Installation and service VIESMANN instructions · PDF fileInstallation and service VIESMANN...

Supplied By www.heating spares.co Tel. 0161 620 6677

VIESMANNInstallation and serviceinstructionsfor heating engineers

Vitodens 100Type WB1AGas fired wall mounted condensing boilerNatural gas version

See applicability on the last page

VITODENS 100

5862 670 GB 2/2005 Please keep safe


Please follow these safety instructions closely to prevent accidents andmaterial losses.

Safety instructions explained

DangerThis symbol warns against therisk of injury.

! Important informationThis symbol warns against therisk of material losses andenvironmental pollution.

NoteDetails identified by the word "Note"contain additional information.

Target group

These instructions are exclusivelydesigned for qualified personnel.& Work on gas equipment must onlybe carried out by a CORGI regis-tered gas fitter.

& Electrical work must be compliantwith Part P of the building regula-tions

& The system must be commissionedby the system installer or a qualifiedperson authorised by the installer.

If you notice the smell of gas

DangerEscaping gas can cause explo-sions which may lead to ser-ious injury.& Do not smoke. Preventnaked flames and sparks.Never operate light switchesor those of electrical equip-ment.

& Open windows and doors.& Close the gas shut-off valve.& Heating system shutdown& Remove all personnel fromthe danger zone.

& Observe the safety regula-tions of your local gas sup-plier, found on the gas meter.

& Notify your heating contrac-tor from outside the building.

If you smell flue gas

DangerFlue gas may lead to life-threa-tening poisoning.& Heating system shutdown& Ventilate the boiler room.& Close all doors leading to theliving space.

& Do not operate electricalswitches.

Safety instructions

2

Safety instructions

5862670GB


Working on the heating system

& Isolate the system from the mainselectric power supply, e.g. byremoving a separate fuse or bymeans of a mains electrical isolator,and check that it is no longer 'live'.

& Isolate the gas supply and safe-guard against unauthorised reopen-ing.

Repair work

! Important informationRepairing components whichfulfil a safety function can com-promise the safe operation ofyour heating system.Replace faulty componentsonly with original Viessmannspare parts.

Ancillary components, spare andwearing parts

! Important informationSpare and wearing parts whichhave not been tested togetherwith the heating system cancompromise its function. Instal-ling non-authorised compo-nents and non-approvedmodifications/conversion cancompromise safety and mayinfringe our warranty condi-tions.For replacements, use only ori-ginal spare parts fromViessmann or those which areapproved by Viessmann.

Safety instructions (cont.)

3

Safety instructions5862670GB


Installation instructionsPreparing for installationProduct information .................................................................................... 5General Information .................................................................................... 5Technical Specification ............................................................................... 6Installation Requirements ........................................................................... 15Preparations for boiler installation ............................................................... 29

InstallationInstalling the boiler and making all connections ........................................... 32Flue outlet .................................................................................................. 39Electrical connections................................................................................. 41Commissioning and testing ......................................................................... 47

Service instructionsInitial start-up, inspection, maintenance ................................................. 58

Service InstructionsRoutine Servicing Instructions .................................................................... 58

TroubleshootingFault finding................................................................................................ 69Repairs ...................................................................................................... 74

DesignsConnection and wiring diagrams – combi boiler .......................................... 82Connection and wiring diagram - system boiler ............................................ 84

Parts lists .................................................................................................. 86

CertificatesDeclaration of conformity ............................................................................ 92

Keyword index .......................................................................................... 93

Index

4

Index

5862670GB


Vitodens 100, Type WB1A

Set up for operation with natural gas.

General Information

Appliance description

The Vitodens 100 is a fully automatic,wall hung, fan assisted balanced fluecondensing boiler for use with NaturalGas (G20).The Vitodens 100 is fully modulatingand provides central heating outputsbetween 8.0 kW (27,300Btu/h) and24.0 kW (84,300Btu/h)/30.0 kW(93,550 Btu/h) and instantaneous hotwater at outputs between 8.0 kW(27,300 Btu/h) and 24.0 kW(84,300Btu/h)/30.0 kW (93,550 Btu/h).The appliance always gives priority todomestic hot water supply.

The appliance is designed for usewith sealed primary water systems(only) and incorporates a circulationpump, diverter valve assembly, flowswitch (combi boiler only), DHW plateheat exchanger (combi boiler only),safety valve and CH expansion ves-sel. A separate DHW expansion ves-sel is not required.Internal frost protection and an elec-tronic control unit is fitted as standardequipment and the boiler may be usedwith any suitable room thermostat and/ or time clock in addition to theoptional controls available fromViessmann.

Certification details

The Vitodens 100 is certified to com-ply with the requirements of prEN 483and EN 625 for use in GB and IE(Great Britain and Ireland) using gascategory 2H (G20 with a governedgas supply at 20 mbar (8 in.wg) inletpressure).

The appliance classification is eitherC13x or C33x depending upon whethera horizontal or vertical flue terminal isused.

Product information

5

Preparing for installation5862670GB

Installation


General Specifications and Performance Data

Rated output rangeTV/TR 50/30 °C kW 8 to 24 8 to 30TV/TR 80/60 °C kW 7.3 to 21.8 7.3 to 27.3

Rated output range kW 7.4 to 22.3 7.4 to 28.0Maximum gas rate m3/h 2.50 3.14Combi boiler:Design domestic hot water performance(specific rate)

l/min 7.5 12.8

Domestic hot water temperature range °C 38 - 57 38 - 57Maximum mains water inlet pressure bar 10 10Minimum mains water inlet pressure foroperation

bar 1 1

Total water capacity (Including expansionVessel)

l 3.5 3.5

Minimum CH system pressure (statichead) – Cold

bar 1.0 1.0

Maximum CH system pressure (statichead) – Hot

bar 3.0 3.0

Maximum CH flow temperature °C 80 80Integral expansion vessel capacity l 8 8Integral expansion vessel pre-chargepressure

bar 0.75 0.75

Lift weight- Combi boiler kg 43 43- System boiler kg 42 42Total weight inc. packaging- Combi boiler kg 48 48- System boiler kg 47 47Electrical supply 230 V, 50Hz 230 V, 50HzInternal fuse A 4 4Maximum power consumption W 150 150Flue outlet (clearance 7): mm 60 60Ventilation pipe (outside 7) mm 100 100Product ID _-0085 BQ 0017

Technical Specification

6

Preparing for installation

5862670GB


Overall Appliance Dimensions

Combi boiler

A Condensate drain: Plastic pipe722 mm

B Heating flow: 722 mmC DHW: 715 mm

D Gas connection: Rp ½E Cold water: 715 mmF Heating return: 722 mmG Safety valve drain: 715 mm

Technical Specification (cont.)

7


Installation


System boiler

A Condensate drain: Plastic pipe722 mm

B Heating flow: 722 mmC DHW cylinder flow: 722 mm

D Gas connection: Rp ½E DHW return: 722 mmF Heating return: 722 mmG Safety valve drain: 715 mm


8


5862670GB


Minimum installation clearances

The following minimum clearances (mm) must be maintained for installing andservicing the appliance.

