas shut-off valve, remove the manometer and re-tighten the screw in the test nipple A .

11.

Open gas shutoff valve and check that the test nipple

A and all gas connections are gas-tight.

WARNING

Ensure that there is no open flame in the room.

WARNING

Never purge a gas line into a combustion chamber.

Never use matches, candles, flame, or other sources of ignition for purpose of checking leakage. Use a soap-and-water solution to check for leakage. A failure to follow this warning could result in fire, explosion, personal injury, or death.


Steps

(continued)



5. How the Vitodens 100-W boiler operates...


Legend

A Inlet gas pressure measurement port

B Outlet pressure port

C Low-fire adjustment screw / cover

D Hi-fire adjustment screw

The Vitodens 100-W boiler uses a premix combustion system, which is designed to deliver a measured air-gas mixture to the burner for complete combustion.

The gas is injected upstream of the blower. The burner and heat exchanger are part of a forced-draft design.

The benefits of forced-draft systems are lower component temperatures, direct air-fuel connection (premix) for improved mixing, and longer service life of the boiler due to mild to moderate ambient conditions.

The matrix cylinder burner blower and the combination gas valve are factory calibrated and pre-adjusted for optimum boiler performance at all firing rates through a pneumatic link between combustion air and gas flows.

Blower speed is automatically increased or decreased based on heat demand, thereby regulating the amount of combustion air drawn. The pneumatic link between air and gas introduces the required amount of gas for correct combustion to meet the current heat demand, based on a linear relationship between ∆ P air and ∆ P gas.

61

62


Steps

(continued)


A Flue gas measuring port

Legend

A Heating mode pump output on

B Heating mode

C Boiler water temperature in °F or fault code

D Water temperature unit in °F

E Service mode

F Current burner firing rate

G Burner in operation

H Fault

I Comfort function started

J Comfort function stopped


6. Relay tests (burner tests)

The Vitodens 100-W boiler is factory preset for operation with natural gas. It is recommended that a CO

2

check be performed at the boiler vent pipe adaptor as part of the initial start-up/maintenance procedure.

For high altitude operation above 5,000 ft (1,500 m), refer to page 64 first.

For conversion to propane, see the separate instructions.

The CO

2

value lies within the range of;

- 7.5 to 10.5 % for natural gas and 10 to 12% for

liquid propane gas. The CO

2

value measured must

be compared with the above CO

2

value.

NG range

Target value

LPG range

Target value

CO2 high-fire low-fire

7.5-10.5% 7.5-10.5%

9.0% 8.7%

10.0-12.0% 10.0-12.0%

10.8% 10.5%

Note: When the boiler is initially turned on, a self-

diagnostic check is initiated. Wait until the

temperature display is stabilized and the boiler’s

actual temperature is displayed.

Note: If step 14 is not performed, the process will end

automatically after 30 minutes.

If the CO

2

value measured lies more than 1% outside the stated range, perform the following step:

- Check the venting system for leaks (refer to the

Vitodens Venting System Installation Instructions).

1.

Bring the boiler to a high-fire test position by turning

the selector dial “ tr ” clockwise all the way to

“ U Reset ” and then back again into the high-fire control

range (in less than 2 seconds).

The display shows “ SERV ”, the boiler water temperature,

five bars “

<

< < < < ” for high-fire test, burner in operation

“ A ” and “ r ” pump operation.

Control range - high-fire


Steps

(continued)



6. Relay tests (burner tests) (continued)

Note: During the relay test (if required) the selector dial

“ tr ” position can limit the boiler input according to the following table;

Dial setting

1 & below

6 & above

Input setting low fire between 1 & 6 between low & high fire high fire

<

Display flashing

<

< <

<

< < < <

IMPORTANT

Steady state conditions must be established before measuring flue gases.

2.

Check the flue gas CO

2

content. Should the actual value

deviate by more than 1% from the range shown in the

table, check the seals in the balanced flue system.

Adjust if necessary.

3.

Enter actual values into the service report.

4.

Bring the boiler to a low-fire test position by turning

the selector dial “ tr ” clockwise all the way to “ U Reset ”

and then back again into the low-fire test control range


high-fire position, turn the dial to the low-fire postion.


one bar “ < ” for low-fire test, burner in operation “ A ”

and “ r ” pump operation.

7.

Check the CO

2

content for high- and low-fire again.

If the CO

2

content is still not within the given range

(refer page 62), adjust the CO

2

content.

8.

Adjusting the CO

2

content.

See CO

2 table on page 62.

9.

Adjust the high-fire (natural gas or liquid propane gas).

With the adjusting screw B , using a hex head wrench (4 mm), adjust the high-fire CO

2

content to

9% for NG or 10.8% for LPG. Clockwise rotation decreases gas flow and counter-clockwise rotation increases gas flow.

High-fire increase gas flow

Low-fire increase gas flow

Control range - low-fire

Note: Once in a low / high-fire test range, you can switch back and forth between the high and low by simply positioning the control range for the required test.

Note: The heat generated by the boiler during the high-low-fire relay test must be removed. The heating load must be imposed on the boiler (DHW or heating) during the duration of the test. Boiler temperature is automatically adjusted to a maximum of 178º F (81º C).

5.

Check the flue gas CO

2

content. Should the actual value deviate by more than 1% from the above range, check the seals in the balanced flue system.

6.

Enter actual values into the service report.

10.

Adjust the low-fire (natural gas or liquid propane gas).

Remove cover C from the gas valve. With the adjusting screw under the cover and using a T40 size Torx head wrench, set the low-fire CO

2

content to 8.7% for NG or 10.5% for LPG. Clockwise rotation increases gas flow and counter-clockwise rotation decreases gas flow.

11.

Reinstall cover C .

12.

Shut the boiler down, remove flue gas analyzer and close flue gas measurement port A .

13.

Return selector dial “ ” and “ tr ” to the original positions.

14. To cancel the relay test, switch the boiler OFF then back ON. If not cancelled, the relay test is automatically deactivated after 30 minutes.

63

64


Steps

(continued)

Start-up and Maintenance 7. High altitude setting


Note: When the boiler is initially turned on, a self- diagnostic check is initiated. Wait until the temperature display is stabilized and the boiler’s actual temperature is displayed.

1.

Simultaneously turn selector dials “ ” and “ tr ” to their center position. “ SERV ” appears in the display.

(To do the following step, “ SERV ” must still be shown in the display.)

Note: If one (or both) of the rotary selector dials are already in the central position, take it (or them) out of the central position and then simultaneously turn both rotary selectors back to the central position.

