Viessmann Vitodens 100-W Installation And Service Instructions Manual
Viessmann Vitodens 100-W is a natural gas and LPG compatible wall mounted gas condensing boiler, featuring a wide modulation range, weather-compensated control, built-in expansion tank, frost protection, and automatic air vent. It is suitable for central heating and hot water production in residential and light commercial applications.
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Installation and service instructions
for contractors
VIESMANN
Vitodens 100-W
Type WB1B, 7.9 to 35.0 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
Gas Council no.: 41-819-21; 41-819-22; 41-819-23; 41-819-24;
41-819-25
For applicability, see the last page
VITODENS 100-W
5368 662 GB 1/2012
Please keep safe.
2
Safety instructions
Safety instructions
Please follow these safety instructions closely to prevent accidents and material losses.
Safety instructions explained
Danger
This symbol warns against the risk of injury.
!
Please note
This symbol warns against the risk of material losses and environmental pollution.
Note
Details identified by the word "Note" contain additional information.
■ all current safety regulations as defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable standards,
■ Gas Safety (Installation & Use) Regulations
– the appropriate Building Regulation either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ireland),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regulations.
Target group
If you smell gas
These instructions are exclusively designed for qualified personnel.
■ Work on gas equipment must only be carried out by a qualified gas fitter.
■ Work on electrical equipment must only be carried out by a qualified electrician.
■ The system must be commissioned by the system installer or a qualified person authorised by the installer.
Regulations
Observe the following when working on this system
■ all legal instructions regarding the prevention of accidents,
■ all legal instructions regarding environmental protection,
■ the Code of Practice of relevant trade associations,
Danger
Escaping gas can lead to explosions which may result in serious injury.
■ Never smoke. Prevent naked flames and sparks. Never switch lights or electrical appliances ON or OFF.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Remove all people from the danger zone.
■ Notify your gas or electricity supplier from outside the building.
■ Shut off the electricity supply to the building from a safe place
(outside the building).
Safety instructions
Safety instructions
(cont.)
If you smell flue gas
Danger
Flue gas can lead to life-threatening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the living space.
Working on the system
■ When using gas as fuel, also close the main gas shut-off valve and safeguard against unauthorised reopening.
■ Isolate the system from the power supply and check that it is no longer 'live', e.g. by removing a separate fuse or by means of a main isolator.
■ Safeguard the system against unauthorised reconnection.
!
Please note
Electronic modules can be damaged by electro-static discharges.
Touch earthed objects, such as heating or water pipes, to discharge static loads.
Repair work
!
Please note
Repairing components which fulfil a safety function can compromise the safe operation of your heating system.
Replace faulty components only with original Viessmann spare parts.
Ancillary components, spare and wearing parts
!
Please note
Spare and wearing parts which have not been tested together with the heating system can compromise its function. Installing non-authorised components and non-approved modifications/conversion can compromise safety and may invalidate our warranty.
For replacements, use only original spare parts from Viessmann or those which are approved by
Viessmann.
3
Index
Index
Installation instructions
Preparing for installation
Installation sequence
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 18
Troubleshooting
Gas type conversion
Control unit
Functions and operating conditions in weather-compensated mode................... 47
Designs
Parts lists............................................................................................................ 51
Specification....................................................................................................... 54
Certificates
4
Preparing for installation
Product information
Vitodens 100-W, WB1B
Preset for operation with natural gas.
Conversion to LPG P requires a gas conversion kit.
In principle, the Vitodens 100-W may only be supplied to the countries listed on the type plate. For deliveries to alternative countries, an approved contractor, on his own initiative, must arrange individual approval in accordance with the law of the country in question.
5
Preparing for installation
Preparing for installation
Preparing for the boiler installation
Dimensions and connections
47
93
375
25
A B
5
151
26 a
D
C
119 b
A Heating flow 7 22 mm
B Heating return 7 22 mm
C Condensate drain: Plastic hose
7
22 mm a b
Rated heating output range kW
mm mm
7.9 - 13
285
123
D Gas connection R ½
7.9 - 16
285
123
7.9 - 19
285
123
7.9 - 26 11.0 - 35
285
123
340
171
6
Preparing for installation
(cont.)
Fitting the wall mounting bracket
25
B
Ø10
Preparing for installation
A
A Vitodens installation template B Opening for the balanced flue
7
8
Preparing for installation
Preparing for installation
(cont.)
1. Align the supplied installation template on the wall.
2. Drill 7 10 mm holes and insert the rawl plugs supplied.
3. Fit wall mounting bracket with screws supplied.
Preparing the connections
!
Please note
To prevent equipment damage, install all pipework free of load and torque stresses.
