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Installation and service11.4 MB

1. 25 2 8 13 5 18 5 22 25 23 Commissioning inspection maintenance Further details regarding the individual steps cont Correction factor 1 2 3 4 5 6 Balanced flue operation 21 6 10 13 16 19 60 100 mm coaxial 25 1 4 7 10 12 13 5 Observe max flue lengths A calculated performance verification is required if the max flue lengths in the table are excee ded Adjusting the circulation pump to the heating system In the delivered condition the circulation pump in heating mode is set to stage 1 If necessary to suit the heating system the circulation pump can be changed over to stage 2 700 A CH N eo 100 Q NS O 200 400 600 800 1000 1200 1400 Flow rate in l h CH Co e Residual head in mbar A Gas condensing combi boiler D Gas condensing combi boiler 30 26 kW pump stage 1 and 35 kW pump stage 2 Gas condensing combi boiler 30 E Upper operational limit and 35 kW pump stage 1 C Gas condensing combi boiler 26 kW pump stage 2 1 Turn ON OFF switch on 24 5609 913 GB 5609 913 GB Commissioning inspection maintenance Further details regarding the individual steps cont May RESET RESET o N A e u S E H A ja 2 Turn both rotary selectors J and QM simultaneously into their cen tre position SERV appears on the dis
2. 0005 0004 0003 0002 0001 5609 913 GB 5609 913 GB Hydraulic assembly 0001 0002 0003 0004 0005 0006 0007 0008 0009 Diaphragm expansion vessel Support block diaphragm expan sion vessel Gasket A 10 x 15 x 1 5 set Connection line diaphragm expansion vessel Heating water return connection elbow Moulded hose heating water return Hose clip DN 25 Clip 10 5 pce Clip 8 5 pce 0010 0011 0012 0013 0014 0015 0016 0017 0018 0019 0020 0021 Parts lists O ring gasket set 20 6 x 2 6 Temperature sensor Round sealing ring 8 x 2 5 pce Moulded hose heating water flow Clip 18 5 pce O ring 17 x 4 5 pce Pressure gauge Clip 8 5 pce Hose connector adaptor Thermal circuit breaker Heating water flow connection elbow Hydraulics 61 Parts lists Hydraulic assembly cont 0002 0001 0005 0007 0010 0007 0006 L 0007 0017 0011 a 0007 700 fas dai 0013 L 0007 0007 Eos 0007 0014 0015 L 0014 e 0015 0021 62 5609 913 GB 5609 913 GB Combi hydraulic assembly 0001 0002 0003 0004 0005 0006 0007 0008 0009 Air vent valve O ring 34 x 3 5 pce Plate heat exchanger Gasket set plate heat exchanger Safety valve Clip 8 5 pce Safety valve clip 5 pce Pump motor Bypass cartridge 0013 0014 0015 0016 0017 0018 0020 0021 0022 Parts lists E
3. C Gas connection G D Cold water G E Heating return G For fittings on the heating water side and DHW side see separate installation instructions m A Heating flow G Hot water G Gas connection 1 Connect gas shut off valve to con nection A 11 c e E RO S D Installation sequence Fitting the boiler and making connections cont 12 2 Carry out a tightness test Note For the tightness test use only suita ble and approved leak detecting agents EN 14291 and devices Leak detecting agents with unsuita ble contents e g nitrites sulphides can result in material losses Remove residues of the leak detect ing agent after testing Please note H Excessive test pressure may damage the boiler and the gas valve Max test pressure 150 mbar Where higher pressure is required for tightness tests separate the boiler and the gas valves from the gas sup ply pipe undo the fitting 3 Vent the gas line 5609 913 GB 5609 913 GB Installation sequence Fitting the boiler and making connections cont Connection safety valve and condensate drain m The condensate line is connected with the safety valve discharge pipe The condensate hose supplied meets the temperature requirements that are part of the CE certification m Connecting the condensate hose internally to the domestic waste water System either directly or via a dri
4. tion Product description The Vitodens 100 W is available as a gas condensing combi boiler with inte gral plate heat exchanger for DHW heat ing For the connection of heating circuits and the DHW line see from page 9 The Vitodens 100 W is set up for opera tion with constant boiler water tempera ture The following are integrated one sealed unvented hydraulic system with 2 con nections for heating flow and return and 2 connections for DHW heating If the Vitodens 100 W is installed in an S plan or Y plan system both of the inter nal connections must be sealed off as they are not required The following components are integra ted into the hydraulic system m Circulation pump m 3 Way diverter valve m Safety valve m Diaphragm expansion vessel m Plate heat exchanger for DHW heating 6 Connection accessories A time switch is connected with low volt age to the control unit 5609 913 GB 5609 913 GB Preparing for installation Preparing for installation Preparing for the boiler installation Dimensions and connections 400 JB 156 25 N lt e MO S D 700 860 OT Sek 34 L ae 125 A Heating flow 2 22 mm compression E Heating return 22 mm compres fitting sion fitting Hot water 7 15 mm compression P Condensate drain safety valve fitting drain
5. 68 I o o ifo EE 32 Ignition electrodes 32 lonisation electrode 32 0 Outlet temperature sensor 46 Output matching m Flue pipe engt 23 P Plate heat exchanger 49 Power SUpply etenim 17 P mp Stage 2 rette 24 R Reset iet ees 42 S Safety chaln rrr 45 Safety valve ens 13 SIDN ON secet 14 33 Specification erac costs eene 66 Static pressure eee 26 Supply Dreseure ec eeeeeeeeeeeees 25 System pressure sacas ieu 21 T Temperature limiter 45 Troubleshooting 43 V Ventilation air pipe 14 i i EUR 22 W Wall mountmg eene 8 Water COnNECtiONS iiris 11 5609 913 GB 89 16 6099 69 89 16 6099 70 89 16 6099 71 Applicability These service instructions apply for appliances with the following serial num bers see type plate 7501297 7501298 7501823 7501824 Viessmann Werke GmbH amp Co KG Viessmann Limited D 35107 Allendorf Hortonwood 30 Telford Telephone 49 6452 70 0 Shropshire TF1 7YP GB Fax 49 6452 70 2780 Telephone 44 1952 675000 www viessmann com Fax 44 1952 675040 E mail info uk viessmann com 72 Subject to technical modifications 5609 913 GB