2.

Turn selector dial “ tr ” clockwise all the way to the “ U Reset ” position.

3.

“ r ” appears on display along with flashing set value “ i ” or “ 2 ”.

4.

With selector dial ” ”, set the value to “ 2 ” for operation above 5,000 ft. (1,500 m).

Turn the selector dial “ position to the right or left.

” from the center

Value Operation

1

2

Altitude < 5,000 ft. (1,500 m)

Altitude > 5,000 ft. (1,500 m)

5.

Do not adjust the selector dials for at least 15 seconds.

The set value “ 1 ” or “ 2 ” is then saved and the control unit returns to standard mode.

6.

Turn ON/ /OFF switch OFF and then ON. When completed, it will activate the designated setting


Steps

(continued)



8. Set maximum heating input

Control range

- The maximum input (or output) for heating operation

can be limited (does not affect DHW heating).

The limit is set via the modulation range.

The maximum adjustable heating input (or output) may

be limited by programming.

1.

Start up the boiler.

2.

Bring the boiler to a high-fire test position by turning

the selector dial “ tr ” clockwise all the way to

“ U Reset ” and then back again into the middle position

range (in less than 2 seconds) and back to “6”.


five flashing bars “

< <

< < < ” for high-fire, burner in operation

“ A ” and “ r ” heating system pump operation.

3.

With selector dial. select the max. input (or output)

for heating operation by selecting number from 1 to 6

on selector dial “ tr “ for required value in % of the

rated input (or output).

Note: For example, if the selector dial is set at “1” only one bar will be flashing on the display and the input will be reduced to 40% of max input.

4.

Turn the water temperature selector dial “ “

clockwise (in less than 2 seconds and back again into

operation range. The icon will appear for a

moment on display, the control accepted the setting.

5.

Press the ON/OFF switch.

6.

Start the boiler and the maximum input will be set.

Note: When the boiler is initially turned on, a self- diagnostic check is initiated. Wait until the temperature display is stabilized and the boiler’s actual temperature is displayed.

65

66


Steps

(continued)

Start-up and Maintenance 9. Clock natural gas meter

IMPORTANT

A boiler underfired by 5% is still acceptable.

Do not overfire the boiler.

CAUTION

Always contact your gas utility to obtain the correct heating value before clocking the meter.


Clock natural gas meter to verify input

1.

Ensure all other gas equipment served by the meter is turned off during timing of gas input to the Vitodens

100-W boiler.

2.

Measure the time in seconds it takes for the boiler to use 10 cu. ft. of gas. Divide 3600 x 10 by the number of seconds and you get the number of cu. ft.

of gas used per hour. Multiply this number by the heating value of the gas to obtain Btu per hour input.

For example:

A Vitodens 100-W boiler (118 000 Btu/h input) requires 305 seconds to use 10 cu. ft. of natural gas.

After contacting the local utility, you find the heating value is e.g.

1000 Btu per cu. ft.

Therefore,

((3600 x 10)/305) x 1000 { 118 000 Btu/h input.

Therefore, the boiler input is correct.

Burner input formulas (up to 4500 ft.):

INPUT=(3600 t) x 1000 where t=TIME (sec.) for 1 ft.

3

INPUT=(3600 x .01 x 1000 x 35.31) T where

T = TIME (sec.) for .01 m 3 natural gas

Start-up and Maintenance 10. Check all primary and secondary circuit connections for leaks

Check heating system and domestic hot water connections (if applicable). Ensure all connections are pressure tight.

Correct any leaks found on fittings, pumps, valves, etc.

Start-up and Maintenance 11. Perform combustion analysis

IMPORTANT

A CO

2

measurement (see page 62) must be taken before and after working on gas appliances to eliminate health risks and to guarantee the satisfactory condition of the system.

Record the measured combustion values in the sequence stated in the Maintenance Record on page 98 in this manual.


Steps

(continued)



Legend

A Flue gas measurement port

B Combustion air measurement port

12. Check venting system for leaks (circular air gap measurement)

For sealed combustion, coaxial vent only

Viessmann strongly recommends that the heating contractor perform a simplified leak test during boiler start-up. For this purpose it is sufficient to measure the

CO

2

concentration of the combustion air in the coaxial gap of the air intake pipe. The vent pipe is considered sufficiently leak-proof if a CO

2

concentration in the combustion air no higher than 0.2% or an O

2

concentration no lower than 20.6% is measured.

If higher CO

2

values or lower O

2

values are measured, check venting system thoroughly.

Note: The vent pipe adaptor comes with two measurement

ports, one for combustion air intake measurement

and one for flue gas measurement.

Note: This test is not applicable for single-wall venting

systems (non-sealed combustion).


13. Removing front panel

To ensure continued efficient operation of the boiler, it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend on the particular installation conditions and usage but in general once a year should be adequate.

Any service work must be carried out by a licensed professional heating contractor.

The boiler incorporates a flue gas measurement port. The flue gases can be analyzed (if required). The push fit cap may be removed and a sample tube installed. The push fit cap must be refitted after use. The flue gas sample will enable the heating contractor to judge whether any adjustments are required. Before commencing any service operation, isolate and secure the main power supply against accidental reactivation, and turn off the main gas supply.

1.


2.


67

68


Steps

(continued)

Maintenance



14. Remove burner

1.

Switch the burner OFF (shut off main service switch).

2.

Shut off the gas supply.

3.

Pull power cables from fan motor A , gas valve B and electrode block C .

4.

Pull the Venturi extension D from the fan.

CAUTION

To avoid damage to the burner, do not lay burner on its cylindrical burner tube.

Failure to heed this caution may cause damage to the burner tube, which may lead to improper operation.

5 . Release gas supply pipe fitting E .

Note: There is a gasket between the gas valve and

this connection.

6.

Loosen four Torx (T-30) screws F and remove burner.

Maintenance 15. Check burner gasket and cylinder assembly for damage

Check the burner gasket A and burner cylinder assembly

D for damage and replace if necessary. Replace the cylinder burner assembly if damaged.

1.

Remove electrode block B .

2.

Loosen the three Torx screws and remove the thermal insulation ring C .

3.

Loosen the four Torx screws and remove burner cylinder assembly D and assembly gasket E .

4.

Fit and secure new burner cylinder assembly D and new assembly gasket E . Tighten to a torque of 3.5 Nm (31 lb.in.) using a calibrated torque wrench.

5.

Reinstall thermal insulation ring C .

6.

Reinstall electrode block B . Tighten to a torque of 3.5 Nm (31 lb.in.) using a calibrated torque wrench.