A Front (behind removable panel) B Front (for service)

Flue System Specifications

Concentric Horizontal Flue System

Standard horizontal flue kit: The appli-ance is supplied complete with a stan-dard concentric horizontal balancedflue terminal assembly, suitable forflue lengths of up to 620 mm from thecentre of the flue outlet, whichequates to wall thicknesses of up to480 mm for rear flues and 463 mm forside flues, including minimum clear-ances.

Extension ducts can be used toincrease the straight flue length up to6 m and include one 87° elbow.


9


Installation


An extra 87° elbow can be used butthis reduces the maximum permissi-ble length by 1 m . An extra 45° elbowcan be used but this reduces the max-imum permissible length by 0.5 m .

A Combined length of flue outlet/ventilation pipe max 6m.

B Flue outlet/ventilation pipe (canbe shortened as necessary)

Concentric Vertical Flue System

The vertical flue kit (optional extra)with extensions may be used for upto10 m applications.

An extra 87° elbow can be used butthis reduces the maximum permissi-ble length by 1 m. An extra 45° elbowcan be used but this reduces the max-imum permissible length by 0.5 m.


10


5862670GB


Before commencing the installationrefer to diagram below to determinewhich optional extension kits arerequired, if any.

A Combined length of flue outlet/ventilation pipe max. 10 m.

B Flue outlet/ventilation pipe (canbe shortened as necessary)


11


Installation


Elbows and extensions

Extension

Elbow 87°

Elbow 45°


12


5862670GB


Hydraulic circuit

Combi boiler

A BoilerB heat exchangerC circulation pumpD Three-way diverter valve

E Plate heat exchangerF DHW outletG Cold water inletH Heating circuit


13


Installation


System boiler

A DHW cylinderB BoilerC heat exchanger

D circulation pumpE Three-way diverter valveF Heating circuit


14


5862670GB


Sectional Diagram

Combi boiler illustrated

Installation Requirements

Statutory Requirements

Gas safety (installation and use) regulations (current issue)

It is in your own interest and safety, toensure that the law is complied with.


15


Installation


In addition to the above regulations,this appliance must be installed inaccordance with the current IEE Wir-ing Regulations for electrical installa-tion (BS 7671), local buildingregulation, the Building Standards(Scotland) (Consolidation) Regula-tions, bye laws of the local waterundertaking and Health and SafetyDocument No. 635 ‘The Electricity atWork regulations 1989’.It should also be in accordance withthe relevant recommendations in thecurrent editions of the following BritishStandards and Codes of Practice: BS5449, BS 5546, BS 5440:1, BS5440:2, BS 6798, BS 7593, BS 6891and IGE/UP/7.From 1 April 2005, all CORGI Regis-tered Installers will be required tonotify CORGI when they haveinstalled or exchanged a gas appli-ance in a residential dwelling.

CORGI will then issue either a Build-ing Compliance Certificate (for Eng-land and Wales) or a Declaration ofSafety (for Scotland, Northern Ireland,Isle of Man or appliances out of thescope of Building Regulations) to thehomeowner, which will confirm thatthe work has been carried out by acompetent CORGI Registered Instal-ler. This document will be used toform part of the Home InformationPack (HIP) that becomes a require-ment from January 2007 in order tosell your house.

! Important informationManufacturers instructionsmust not be takenin any way as overriding statu-tory obligations.

Boiler Position

The following limitations must beobserved when siting the boiler:

& The boiler is not suitable for exter-nal installation. The positionselected for installation should bewithin the building, unless otherwiseprotected by a suitable enclosureand must allow adequate space forinstallation, servicing and operationof the appliance and for air circula-tion around it.

& This position must allow for a suita-ble flue system and terminal posi-tion. The boiler must be installed ona flat vertical wall capable of sup-porting the weight of the applianceand any ancillary equipment whenfull.

Installation Requirements (cont.)

16


5862670GB


& Due consideration should be givento the routing of the condensatedrain from the chosen position.

& If the boiler is to be fitted in a timberframed building it should be fitted inaccordance with the British Gaspublication ‘Guide for Gas Installa-tions In Timber Frame Housing’,reference DM2. If in doubt, advicemust be sought from British Gas.

& If the appliance is to be installed in aroom containing a bath or shower,any electrical switch or control utilis-ing mains electricity, it must be sosituated, that it cannot be touchedby a person using the bath orshower. Attention is drawn to therequirements of BS 7671 (the cur-rent I.E.E Wiring Regulations) andin Scotland the electrical provisionsof the Building Regulations applic-able in Scotland.

& A compartment used to enclose theappliance must be designed andconstructed specifically for this pur-pose. An existing cupboard or com-partment may be used provided it ismodified accordingly. BS 5376:2gives details of the essential fea-tures of cupboard / compartmentdesign, including airing cupboards

& Where installation will be in an unu-sual location, special proceduresmay be necessary. BS 6798 givesdetailed guidance on this aspect.


17


Installation


Flue terminal position

Horizontal flue systems

Position Minimum spacingmm

aDirectly below an window that can be opened,air vent or any other ventilation opening

300

b Below gutter drain or soil pipe 75c Below eaves 200d Below a balcony 200e From vertical drain or soil pipes 150f From internal and external corners 300g Above adjacent ground or balcony level/roof 300h From a surface facing the terminal 600i Facing terminals 1200

jFrom opening door/window in carport intodwelling

1200

k Vertically from a terminal on same wall 1500l Horizontally from a terminal on same wall 300m Adjacent to opening 300n Below carport/roof 200


18


5862670GB


Vertical flue systems

Position Minimum spacingmm

o From adjacent wall 300p From adjacent opening window 1000q From another terminal 600r Minimum height 300

Flue Terminal Location

Detailed recommendations for flueinstallation are given in BS 5440:1.The following notes are for generalguidance.

& The boiler must be installed so thatthe terminal is exposed to externalair.

& It is important that the position of theterminal allows free passage of airacross it at all times.


19


Installation


& It is essential to ensure that pro-ducts of combustion dischargingfrom the terminal cannot re-enterthe building or any other adjacentbuilding, through ventilators, win-dows, doors, other sources of nat-ural air infiltration or forcedventilation / air conditioning.

& The minimum acceptable dimen-sions from the terminal to obstruc-tions and ventilation openings arespecified in on page 16(BS 5440Part 1).

& If the terminal discharges into apathway or passageway check thatcombustion products will not causenuisance and that the terminal willnot obstruct the passageway.

& Where the lowest part of the term-inal is fitted less than 2 m aboveground, above a balcony or above aflat roof to which people haveaccess, the terminal must be pro-tected by a purpose designedguard. (Available as an optionalextra).

& Where the terminal is fitted within850 mm of a plastic or painted gut-ter, or 450 mm of painted eaves, analuminium shield, at least 750 mmlong, must be fitted to the undersideof the painted surface.

& The air inlet / flue outlet duct mustnot be closer than 25 mm to com-bustible material.

& Due to the high efficiency of the boi-ler the terminal may emit a plume ofvapour. This is normal but positionswhere this would cause a nuisanceshould be avoided.

Ventilation Requirements

Detailed recommendations for airsupply are given in BS 5440:2. Thefollowing notes are for general gui-dance.

& It is not necessary to have a pur-pose provided air vent in the roomor internal space in which the appli-ance is installed.

& If the boiler is to be installed in acupboard or compartment, no per-manent air vents are required forcooling purposes in the cupboard orcompartment, however, it is essen-tial to ensure that the minimumclearances stated in page 9 aremaintained.