6. OOo 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 noz zle and convert the gas type in the con trol unit 22 Separate installation instruc tions Changing from LPG to natural gas see page 51 5609 913 GB 5609 913 GB Commissioning inspection maintenance Further details regarding the individual steps cont Matching the burner output to the flue system To match the burner output to the sys tem s flue pipe length a correction factor can be set 1 Turn ON OFF switch on 2 Turn both rotary selectors J and LIII simultaneously into their cen tre position SERV appears on the display 3 Refer to the following table for the correction factor required for the con nected flue system 4 Within 2 s turn rotary selector laan to the top left range The display then shows II amp and the selected correction fac tor begins to flash In the delivered condition factor O has been set 5 Within 15 s set rotary selector LIII to the required correction fac tor 6 The set correction factor is saved when the value stops flashing and the control unit returns to standard mode Correction factor 1 2 3 4 5 6 Flue system Rated Max run length m heating output kw Open flue operation 2 60 mm 21 4 10 16 22
7. o 50 906 Sco DO Oza Em o 2 OI gt a E 0 o o x Je TE c 8 ao of o Ss Q com l o Oo c Seo ror 56 5609 913 GB Sheet metal parts assembly 0001 Front panel 0002 Profiled seal 0003 Logo 0004 Strain relief upper part 0002 0003 4 00024 0001 0003 Parts lists 0005 Air box floor 0006 Diaphragm grommets set 0007 Wall mounting bracket 0005 57 Parts lists Heat cell assembly 0001 0002 0003 0004 0005 0006 0007 0008 58 Gasket DN 60 0009 Tee Boiler flue connection 0010 Gas pipe Boiler flue connection plug 0011 Gasket 17 x 24 x 2 set Flue gas gasket 0012 Burner Flue gas temperature sensor 0013 Thermal insulation block Heat exchanger 0014 Heat exchanger mounting set Condensate hose 0015 O ring gasket set 20 6 x 2 6 Siphon 0016 Condensate hose 400 mm long aS O 0001 0005 0002 0001 5609 913 GB 5609 913 GB Burner assembly 0001 0002 0003 0004 0005 0006 0007 Burner gasket Thermal insulation ring Cylinder burner gauze assembly Burner gauze assembly gasket Burner door lonisation electrode gasket Ignition and ionisation electrode 0008 0009 0010 0012 0013 0014 Parts lists Burner door flange gasket Radial fan Gas valve Venturi extension Gasket set Conversion kit G2 350 G27 59 Parts lists Burner assembly cont m0007 0006 0006 60
8. Plastic hose 7 22 mm C Gas connection 24 22 mm D Cold water 15 mm compression fitting Preparing for installation Preparing for installation cont Fitting the wall mounting bracket A Vitodens installation template 5609 913 GB 5609 913 GB Preparing for installation Preparing for installation cont 1 Align the supplied installation tem plate on the wall 2 Mark out the rawl plug holes 3 Drill 10 mm holes and insert the supplied rawl plugs 4 Fitwall mounting bracket with screws supplied Fit installation aid or mounting frame Installation aid or mounting frame installation instructions Preparing the connections Please note R 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 m Power cable NYM J 3 x 1 5 mm m Accessory cables NYM O 2 core min 0 5 mm c e MO S D Installation sequence Fitting the boiler and making connections Removing the front panel and mounting the boiler 1 Undo screws at the bottom of the 3 Hookthe boiler into the wall mounting boiler do not remove completely bracket 2 Remove front panel 5609 913 GB 5609 913 GB Installation sequence Fitting the boiler and making connections cont Making connections on the water side
9. and burner gauze assembly Check burner gasket A for damage and Replace the burner gauze assembly if it replace if required is damaged 1 Remove electrode 8 4 Insert a new gasket B into the new burner gauze assembly D and 2 Undo two Torx screws and remove Secure thermal insulating ring C Please note 3 Undo two Torx screws and remove H Tighten screws far enough burner gauze assembly D with its to prevent damage to compo gasket E nents and to ensure the func tion is guaranteed 31 Commissioning inspection maintenance Further details regarding the individual steps cont 5 Fit thermal insulation ring C 6 Fit electrode B Please note Please note H Tighten screws far enough H Tighten screws far enough to prevent damage to compo to prevent damage to compo nents and to ensure the func nents and to ensure the func tion is guaranteed tion is guaranteed Checking and adjusting electrodes 2 Clean the electrode with a small brush not with a wire brush or sand 1 paper 3 Checkthe electrode gaps If the gaps TR are not as specified or the electrode 2 is damaged replace and align the electrode together with a new gasket e Tighten electrode fixing screws 405 o t Please note H Tighten screws far enough to prevent damage to compo nents and to ensure the func L tion is guaranteed 1 Check the ele