Steps

(continued)



16. Check and adjust ignition and ionization electrodes

1.

Check ignition and ionization electrode for wear, contamination or warping.

2.

Clean electrodes with a small brush or emery paper.

3.

Check clearances. If clearances are not satisfactory or the electrodes are damaged, replace electrode block and gasket and align. Tighten fastening screws for the electrodes to a torque of 3.5 Nm (31 lb.in.) using a calibrated torque wrench.

4.

Reinstall grounding wire.

Legend

A Ignition ionization electrode

B Ground

Maintenance


17. Check condensate drain and clean siphon (P-trap)

1.

Check the siphon to ensure unimpeded drainage of condensate.

2.

Remove all hoses from siphon A .

3.

Release locking tabs at opening B from underneath and remove siphon A upwards.

4.

Clean siphon A and reinstall.

5.

Refit all hoses. Secure drain hose with cable ties.

6.

Fill the siphon A with water by pouring 10 fl. oz.

(0.3L) of water into the combustion chamber.

IMPORTANT

If the condensate does not drain freely, condensate will accumulate in bottom part of boiler resulting in a burner shut-down (fault message F4). The combustion chamber refractory will also become wet at the bottom. Do not restart the boiler immediately with a wet combustion chamber refractory. This will damage the refractory.

Either dry the refractory (ie. using a hairdryer) or replace it.

Installation Instructions Neutralization Unit

(if applicable)

69

70


Steps

(continued)

Maintenance


18. Check neutralization unit (if applicable) Accessory

1.

Check the pH value of the condensate with a pH measuring strip. If the pH value is less than 6.5, replace granulate.

2.

If contaminated: Rinse neutralization unit with tap water.

3.

Add granulate as marked on the cartridge.

IMPORTANT pH measuring strip is field supplied.

Maintenance

IMPORTANT

The granulate is consumed as it neutralizes the condensate.

The red marking indicates the min. filling level.

Installation Instructions Neutralization Unit

19. Clean combustion chamber/heat exchanger surfaces

1.

Remove burner cover panel as per the removal instructions on page 67 in this manual, and reinstall panel upon completion of service work.

2.

If necessary, clean the combustion chamber A and heat exchanger surfaces B with a brush and/or rinse with water. Use solvent-free cleaning agents to remove residues:

- Remove combustion by-product deposits with

alkaline agents containing tenside.

- Remove coatings and (yellowish brown) surface

discoloration with phosphoric acid-based

“Antox 75 E Plus”, or citric acid-based CitriSurft

3050 by Stellar Solutions Inc.

- Rinse thoroughly with water.

Note: Be careful not to scratch parts which are in contact with flue gas. Use plastic brushes, not wire brushes! The cleaning agents must not contain hydrocarbon-based solvents or potassium.

3.

Connect electrical cables to corresponding parts.

WARNING

Follow cleaning agent manufacturer’s safety instructions and wear appropriate protective equipment.

IMPORTANT

Perform leak test.


Steps

(continued)



20. Check diaphragm expansion tank and system pressure



Perform check on the system when cold.

1.

Drain boiler/system and reduce pressure until the manometer reading is “0”.

2.

If the nitrogen pressure of the pre-charged expansion tank is less than the static pressure of the system, inflate membrane pressure to slightly exceed pressure of system.

The static pressure required at the tank is based upon the static height of the system. The system fill pressure value must be equal to the expansion tank pressure value at approx. 60º F (15.6º C).

Note: Static head of 33 ft. (10 m) (distance between boiler and topmost heat emitter surface) corresponds to a static pressure of 1 bar (15 psig).

3.

Top up with water until filling pressure is higher than the inlet pressure of the diaphragm expansion tank.

Note: With the system cold, the filling pressure must be approx. 3 psig higher than the static pressure.

Max. boiler operating pressure............45 psig

Min. boiler operating pressure....14 to 23 psig

Pressure relief valve.......................... 30 psig

4.

When starting up the system for the first time, mark this value as the minimum filling pressure on the manometer.

Note: A lower manometer reading usually indicates loss of water due to leakage. All leaks must be repaired.

21. Check functioning of safety valves

Ensure proper operation of low water cut-off(s)

(if applicable), pressure relief valve, and pump(s).

Check pressure gage, air vent and pressure relief valve.

Ensure that pressure relief valve does not leak and that it operates in accordance with information provided by the original manufacturer.

Refer to maintenance instructions supplied

with low water cut-offs, pumps, etc.

Flush float water type low water cut-offs (if used).

Follow local regulations with respect to backflow preventers.

If oil-lubricated pumps are used, ensure proper lubrication.

If motorized zone valves are used, refer to maintenance instructions provided with zone valves.

71

72


Steps

(continued)



22. Check gas pipes and fittings for leaks

WARNING

The gas supply piping must be leak tested before placing the boiler in operation.

CAUTION

Ensure all joints of gas line are pressure tight and that gas valves do not leak when under normal operating pressure (use approved leak detection liquid). Do not use open flame.



23. Reinstall burner

1.

Replace electrical cables from fan motor A , mount burner, and diagonally tighten 4 Torx T-30 screws F to a torque of 4 Nm (35 lb.in.).

2.

Insert new supplied gasket and tighten the fitting E on the gas connection pipe to a torque of 15 Nm (132 lb.in.).

3.

Plug the Venturi extension D into the fan.

4.

Replace electrical cables from gas valve B , and electrode block C .

5.

Open gas shutoff valve and switch on power supply.

6.

Check the gas connection for tightness.

7.

Install front panel, as shown on page 52.


Troubleshooting Steps

Diagnosis

Troubleshooting

1.

Establish fault message or diagnose behavior of system.

2.

Look for corresponding cause of fault in the diagnostics table.

3.

Find corrective measures in the table.

4.

Perform corrective measures (page 74 to 76).

Note: See page 54 and 55 for an overview of controls, indicators and system components.

Correction

Changing Room Temperature

In case a separate external room temperature controller

(thermostat) is installed, the desired room temperature will be adjusted using this device.

Make adjustments using the appropriate operating instructions only.

Note: lf thermostatic radiator valves are installed in the room where the control is installed they must be fully open.

In case the room temperature setting on the separate room temperature controller is not sufficient to achieve the desired room temperature (e.g. during a particularly cold winter), the boiler water temperature can be adjusted accordingly using the boiler water temperature selector dial tr .

73

74

Troubleshooting

Diagnosis

Sequence of operation and potential faults during each start-up cycle

Call for heat by control (boiler water set-point temperature is 9º F

(5º C) above current boiler water temperature).

yes 6

Water flow switch activates plug 33.