1. Prepare the water connections. Flush the heating system.
2. Prepare the gas connection.
3. Prepare the electrical connections.
Observe applicable IEEE standards.
■ A 1.5 m power cable is fitted in the delivered condition.
■ A 1.5 m connecting cable for the circulation pump is provided separately.
■ Accessory cables:
NYM-O two-core min. 0.5 mm
2
.
Installation sequence
Fitting the boiler and making connections
Removing the front panel and mounting the boiler
3.
2.
1.
2x
1. Undo screws at the bottom of the boiler; do not remove completely.
2. Remove front panel.
3. Hook the boiler into the wall mounting bracket.
Note
Align the boiler vertically or horizontally on all three axes.
9
Installation sequence
Fitting the boiler and making connections
(cont.)
Making connections on the water side
Note
Install a shut-off valve and drain & fill valve on site in the heating water return.
A Heating water flow
B Heating water return
Y-plan system
B
D
C
E
F F
A
A Cylinder
B Vitodens 100-W
10
C Circulation pump
D Feed and expansion tank
Fitting the boiler and making connections
(cont.)
Installation sequence
F Radiators E 3-way diverter valve
Gas connection
A
1. Connect gas shut-off valve to connection A.
2. Carry out a tightness test.
Note
Only use suitable and approved leak detection agents (EN 14291) and devices for the tightness test. Leak detection agents with unsuitable constituents (e.g. nitrites, sulphides) can cause material damage.
Remove residues of the leak detection agent after testing.
!
Please note
Excessive test pressure may damage the boiler and the gas valve.
Max. test pressure 150 mbar.
Where higher pressure is required for tightness tests, disconnect the boiler and the gas valves from the gas supply pipe (undo the fitting).
3. Vent the gas line.
11
Installation sequence
Fitting the boiler and making connections
(cont.)
Condensate connection
1. Pull condensate pipe A so far out of the appliance that no unnecessary bends are created inside the appliance. Ensure that the siphon is properly connected.
2. Connect condensate pipe A with a constant fall and a pipe vent to the public sewage system.
Observe the local waste water regulations.
A
■ Connecting the condensate hose internally to the domestic waste water system, either directly or via a drip water funnel (tundish) is recommended.
■ If the condensate pipe is routed outside the building, use a pipe of at least
7
30 mm and insulate it against frost.
Avoid long external pipelines.
!
Please note
A frozen condensate pipe can result in faults and boiler damage.
Always insulate condensate lines against frost.
■ Observe the local building regulations.
12
Fitting the boiler and making connections
(cont.)
Installation sequence
Filling the condensate connection siphon with water
!
Please note
At commissioning, flue gas may be emitted from the condensate drain.
Therefore fill the siphon with water before commissioning.
Pour a minimum of 0.3 l of water into the flue outlet.
Balanced flue connection
A
B
Connect the balanced flue.
During installation and positioning of the flue system, observe building regulations Part L and BS 5440.
Flue system installation instructions.
A Flue gas
B Ventilation air
13
Installation sequence
Opening the control unit casing
!
Please note
Electronic assemblies can be damaged by electrostatic discharge.
Before beginning work, touch earthed objects, such as heating or water pipes, to discharge static loads.
2.
3.
1.
4x
Electrical connections
Information on connecting accessories
For this connection, observe the separate installation instructions provided with the accessories.
14
Installation sequence
Electrical connections
(cont.)
X21
X20
X7
GAS PUMP FAN
?
L N 1 L N
E
X1
B
4 3 2 1
5
F G
C
BN BU GN/YE
M
1~
D
A
A Only for weather-compensated mode:
Outside temperature sensor (accessory).
B Connecting cable (accessory).
C Terminal box cylinder demand
(accessory; see separate installation instructions).
D Circulation pump connecting cable
(supplied).
Note
If the circulation pump is not connected to the control unit, connect an external frost stat.
E Jumper (1 - L).
F Power supply (230 V, 50 Hz).
Danger
Incorrect core allocation can result in serious injury and damage to the appliance.
Never interchange cores
"L1" and "N".
The power supply must be from a fused spur with a 2 pole isolator switch, fitted with a 3 A fuse.
Wire the power supply with a neutral conductor. Connect water pipes to the earth bonding of the building in question.
G Connections for external 230 V controls:
■ Vitotrol 100 (room temperature controller)
15
Installation sequence
Electrical connections
(cont.)
Separate installation instructions
■ On-site room temperature controller
■ Input for Y-plan or S-plan heating systems
Remove jumper E (1 - L) when connecting a 230 V control, leaving the capacitor in place.
Take power for external controls from "L" and "N". The switched live to start the boiler goes into "1".