10. the entire heating system prior to filling it m Only fill with water of potable quality 20 m Soften fill water harder than 300 ppm m An antifreeze additive suitable for heating systems can be added to the fill water Close the gas shut off valve Switch ON the power supply Turn rotary selector TTT In fully anti clockwise for less than 2 s and then clockwise back to the control range The display shows SERV IT and The filling function has been activated This function will end automatically after 20 min or after the ON OFF switch has been turned off Open shut off valves A and B 5609 913 GB 5609 913 GB Commissioning inspection maintenance Further details regarding the individual steps cont 5 Fill heating system System pres sure 0 8 to 1 2 bar The system can be filled using a sep arate filling point fitted ata convenient position on the heating circuit The connection must be removed when filling is completed Where local Water Authority regulation does not allow temporary connection a sealed System filler pump with break tank must be used The heating system will not be filled automatically from the domestic hot water side Alterna tive methods of filling sealed systems are given in BS 5449 21 Commissioning inspection maintenance Further details regarding the individual steps cont Venting the boiler by flushing O
11. Installation and service VI ESMAN Ri instructions for contractors Vitodens 100 W Type BPJA 6 5 to 25 0 kW Wall mounted gas condensing boiler Natural gas and LPG version Gas Council no 41 819 30 25 KW 41 819 31 29 kW For applicability see the last page VITODENS 100 W 5609 913 GB 1 2012 Please keep safe Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate rial 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 envi ronmental pollution Note Details identified by the word Note con tain additional information Target group These instructions are exclusively designed for qualified personnel m Work on gas equipment must only be carried out by a qualified gas fitter m Work on electrical equipment must only be carried out by a qualified elec trician m The system must be commissioned by the system installer or a qualified per son authorised by the installer Regulations Observe the following when working on this system m all legal instructions regarding the pre vention of accidents m all legal instructions regarding envi ronmental protection m the Code of Practice of relevant trade associations m all current safety regulations as defined by DIN EN DVGW TRGI TRF VDE and all locally appli
12. cable standards m Gas Safety Installation amp Use Regu lations the appropriate Building Regulation either the Building regulations the Building Regulation Scotland Building Regulations Northern Ire land the Water Fittings Regulation or Water Bylaws in Scotland the current LE E Wiring Regula tions If you smell gas N Danger Escaping gas can lead to explo sions which may result in serious injury m Never smoke Prevent naked flames and sparks Never Switch lights or electrical appli ances ON or OFF m Close the gas shut off valve m Open windows and doors m Remove all people from the danger zone m Notify your gas or electricity supplier from outside the build ing m Shut offthe electricity supply to the building from a safe place outside the building 5609 913 GB 5609 913 GB Safety instructions cont If you smell flue gas Safety instructions Ancillary components spare and wearing parts Danger Flue gas can lead to life threat ening poisoning H m Shut down the heating system m Ventilate the boiler room m Close all doors leading to the living space Working on the system m When using gas as fuel also close the main gas shut off valve and safeguard against unauthorised reopening m Isolate the system from the power sup ply and check that it is no longer live e g by removing a separate fuse or by means of a main isolator m Safeguard the sy
13. ctrode for wear and contamination 32 5609 913 GB 5609 913 GB Commissioning inspection maintenance Further details regarding the individual steps cont Cleaning the heat exchanger 1 Please note a Scratches on parts that are in contact with flue gas can lead to corrosion Never use brushes to clean the heat exchanger Use a vacuum cleaner to remove res idues from heat exchanger A inside the combustion chamber 2 If required spray slightly acidic chloride free cleaning agents based on phosphoric acid onto heat exchanger A and let the solution soak in for at least 20 min 3 Thoroughly flush heat exchanger A with water Checking the condensate drain and cleaning the siphon 1 Pull siphon A upwards out of the drain connection 2 Detach supply hose B from siphon 3 Clean siphon A 4 Reconnect supply hose 8 5 Refit siphon A to the drain connec tion 6 Fill siphon A with water by pouring about 0 3 of water into the combus tion chamber 33 Commissioning inspection maintenance Further details regarding the individual steps cont freely and that the connections are 7T Check that condensate can drain tight Burner installation 4x 89 16 6095 34 5609 913 GB Commissioning inspection maintenance Further details regarding the individual steps cont 1 Fit
14. e with the following Directives this product is designated with C 0085 92 42 EEC 2006 95 EC 2004 108 EC 2009 142 EC This product complies with the requirements of the Efficiency Directive 92 42 EEC for condensing boilers Allendorf 01 January 2012 Viessmann Werke GmbH amp Co KG A Mus pp Manfred Sommer 67 Keyword index Keyword index B Boiler water temperature sensor 44 Burner gasket eiecit ress 31 Burner gauze assembly 31 Burner installation 34 Burner removal ria isnisiiniiisare 30 C Combustion chamber cleaning 33 Commissloninmg 20 Condensate eee 13 Condensate drain 13 33 Connection diagram 53 COMMECHIONS PARERE DD veces 11 Control unit opening 15 D Declaration of Conformity 67 E Electrical connections 16 F Fault code eene 39 Fault messages 39 Filling function iic 20 Filling the system 20 21 Flow limiter eee 48 Flue gas temperature sensor 47 Fl e pipe ines 14 Function seguenmce venn 38 grls 50 G Gas connection icu nciceeiezcets 11 Gas supply pressure 26 EE p 26 Gas type conversion 51 E PG RBS 22 m Natural oa 51 H Heat exchanger cleaning 33