20


5862670GB


Central Heating System (typical system designs)

& The Vitodens 100 is designed for connection to sealed central heating watersystems.

& A sealed system must only be filled by a competent person.Filling the heating system see page 48. Do not fill up the whole system usingthe internal filling loop (the internal filling loop is only for topping-up).

Combination boiler

NoteThe boiler incorporates an internal bypass to ensure adequate water flow. Cer-tain thermostatic radiator valve manufacturers may require that a bypass valveis fitted in addition to the integral by pass. Specifications as to the individualrequirements should be sought prior to installation.


21


Installation


A RadiatorsB BoilerC Lockshield valveD CH flow

E CH returnF Drain cock at lowest point in the

systemG Hot water taps


22


5862670GB


H Water mainK BS stop valveL Pressure reducing valve (if neces-

sary)M Control unitN Room temperature control (on

site)Connection of ViessmannVitotrol 100 see page 42

O Time switchP Frost statR Open therm-connection(alterna-

tive)Connection see page 42

S Connection box (not supplied)T Fuse 3 AU Mains ON/OFF switchV When connecting, remove bridgeW Temporary filling loopX Water mainsfÖ Power supplygH Mains connection accessories/

room temperature control/DHWcylinder control

LR Connection of room temperaturecontrol

LS Connection of DHW cylinder con-trol

& The following Viessmann controlconfigurations are available:Constant temperatureTimer with constant temperatureVitotrol 100 UTD

& The boiler requires a permanent livefeed via plug 40.

System boiler

Cylinder connected directly to boiler.

NoteThe boiler incorporates an internal bypass to ensure adequate water flow, how-ever one radiator should be permanently open (fitted with two lockshield valves)to dissipate any excess heat.


23


Installation


A RadiatorsB BoilerC DHW-CylinderD Lockshield valve

E CH flowF CH returnG Drain cock at lowest point in the

system


24


5862670GB


H Control unitK Cylinder thermostatL Room temperature control (on

site)Connection of ViessmannVitotrol 100 see page 42

M Time switchN Frost statO Open therm-connection(alterna-

tive)Connection see page 42

P Connection box (not supplied)R Fuse 3 A

S Mains ON/OFF switchT When connecting, remove bridgeU Temporary filling loopV Water mainsfÖ Power supplygH Mains connection accessories/

room temperature control/DHWcylinder control

LR Connection of room temperaturecontrol


& The following Viessmann controlconfigurations are available:Constant temperatureTimer with constant temperatureVitotrol 100 UTD

& The boiler requires a permanent livefeed via plug 40.

& The DHW cylinder must have anintegrated temperature control con-nected to the Vitodens 100

& The DHW will always take priorityover the central heating when timeddemand is selected.

Hydraulic components in the boiler

Pump

The available head shown in followingfigure is that in excess of the appli-ance hydraulic resistance, i.e thatavailable for the system.


25


Installation


Expansion vessel

The table shows the maximum systemvolume that the integral expansionvessel can sustain under differentcharge pressure conditions. If the sys-tem volume exceeds that shown, anadditional expansion vessel must befitted and connected to the heatingsystem primary return pipe as closeas possible to the appliance. If anextra vessel is required, ensure thatthe total capacity of both vessels isadequate.

Further details are available in thecurrent issues of BS 5449 and BS6798.

NoteIf the pressure gauge rises by 1.5 barwhen the appliance is at maximumtemperature with all radiators in circu-lation an extra expansion vessel isrequired.

Vessel charge and initial systempressure

bar 0.5 1.0 1.5psi 7.3 14.5 21.5

Total water content of systemusing 8 litre capacity expansionvessel supplied with appliance

litres 106 75 42

gallons 23 16.5 9

For systems having larger capa-city, multiply the total system ca-pacity in litres by the factor toobtain the total minimum expan-sion vessel capacity required

0.0833 0.11 0.16


26


5862670GB


Pressure relief valve

A pressure relief valve set at 3 bar(43.5 psi) is supplied with the appli-ance.

Domestic Hot Water System (Combi boiler only)

& Check that the mains water pres-sure is sufficient to produce therequired DHW flow rate of 7,5 l/min(24 kW)/12,8 l/min (30 kW), butdoes not exceed the maximumDHW pressure (10 bar). If neces-sary, a pressure reducing valvemust be fitted to the mains supplybefore the DHW inlet connection.

& The final 600 mm (24 in) of themains supply pipe to the boiler mustbe copper.

& A regulator is fitted to control themaximum water flow rate.

& If the appliance is installed in anarea where the temporary hardnessof the water supply is high (over 150ppm) the fitting of an in line scaleinhibitor may be an advantage. Con-sult the Local Water Authority if indoubt.

& For specific information relating tofittings (e.g.. showers, washingmachines etc) suitable for connec-tion in the DHW circuit, consult theLocal Water Authority. However, thefollowing information is given forguidance.Domestic hot/cold water supply tapsand mixing taps: All equipmentdesigned for use at mains waterpressure is suitable.Showers and bidets: Any mainspressure shower or bidet complyingwith the Local Water Authority regu-lations is suitable.

Gas Supply

& The Gas Supplier should be con-sulted at the installation planningstage in order to establish the avail-ability and supply of an adequatesupply of gas.

& A gas meter can only be connectedby the gas supplier or by their con-tractor.

& An existing meter and / or pipeworkshould be of sufficient size to carrythe maximum boiler input plus thedemand of any other installed appli-ance. (BS 6891: 1988). A minimumof 22 mm dia. pipework is requiredto within 1 metre of the appliancegas cock.


27


Installation


& The governor at the meter must givea constant outlet pressure of 21mbar +/- 1mbar. when the applianceis running.

& The gas supply line should bepurged.Warning: Before purging open alldoors and windows, also extinguishany cigarettes, pipes and any othernaked lights.

& The complete installation must betested for gas soundness.

Electricity Supply

& Wiring external to the appliancemust be in accordance with BS7671 (the current I.E.E Wiring Reg-ulations) for electrical installationand any local regulations whichapply.

& The mains cable must be at least0.75 mm2(24/0.2 mm) PVC insu-lated to BS 6500 table 16.

& Warning: This Appliance must beearthed. (Failure to provide a satis-factory earth connection would be asafety hazard and may also result inappliance malfunction).

& The method of connection to themains supply must facilitate com-plete electrical isolation of the appli-ance. Either a 3A fused three pinplug and unswitched shutteredsocket outlet, both complying withBS 1363, or a 3A fused double poleswitch having a 3 mm contactseparation in both poles and servingonly the boiler (and its external con-trols) may be used.

External Controls

To ensure optimum performance,Viessmann offer a range of externalcontrols however the appliance maybe used with any certificated roomthermostat or time clock room thermo-stat.


28


5862670GB


Unpacking the appliance

The appliance is supplied in 2 sepa-rate packages plus any optional fluepackages. Check the availability andcontents of each package beforecommencing the installation.

Boiler package

Combi boiler& Boiler (assembled)& 5 shut-off valves& Wall mounting fixture& 2 wall plugs and 2 screws& Installation template

System boiler& Boiler (assembled)& 3 shut-off valves& 2 connection elbows& Wall mounting fixture& 2 wall plugs and 2 screws& Installation template

Wall mounting bracket installation

Important: Before installing the appliance, check that the chosen position is sui-table, adequate installation clearances are available and that the requirementsfor flue terminal position are satisfied.