Please note that if there are two circuits connected, e.g. heating and hot water, you cannot use a plug-in timer or programmable room thermostat receiver. Two channel switching must be external to the boiler.
The only exception is if weather compensation is also fitted.
Outside temperature sensor (accessory)
1. Fit outside temperature sensor.
Installation site:
■ North or north-westerly wall, 2 to
2.5 m above ground level; in multi storey buildings, in the upper half of the second floor
■ Not above windows, doors or ventilation outlets
■ Not immediately below balconies or gutters
■ Never render over
■ Connection:
2-core lead, length max. 35 m with a cross-section of 1.5 mm 2
2. Plug the power cable supplied with the outside temperature sensor into slot "X21".
3. Connect the outside temperature sensor to terminals 3 and 4 (see
16
Installation sequence
Electrical connections
(cont.)
Routing connecting cables and closing the control unit casing
!
Please note
Connecting cables will be damaged if they touch hot components.
When routing and securing cables/leads on site, ensure that the maximum permissible temperatures for these cables/leads are not exceeded.
3.
1.
2.
17
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
• • •
•
• • •
• • •
•
• •
• •
• •
• •
• •
• •
• • •
• • •
• • •
• • •
• •
•
1. Filling the heating system.............................................. 19
2. Venting the boiler........................................................... 20
3. Changing to operation with LPG................................... 21
4. Checking the static and supply pressure..................... 21
5. Checking the CO
2
or O
2
content.................................... 23
6. Burner removal .............................................................. 24
7. Checking the burner gasket and burner gauze
assembly......................................................................... 25
8. Checking and adjusting electrodes.............................. 26
9. Cleaning the heat exchanger......................................... 27
10. Checking the condensate drain and cleaning the
siphon.............................................................................. 27
11. Burner installation ......................................................... 28
12. Checking all connections on the heating water side and DHW side for leaks
13. Checking flue system for unrestricted flow and tightness
14. Checking firm seating of electrical connections
15. Checking all gas equipment for tightness at operating
pressure .......................................................................... 29
16. Fitting the front panel..................................................... 29
17. Instructing the system user........................................... 30
18
Commissioning, inspection, maintenance
Further details regarding the individual steps
Filling the heating system
!
Please note
Unsuitable fill water increases the level of deposits and corrosion and may lead to boiler damage.
■ Thoroughly flush the entire heating system prior to filling it with water.
■ Only fill with water of potable quality.
■ Soften fill water harder than
300 ppm.
■ An antifreeze additive suitable for heating systems can be added to the fill water.
Fill and vent the heating system.
19
Commissioning, inspection, maintenance
Further details regarding the individual steps
(cont.)
Venting the boiler
A
B
1. Close shut-off valve in heating water return.
2. Remove cover panel.
3. Connect drain hose to air vent valve
A with a drain connection.
4. Open air vent valve A and on-site fill valve in heating water return B.
Vent (flush) under mains pressure until no more air noise can be heard.
Note
If the heating system has not been completely vented, the heating water flow rate can be too low. This can lead to the burner being switched off by internal safety equipment before the specified set boiler water temperature is achieved.
5. First close air vent valve A and then the fill valve in heating water return
B.
6. ■ Sealed unvented heating system:
Adjust operating pressure to
≥ 0.8 bar with fill valve B.
■ Open vented heating system:
The static head must be at least
0.2 bar.
7. Open shut-off valve in heating water return.
20
Commissioning, inspection, maintenance
Further details regarding the individual steps
(cont.)
Changing to operation with LPG
In the delivered condition, the boiler is set up for operation with natural gas. For operation with LPG, change the gas nozzle and convert the gas type in the control unit.
Separate installation instructions.
Changing from LPG to natural gas - see
Checking the static and supply pressure
Danger
CO build-up as a result of incorrect burner adjustment can have serious health implications.
Carry out a CO test before and after work on gas appliances.
Operation with LPG
Flush the LPG tank twice during commissioning or replacement. Vent the tank and gas supply line thoroughly after flushing.
1. Close the gas shut-off valve.
A
21
Commissioning, inspection, maintenance
Further details regarding the individual steps
(cont.)
2. Undo the screw inside the test nipple
A on the gas train, but do not remove it; then connect the pressure gauge.
3. Open the gas shut-off valve.
4. Check the static pressure.
Set value: max. 57.5 mbar
5. Start the boiler.
7. Record the actual value in the report on page.
Take the action shown in the following table.
8. Shut down the boiler, close the gas shut-off valve, remove the pressure gauge and close test nipple A with the screw.
9. Open the gas shut-off valve and start the appliance.
Note
During commissioning, the boiler can enter a fault state because of airlocks in the gas line. After approx. 5 s, press Reset to reset the burner.