15. ge 46 Sor 52 Burner blocked Short circuit flow Check connections and sensor lead replace sensor if required 59 No DHW heating Lead break outlet Check the sensor see temperature sen page 46 sor 5A Burner blocked Lead break flow Check connections and sensor lead replace sensor if required 39 Troubleshooting Fault messages on the display cont Displayed Cause Measures fault code tics b Burner blocked Short circuit flue Check the sensor see gas temperature page 47 sensor b8 Burner blocked Lead break flue Check the sensor see gas temperature page 47 sensor ES Burner in a fault Fault in safety Check the temperature state chain limiter and connecting leads see page 45 Check the control unit and replace if required E5 Burner blocked Internal fault Check the ionisation elec trode and connecting cables Press Reset see page 42 FO Internal fault Replace control unit F1 Burner in a fault Max flue gas tem Check heating system fill state perature exceeded level Check circulation pump Vent the system Press Reset see page 42 F2 Burner in a fault The temperature Check heating system fill state limiter has respon level Check circulation ded pump Vent the system Check the temperature limiter and connecting leads see page 45 Press Reset see page 42 F3 Burner in a fault Flame signal is Check ionisation elec 40 state already present at b
16. ge static loads 15 c e MO S D Installation sequence Electrical connections o TED e een Oaa pa GAS PUMP FAN E E ol LNILN g 16 Only for weather compensated Information on connecting mode accessories Outside temperature sensor acces For this connection observe the sory separate installation instructions OpenTherm device provided with the accessories Connecting cable accessory Jumper Power supply 230 V 50 Hz See page 17 Vitotrol 100 or on site room temper ature controller 230 V switched input Remove jumper D when making this connection Separate installation instruc tions 5609 913 GB 5609 913 GB Electrical connections cont Cable entry A Power cable remote control con necting cable LV leads sensor leads Power supply Regulations and Directives N Danger Incorrect electrical installations can result in injuries from electri cal current and in appliance dam age Connect the power supply and implement all safety measures e g RCD circuit in accordance with the following regulations m IEC 60364 4 41 m VDE regulations IEE or local reg
17. ing output Test the CO content for lower heat ing output The CO content must be between 0 3 and 0 9 below the value for the upper heating output 5609 913 GB 5609 913 GB Commissioning inspection maintenance Further details regarding the individual steps cont 8 10 11 m f the CO content is within the given range continue with point 10 m If the CO content is outside the given range check the flue gas ventilation air system for tight ness remove any leaks Replace gas train if required Test the CO content for upper and lower heating output again Shut the boiler down remove flue gas analyser and close flue gas port Turn both rotary selectors and IIS simultaneously into their orig inal positions 29 Commissioning inspection maintenance Further details regarding the individual steps cont Burner removal E 4x 9 a 1 Switch off the power 5 Undo gas supply pipe fitting E 2 Shut off the gas supply 6 Undo four screws F and remove the burner 3 Pull power cables from fan motor A gas valve B and electrodes Please note Prevent damage Never rest the burner on the 4 Pullthe venturi extension D from the burner gauze assembly fan 30 5609 913 GB 5609 913 GB Commissioning inspection maintenance Further details regarding the individual steps cont Checking the burner gasket
18. ion with LPG The set operating mode is saved when the value stops flashing and the control unit returns to standard mode 5609 913 GB 5609 913 GB Designs Connection and wiring diagram E 123456 A Stepper motor diverter valve Vitotrol 100 type UTA or on site Ignition ionisation room temperature controller switched 230 V input 53 Designs Connection and wiring diagram cont D Vitotrol 100 type RT or on site 3 Boiler water temperature sensor room temperature controller 4 Outlet temperature sensor switched 230 V input 5 No function B Vitotrol 100 type UTDB oron site 15 Flue gas temperature sensor room temperature controller 20 Circulation pump 230 V switched 230 V input 35 Gas solenoid valve B Power input 230 V 50 Hz 47 Temperature limiter 6 Gas pressure switch Open 100 Fan motor 230 V Therm appliance 100 A Fan control H PCB inside the control unit Aal Flow sensor Xs Electrical interface 54 5609 913 GB 5609 913 GB Ordering parts The following information is required m Serial no see type plate A m Assembly from this parts list m Position number of the individual part within the assembly from this parts list Parts lists Standard parts are available from your local supplier 55 Parts lists Overview of the assemblies 89 16 6095 gt gt 20x ERS po E