Corrective action

Increase boiler water set-point

4 temperature and ensure that there is heat demand.

Check water flow switch. Replace

4 if necessary (min. flow 1.8 USG/m

(400 L/h).

Check boiler pump operation.

Blower starts up.

6 yes

Display message no

Fault F9 after

4 approximately

51 seconds.

6 yes

Ignition.

no 4

Fault F4

6 yes

Gas combination valve opens.

no 4

Fault F4 yes 6

Ionization current builds up / flame established (symbol A appears).

no 4

Fault F4

6

Burner is operating.

yes

Burner shuts off when the boiler temperature is below the selected boiler set-point temperature and immediately starts up again(cycles).

Check cabling and plug-in connectors

4 of the blower, as well as the blower itself. Check proper power supply to the blower.

Check ignition transformer unit and

4 its plug-in connections.

Check gas combination valve

4 104VRAC (DC) between brown and blue must be present during start-up,

(plug 35). Check gas supply pressure.

Check electrode settings, purge gas

4 supply line. Check condensate line and flue gas system for leaks.

Check ignition cable resistance

(4.5K to 5K Ohms).

Check flue gas system for leakage

4 (flue gas recirculation), check running gas pressure.


Diagnosis

(continued)

Troubleshooting

Faults are indicated by a flashing fault code with fault code symbol “ U ” on the display.

For fault code explanations see the following table.

Diagnostics table: Faults with fault display on control unit

Fault code in display window

10

18

30

38

System characteristics * 1

Constant mode

Burner blocked

Burner blocked

Cause

Outside temperature sensor shorted out

Outside temperature sensor wire broken

Boiler water temperature sensor shorted out

Boiler water temperature sensor wire broken

Jumper connection shorted out, removed or missing

50

51

No DHW tank heating or external heat demand

No DHW heating with CombiPLUS only

Outlet temperature sensor shorted out

52

58

59

5a

Burner blocked (with


No DHW heating (used with storage tanks)

No DHW heating (with

CombiPLUS only)

Burner blocked

Flow sensor shorted out

(in CombiPLUS)

Jumper connection shorted out, removed or missing

Outlet temperature sensor wire broken

Flow sensor wire broken a9 b0

Regulated operation without OpenTherm device

Burner blocked

Communication fault

OpenTherm device

Corrective measures

Check the optional outside temperature sensor and wiring (see page 78).

Check the outside temperature sensor and wiring (see page 78).

Check the boiler water temperature sensor

(see page 77).

Check the boiler water temperature sensor

(see page 77).

Install PPM jumper

(see page 31)

Check sensor

(see pages 29 and 82).

Check connections and wire; replace sensor if required.

Check PPM jumper. (see page 31)

Check the sensor (see page 29).

Check connections and wire; replace sensor if required.

Check connections and wire; replace

OpenTherm device if required.

b8 e5 f0

Burner blocked

Burner blocked

Burner blocked

Flue gas temperature sensor shorted out

Flue gas temperature sensor wire broken

Internal fault

Internal fault

Check sensor

(see page 80).

Check sensor

(see page 80)

Check the ionization electrode and connecting cable. Press reset (see page

69).

Replace the control unit.

* 1 Constant mode: Boiler operates based on “ tr ” temperature setting

Burner blocked: If fault cause is corrected, burner resumes operation.

Burner in fault mode: Boiler control requires manual reset before burner can resume operation.

75

76

Troubleshooting

Diagnosis

(continued)


Diagnostics table: Faults with fault display on control unit (continued)

Fault code in display window f1 f2

System characteristics * 1

Cause

Burner in fault mode Maximum flue gas temperature exceeded

Burner in fault mode Fixed high limit tripped f3 f4 f8 f9 fa fc fd

Burner in fault mode Flame signal is already present at burner start

Burner in fault mode No flame signal is present

Burner in fault mode The combination gas valve closes too late

Burner in fault mode Blower speed too low at burner start

Burner in fault mode Blower not at stand-still

Burner blocked

Burner blocked

Electrical fan control (control unit) faulty

Burner control unit fault

Corrective measures

Check the flue gas system.

Reset control.

Check the heating system water level.

Check the circulation pump. Bleed the system. Check the fixed high limit and connecting cables. Reset control.

Check the isolation electrode and connecting cable. Reset control.

Check ignition electrodes and wires.

Measure the ionization current, check the gas pressure, check the gas train, ignition, ignition module and condensate drain. Reset control. Check ignition cable resistance (4.5K to 5K ohms).

Check the gas train. Check both control paths. Reset control.

Check the blower, check the blower cables and supply; check the blower control.

Reset control.

Check the blower, blower connecting cables and blower control. Reset control.

Check fan connecting cable; if required replace cable or replace control unit. Reset control.

Check ignition electrodes and connecting cables. Check whether a strong interference (EMC) field exists near the equipment (correct if applicable). Reset control. Replace control unit if the fault persists.

* 1 Constant mode: Boiler operates based on “ tr ” temperature setting

Burner blocked: If fault cause is corrected, burner resumes operation.

Burner in fault mode: Boiler control requires manual reset before burner can resume operation.

How to reset faults

Turn rotary selector “ tr ” less than 2 seconds to “ U

Reset ”, then back to the control range.

This operation will put the boiler in relay test mode if no fault is present (turn boiler off then back on to start again).


Boiler Connection

Remove front panel

Troubleshooting

1.


2.



Check boiler temperature sensor

1.

Disconnect cables from boiler temperature sensor A .

2.

Measure resistance of the boiler temperature sensor and compare with resistance/boiler water temperature curve shown.

3.

If the value measured differs significantly, replace the sensor.

WARNING

The boiler temperature sensor is immersed in the heating water (risk of scalding).

Drain the boiler before replacing the sensor.

Boiler water temperature

77

Troubleshooting


(continued)

Check outdoor temperature sensor


1.

Disconnect cables from outdoor sensor.

2.

Measure resistance of the outdoor sensor and compare with resistance / outdoor sensor curve shown below.

3.

If the value measured differs significantly, replace the sensor.

In weather-compensated mode (optional), the boiler water temperature is regulated subject to the outside temperature.

Frost protection function

Built-in automatic frost protection allows the boiler to be shut off for an extended period of time while protecting it against freeze-up. Frost protection is continually active. The burner is switched ON when the boiler water temperature reaches 41º F (5º C) and is switched OFF again when the boiler water temperature reaches at least 59º F (15º C)

[but not more than 68º F (20º C)].