6. Check the supply (flow) pressure.
Set value:
■ Natural gas: 20 mbar
■ LPG: 37 mbar
Danger
Gas escaping from the test nipple leads to a risk of explosion.
Check gas tightness at test nipple A.
Note
The maximum pressure drop between the gas shut-off valve and test nipple A on the gas train is
0.5 mbar.
Note
Use a suitable measuring device with a resolution of at least 0.1 mbar to check the supply pressure.
Supply pressure (flow pressure)
For natural gas
Below 17.4 mbar
For LPG
Below 25 mbar
17.4 to 25 mbar
Above 25 mbar
25 to 47 mbar
Above 47 mbar
Action
Do not start the boiler. Notify your gas supply utility or LPG supplier.
Start the boiler.
Install a separate gas pressure governor upstream of the system and regulate the pre-charge pressure to 20 mbar for natural gas or 37 mbar for LPG. Notify your gas supply utility or LPG supplier.
22
Commissioning, inspection, maintenance
Further details regarding the individual steps
(cont.)
Checking the CO
2
or O
2
content
The Vitodens100-W is factory-set for natural gas. During commissioning or maintenance, the CO
2
and CO have to be measured at the boiler flue adaptor test point to check the flue integrity. Subject to the Wobbe index, the CO
2
content fluctuates between 7.4 % and 10.5 %.
CO of up to 500 ppm during ignition is acceptable.
We recommend measuring O
2
as the value is unmistakable regarding lambda
(air/gas). The O
2
content fluctuates between 7.5 % and 3.2 %. The CO/CO
2 ratio has to be less than 0.004.
If the actual CO
2
or O
2
and CO values deviate from the stated range, check the balanced flue systems for leaks. If flue installation is OK, change the gas valve.
Note
Operate the appliance with uncontaminated combustion air to prevent operating faults and damage.
A
1. Connect a flue gas analyser to flue gas port A on the boiler flue connection.
2. Start the boiler.
3. Check the CO
2
or O
2
content.
If the CO
2
content or O
2
content fall outside the range specified above, carry out the described measures.
4. Shut down the boiler, remove the flue gas analyser and close flue gas port
A.
23
Commissioning, inspection, maintenance
Further details regarding the individual steps
(cont.)
Burner removal
4x
E C B A D
1. Switch off the power.
2. Shut off the gas supply.
3. Disconnect power cables from fan motor A and gas valve B.
4. Open control unit casing (see
page 14) and disconnect the lead to
ignition electrode C.
5. Disconnect the venturi extension from fanA.
6. Release gas supply pipe fitting D.
7. Undo four screws E and remove the burner.
!
Please note
To prevent damage, never rest the burner on the burner gauze assembly.
24
Commissioning, inspection, maintenance
Further details regarding the individual steps
(cont.)
Checking the burner gasket and burner gauze assembly
Check burner gasket A and burner gauze assembly D for damage and replace if necessary.
E D C A
4x
B
1. Remove electrode B.
2. Undo the three cheese head screws and remove thermal insulating ring
C.
3. Undo four Torx screws and remove burner gauze assembly D with gasket E.
4. Insert new burner gauze assembly
D with new gasket E and secure.
!
Please note
Tighten screws far enough to prevent the components being damaged and to ensure they function correctly.
5. Fit thermal insulation ring C.
!
Please note
Tighten screws far enough to prevent the components being damaged and to ensure they function correctly.
25
Commissioning, inspection, maintenance
Further details regarding the individual steps
(cont.)
6. Fit electrode B.
4
+0,5
!
Please note
Tighten screws far enough to prevent the components being damaged and to ensure they function correctly.
Checking and adjusting electrodes
1. Check the electrode for wear and contamination.
2. Clean the electrode with a small brush (not with a wire brush) or sandpaper.
3. Check the electrode gaps. If the gaps are not as specified or the electrode is damaged, replace and align the electrode together with a new gasket.
!
Please note
Tighten screws far enough to prevent the components being damaged and to ensure they function correctly.
26
Commissioning, inspection, maintenance
Further details regarding the individual steps
(cont.)
Cleaning the heat exchanger
1.
!
Please note
Scratches on parts that are in contact with flue gas can lead to corrosion.
Never use brushes to clean the heat exchanger.
A
Use a vacuum cleaner to remove deposits from heat exchangers A in the combustion chamber.
2. If necessary, spray heat exchanger A with slightly acidic, chloride-free cleaning agents based on phosphoric acid and let the solution soak in for at least 20 min.