Preparations for boiler installation

29


Installation


A Installation template B Observe the minimum slope of 3°(5mm/m) towards the boiler

1. Position the installation templateon the wall.

2. Mark wall plug holes and balancedflue pipe opening.

Preparations for boiler installation (cont.)

30


5862670GB


3. Drill 710 mm holes and insert therawl plugs.

4. Cut flue pipe opening to 100 mm7.

5. Fit wall mounting frame withenclosed screws.

Preparing the connections

NoteFor dimensions for on-site preparations of the gas and water side connectionssee "Overall Appliance Dimensions" on page 7.

1. Prepare the water connections.Flush the heating system.

2. Prepare gas connection to BS6891.

3. Prepare the electrical connections.& Mains cable: H05V2V2-F 3 G1,0 mm2, 230 V~, 50 Hz.A 1.5m power cable is part of thestandard delivery.

& Accessory cables: H05V2V2-F 3G 1.0 mm2 for connection of roomtemperature control and DHWcylinder control (system boiler).

Preparations for boiler installation (cont.)

31


Installation


Remove front panel and mount boiler

NoteThe front panel must be removed before mounting the boiler.

1. Remove the screw at the top of theboiler.

2. Press down the springs on theunderside of the boiler and removethe front panel.

3. Hook the boiler on to the wallmounting frame.

Installing the boiler and making all connections

32

Installation

5862670GB


Gas connection

A Gas connection: ½ BSP

1. Connect the gas supply to the gasinlet connection on the gas cockA. Upon completion, tighten theunion connection.

2. Carry out a gas soundness test.

3. Purge the gas supply pipe.

Installing water fittings

Combi boiler

Installing the boiler and making all connections (cont.)

33

Installation5862670GB

Installation


A Heating flow: 722 mmB DHW: 715 mmC Gas connection: ½ BSP

D Cold water: 715 mmE Heating return: 722 mm

System boiler

For operation without a DHW cylinder, shut-off connections B and D.

A Heating flow: 722 mmB DHW cylinder flow: 722 mm

C Gas connection: ½ BSP

D DHW return: 722 mmE Heating return: 722 mm


34

Installation

5862670GB


Connect safety valve drain

A 715 mm

Connect a suitable discharge pipe tothe pressure relief valve outlet. Thepipe discharging to a safe place mustbe a minimum of 15 mm copper andrun continually downwards.The pipe from the pressure reliefvalve must not discharge above anentrance, window or any type of publicaccess area.The pipe must be routed to a positionso that any discharge of water possi-bly boiling, or steam, cannot createany danger to persons, damage toproperty or external electric compo-nents and wiring. The point of dis-charge must be clearly visible.To ease future servicing it is advisableto use a compression type fitting toextend the discharge pipe.


35


Installation


Condensate connection

Vitodens 100 has within a syphonic condensate trap.

A 722 mm plastic condensate pipe

Routing

The condensate pipe can terminate into any one of the following areas.It is always the best practice to terminate the condensate pipe via an internalwaste system.& The pipe run should take the shortest practical route with a downward slope ofat least 2.5 ° (4.5 mm/m)

& The external pipework should be insulated to prevent freezing& The pipework should terminate as close as possible to the ground or drain,whilst still allowing the condensate to safely disperse.

& The condensate pipe must be of non corrosive material, preferably plastic.Note: ferrous materials or copper must not be used.


36

Installation

5862670GB


Terminating into an internal wastesystem

A 722 mm plastic condensate pipeB External length of pipe 3 m max.C Open end direct into gully, below

ground but above water level

Terminating into an external wastesystem




37


Installation


Terminating into an external purposemade soakaway



Terminating into the rainwater system

A 722 mm plastic condensate pipeB Internal soil and vent stack

Filling the siphon with water

Fill a minimum of 0.3 l of water into theboiler connect kit flue outlet.

! Important informationAt initial start-up, flue gas maybe emitted from the condensatedrain.Fill the siphon with water beforestart-up.


38

Installation

5862670GB


External wall terminal C13x

1. Insert pipe bend into the boiler flueoutlet.

2. Insert external flue terminal into thewall outlet.

3. Secure the wall bezel internally.

4. Connect external flue terminal topipe bend.Install flue and supply pipesaccordingly,with a minimum of 3° slope (ca.50 mm/m) towards the boiler.

5. Secure the wall bezel externally.

Flue outlet

39


Installation


Vertical roof terminal C33x

1. Install the universal roof tile.

2. Install flue and supply pipesaccordingly.

3. Push roof terminal through roof andinsert into flue/supply pipe.

4. Seal roof terminal.

Flue outlet (cont.)

40

Installation

5862670GB


Opening the control unit housing

Electrical connections

41


Installation


Making connections

Notes regarding the connection of accessoriesFor details of accessories, also observe the separate installation instruc-tions provided.

Notes regarding the connection of room temperature and DHW cylindertemperature controlFor more information about the connection of on site temperature controls seepage 21.

Electrical connections (cont.)

42

Installation

5862670GB


fÖ Mains power connection 230 V ~50 Hz (green plug)Do not interchange the supplyconductors L1 and the neutralconductor N.A two pole shut off switch with acontact separation of at least3 mm must be fitted in the mainssupply to the boiler with a maxi-mum fuse value of 3 A.

gH Mains connection accessories/room temperature control/DHWcylinder control (black plug)

A Room temperature control withzero volt contact e.g. Vitotrol 100UTDIf making the connection between,"L" and "LR" remove jumpergH.

LR Connection of room temperaturecontrol& Vitotrol 100 UTA& Vitotrol 100 UTDIf making the connection between,"L" and "LR" remove jumper.



43


Installation


Connect DHW cylinder temperature control

Connect Vitotrol 100

A Vitotrol 100 UTD B Vitotrol 100 UTAC When connecting, remove link


44

Installation

5862670GB


Routing connecting cables

! Important informationConnecting cables can be damaged if they touch hot components.When routing and securing connecting cables on site, ensure that themaximum permissible cable temperatures are not exceeded.

A Low voltage connections B 230 V connections


45


Installation


1. Connect strain relief to the externalcable and clip into the mountingplate aperture.

2. Fit cover.

3. Pivot the control unit upwards.

Front panel installation

1. Hang the front panel to the wallmounting frame by the appropriatehook.

2. Press down the front panel at thebottom.

3. Insert the screw at the top of theboiler.

NoteThe outer case forms a seal withthe combustion box. It must there-fore be securely fitted with thescrew provided.


46

Installation

5862670GB


Before commissioning the appliance, the whole gas installation including themeter must be purged and tested for gas soundness in accordance with BS6891: 1988.

DangerOpen all doors and windows; extinguish naked lights and do not smokewhilst purging the gas line.

Before commencing the commissioning procedure, ensure that the gas servicecock is turned on, the electricity supply is isolated and that the DHW and CHpipework is complete.Clean and flush the system to BS 7593.Fill the system with cold water. It may be convenient to carry out this procedurebefore fitting the boiler to the piping frame. Vent the system via the radiatorvalves and system air vents in accordance with normal practice, close all airvents and check for system soundness. Drain the entire system to flush out anydebris.