For details on the control, please refer to the

Vitodens 100-W Operating Instructions.

78

Temperature



(continued)

Determining the boiler set-point

Outside temperature

Legend

A Selector dial “ tr ” setting: 1

B Selector dial “ tr ” setting: 2


D Selector dial “ tr ” setting: 4

E Factory default

F Selector dial “ tr ” setting: 5

G Selector dial “ tr ” setting: 6

Troubleshooting

Room dependent control:

Outdoor temperature sensor not connected

With no outdoor sensor installed, the “ tr ” dial will provide a constant temperature set-point for the boiler based on the dial position selected.

Setting the dial between 1 and 6 will provide a set-point value of 81º F to 178º F (27º C to 81º C) respectively.

The dot between 4 and 5 represents the factory default set-point value of 140º F (60º C).

Weather dependent control:

Outdoor temperature sensor connected

With the outdoor sensor connected, the boiler will automatically recognize the sensor and switch the setpoint dial operation from constant temperature calculated to outdoor reset calculated.

Adjusting the “ tr ” dial will select the heating curve corresponding with the heating curve chart. The setpoint will be calculated from the design boiler water temperature associated with the heating curve selected, and reset from the actual outdoor air temperature. Setting the dial between 1 and 6 will select the corresponding curve from the chart. The dot between 4 and 5 is the factory default curve.

Note: Both the room dependent control and the outdoor reset control strategies require a closed contact at terminals RT to generate a call for heat to the boiler.

Setting the dial to “0” places the boiler in freeze protection mode regardless of the control option selected or the contact position at RT.

Factory default

79

Troubleshooting


(continued)

Check fixed high limit


If the burner control unit cannot be reset after a fault shutdown (F2), even though the boiler water temperature is below approx. 203° F (95° C), check the fixed high limit.

1.

Pull the leads from fixed high limit A .

2.

Check the continuity of the fixed high limit with a multimeter.

3.

Remove faulty fixed high limit.

4.

Coat the replacement fixed high limit with heat conducting paste and install.

5.

To reset, refer to page 76.

80

Check flue gas temperature sensor

1.

Pull the leads from flue gas temperature sensor A .

2.

Check the sensor resistance and compare it with the curve.

3.

Replace the sensor in case of severe deviation.

Temperature



(continued)

Check fuses

Troubleshooting

Control unit fuse

1.

Switch off main power supply.

2.

Flip down control unit.

3.

Remove cover A .

4.

Check fuse F4 T 2.5A (slow blow). Replacements fuses are available from Viessmann in packs of 10 (Part No. 7404 396).



Power pump module fuse

1.

Switch off main power supply.

2.

Flip down and remove control unit A .

Also refer to pages 50 and 52.

3.

Remove power pump module cover plate B .

4.

Check fuse F1 T6.3A (slow blow).

Replacements fuses are available from Viessmann in packs of 10 (Part No. 7815 580).

IMPORTANT

The ON / OFF switch located on the boiler does not disconnect power to power pump module, therefore the main service switch or breaker must be turned off.

81

82

Troubleshooting

CombiPLUS Connection

Check outlet temperature sensor


1.

Pull the leads from outlet temperature sensor A .

2.

Check the sensor resistance and compare it with the curve.

3.

Replace the sensor in case of severe deviation.

Replacing the flow limiter

Temperature

Note: Water can leak when replacing the outlet temperature sensor. Shut off the cold water supply. Drain the DHW line and the plate type heat exchanger (DHW side).

1.

Drain the boiler and combiPLUS.

2.

Remove screws from the cover and remove cover.

3.

Undo screws A .

4.

Remove the cap B .

5.

Remove faulty flow limiter C .

6.

Select new flow limiter C corresponding to boiler size (see boiler rating plate). See page 26.

7.

Insert new flow regulator C .

8.

Fit new cap B provided.


CombiPLUS Connection

(continued)

Checking or replacing the plate type heat exchanger

Troubleshooting

1. Shut off and drain the boiler on the heating water and the DHW side.

2. Disconnect diverting valve motor connection

3. Push the three-way drive A slightly upwards.

4. Turn the three-way valve B with drive A 1/8 turn counterclockwise and remove.

5. Remove two screws C from the plate-type heat exchanger and remove the plate-type heat exchanger

D with gaskets.

Note: During removal, small amounts of water may

trickle out and escape from the removed plate-

type heat exchanger.

6. Check the DHW side for scaling and if required, clean or replace the plate-type heat exchanger.

7. Check the heating water side for contamination and if required, clean or replace the plate-type heat exchanger.

8. Install in reverse order with new gaskets.

Note: Refer to the installation Instructions for

additional mounting options.

Legend

A Three-way valve drive

B Three-way valve

C Screws

D Plate-type heat exchanger

E Heating water supply

F Heating water return

G DCW

H DHW

To remove, push to unlock

83

Additional Information Vitodens 100-W, WB1B Installation & Service

Electrical Connections to the Terminal Strip for Accessories

Boiler control

Boiler reset module (0-10V controller)

OT-Devices

Follow the installation instructions of field supplied operating controls.

What is OpenTherm?

The OpenTherm (OT) protocol is a point-to-point communication system, which connects a boiler with a room controller or other devices. The room unit calculates a heating demand (water temperature request) and transmits it to the boiler. The boiler will adjust the heat input accordingly (low-high modulation).

The Viessmann Input Module is designed to accept a

0-10(DC) modulating input signal from a boiler reset module controller and send this signal to the Vitodens

100 with OpenTherm communication.

Boiler control base

GAS PUMP FAN

Diverting valve

DHW / flow sensor

Legend

A Viessmann outdoor temperature sensor (field wiring)

B OpenTherm (field wiring)

C Connection cable terminal

D Power pump module

Follow the installation instructions of the field supplied operating controls.

84

Terminal strip for accessories connections.


Technical Data

Additional Information

Call for heat priority logic table

The Vitodens 100-W, WB1B boiler has several operating control options. The following table provides the priority levels of each of the different operating controllers.

2

3

4

Priority Control operating mode Required signal * 1

1 Freeze protection Boiler temperature < 41º F (5º C)

OpenTherm

CombiPLUS

DHW / external heat demand

OT signal

DHW flow sensor / temp. sensor

Close DHW contact in power / pump module

- boiler set-point temp. = 78º C

(non-adjustable)

5

6

Outdoor temperature sensor* 2

Room thermostat

(RT terminal)

- Temperature dial “ tr ” setting

- RT contact closed or OT

connection terminals 1 & 2 shorted.

Close RT contact in power / pump module.