3. Flush heat exchanger A thoroughly with water.
Checking the condensate drain and cleaning the siphon
B A
1. Check that the condensate can drain freely at siphon A.
2. Place an appropriate drip pan below siphon A.
3. Undo locking cap B and drain the contents of siphon A into the drip pan.
4. Refit locking cap B with a gasket.
5. Fill siphon A with water. Also pour approx. 0.3 l of water into the combustion chamber.
27
Commissioning, inspection, maintenance
Further details regarding the individual steps
(cont.)
Burner installation
4x
A E D C B
1. Fit burner and tighten four screws
A crosswise.
!
Please note
Tighten screws far enough to prevent the components being damaged and to ensure they function correctly.
2. Insert new gasket and tighten the fittings on gas supply pipe B.
3. Connect the venturi extension to fan
C.
4. Connect electrical cables to fan motor C and gas valve D.
28
5. Plug ignition electrode cable E into the control unit and close the control unit casing.
6. Reopen gas supply and switch on power supply.
7. Check the gas connections for tightness.
Danger
Escaping gas leads to a risk of explosion.
Check all fittings for gas tightness.
Commissioning, inspection, maintenance
Further details regarding the individual steps
(cont.)
Checking all gas equipment for tightness at operating pressure
Danger
Escaping gas leads to a risk of explosion.
Check gas equipment for tightness.
Note
Only use suitable and approved leak detection agents (EN 14291) and devices for the tightness test. Leak detection agents with unsuitable constituents (e.g.
nitrites, sulphides) can cause material damage.
Remove residues of the leak detection agent after testing.
Fitting the front panel
3.
2.
4.
2x
1.
29
Commissioning, inspection, maintenance
Further details regarding the individual steps
(cont.)
Instructing the system user
The system installer must hand the operating instructions to the system user and instruct the user in operating the system.
30
Troubleshooting
Function sequence and possible faults
Control unit issues a heat demand
Yes
Fan starts No
Display
No
No fault display
After approx. 51 s fault F9
Yes
Ignition
Yes
Gas train opens
No
No
Fault F4
Fault F4
Action
Increase set value and ensure heat is drawn off
Heating water flow rate too low. Increase flow rate and ensure heat is drawn off.
Check flow sensor and connecting cable.
Check the fan, fan connecting cables, power at the fan and fan control
Check the ignition module connection
Check the gas train (control voltage 230 V); check the gas supply pressure
31
32
Troubleshooting
Function sequence and possible faults
(cont.)
Yes
Ionisation current builds (higher than
2 µA)
Symbol A
No Fault F4 Check the ionisation current, check the electrode adjustment, check the condensate drain and the gas line for airlocks
Yes
Burner in operation
No Stops below the set boiler water temperature and restarts immediately
Check the flue system for tightness
(flue gas recirculation), check the condensate drain, check the gas flow pressure
Fault messages on the display
f 2
Faults are indicated by a flashing fault code with fault symbol "U" on the display.
For fault code explanations see the following table.
■ Flashing fault symbol "U": Reset with
"U RESET" (see page 36) after cor-
recting the fault.
■ Constantly displayed fault symbol "U":
Automatic reset after the fault has been remedied.
Troubleshooting
Fault messages on the display
(cont.)
Displayed fault code
10
18
30
38
50
58
60
68
A9 b0 b8
E5
F0
System characteristics
Constant mode
Constant mode
Burner blocked
Burner blocked
No DHW heating
No DHW heating
Burner blocked
Burner blocked
Control mode without
Open Therm device
Burner blocked
Burner blocked
Burner blocked
Burner blocked
Cause
Short circuit, outside temperature sensor
Lead break, outside temperature sensor
Short circuit, boiler water temperature sensor
Lead break, boiler water temperature sensor
Terminal box cylinder demand fault
Terminal box cylinder demand fault
Short circuit, return temperature sensor
Lead break, return temperature sensor
Communication error Open Therm device
Short circuit, flue gas temperature sensor
Lead break, flue gas temperature sensor
Internal fault
Internal fault
Measures
Check the outside temperature sensor and lead
Check the outside temperature sensor and lead
Check the boiler water temperature sensor (see
Check the boiler water temperature sensor (see
Check terminal box connections and replace the terminal box if required.
Check terminal box connections and replace the terminal box if required.
Check the return temperature sensor (see
Check the return temperature sensor (see
Check connections and cable; replace Open
Therm device if required.
Check the sensor (see
Check the sensor (see
Check the ionisation electrode and connecting cables.
Press "Reset" (see
Replace control unit.
33
Troubleshooting
Fault messages on the display
(cont.)