Additives from the approved list below may be used. The use of nonapproved additives will invalidate the warranty on this product.& Anti-scaling: Sentinel X200& Anti-bacterial:– System Cleaner (Fernox)– Sentinel X300...

& Anti-freeze:– Glycol (30% max.)– Antifreeze (Fernox)– Sentinel X500...

& Anti-corrosion:– Inhibitor (Fernox)– Sentinel X100...

& Cleaner:– Cleanser (Fernox)– Sentinel X300...

Do not use non approved additives or any chemicals from the followinglist& Boiler noise silencer& Leak sealer& Fuel, Oil, Grease, Washing powder/liquid& pipe jointing compound (like boss white and boss green, Sentinel)& Anti-blockage

Commissioning and testing

47


Installation


NoteAdditive combinations are permitted only if approsed additive suppliers recom-mend it and always according to supplier´s dosage recommendation.

Filling the heating system

! Important informationUnsuitable fill water increases the level of deposits and corrosion andmay lead to boiler damage.& Thoroughly flush the entire heating system prior to filling with water.& Only use fill water of potable quality.& Soften fill water harder than 150 ppm temporary hardness.& Inhibitors or antifreeze additives suitable for heating systems shouldbe injected or added manually.

1. Close the gas shut-off valve.

2. Only when operating with DHWcylinder: Prevent heat demand fromthe DHW cylinder.

3. Switch on mains supply and turnrotary selectors "tr" and "tw"counter clockwise to the end stop.

NoteThe display will show the actualoperating pressure, will position thethree-way valve in the centre andthe circulation pump is switched onin cycles.

Commissioning and testing (cont.)

48

Installation

5862670GB


4. Close the shut off valves A to pre-vent water leaving the boiler (toggleat 90 to the pipe). Connect a hose-pipe to outlet D ready to vent theboiler later.

5. Turn valve B to the draining posi-tion (toggle to the front). This willallow the system pressure readingto be displayed on the boiler controlpanel.

6. Fill and vant the system throughyour external temporary filling loopensuring that most of the air hasbeen removed from all drain andvent points on the system.

7. Turn on valve B (toggle to therear) to allow water into the boilerand at the same time turn valve Ato the draining position (toggle tothe front) with the drain toggle open(a jubilee type clip will ensure nowater loss an secure the hose inplace on the drain point).

8. Fill heating system. (minimum sys-tem pressure > 1.0 bar).The actual system pressure is dis-played electronically on the boilerdisplay.

9. Shut off valve C(toggle down).


49


Installation


Venting the boiler by flushing out (after venting system)

1. Leaving the hose connections fromfilling the system continue to fil thebiler from the external filling loopand draininig the ewater to a drainfrom connection D.

2. Continue flushing the water throughthe boiler until no air pockets aredischarged out of the drain hose.

3. Slowly turn off the valve D andturn off the temporary filling loop toregulate the pressure in the boilerand system to approx 1.2 bar.

4. Turn valve A to open position(toggle to rear).

5. Turn on the appliance to circulatethe pump in both DHW and CHpositions in order to continue vent-ing. Continue venting and reversethe filling procedure if required.Note: It is essential that there isno air in the heat exchanger andthe system prior to firing theappliance. This will caus en F1fault and prevent you finishingthe installation without hinder-ance.

6. Turn off shut off valves (C and D)when the biler is vented and filledfully

7. Turn boiler isolation valves A andB to operating position (toggle tothe back), seal with the caps pro-vided.


50

Installation

5862670GB


8. Turn temperature gauge controls tothe desired operating position.Note: Be aware thath the boilermay still need to be vented as airpockets are drawn into the heatexchanger.

9. Turn rotary knobs "tr" and "tw"into control range again.

Filling the Domestic Hot Water Circuit (Combi boiler only)

1. Open the DHW inlet valve A andoutlet valve B.

2. Open all DHW taps in turn to ventany air from the DHW pipework.

Checking static and supply pressure

DangerCO formation, as a result of incorrect burner adjustment,can lead tosevere health problems.Carry out a CO test prior to, and after, work on gas equipment.


51


Installation


1. Close the gas shut-off valve.

2. Release the screw inside test nip-ple "IN" A on the gas combinationvalve , but do not remove, and con-nect the pressure gauge.

3. Open the gas shut-off valve.

4. Check the static pressure; it shouldbe a max. 20 mbar +/- 1mbar.

5. Switch on mains voltage and startup the boiler.

NoteDuring commissioning, the boilercan enter a fault state because ofairlocks in the gas pipe.To reset press "U" key. The ignitionprocedure will then be repeated.

6. Check the inlet working pressure =20 mbar.& Minimum working pressure = 12mbar

& Maximum working pressure = 20mbar

NoteUse suitable test equipment, with aresolution of at least 0.5 mbar, tomeasure the supply pressure.

7. Shut down the boiler, close the gasshut-off valve, remove the pressuregauge, and close test nipple Awith the screw.


52

Installation

5862670GB


8. Open the gas shut-off valve andstart the boiler.

DangerGas escaping from the testnipple leads to a risk ofexplosion.Check test nipple A forsoundness.

Checking the CO2 settings

Vitodens100 is factory-set for natural gas.During commissioning or maintenance, the CO2 setting can be measured at theboiler flue adaptor testpoint. Checking CO2 levels is not a requirement.Subject to the Wobbe index, the CO2 content fluctuates between 7.4% and10.5%If the actual CO2 value deviates from the stated ranges by more than 1%, checkthe balanced flue system for leaks.

1. Connect a flue gas analyser at fluegas connector A on the flue outlet.

2. Open the gas shut-off valve, com-mission the boiler and create a heatdemand.


53


Installation


3. Set the upper rated output.Turn rotary selector "tr" less than3 seconds clockwise to the endstop, then back again into the cor-rect control range.

4. Check the CO2 content. Should theactual value deviate by more than1% from the above range, checkthe seals in the balanced flue sys-tem.

5. Enter actual values into the servicereport.

6. Select the lower rated output.Turn rotary selector "tr" to theleft control range.

7. Check the CO2 content. Should theactual value deviate by more than1 % from the above range, checkthe seals in the balanced flue sys-tem.

8. Enter actual values into the servicereport.

9. Once checked, turn the rotaryselector "tr" less than 3 s to theright to the end-stop and backagain into the control range.

NoteThe process will automatically endafter 30 minutes


54

Installation

5862670GB


Setting the max. output

NoteThe gas control is fully modulating and will normally facilitate a rapid heat up atmaximum output followed by a continually controlled heat output. If the systemhas a particularly low heating load it is possible to restrict the maximum heatingoutput to prevent short cycling.You can limit the output via the modulation range.

1. Switch OFF the mains power.

2. Unhook the front of the control unitand flip down.

3. Start up the boiler and at the poten-tiometer A select the maximumboiler output . Check the adjust-ment for the corresponding gasthroughput.

4. Flip up the control unit front andsnap into position.

Domestic hot water flow rate and temperature (Combi boileronly)

A flow regulator is fitted to ensure that no adjustment of maximum flow is neces-sary.


55


Installation


Setting DHW temperature:Set rotary selector tw to the desiredDHW temperature.The display shows w the set tem-perature is shown.

Adjusting the boiler water temperature

The boiler water temperature must be set at an adequate level to satisfy therequirements of the heating system.

Selecting the boiler water tempera-ture:Set rotary selector tr to the desiredDHW temperature.The display shows r the set tem-perature is shown.