On

On

Pump output

On

On

On

On

Pump off delay

4 minutes (240 seconds)

20 seconds none

20 seconds



* 1 Boiler control will adjust the boiler water temperature set-point to the highest of all input signals.

* 2 Priority #6 (outdoor temperature sensor / RT contact) not functional when OT inputs are recognized by the boiler control.

85

86


Technical Data


Rated voltage:................................................120 VAC

Rated frequency: .................................................60 Hz

Rated current:...................................................6.0 A~

Max. ambient temperature

- at operation:.................32º to 104º F (0º to +40º C)

- when storing and transporting:...........-4º to +149º F

(-20º to +65º C)

Setting of adjustable electronic high limit:...176º F (80º C)

Setting of fixed high limit safety cut-out (fixed setting):....................210º F (99º C)

Main fuse:....................................................max. 15 A

Power consumption

- Burner:.................................................max. 105 W

- Control unit:..........................................max. 10 VA

Boiler Model

Natural gas and LPG


CSA output/DOE * 1 heating capacity

Net I=B=R rating * 2

Heat exchanger surface area

Min. gas supply pressure

Natural gas

LPG

Max. gas supply pressure * 3

Natural gas and LPG

A.F.U.E.

Weight


Shipping weight

Boiler water content

Model No.

“w.c.

“w.c.

Boiler max. flow rate* 4

MAWP

(max. allowable working pressure) at 210º F (99º C)

Boiler water temperature

- Adjustable high limit (AHL) range

space heating (steady state)

DHW production (set-point) psig bar

ºF (ºC)

ºF (ºC)

- Fixed high limit (FHL)

Boiler connections

Boiler heating supply and return

Pressure relief valve

Drain valve

ºF (ºC)

NPTM (male) “

NPTF (female) “

(male thread) “

“w.c.

% lbs kg lbs kg

USG

L

GPM

L/hr.

MBH kW

MBH kW

MBH ft.

2 m 2

WB1B 26

37-91

10.8-26.7

34-83

9.9-24.3

72

10.23

0.95

4

10

14

95.2

78

34.1

95

43

0.87

3.3

6.2

1400

45

3

Standard heating boiler

86 to 176 (30 to 80)

176 (80)

210 (99) c c c

WB1B 35

37-118

10.8-34.6

34-108

9.9-31.6

94

10.23

0.95

4

10

14

95.2

78

34.1

95

43

0.87

3.3

6.2

1400

45

3 c c c

* 1 Output based on 140º F (60º C), 120 º F (49º C) system supply / return temperature.

* 2 Net I=B=R rating based on piping and pick-up allowance of 1.15.

* 3 If the gas supply pressure exceeds the maximum gas supply pressure value, a separate gas pressure regulator must be installed upstream of the heating system.

* 4 See “Typical System Flow Rates” on page 36 in this manual.


Technical Data

(continued)


Boiler Model

Dimensions

Overall depth

Overall width

Overall height

Gas supply connection

Flue gas * 5

Temperature at boiler return temperature of

86º F (30º C)

- at rated full load

- at rated partial load

Temperature at boiler return temperature of 140º F (60º C)

Flue gas value

Mass flow rate (of flue gas)

- at rated full load

Model No.

inches mm inches mm inches mm

NPTF

(female)”

ºF (ºC)

ºF (ºC)

ºF (ºC)

WB1B 26

14 d

360

15 c

400

28 b

725 c ”

127 (53)

90 (32)

167 (75)

Standard heating boiler

WB1B 35

14 d

360

15 c

400

28 b

725 c ”

131 (55)

90 (32)

172 (78)

- at rated partial load lbs/h kg/h lbs/h kg/h

79.2

36.0

33.0

15.0

100.1

45.5

33.0

15.0

Available draught Pa mbar

100

1.0

100

1.0

Flue gas temperature sensor limit

Average condensate flow rate *

6 with natural gas

- T S /T R =122 / 86º F (50 / 30º C)

ºF (ºC) 230 (110) 230 (110)

Condensate connection * 7

Boiler flue gas connection *

8

Combustion air supply connection * 8

Noise level (at 1 meter)

- at full load

- at partial load

High altitude (factory set) * 9

USG/day

L/day hose nozzle

Ø in.

Ø in. (mm) outer

Ø in (mm)

(dB)

(dB) ft. (m)

1.95-2.3

2 e

8-9

1”

(60)

4 (100)

47

40

0-5,000 (0-1,500)

2.5-2.8

9.4-10.5

2 e

1”

(60)

4 (100)

49

42

0-5,000 (0-1,500)

* 5 Measured flue gas temperature with a combustion air temperature of 68° F (20° C).

* 6 Based on typical boiler cycles, including partial load conditions.

* 7 Requires 1”(25 mm) tubing. See Vitodens 100-W Installation Instructions for details.

* 8 For detailed information refer to the Vitodens Venting System Installation Instructions.

* 9 For 5,000 to 10,000 ft. (1,500 to 3,048 m) operation, a coding address change is required. Refer to the Installation and Service Instructions for details.

u For information regarding other Viessmann System Technology componentry, please reference documentation of respective product.

87

88


Technical Data

(continued)


Integrated with the Boiler

DHW supply temperature

Continuous draw rate 1 with DCW temp. of 56º F (13º C)

Continuous draw rate 2 at ∆ t= 63º F (35K)

Maximum allowable working pressure (potable water)

Test pressure

Connections, DHW and DCW

Connections to boiler supply/return and to heating supply/return

Dimensions

Overall depth

Overall width

Overall height

Height with pipe connector

Model No.

ºF (ºC)

USG/h

L/h

USG/h

L/h psi psi

NPTM (male) “

NPTM (male) “ inches mm inches mm inches mm inches mm

WB1B 26

140 (60)

99

374

156

589

150

300 b c

9.8

250

17

432

8.7

223

13

331

CombiPLUS Kit

WB1B 35

140 (60)

147

556

216

800

150

300 b c

Integrated pump flow rate

DHW production @ 23 ft. (9.8 m)

Head pressure

Heating system operation with system side additional drop in pressure of max. 6 ft. of water (1.8 m)

Weight

USG/min.

L/h

USG/min.