19. ng cables power at the fan and fan control Yes Ignition No Fault F4 Check the ignition m module connec tion Yes Gas train opens No Fault F4 Check the gas m train control volt age 230 V and gas supply pres sure Yes lonisation current No Fault F4 Check the ionisa builds higher than dA tion current check 2 uA the electrode Symbol E adjustment check the condensate drain and the gas line for airlocks 38 5609 913 GB 5609 913 GB Troubleshooting Function sequence and possible faults cont Yes Burner in opera tion No Stops below the set boiler water tem perature and restarts immedi ately Check the flue sys tem for tightness flue gas recircula tion check the gas flow pressure Fault messages on the display Faults are indicated by a flashing fault n code with fault symbol 4 on the dis ar play For fault code explanations see the fol lowing table Displayed System characteris Cause Measures fault code tics 30 Burner blocked Short circuit boiler Check the boiler water water temperature temperature sensor see sensor page 44 38 Burner blocked Lead break boiler Check the boiler water water temperature temperature sensor see sensor page 44 51 No DHW heating Short circuit outlet Check the sensor see temperature sen pa
20. ng steps Inspection steps I Maintenance steps Page ER Geh We 1 Filling the heating system 20 on Nem ue 2 Venting the boiler by fushing 22 opo 3 Changing to operation with LPG 22 4 Matching the burner output to the flue system 23 5 Adjusting the circulation pump to the heating system 24 E Ne ue 6 Checking the static and supply pressure 25 e 7 Checking the CO content 27 em We 8 Burner removal ereere 30 ee 9 Checking the burner gasket and burner gauze TOL LEE EN ER We 10 Checking and adjusting electrodes ee 32 E We 11 Cleaning the heat exvchanger neeese 33 oo 12 Checking the condensate drain and cleaning the SIPHON RT 33 ee 13 Burner installation sse 34 ex We 14 Checking the diaphragm expansion vessel and system Dressure oo eee e eee ee eter eect eeeeeeeeeeeeeeeeeees 35 Checking all connections on the heating water side and DHW side for leaks Checking firm seating of electrical connections Checking gas equipment for tightness at operating Pressure cee senate eei busca wees 36 Fitting the front panel nnne neer ners neerrrre ne 36 Instructing the system user 37 19 Commissioning inspection maintenance Further details regarding the individual steps Filling the heating system Please note Unsuitable fill water increases the level of deposits and corro sion and may lead to boiler dam age m Thoroughly flush
21. orrectly Install the plate heat exchanger with the correct orienta tion 5609 913 GB 5609 913 GB Gas type conversion Converting from LPG to natural gas Removing gas restrictor N Pull power cable from gas train A 6 Remove or void gas type sticker on the top of the boiler next to the type Undo union nut B plate Undo two screws C andremovegas 7 Start the boiler and check for leaks train A Danger Remove gas restrictor D from gas Escaping gas leads to a risk of train A explosion Check gas equipment for Fit gas train A with new gaskets tightness E and P Please note H Tighten screws far enough to prevent damage to compo nents and to ensure the func tion is guaranteed 51 Gas type conversion Converting from LPG to natural gas cont Changing the gas type at the control unit 3 4 D jur 3 4 A 5 1 RESET ju DA e 5 0 3 in 1 0 jm Checking the CO content See page 52 1 2 Turn ON OFF switch on Turn both rotary selectors and LIII simultaneously into their cen tre position SERV appears on the display Turn rotary selector B III fully anti clockwise within 2 s and the new selected value flash on the display Adjust the control unit to natural gas or LPG by turning the rotary selector Jaa The display shows m 0 for operation with natural gas or m 1 for operat
22. ot the control unit downwards Undo screws A Remove cap 8 Remove faulty flow limiter C Select a new flow limiter C from the following table Flow rate Colour l min Insert new flow limiter C Fit new cap 8 supplied 5609 913 GB 5609 913 GB Repairs cont Troubleshooting Checking or replacing the plate heat exchanger O CO OD CO m NN E Heating water flow F Heating water return 1 Shut off and drain the boiler on the heating water and the DHW side 2 Flip down control unit 3 Push servomotor A slightly upwards 4 Turn adaptor 8 with servomotor A 1 8 of a turn anticlockwise and remove 6 Cold water B DHW 5 Remove two screws C from the plate heat exchanger and remove plate heat exchanger D with gas kets Note During removal small amounts of water may trickle out and escape from the plate heat exchanger 49 Troubleshooting Repairs cont 6 Check the DHW side for scaling and if required clean or replace the plate heat exchanger 7T Checkthe heating water side for con tamination and if required clean or replace the plate heat exchanger Checking the fuse 1 Switch off the power 2 Open control unit casing see page 15 3 Check fuse F4 50 8 Install in reverse order with new gas kets Note During installation ensure that fixing holes are aligned and gaskets seated c
23. p water funnel tundish is recommen ded m If the condensate line is routed outside the building use a pipe of at least 30 mm and insulate it against frost Avoid long external pipelines Please note H A frozen condensate pipe can result in faults and boiler dam age Always insulate condensate lines against frost c S E fe s 7 m Observe the local building regulations Connect condensate line A with a con stant fall and a pipe vent to the public sewage system Observe the local waste water regula tions Note Fill the siphon with water before com missioning 13 Installation sequence Fitting the boiler and making connections cont Filling the siphon with water d Ce C N NS Su BW z J I Ne N GF c m Pd M S 14 Fill a minimum of 0 3 I of water into the flue outlet Please note H At commissioning flue gas may be emitted from the condensate drain Fill the siphon with water before commissioning Connect the balanced flue During installation and positioning of the flue system observe Part L and BS 5440 building regulations Flue system installation instruc tions 5609 913 GB 5609 913 GB Installation sequence Opening the control unit casing Please note H Electronic assemblies can be damaged by electrostatic dis charge Before beginning work touch earthed objects such as heating or water pipes to dischar