Displayed fault code
F1
F2
F3
F4
F8
F9
FA
System characteristics
Burner in a fault state
Burner in a fault state
Burner in a fault state
Burner in a fault state
Burner in a fault state
Burner in a fault state
Burner in a fault state
Cause
Max. flue gas temperature exceeded
The temperature limiter has responded
Flame signal is already present at burner start
No flame signal detected
Fuel valve closes too late
Fan speed too low during burner start
Fan not at standstill
Measures
Check heating system fill level. Check circulation pump. Vent the system.
Press "Reset" (see
Check heating system fill level. Check circulation pump. Vent the system.
Check temperature limiter and connecting cables.
Press "Reset" (see
Check ionisation electrode and connecting cable.
Press "Reset" (see
Check the ionisation electrode and connecting cables, check the gas pressure, check the gas train, ignition, ignition module and condensate drain.
Press "Reset" (see
Check gas train. Check both control paths.
Press "Reset" (see
Check fan, fan connecting cables and power supply; check fan control.
Press "Reset" (see
Check fan, fan connecting cables and fan control.
Press "Reset" (see
34
Troubleshooting
Fault messages on the display
(cont.)
Displayed fault code
FC
Fd
System characteristics
Burner blocked
Burner blocked
Cause
Electrical fan control (control unit) faulty
Fault, burner control unit
Measures
Check fan connecting cable; if required, replace or replace control unit.
Check ignition electrodes and connecting cables.
Check whether a strong interference (EMC) field exists near the appliance.
FF Burner blocked Fault, burner control unit
Press "Reset" (see
Replace control unit if fault persists.
Check ignition electrodes and connecting cables.
Check whether a strong interference (EMC) field exists near the appliance.
Press "Reset" (see
Replace control unit if fault persists.
35
Troubleshooting
Fault messages on the display
(cont.)
Press reset
Note
Only press RESET if fault symbol "
U
" flashes.
Turn rotary selector "rt" between 1 s and 2 s to position "U RESET" and then back to the control range.
r
36
Troubleshooting
Repairs
Remove front panel and pivot control unit downwards
2.
3.
4.
1.
2x
37
Troubleshooting
Repairs
(cont.)
Outside temperature sensor
X21
X20
X7
1. Open the control unit casing. See
2. Disconnect leads from outside temperature sensor.
4 3 2 1
60
40
20
6
4
-15
-10
-5 0 10 20 30
Temperature in °C
3. Check the sensor resistance and compare it with the curve.
4. Replace the sensor in the case of severe deviation.
38
Troubleshooting
Repairs
(cont.)
Checking the boiler water temperature sensor and return temperature sensor
B
A
1. Remove the leads from the boiler water temperature sensor A or return temperature sensor B and check the resistance.
39
Troubleshooting
Repairs
(cont.)
20
6
4
2
0.6
0.4
10 30 50 70 90 110
Temperature in °C
Checking volumetric flow rate
The volumetric flow rate through the boiler is monitored by recording the differential between boiler water temperature and return temperature. Monitoring of the temperature spread with the boiler water temperature sensor and the return temperature sensor is an additional safety mechanism.
2. Check the sensor resistance and compare it with the curve.
3. In the case of severe deviation, drain the boiler on the heating water side and replace the sensor.
Danger
The boiler water temperature sensor is immersed in the heating water (risk of scalding).
Drain the boiler before replacing the sensor.
■ In the case of differentials
> 25 K/< 30 K, the burner is operated at lower heating output.
■ In the case of differentials > 30 K, the burner is switched off.
In such cases, check whether the heating system is adequately vented and the circulation pump is pumping sufficient heating water.
40
Troubleshooting
Repairs
(cont.)
Checking the flue gas temperature sensor
1. Remove the leads from the flue gas temperature sensor A and check the resistance.
A
20
6
4
2
0.6
0.4
10 30 50 70 90 110
Temperature in °C
2. Check the sensor resistance and compare it with the curve.
3. Replace the sensor in the case of severe deviation.
41
Troubleshooting
Repairs
(cont.)
Checking the temperature limiter
If the burner control unit cannot be reset after a fault shutdown, although the boiler water temperature is below approx. 95 °C, check the temperature limiter.
1. Disconnect the leads from temperature limiter A.
2. Check the continuity of the temperature limiter with a multimeter.
3. Remove the faulty temperature limiter.
4. Install a new temperature limiter.
5. Press "Reset" at the control unit (see
A
42
Repairs
(cont.)
Checking the fuse
Troubleshooting
1. Switch off the power.
2. Open control unit casing (see
3. Check fuse F4.
F4
43
Gas type conversion
Changing from LPG to natural gas
Replacing the gas restrictor
A
D
C
B
E
1. Removing the burner (see page 24).
2. Undo three screws A and remove gas train B.
3. Remove gas restrictor C (if installed) from gas train B and insert new gas restrictor C into gas train B.
4. Fit gas train B with new gasket D.
!