L/h lbs kg

5.63

1278

6.2

1408

25

11

1 Based on boiler max. output and boiler supply temperature of 176º F (80º C).

2 DCW and DHW temperature rise would be proportional. Maximum DHW supply temperature is 140º F (60º C).

5.63

1278

6.2

1408

25

11

9.8

250

17

432

8.7

223

13

331


Burner Program Sequence of Operation


1: 2:

O:

Stand-by

Call for heat

Fan control

Fan required signal

Ignition

Combination gas valve


Sequence time max. 70 s *1 max. 20 s

>1500 rpm

0.9 s

4:

Pre-ignition time

5:

0.3 s

Transition

6:

7:

Forced low fire

8:

Burner in operation:

9:

>1500 rpm min. 4.2 s max. 4.8 s

5 s 0.12 s

Modulation range

1.4 s *2

10: Combination gas closer test

O:

Stand-by

* 1 50 seconds for no flame present check and 20 seconds for blower stand-stil check (total 70 seconds).

* 2 20 second fan operation if flame failure is detected.

5

6

7

8

9

10

0

Phase

0

1

Explanation

Stand by

Stand-still status test (safety check)

2 Maximum blower RPM verification

3 Pre-purge

Pre-ignition time

Ignition / safety timing

Flame stabilization time

Forced low-fire

End of sequence

Continue to next phase

Safety shutdown



Retrial for ignition or safety shutdown




Burner in operation: controller active

Post-purge

Continue, or if FHL tripped, 15 minute forced fan operation


Combination gas valve proof of closure test Continue to next phase

Boiler shutdown / stand-by Waiting for next call for heat

89

90


Burner Program Sequence of Operation

(continued)


Phase 0: Stand by

Complete shutdown until the next call for heat.

In this phase both the combination gas valve and the blower are not energized.

Phase 7: Forced low-fire

The controller will go into low-fire until required modulation signal (high-low) is processed (eg. boiler actual water temperature).

Phase 1: Stand-still status test (blower)

A call for heat initiates internal blower sensory communications to confirm that the blower is truly in stand-still position. Blower speed measured must be < 300 rpm within a 70 second period.

Phase 8: Burner operation

At the end of the flame stabilization period

(5 sec.), a release for modulation occurs and the burner temperature controller will take over from the flame safeguard. Forced shutdown after 24 hours continuous operation.

Phase 2: Pre-purge speed test

Controller sends and receives signal to / from fan speed controller to verify maximum rpm of the blower.

Phase 9: Post-purge speed test

Both gas valves are closed during this phase.

End call for heat.

Post-purge occurs during the programmed period. If the fixed high limit trips during normal operation, the blower will purge for

15 minutes to cool the heat exchanger.

Phase 3: Pre-purge

Pre-purge cycle starts within the pre-programmed timing. Pre-purge timing is in addition to previous phase (2). The fan speed must be greater than

1500 rpm.

Phase 4: Pre-ignition

The ignition spark is initiated and controlled.

Phase 5: Ignition / safety timing

The gas valve opens during the safety timing period (4.8 secs.). If a flame is detected, this phase ends immediately in < 4.8 secs. If the flame is not established after 3 trials, the burner will lock out and will require a manual reset.

Phase 10: Combination gas valve proof of closure test

If during the normal operation of the burner a controlled (or uncontrolled) shut-down occurs, a complete mechanical and electrical gas valve proof of closure test will be performed by the flame safeguard. After a successful mechanical and electrical proof of closure test, the flame safeguard will expect that the flame is not present. If, however, the flame existed for a period of >30 seconds, the flame safeguard will go into permanent lock-out.

Phase 6: Flame stabilization

Controller required time for flame stabilization.


Wiring Diagram - Natural gas / Propane


91

92


Service Function Overview


Service /

Function

Filling

Relay Test

Red. Max.

Heat

Capacity

Eco

Comfort

Boiler with or without

Combi Plus

Addition /

Condition

-

-

Activated

Relay

Test

-

-

-

Selector

Dial r

1.

Position /

Selection

Selector

Dial Left r w

Selector

Dial Right

Selector

Dial Right

Activation Sequence

Selector

Dial r

2.

Position /

Selection

Control

Range r w

Control

Range

Control

Range

Selector

Dial

-

3.

Position /

Selection

r

-

Position 1

And Below

→ Minimum

Load

Between

1 And 6

→

Selected

Inputs

Position 6

And Above

→ Full Input

-

SERV

Static

SERV

Static

SERV

Static

SERV

Static

SERV + A

Static r w w

+ w

Selector

Dial Left

Selector

Dial Right

Mid-

Position w w w

Control

Range

Control

Range

Right

Control

Range

-

r

Display r + w

Static

A

Static

A

Static

A

Static

< <

<

Flashing

-

-

Left Control

Range

Without

Combi Plus

SERV momentary

SERV momentary

SERV

Static

SERV

Right Control

Range With

Combi Plus

Static

ECO

Static

COMFORT

Static w

Static w

Static

Gas

High

Altitude

Adjustment

-

r r

+

+ w w

Mid-

Position

Mid-

Position r r

Left

Control

Range

Right

Control

Range w w

Left Control

Range

Natural Gas

Right Control

Range

Propane Gas

Left Control

Range

0 - 5000 ft.

Right Control

Range 5000

- 10000 ft.

SERV

Static

SERV

Static

SERV

Static

SERV

Static

A

Static

A

Static r

Static r

Static

-

-

<

Flashing

< < <

Flashing

< < < < <

Flashing

1

Flashing

0

Flashing

1

Flashing

1

Flashing

2

Flashing

-.-.-

Flash

-

-

-

-

0

Flashing


Parts List

Model No.

WB1B 26

WB1B 35

WB1B 26c

WB1B 35c

Serial No .

7374861 £££££££££

7374862 £££££££££

7457960 £££££££££

7457961 £££££££££

Ordering Replacement Parts:

Please provide Model and Serial Number from rating plate

A when ordering replacement parts. Order replacement components from your Viessmann distributor.