24. play Within 2 s turn rotary selector II to the top right range LIII is displayed and the set value flashes Adjust the control unit to stage 1 or 2 by turning rotary selector p The display shows m 1 for operation with stage 1 or m 2 for operation with stage 2 The set operating mode is saved when the value stops flashing and the control unit returns to standard mode Checking the static and supply pressure Danger CO build up as a result of incor rect 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 com missioning or replacement Ventthe tank and gas supply line thoroughly after flushing 25 Commissioning inspection maintenance Further details regarding the individual steps cont 26 Close the gas shut off valve Undo screw A inside test nipple IN on the gas train but do not remove it and connect the pressure gauge Open the gas shut off valve Check the static pressure Set value max 57 5 mbar Start the boiler 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 Check the supply flow pressure Set value m Natural gas 20 mbar m LPG 37 mbar Note Use a suitable measuring device with a resol
25. ry supply 3A IP rating IP X4 to EN 60529 Permissible ambient temperature m during operation 0 to 40 C m during storage and transport 20 to 65 C Gas boiler category ll 243p Rated heating output range in heating mode Ty Tg 50 30 C kW 6 5 21 6 5 25 Tvy Tg 80 60 C kW 5 9 19 1 5 9 22 8 Rated heating output range for DHW heating Oo dnos Tr Rated heat input range kW 6 1 19 6 6 1 23 4 Connection values relative to the max load with Natural gas E m h 2 1 2 5 LPGP kg h 1 5 1 8 Power consumption max W 97 97 DHW heating Permissible operating pressure bar 10 10 Rated water volume l min 10 2 11 3 at AT 35 K to EN 13203 Set flow rate max l min 12 12 Product ID C 0085BT0029 The connection values are only for documentation purposes e g in the gas con tract application or to estimate a supplementary volumetric settings check Due to the factory settings the gas pressure must not be altered from these values Ref erence 15 C 1013 mbar 66 5609 913 GB 5609 913 GB Certificates Declaration of conformity Declaration of Conformity for the Vitodens 100 W We Viessmann Werke GmbH amp Co KG D 35107 Allendorf confirm as sole respon sible body that the product Vitodens100 W complies with the following standards EN 297 EN 55 014 2 EN 483 EN 60 335 1 EN 625 EN 60 332 2 102 EN 677 EN 61 000 3 2 EN 806 EN 61 000 3 3 EN 12 897 EN 62 223 EN 55 014 1 In accordanc
26. sequence and possible faults ia 38 Fault messages on the display tocca terae sot eret v o cr sent cedex cuan armas 39 IMPLIES 43 Gas type conversion Converting from LPG to natural gas sss e 51 Designs Connection and wiring dagram sese 53 Parts lists Ordering parts essas iasasais 55 Overview of the assemblies D i Sheet metal parts assembly aus D7 Heat cell assembly 58 Burner assembly nine ei eve cen tete krone dan ee Leo sas CE Re ED dren Re EE ERN kept 59 Hydraulic assembly me eet Ert me ober estet ice 61 Combi hydraulic assembly 63 Controlunit assembly EE 64 Miscellaneous assembly ecce eeeeeccbees nennen niet tt eene sancmnan sanar eee 65 E d sron 66 Certificates D cl ration of COnTOMMMtY 1o eco cde sete ofer tenebre eue ton 67 5609 913 GB 5609 913 GB Index Keyword BT E TE 68 Product information Product information Vitodens 100 W type BPJA Preset for operation with natural gas Conversion to LPG P requires a gas con version kit Conversion for other countries The Vitodens 100 W should generally only be delivered to those countries specified on the type plate For deliveries to alternative countries an approved contractor on his own initiative must arrange individual approval in accord ance with the law of the country in ques
27. stem against unau thorised reconnection Please note H Electronic modules can be dam aged by electro static dis charges Touch earthed objects such as heating or water pipes to dis charge static loads Repair work Please note H Repairing components which ful fil a safety function can compro mise the safe operation of your heating system Replace faulty components only with original Viessmann spare parts Please note Spare and wearing parts which have not been tested together with the heating system can com promise its function Installing non authorised components and non approved modifications con version can compromise safety and may invalidate our warranty For replacements use only orig inal spare parts from Viessmann or those which are approved by Viessmann Index Index Installation instructions Product information ene da nra SENGES ties EA ERR Ee ERE EEN DOR YE 6 Preparing for installation cei eden 7 Installation sequence Fitting the boiler and making Conpechons ee cece eeeeeeeeeenteeeteeaeeeteneeeene 10 Opening the control unit casing cecinere nennen entere tenete SEENEN 15 Electrical COnnectioris e nne e Irt eret e ER REP soe rie ndun Ee 16 Service instructions Commissioning inspection maintenance Steps commissioning inspection and Maintenance 19 Further details regarding the individual steps 20 Troubleshooting Function