Final checks

1. If a time switch has been built intothe control unit:Set required activation periods asper the time switch operatinginstructions.

Time switch operatinginstructions

2. Fill in the relevant details for theinstallation in the benchmark log-book supplied in the instructionspack and affix the self adhesive barcode strip from the outside of theboiler packaging to this logbook.


56

Installation

5862670GB


User´s instructions

Upon completion of commissioningand testing, hand the appliance overto the user, with reference to the fol-lowing.& Give the users instructions to theresponsible person for the propertyand emphasise their responsibilitiesunder the current edition of the GasSafety (Installation and Use) Regu-lations.

& Explain and demonstrate the light-ing and shutdown procedures.

& Advise the householder on the effi-cient use of the system, includingthe use and adjustment of all sys-tem controls for both DHW and CH.

& Advise the user of the precautionsnecessary to prevent damage to thesystem and to the building in theevent of the system remaining inop-erative during frost conditions.

& Explain the function of the boilersafety controls and how to resetthem. Emphasise that if cut-out per-sists, the boiler should be turned offand the installer or service engineerconsulted.

& Stress the importance of an annualservice by a registered heatingengineer.


57


Installation


To ensure continued efficient operation of the appliance, it is recommended thatit is checked and serviced as necessary at regular intervals. The frequency ofservicing will depend upon the particular installation conditions and usage but ingeneral once a year should be adequate. It is the law that any service workmust be carried out by a competent CORGI registered person.The boiler incorporates a flue sampling point in front of the flue outlet. The fluegases can be analysed if required. The push fit cap may be removed and a sam-ple tube fitted. The push fit cap must be replaced after use. The flue gas samplewill enable the service engineer to judge whether any major action is required.Before commencing any service operation, isolate the mains electrical supplyand turn off the gas supply at the main service cock.

Removing front panel

Routine Servicing Instructions

58

Service Instructions

5862670GB




3. Lift the front panel from the wallmounting frame.

Burner removal


2. Close the gas shut-off valve andsafeguard against reopening.

3. Pull electrical cables from fanmotor A, gas train B, and ignitionunit E.

4. Remove connection hose from airpressure switch D.

Routine Servicing Instructions (cont.)

59

Service Instructions5862670GB

Service


5. Release gas connection pipe E. 6. Release four screws F andremove the burner.

! Important informationTo prevent damage,never rest the burner on thegauze assembly.

Check the burner gasket and burner gauze assembly fordamage.Check the burner gasket A for damage and replace if necessary.

Replace the burner gauze assembly if it is damaged.


60


5862670GB


1. Remove electrode B.

2. Release the three Torx screws, andremove thermal insulating ring C.

3. Release the four Torx screws, andremove burner gauze assembly Dwith its gasket E.

4. Insert and secure a new burnergauze assembly D with a newgasket E.Torque: 3.5 Nm.approx.

5. Refit the thermal insulation ring C.

6. Refit the electrode B.Torque: 2.5 Nm.approx.

Checking and adjusting the ignition and ionisation electro-des

A Ignition and ionisation electrode

1. Check the electrode for wear andcontamination.


61


Service


2. Clean the electrode with a smallbrush (not with a wire brush) oremery paper.

3. Check all clearances. If the gapsare not as specified or the elec-trode is damaged, replace andalign the electrode together withnew gaskets. Tighten the electrodefixing screws. (2.5 Nm approx.).

Cleaning the heating surfaces

If required, clean heating surfaces Awith a brush or flush with water.

! Important informationScratches on parts which are incontact with flue gases canlead to corrosion.Only use plastic brushes andNOT wire brushes.


62


5862670GB


Checking the condensate drain and cleaning the siphon

1. Check at the siphon, that the con-densate can freely drain.

2. Place an appropriate containerunder the siphon A.

3. Remove the locking cap B anddrain the siphon content.

4. Replace the locking cap B.

5. Fill the siphon A with water bypouring about 0.3l of water into thecombustion chamber.


63


Service


Burner installation

1. Install the burner and torquescrews A diagonally. (4 Nm.approx.)

2. Insert new gasket and tighten thefittings on the gas connection pipeB

3. Insert air pressure switch connec-tion pipe C onto the gas valve"OUT" connector.

4. Replace electrical cables from fanmotor D, gas valve E, and igni-tion unit E.

5. Open gas shut-off valve and switchon the mains.


64


5862670GB


6. Check the gas connections forsoundness.

DangerEscaping gas leads to a riskof explosion.Check all fittings for sound-ness.

Check primary and secondary connections for leaks

Checking diaphragm expansion vessel and system pressure

NoteCarry out this test on a cold system.

1. Empty the system until a pressureof "0" is displayed.

NoteTo view the operating pressure,turn rotary selectors "tr" and"tw" counter clockwise to the endstop.


65


Service


2. Check the inlet pressure of the dia-phragm expansion vessel at thetest nipple A.

3. If the inlet pressure of the dia-phragm expansion vessel is lowerthan the static system pressure,top up with nitrogen until the inletpressure is raised by 0.1 to 0.2 bar.

4. Top up your heating system withwater and vent until the filling pres-sure of a cool system is 0.2 barhigher than the inlet pressure of thediaphragm expansion vessel.Max. operating pressure: 3 barMin. operating pressure: 1.0 bar

Topping up heating water via the filling loop (combi boileronly)

1. Turn both rotary selectors "tr"and "tw" counter clockwise to theend stop.The display shows the operatingpressure.

2. Open shut-off valve A (secondaryside).

3. Slowly open the shut-off valve B(primary side) and top-up withwater.

4. After topping-up first close shut-offvalve B.

5. Return both rotary selectors "tr"and "tw" to their original positions.


66


5862670GB


Checking function of all safety valves

Checking tightness of electrical connections

Checking static and supply pressure

See page 51.

Front panel installation

1. Hang the front panel to the wallmounting frame by the appropriatehook.

2. Press down the front panel at thebottom.


67


Service


3. Insert the screw at the top of theboiler.

NoteThe outer case forms a seal withthe combustion box: It must there-fore be securely fitted with thescrew provided.

Start-up the boiler

1. Open gas shut-off valve and switchon mains voltage.

2. Check the operation of the appli-ance in both central heating andDHW modes.

Checking the CO2 settings

See page 53.

Checking all gas equipment for soundness at operating pres-sure

DangerEscaping gas leads to a risk ofexplosion.Check gas equipment forsoundness.

Final checks

1. Check that the flue terminal in isgood condition and clear of anyobstructions.

2. Return all appliance and externalcontrols (if fitted) to their originalsettings.


68


5862670GB


NoteIt is the law that any service work must be carried out by a competent CORGIregistered engineer.

General

Before looking for a fault condition,check that:& The mains electrical supply isturned on.

& The clock and / or room thermostat(if fitted) are calling for heat (CH‘faults’ only).

& The gas service cock is open.& The DHW (Combi only) and CH iso-lation cocks are open.

& The system is at design pressure.

Before attempting any electrical faultfinding, always conduct the prelimin-ary electrical system safety checks.On completion of any service or faultfinding operation involving making orbreaking electrical connectionsalways check for earth continuity,polarity and resistance to earth.