Please note
Tighten screws far enough to prevent the components being damaged and to ensure they function correctly.
44
Gas type conversion
Changing from LPG to natural gas
(cont.)
5. Refit burner with new gasket E and tighten the union nuts.
!
Please note
Tighten union nuts far enough to prevent the components being damaged and to ensure they function correctly.
Changing the gas type at the control unit
1. Turn ON/OFF switch ON.
2. Turn both rotary selectors "à" and
"tr" simultaneously to their centre position.
"SERV" appears on the display.
r
3. Turn rotary selector "tr" fully anticlockwise within 2 s.
The display shows "A" and the selected value flashes.
4. Turn the rotary selector "à" to convert the control unit to natural gas or
LPG.
The display shows:
■ "0" for operation with natural gas or
■ "1" for operation with LPG.
45
Gas type conversion
Changing from LPG to natural gas
(cont.)
5. Do not adjust the rotary selectors for
15 s. The set operating mode is then saved and the control unit returns to standard mode.
6. Switch ON/OFF switch OFF and ON again. The selected gas type is now enabled.
Checking the CO
2
content
46
Control unit
Functions and operating conditions in weather-compensated mode
In weather-compensated mode, the boiler water temperature is regulated subject to the outside temperature.
Note
Y-plan and S-plan systems cannot be operated in weather-compensated mode.
For further information, see separate terminal box cylinder demand (accessory) installation instructions.
Heating curve of weather-compensated control unit
90
G
80
70
F
E
D
60
50
40
C
B
A
30
Boiler water or flow temperature in °C
20
10
0
20 15 10 5 0 -5 -10 -15 -20
Outside temperature in °C
Rotary selector setting "tr"
A = 1
B = 2
C = 3
D = 4
E = delivered condition
F = 5
G = 6
Frost protection function
Frost protection function is only possible when an outside temperature sensor is connected.
At an outside temperature < 5°C, the frost protection function is enabled. The burner is switched on and the boiler water temperature is held at 20 °C.
47
Control unit
Functions and operating conditions in…
(cont.)
Note
The frost protection function is only enabled if the circulation pump is connected to the boiler control unit. Otherwise install an external frost stat.
48
Connection and wiring diagram
Designs
A Ignition/ionisation B Vitotrol 100, type UTA or on-site room temperature controller
(switched 230 V input)
49
Designs
Connection and wiring diagram
(cont.)
C
D
E
F
G
H
K
Vitotrol 100, type RT or on-site room temperature controller
(switched 230 V input)
Vitotrol 100, type UTD or on-site room temperature controller
(switched 230 V input)
Power supply 230 V/50 Hz
Open Therm connection (remote control, if installed)
Outside temperature sensor
(accessory)
Time switch (accessory)
Gas pressure switch (accessory)
L PCB inside the control unit
X ...
Electrical interface
§ Boiler water temperature sensor
% Terminal box cylinder demand aG aJ sÖ dD
(accessory)
Flue gas temperature sensor
Return temperature sensor dG fJ
Circulation pump
Flow limiter
Gas solenoid valve
Temperature limiter a-Ö Fan motor 230 V~ a-ÖA Fan control
50
Parts lists
Parts lists
When ordering spare parts:
Quote the part and serial no. (see type plate) and the item number of the required part (as per this parts list).
Standard parts are available from your local supplier.
001 Heat exchanger
002 Heating water flow connection pipe
003 Heating water return connection pipe
004 Gas supply pipe
005 Boiler flue connection with gasket
006 Siphon
007 Flue gas gasket
008 Boiler flue connection plug
009 Thermal insulation block
010 Condensate pipe
011 Condensate hose
012 Fixing clips
013 Clip 7 8 (5 pce)
014 Burner gasket
015 Thermal insulation ring
016 Burner gauze assembly
017 Burner gauze assembly gasket
018 Ignition and ionisation electrode
019 Gasket ignition and ionisation electrode (5 pce)
020 Fan
021 Gas valve
022 Burner door
024 Venturi extension
025 Control unit
026 Cover, wiring chamber
027 Thermal circuit breaker
028 Boiler water temperature sensor
029 Flow control switch
034 Fuse 2.5 A (slow) (10 pce)
039 Wall mounting bracket
040 Front panel
043 Flue gas temperature sensor
046 Air vent valve
Wearing parts
018 Ignition and ionisation electrode
Parts not shown
023 Conversion kit G 31
030 Gas solenoid valve cable harness
35
031 Fan cable harness 100
032 Cable harness X20
033 Power cable, auxiliary earth
035 Cable fixing
036 Spray paint, Vitowhite
037 Touch-up paint stick, Vitowhite
038 Special grease
041 Installation and service instructions
042 Operating instructions
044 Power cable
045 Circulation pump connecting cable
A Type plate
51
Parts lists
Parts lists
(cont.)