28. t burner con trol unit Check ignition electrodes and connecting cables Check whether a strong interference EMC field exists near the appliance Press Reset see page 42 Replace control unit if fault persists Press reset range o 42 Turn rotary selector IT Hr less than 2 s to RESET then back to the control 5609 913 GB 5609 913 GB Troubleshooting Repairs Removing the front panel 1 Release screws at the bottom of the 2 Remove front panel boiler do not remove completely 43 Troubleshooting Repairs cont Boiler water temperature sensor 1 Pull the leads off boiler water temper ature sensor A and check the resist ance 44 5609 913 GB 5609 913 GB Troubleshooting Repairs cont 20 2 Check the sensor resistance and 10 compare it with the curve 3 In the case of severe deviation drain 4 boiler on the heating water side and Q replace the sensor 2 3 Danger S 1 The boiler water temperature 2 AG sensor is immersed in the 04 heating water risk of scald 40 30 50 70 90 110 ing Temperature in C Drain the boiler before replac ing the sensor 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 Pull the leads from
29. temperature lim iter A 2 Check the continuity of the tempera ture limiter with a multimeter 3 Remove the faulty temperature lim iter 4 Install a new temperature limiter 5 Press Reset at the control unit see page 42 45 Troubleshooting Repairs cont Checking the outlet temperature sensor 1 Pullthe leads from outlet temperature sensor A 2 Check the sensor resistance and compare it with the curve 20 3 Replace the sensor in the case of severe deviation 3 6 Note 4 Water can leak when replacing the e outlet temperature sensor Shut off 2 the cold water supply Drain the DHW g line and the plate heat exchanger S 1 DHW side o 0 8 2 0 6 amp 0 4 10 30 50 70 90 110 Temperature in C 46 5609 913 GB 5609 913 GB Troubleshooting Repairs cont Check flue gas temperature sensor 1 Pull leads from flue gas temperature sensor A 2 Check the sensor resistance and compare it with the curve 47 Troubleshooting Repairs cont 20 10 8 6 a 4 x E 92 o o S 1 0 8 0 6 0 4 10 30 50 70 90 110 Temperature in C Replacing flow limiter og 48 3 Replace the sensor in the case of severe deviation Drain the boiler from the DHW side Piv
30. th nitrogen until the pre charge pressure is raised by 0 1 to 0 2 bar 3 Top up with water until the charge pressure of the cooled system is at least 1 0 bar and 0 1 to 0 2 bar higher than the pre charge pressure of the diaphragm expansion vessel Permiss operating pressure 3 bar 35 Commissioning inspection maintenance Further details regarding the individual steps cont Checking gas equipment for tightness at operating pressure Danger Please note Escaping gas leads to a risk of z The use of leak detection spray explosion can result in incorrect functions Check gas equipment for tight Leak detection spray must not ness reach electrical contacts or seal diaphragm openings on the gas valve Fitting the front panel 1 Hook the front panel into place 2 Tighten screws at the bottom 36 5609 913 GB 5609 913 GB Commissioning inspection maintenance Further details regarding the individual steps cont Instructing the system user The system installer must hand the oper ating instructions to the system user and instruct the user in the operation of the system 37 Troubleshooting Function sequence and possible faults Display Action Control unit issues No Increase set value a heat demand and ensure heat is drawn off Yes Fan starts After approx 1 min Check the fan fan fault F9 connecti
31. the burner and tighten four screws A across Please note 5 Tighten screws far enough to prevent damage to compo nents and to ensure the func tion is guaranteed 2 Insert new gasket and tighten the fit tings on gas supply pipe 8 3 Plug the venturi extension C into the fan 4 Fit electrical cables to fan motor D gas valve E and ignition unit F 5 Reopen gas supply and switch on power supply 6 Check the gas connections for tight Danger Escaping gas leads to a risk of explosion Check all fittings for gas tight ness Please note The use of leak detection spray can result in incorrect functions Leak detection spray must not reach electrical contacts or seal diaphragm openings on the gas valve Checking the diaphragm expansion vessel and system pressure Note The diaphragm expansion vessel can lose some charge pressure over a time in use When the boiler heats up the pressure gauge will indicate a higher pressure of 2 or 3 bar The safety valve too can respond and discharge excess pressure Check whether the installed diaphragm expansion vessel is adequate for the System water volume Carry out this test on a cold system 1 Drain the system or close the cap valve on the diaphragm expansion vessel and reduce the pressure until the pressure gauge indicates O If the pre charge pressure of the dia phragm expansion vessel is lower than the static system pressure top up wi
32. the system and regulate the pre charge pressure to 20 mbar for natu ral gas or 37 mbar for LPG Notify your gas supply utility or LPG supplier If the actual CO or O and CO values deviate from the stated range check the balanced flue systems for leaks If flue installation is o k change the gas valve Note Operate the appliance with uncontami nated combustion air to prevent operat ing faults and damage 1 Connect a flue gas analyser to flue gas port A on the boiler flue con nection 2 Start the boiler and check for leaks Danger Escaping gas leads to a risk of explosion Check gas equipment for tightness 27 Commissioning inspection maintenance Further details regarding the individual steps cont 3 4 2 A 0 RESET ju 3 2 1 0 im 3 4 2 e 5 1 A 0 RESET im 28 Tum rotary selector B III fully clockwise for less than 2 s and then back to the control range on the right The display shows SERV gt and the boiler water temperature is shown Adjust the upper heating output Turn rotary selector NDT to the control range on the right until the display shows 5 bars for the upper heating output Measure the CO content for upper heating output The CO content must be between 7 0 and 10 5 Adjust the lower heating output Turn rotary selector II to the control range on the left until the dis play shows 1 bar for the lower heat