Function sequence and possible faults

Display screen Remedy

Control unit is-sues heat de-mand

No Increase set valueand ensure heat isdrawn off

Yes

Fan starts No after approx. 51 sChecking fancables and plugs

FaultF5/F9

Yes

Air pressure lim-iter enables start(contact closedbetween term-inals "X8.7" and"X8.8")

No after approx. 51 s Check fan cablesand fan plug-inconnections,check fan

Fault

F5/F9

Fault finding

69

Troubleshooting5862670GB

Service


Yes

Ignition No Fault Check the con-nection ignitionmodule

F4

Yes

Gas combina-tion valve opens

No Fault Check the gastrain (control vol-tage 230 V) andgas supply pres-sure

F4

Yes

Ionisation cur-rent builds(higher than2 µA) No

Fault Check the ionisa-tion current, checkthe electrode ad-justment and thegas pipe for air-locks.

Symbol A F4

Yes

Burner in opera-tion Stops below set

boiler tempera-ture and restarts

Check flue gassystem for sound-ness (flue gas re-circulation), checkgas flow pressure

Fault finding (cont.)

70

Troubleshooting

5862670GB


Fault messages in the display

Faults are indicated by a flashing faultcode with fault symbol "U" and thereset key is illuminated.For fault code explanations see thefollowing table.

Display faultcode

System char-acteristics

Cause Remedy

30 Burnerblocked

Boiler temperaturesensor shorted out

Check the boiler tem-perature sensor (seepage 76).

38 Burnerblocked

Boiler temperaturesensor lead break

Check the boiler tem-perature sensor (seepage 76).

51 No DHW heat-ing

Draw off tempera-ture sensor shortcircuit

Check sensors (seepage 78).

59 No DHW heat-ing

Draw off tempera-ture sensor shortcircuit

Check sensors (seepage 78).

b1 Control mode Communicationfault – program-ming unit (internal)

Check connections andreplace the programmingunit, if necessary.

b5 Control mode Internal fault Replace control unit.E4 Burner

blockedFault – supply vol-tage

Replace control unit.

E5 Burnerblocked

Internal fault Check the ionisationelectrode and leads.Press"Reset".

E6 Burnerblocked

Water pressuretoo low

Top up water (seepage 66).

F0 Burnerblocked

Internal fault Replace control unit.


71


Service


Display faultcode


Cause Remedy

F2 Burner in faultstate

Temperature limit-er has responded.

Check the heating sys-tem water level. Checkthe circulation pump.Vent the heating system.Check the temperaturelimiter and leads.Press"Reset".


The flame signal isalready present atburner start.

Check the ionisationelectrode and leads.Press"Reset".


No flame signal ispresent.

Check the ionisationelectrode and leads,measure the ionisationcurrent, check the gaspressure, check the gascombination valve, igni-tion, ignition module andcondensate drain.Press"Reset".

F5 Burnerblocked

Air pressureswitch faulty

Check the air pressureswitch and the intercon-necting cable.

F7 Burnerblocked

Faulty water pres-sure sensor

Check the water pres-sure sensor and the in-terconnecting cable.


Fuel valve closestoo late

Check gas combinationvalve. Check both controlpaths.Press"Reset".


Fan speed too lowat burner start

Check the fan, check thefan cables and supply,check the fan control.Press"Reset".

FA Burner in faultstate

Fan not at stand-still

Check the fan, check thefan cables, check the fancontrol.Press"Reset".


72

Troubleshooting

5862670GB


Display faultcode


Cause Remedy

Fd Burnerblocked

Burner control unitfault

Check the ignition elec-trodes and leads. Checkwhether a strong interfer-ence (EMC) field existsnear the equipment.Press"Reset".If the fault is not re-moved, replace the con-trol unit.

FE Burnerblocked

Faulty main PCB Switch OFF the controlunit, if the equipment willnot restart.


73


Service


Removing front panel



3. Lift the front panel from the wallmounting frame.

Drain boiler on the primary side

NoteFor certain repairs the boiler must bedrained on the primary side.

Repairs

74

Troubleshooting

5862670GB


1. Connect the drain hose to valve Aand connect with a drain outlet.

2. Turn toggle on the shut-off valve Bto the front.

3. Turn toggle on the shut-off valve Cto the front.

4. Turn toggle on the valve A to thefront and drain the boiler if neces-sary.Turn toggle back down again.

NoteResidual water left in the boiler.

5. Turn toggle on the shut-off valve Bto the front.

NoteFilling up on the primary side seepage 48.

Repairs (cont.)

75


Service


Boiler temperature sensor

1. Pull the leads from boiler tempera-ture sensor A and measure theresistance.

2. Check the sensor resistance andcompare actual values with thecurve.

3. In case of severe deviation, drainboiler on the primary side (seepage 74) and replace the sensor.

DangerThe boiler temperature sen-sor is immersed in the heat-ing water(risk of scalding).Drain the boiler before repla-cing the sensor.

Repairs (cont.)

76

Troubleshooting

5862670GB


Check the temperature limiter

If the burner control unit cannot be reset after a fault shutdown, although theboiler water temperature is below approx. 75 °C, check the temperature limiter.

1. Pull the leads from temperature lim-iter A.

2. Check the continuity of the tem-perature limiter with a multimeter.

3. Remove faulty temperature limiter.

4. Coat the replacement temperaturelimiter with heat conducting pasteand install.

5. To reset press "Reset" key on thecontrol unit.

Repairs (cont.)

77


Service


Check the DHW temperature sensor (only for gas combina-tion devices)

1. Pull the leads from outlet tempera-ture sensor A

2. Check the sensor resistance andcompare actual values with thecurve.

3. Replace the sensor in case ofsevere deviation.

NoteWater can leak out when replacingthe outlet sensor. Close the coldwater shut-off valve. Drain DHWpipe and plate heat exchanger(secondary side).

Repairs (cont.)

78

Troubleshooting

5862670GB


Replacing flow limiter



3. Drain the boiler from the secondaryside.

4. Pivot the control unit downwards.

5. Release the ties A and screwsB.

6. Remove the flow switch C connec-tor.

7. Replace flow limiter D.

8. Refit the flow switch C connector.

Repairs (cont.)

79


Service


Checking plate heat exchanger

C DHWD Cold water

E Heating water returnF Heating water flow



3. Shut off and drain the boiler on theprimary and the secondary side.Draining on the primary side (seepage 74).

4. Flip down control unit.

5. Remove two screws A at the plateheat exchanger and B remove.

NoteDuring removal, small amounts ofwater may trickle out and escapefrom the removed plate heatexchanger.

6. Check the secondary side for con-tamination and, if necessary, cleanor replace the plate heat exchan-ger.

7. Check the primary side for contami-nation and, if necessary, clean orreplace the plate heat exchanger.

Repairs (cont.)

80

Troubleshooting

5862670GB


8. Install in reverse order using newgaskets.

NoteEnsure that fixing holes and sealsare aligned. Install the heat plateexchanger the correct way round.

Checking the fuse


2. Flip down control unit.

3. Remove cover A.

4. Check fuse F1.

Repairs (cont.)

81


Service


A1 Main PCB A2 Programming unit

Connection and wiring diagrams – combi boiler

82

Designs

5862670GB


A3 Time switch§ Boiler temperature sensor$ DHW outlet sensorsÖ Circulation pump 230V~dÖ Step motor diverter valvedG Gas solenoid valvefÖ Mains input 230V~/50Hz

fJ Temperature limitergH Mains connection accessories/

room temperature controla-ÖA FanaCA Air pressure switchaVL Flow switchaND Water pressure sensor

Connection and wiring diagrams – combi boiler (cont.)