024 018
019
022
017
016
015
014
040 012
004
021
020
026
034
025
52
VIESMANN
Parts lists
Parts lists
(cont.)
013 029 002 007
028
013
003
008
043
A
005
039
028
046
027
009
001
010
006
011
53
Specification
Specification
Rated voltage:
Rated frequency:
Rated current:
Safety category:
IP rating:
230 V~
50 Hz
2.0 A~
I
IP X4 to
EN 60529
Permissible ambient temperature
■ during operation: 0 to +40 °C
■ during storage and transport: -20 to +65 °C
Temperature limiter setting:
Backup fuse (power supply):
100 °C (fixed) max. 16 A
Rated heating output range
T
V
/T
R
50/30 °C
T
V
/T
R
80/60 °C
Rated heat input range
Connection values
*1 relative to the max.
load with natural gas H
LPG P
Min. static head
(open vented systems)
Min. flow rate
(heating water)
Power consump-
tion (max.)
Weight without
front panel (installation)
Product ID kW kW
kW m
3
/ h kg/h bar l/h
W kg
7.9 - 13 7.9 - 16 7.9 - 19 7.9 - 26
7.2 - 11.9 7.2 - 14.6 7.2 - 17.3 7.2 - 23.7
7.4 - 12.2 7.4 - 15.0 7.4 - 17.8 7.4 - 24.3
1.3
0.9
0.2
200
45
24
1.6
1.1
0.2
200
50
24
_
1.9
1.4
0.2
200
55
24
-0085 BT 0029
2.6
1.9
0.2
200
60
24
11 - 35
10 - 31.9
10.3 -
32.7
3.5
2.6
0.2
200
65
32
*1 The connection values are only for documentation purposes (e.g. in the gas contract application) or to estimate a supplementary volumetric settings check. Due to the factory settings, the gas pressure must not be altered from these values. Reference: 15°C, 1013 mbar.
54
Certificates
Declaration of conformity
Declaration of conformity for the Vitodens 100-W
We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm as sole responsible body that the product Vitodens 100-W complies with the following standards:
DIN 4702–6
EN 483
EN 625
EN 677
EN 50 165
EN 55 014
EN 60 335
EN 61 000-3-2
EN 61 000-3-3
In accordance with the following Directives, this product is designated with
_
-0085:
90/396/EEC
92/42/EEC
2004/108/EC
2006/95/EC
This product complies with the requirements of the Efficiency Directive
(92/42/EEC) for condensing boilers.
Allendorf, 01 December 2009 Viessmann Werke GmbH&Co KG
Authorised signatory Manfred Sommer
55
Keyword index
Keyword index
B
Boiler water temperature sensor........39
Burner gasket.....................................25
Burner gauze assembly.....................25
Burner installation..............................28
Burner removal..................................24
C
Checking volumetric flow rate............40
Combustion chamber cleaning..........27
Commissioning..................................19
Condensate connection.....................12
Condensate drain...............................27
Connection diagram...........................49
Connections.......................................10
Connections on the water side...........10
Control unit, opening..........................14
D
Declaration of conformity...................55
E
Electrical connections........................14
F
Fault code..........................................32
Fault messages..................................32
Filling the system...............................19
Flue gas temperature sensor.............41
Flue pipe............................................13
Frost limit...........................................47
Frost protection..................................47
Function sequence.............................31
Fuse...................................................43
G
Gas connection..................................11
Gas supply pressure..........................22
Gas train ...........................................22
Gas type conversion
■ LPG................................................21
■ Natural gas.....................................44
H
Heat exchanger cleaning...................27
Heating curve.....................................47
I
Ignition...............................................26
Ignition electrode................................26
Ionisation electrode............................26
O
Outside temperature sensor .............38
R
Reset..................................................36
S
Safety chain ......................................42
Siphon..........................................13, 27
Spare parts........................................51
Specification ......................................54
Static pressure...................................22
Supply pressure.................................21
T
Temperature limiter............................42
Troubleshooting.................................37
V
Ventilation air pipe.............................13
Venting...............................................20
W
Wall mounting......................................7
Weather-compensated mode.............47
56
57
58
59
Applicability
These service instructions apply for appliances with the following serial numbers (see type plate):
7416302
7499606
7416303 7416304 7416307
Viessmann Werke GmbH&Co KG
D-35107 Allendorf
Telephone: +49 6452 70-0
Fax: +49 6452 70-2780 www.viessmann.com
Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Telephone: +44 1952 675000
Fax: +44 1952 675040
E-mail: [email protected]
60
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