Parts

007 Gas connection pipe

022 Front panel

050 Burner gasket, d=187 x 5.5 mm

051 Combustion chamber door refractory

052 Burner tube

053 Gasket for burner tube

054 Ignition+ionization electrode block

055 Gasket for electrode block

056 Radial fan NRG118-CVI,120/1/60

057 Gas valve/Venturi assembly, 120/1/60

058 Burner mounting flange assembly

059 Venturi extension

060 Gasket for radial fan

061 Gasket set for gas connection pipe

062 Gasket set for gas valve /

Venturi assembly

087 Flip-down cover

Other Parts (not illustrated)

090 Hinges for control housing (set of 10)

107 Touch-up spray paint “Vitowhite”

108 Touch-up paint stick “Vitowhite”

109 Conversion kit, NG > LPG

110 Conversion kit, LPG > NG

400 Installation fittings (see separate Parts List)

420 Installation / Service Instructions

421 Operating Instructions

422 Installation Instructions, Venting System

423 Warranty Sheet Condensing

424 Parts List

A CSA rating plate


93

94


Parts List

Parts

001 Heat exchanger assembly, ASME

002 Heat exchanger connection pipe (supply)

003 Heat exchanger connection pipe (return)

004 Spring clips (set)

006 Fastener set (return pipe)

009 Vent pipe adaptor

010 P-Trap

011 Gasket for flue gases

012 Air intake cover

013 Air intake cap

014 Test port cap (set of 2)

015 Wall-mount bracket

016 Combustion chamber refractory

017 Condensate pipe

018 Condensate hose

019 Gasket for air intake

020 Guide rails (set of 2)

021 Clip d=8 (set of 5)

023 Connector retaining clip (set of 2)

024 Sealing grommet, DN60

025 O-ring set for heat exchanger, 21 x 3 mm

026 Sealing grommet set

027 Air vent with shut-off base, e ”

028 Supply/return o-ring set,18 x 3 mm

029 Support bracket setfor heat exchanger

030 Heating supply connection pipe

031 Heating return connection pipe

070 Heating return connection elbow including air vent (027)


083 Boiler sensor

084 Flue gas sensor

088 Flow switch VK315M

B ASME Rating plate



Parts List

Parts

008 Pressure gage (PSI)

080 Control console

081 Control console cover

085 Fuse, 2.5A/250V (pkg of 10)

(for control console 080)

086 Power/Pump control module


089 Fuse, 6.3A/250V (pkg of 10)

(for 086 Power/pump control module)

063 Control bracket

101 Wiring harness, X20

102 Connecting cable No.35 for gas valve

103 Connecting cable No.100 for radial fan

104 Connecting cable for ignitor

105 Strain relief

106 Grounding wire for ignition electrode

107 Wire harness, X21

Installation fittings

Parts

401 Pressure relief valve

402 Nipple, c ” x 2”

403 Sediment fauset

404 Tee, c ”

405 Nipple, c ” x 3 b ”

406 Gas ball valve, c ”

407 Extension, c ” x 2 a ”


410 Accessory pack (metal stud mount kit)

411 Accessory pack (coaxial venting fasteners)

413 Outdoor temperature sensor

425 Parts list, Installation fittings

A Vitodens boiler see separate parts list and for CombiPLUS Kit see separate parts list


A

95

96


Parts List

CombiPLUS Kit

Part No. 7459 305

Model No.

WB1B 26c

WB1B 35c

Serial No .

7457960 £££££££££

7457961 £££££££££

Ordering Replacement Parts:

Please provide Model and Serial Number

*1 when ordering replacement parts.

Viessmann distributor.

Parts

010 Cover panel

020 Bottom panel

101 Nipple, c ” HEX

102 Flex pipe, c ” x 7”

102 Flex pipe, c ” x 12”

104 Connectors (set of 2)

105 Sealing grommet

106 Accessory pack, anchors

(set of 4)

107 Pressure relief valve, c ” 150 psig

108 Tee, c ” brass

109 Gaskets, assortmentof b ”, c ”

110 Adaptor,

G c ” F x NPT c ” M

111 Adaptor,

G b ” F x NPT b ” M

112 0-ring, 17x4

113 Clip, d=18

200 Harness for sensors

201 Harness for pump

202 Accessory pack, conduit clips

(set of 2)


100 Installation fittings

(items 101 to 111 and 390,

complete set)

400 Installation / Service Instructions

401 Quick Start-up Guide

402 Parts List

403 Installation Template

404 Touch-up spray paint “Vitowhite”

405 Touch-up paint stick “Vitowhite”

*1 Serial no. is located on bottom of unit.

See separate parts list for boiler.



Parts List

Parts

323 Accessory pack, plugs, clips

(340 and 344)

330 Replacement powerhead,

UPS15-78, 120/1/60

331 Plate heat exchanger, 20 plates

332 Gasket set, PWT

333 Step motor, linear

334 Flow sensor

335 Air vent

337 Bypass cartridge





348 Expansion pipe

383 Sensor #3 boiler

390 Flow regulator, 10L

(for use with WB1B-26 only)

391 Flow regulator, 14L

(for use with WB1B-35 only)



97

Measurements

Static pressure “w.c.

Service date: by:

Service date: by:

Service date: by:

Service date: by:

Service date: by:

Service date: by:

Setpoint value max.

14 “w.c.

Running pressure (supply pressure) o Natural gas o Liquid Propane gas

Carbon dioxide content CO

2 n at lower end of rated input range

(low-fire) n at upper end of rated input range

(high-fire)

“w.c.

“w.c.

vol.-% vol.-%

Oxygen content O

2 n at lower end of rated input range

(low-fire) n at upper end of rated input range

(high-fire) vol.-% vol.-%

Carbon monoxide content CO n at lower end of rated input range n at upper end of rated input range ppm ppm

4-14 “w.c.

10-14 “w.c.

Never exceed

50 ppm air-free

Never exceed

200 ppm air-free

5600 332 v1.3


Lighting and Operating Instructions


FOR YOUR SAFETY READ BEFORE OPERATING

W A R N I N G: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don’t try to repair it, call a qualified service technician.

Force or attempted repair may result in a fire or explosion.

B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any

phone in your building.

• Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the

fire department.

D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

Closed

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on this label.

2. Set thermostat or other operating control to lowest setting.

3. Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device which automatically lights the burner.

Do not try to light the burner by hand.

Manual gas shutoff

5. Close main gas shut-off valve.

6. Wait five (5) minutes to clear out any gas.

Then smell for gas, including near the floor.

If you smell gas, STOP! Follow “B” in the safety information above on this label. If you don’t smell gas, go to the next step.

7. Open main gas shut-off valve.

8. Turn on all electric power to the appliance.

9. Set thermostat or other operating control to desired setting.

10. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

Open

TO TURN OFF GAS TO APPLIANCE

1. Set thermostat or other operating control to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Close main gas shut-off valve.

99

5600 332 v1.3

Technical information subject to change without notice.

Printed on environmenally friendly

(recycled and recyclable) paper.

Viessmann Vitodens 100-W WB1B 35 Installation And Service Instructions Manual

Installation and Service

Instructions

VITODENS

100-W

Read and save these instructions for future reference.

(continued)

Related manuals

Table of contents

Viessmann Vitodens 100-W WB1B 35 Installation And Service Instructions Manual

Installation and Service

Instructions

VITODENS

100-W

Read and save these instructions for future reference.

(continued)

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Table of contents