83

Designs5862670GB

Service


A1 Main PCB A2 Programming unit

Connection and wiring diagram - system boiler

84

Designs

5862670GB


A3 Time switch§ Boiler temperature sensorsÖ Circulation pump 230V~dÖ Step motor diverter valvedG Gas solenoid valvefÖ Mains input 230V~/50HzfJ Temperature limiter

gH Mains connection accessories/room temperature control/DHWcylinder control

a-ÖA FanaCA Air pressure switchaND Water pressure sensor

Connection and wiring diagram - system boiler (cont.)

85

Designs5862670GB

Service


Spare parts informationQuote the type and serial no. (see data plate) and the item no. of the requiredpart (as per this parts list).Obtain standard parts from your local supplier.

001 Thermocouple002 Temperature sensor003 Pressure switch004 Control cable005 Diaphragm expansion vessel

connecting cable006 Diaphragm expansion vessel007 Boiler connection plug008 Boiler adaptor009 Flue gas gaskets (set)010 Heat exchanger011 Insulating block012 Heat exchanger mounting (set)013 Condensate hose014 Siphon015 Condensate pipe016 Gas supply pipe017 Heating water flow connection

elbow018 Heating water return connection

elbow019 Heating water flow connection

pipe020 Heating water return connection

pipe021 Plate heat exchanger*1022 Gasket set – plate heat exchan-

ger*1023 Filling Loop*1024 Filling Loop connecting cable*1025 Pipe clip 718 mm*1026 Quick air vent valve cartridge027 Safety valve028 Water pressure sensor029 Flow switch*1030 Step motor cartridge

031 Circulation pump032 Bypass with overflow valve033 Grommets034 Gaskets (set)035 Spring clips (set)036 Flow limiter037 Hydraulic040 Lip seal 7 60 mm041 Ventilation seal 7 100 mm050 Burner gasket051 Insulation ring052 Burner gauze assembly053 Burner gauze assembly gasket058 Mixture damper059 Radial fan060 Venturi top061 Gas train062 Burner door063 Ignition unit080 Control unit081 Cover – wiring chamber200 Front panel201 Spring tie202 Cover flap203 Domestic water fittings (set)*1204 Heating water fittings (set)205 Corner gas tap206 Elbow with locking ring fittings 7

22 mm (set)*2

Wearing parts054 Ignition and ionisation electrode

Parts lists

86

Parts lists

5862670GB

*1Only for serial no. 7179917 and 7179917*2Only for serial no. 7179918


Parts not shown039 Installation and service instruc-

tions090 Cable harness X8091 Cable harness X9092 Cable harness 100/35/54093 Step motor connecting cable

094 Mains power switch cable har-ness

095 Gas valve connecting cable 35096 Ignition transformer/ionisation

connecting cable300 Touch-up spray paint, Vitowhite301 Touch-up paint stick, VitowhiteA Data plate

Parts lists (cont.)

87

Parts lists5862670GB

Service


Parts lists (cont.)

88

Parts lists

5862670GB


Parts lists (cont.)

89


Service


Parts lists (cont.)

90

Parts lists

5862670GB


Parts lists (cont.)

91


Service


Declaration of conformity for Vitodens 100

We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, declare as soleresponsible body, that the product

Vitodens 100

conforms to the following stan-dards:

This product is designated in accor-dance with the following directives:

DIN 4702–6 90/ 396/EECEN 297 89/ 336/EECEN 483 73/ 23/EECEN 625 92/ 42/EECEN 677EN 50,165EN 60,335 as follows:EN 61 000-3-2 _-0085EN 61 000-3-3

EC Declaration of conformity by an authorised body according to EMVG article10.2 Certificate number: E9 02 08 1730.This product complies with the requirements of the Efficiency Directive(92/42/EEC) for:Condensing boilers

Allendorf, 14.01.05 Viessmann Werke GmbH&Co KG

pp. Manfred Sommer

Declaration of conformity

92

Certificates

5862670GB


Aadditives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Appliance description . . . . . . . . . . . . . . . . . . . . 5Appliance Dimensions . . . . . . . . . . . . . . . . . . . 7

BBoiler Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Boiler temperature sensor . . . . . . . . . . . . . 76Boiler temperature sensor . . . . . . . . . . . . . 76Burner removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

CCertification details . . . . . . . . . . . . . . . . . . . . . . . 5Cleaning the heating surfaces . . . . . . . 62Condensate connection . . . . . . . . . . . . . . . . 36Connect room temperature control 42Connect safety temperature control . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Connection diagrams . . . . . . . . . . . . . . . . . . . 82

DDeclaration of conformity . . . . . . . . . . . . . . 92

EElectrical connections . . . . . . . . . . . . . . . . . . 41Electricity Supply . . . . . . . . . . . . . . . . . . . . . . . . . 28

FFault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Fill the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Flow limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Flue outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Function sequence . . . . . . . . . . . . . . . . . . . . . . . 69Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

GGas combination valve . . . . . . . . . . . . . . . . . 52Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Gas supply pressure . . . . . . . . . . . . . . . . . . . . 52General Information . . . . . . . . . . . . . . . . . . . . . . 5

HHorizontal Flue System . . . . . . . . . . . . . . . . . 9

IIgnition electrode . . . . . . . . . . . . . . . . . . . . . . . . . 61Installing fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

MMains connection . . . . . . . . . . . . . . . . . . . . . . . . . 42Mounting boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

OOutlet temperature sensor . . . . . . . . . . . . 78

PPlate heat exchanger . . . . . . . . . . . . . . . . . . . 80

RRemoving front panel . . . . . . . . . . . . . . . . . . . 32

SSafety chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Setting the output . . . . . . . . . . . . . . . . . . . . . . . . . 55Siphon cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Static pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52System pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 49

TTechnical Specification . . . . . . . . . . . . . . . . . . 6Temperature limiter . . . . . . . . . . . . . . . . . . . . . . 77Topping up heating water . . . . . . . . . . . . . . 66

UUser´s instructions . . . . . . . . . . . . . . . . . . . . . . . 57

Keyword index

93

Keyword index5862670GB


VVenting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Vertical Flue System . . . . . . . . . . . . . . . . . . . . . 10

WWall mounting bracket installation . 29

Keyword index (cont.)

94

Keyword index

5862670GB


95

5862670GB


Applicability

Gas fired condensing combi boiler Gas fired condensing boilerType WB1A Type WB1A8 to 24 kW 8 to 24 kWfrom serial no. from serial no.7179 917 5 00001 7179 918 5 000018 to 30 kWfrom serial no.7179 916 5 00001

96

Printedonenvironmentally

-friendly,

chlorine-freebleach

edpaper

5862670GB

Subject

totech

nicalm

odifications

Viessmann LimitedHortonwood 30, Telford, TF1 7YP, GBTelephone: +44 1952 675000Fax: +44 1952 675040www.viessmann.com

Installation and service VIESMANN instructions · PDF fileInstallation and service VIESMANN...

Documents

Transcript of Installation and service VIESMANN instructions · PDF fileInstallation and service VIESMANN...