33. ulations m Connection requirements specified by your local power supply utility Installation sequence Install an isolator in the power supply line that simultaneously isolates all non earthed conductors from the mains with at least 3 mm contact separation We additionally recommend installing an AC DC sensitive RCD RCD class B AXE for DC fault currents that can occur with energy efficient equipment Protect the power cable with an external 3 A fuse to BS 1362 Danger Incorrect core allocation can result in serious injury and dam age to the appliance Take care not to interchange wires L1 and N 17 c S E fe s 7 Installation sequence Electrical connections cont Danger Connect the appliance and pipe The absence of component work to the equipotential bonding earthing in the system can lead to of the building in question serious injury from electrical cur rent if an electrical fault occurs Routing connecting cables and closing the control unit Please note H Power cables will be damaged if they contact hot components When routing and securing cables leads on site ensure that the maximum permissible tem peratures for these cables leads are not exceeded 18 5609 913 GB 5609 913 GB Commissioning inspection maintenance Steps commissioning inspection and maintenance For further information regarding the individual steps see the page indicated Commissioni
34. urner start trode and connecting cable Press Reset see page 42 5609 913 GB 5609 913 GB Fault messages on the display cont Troubleshooting Displayed System characteris Cause Measures fault code tics F4 Burner in a fault No flame signal Check the ionisation elec state detected trode and cables check the gas pressure check the gas train ignition igni tion module and conden sate drain Press Reset see page 42 F8 Burner in a fault Fuel valve closes Check gas train Check state too late both control paths Press Reset see page 42 F9 Burner in a fault Fan speed too low Check fan fan connecting state during burner start cables and power supply check fan control Press Reset see page 42 FA Burner in a fault Fan not at stand Check fan fan connecting state still cables and fan control Press Reset see page 42 FC Burner blocked Electrical fan con Check fan connecting trol control unit cable if required replace faulty or replace control unit 41 Troubleshooting Fault messages on the display cont Displayed System characteris Cause fault code tics Fd Burner blocked Fault burner con trol unit Measures Check ignition electrodes and connecting cables Check whether a strong interference EMC field exists near the appliance Press Reset see page 42 Replace control unit if fault persists FF Burner blocked Faul
35. ution of at least 0 1 mbar to check the supply pressure Record the actual value in the report on page Take the action shown in the follow ing table Shut down the boiler close the gas shut off valve remove the pressure gauge and close test nipple A with the screw Open the gas shut off valve and start the appliance Danger Gas escaping from the test nipple leads to a risk of explo sion Check gas tightness at test nipple A 5609 913 GB 5609 913 GB Commissioning inspection maintenance Further details regarding the individual steps cont Supply pressure flow pressure for natural gas for LPG Action Below 17 4 mbar Below 25 mbar Do not start the boiler Notify your gas supply utility or LPG supplier 17 4 to 25 mbar 25 to 47 mbar Start the boiler Above 25 mbar Above 47 mbar Checking the CO content Vitodens 100 W is factory set for natural gas During commissioning or mainte nance the CO 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 content fluctuates between 7 4 and 10 5 96 CO of up to 500 ppm is acceptable dur ing start up We recommend measuring O as the value is unmistakable regarding lambda air gas The O content fluctuates between 7 5 and 3 2 The CO CO ratio has to be less than 0 004 Install a separate gas pressure governor upstream of
36. xpansion tank Stepper motor adaptor Linear stepper motor Oval cap seal 5 pce Water volume controller Temperature sensor Hydraulics Round sealing ring 8 x 2 5 pce O ring 16 x 3 5 pce 0010 Flow sensor 0023 Check valve 0011 Clip 10 5 pce 0024 Clip 18 5 pce 0012 Clip 16 5 pce Ee 0001 0015 ve l 0002 M C 0002 0016 C 0003 0014 v 0017 9 amp 0004 0005 0020 0001 0004 0006 0007 0009 0010 0011 0013 0014 0016 0017 0018 0024 63 Parts lists Control unit assembly 0001 Cover wiring chamber 0002 Clip hinge 0003 Profiled seal 0004 Control unit 0005 Cable harness X20 0006 Ignition cable with angle plug 5kQ 0005 0006 0007 64 0007 Gas valve connecting cable 0008 Fan connecting cable 0009 Cable harness stepper motor 0010 Fuse 2 5 A slow 250 V 0008 0009 5609 913 GB 5609 913 GB Miscellaneous assembly 0001 Touch up spray paint white 0002 Touch up paint stick white 0003 Special grease gt HL 0004 Operating instructions Parts lists 0005 Installation and service instruc 0001 0002 0003 0004 j 0005 tions 65 Specification Specification Rated voltage 230 V Rated current 2 0A Temperature limiter Rated frequency 50Hz setting 100 C fixed Backup fuse power Safety catego

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