for contractors Natural gas and LPG version Type WB1B VIESMANN

Installation and serviceinstructionsfor contractors

VIESMANN

Vitodens 100-WType WB1B, 7.9 to 35.0 kWWall mounted gas condensing boilerNatural gas and LPG versionGas Council No.: 41-819-21; 41-819-22; 41-819-23; 41-819-24;41-819-25

VITODENS 100-W

5368662 GB 9/2018 Please keep safe.

2

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

Safety instructions explained

DangerThis symbol warns against therisk of injury.

! Please noteThis symbol warns against therisk of material losses and envi-ronmental pollution.

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

Target group

These instructions are exclusivelyintended for qualified contractors.

■ Work on gas installations may onlybe carried out by a registered gas fit-ter.

■ Work on electrical equipment mayonly be carried out by a qualifiedelectrician.

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

Regulations to be observed

■ National installation regulations■ Statutory regulations for the preven-

tion of accidents■ Statutory regulations for environmen-

tal protection

■ Codes of practice of the relevanttrade associations

■ All current safety regulations asdefined by DIN, EN, DVGW, TRGI,TRF, VDE and all locally applicablestandardsa ÖNORM, EN,

ÖVGW G K directives,ÖVGW-TRF and ÖVE

c SEV, SUVA, SVGW, SVTI,SWKI, VKF and EKAS guideline1942: LPG, part 2

Safety instructions

Safety instructions

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Safety instructions for working on the system

Working on the system

■ Where gas is used as the fuel, closethe main gas shut-off valve and safe-guard it against unintentional reopen-ing.

■ Isolate the system from the powersupply, e.g. by removing the separatefuse or by means of a mains isolator,and check that it is no longer live.

■ Safeguard the system against recon-nection.

■ Wear suitable personal protectiveequipment when carrying out anywork.

DangerHot surfaces and fluids can leadto burns or scalding.■ Before maintenance and serv-

ice work, switch OFF theappliance and let it cool down.

■ Never touch hot surfaces onthe boiler, burner, flue systemor pipework.

! Please noteElectronic assemblies can bedamaged by electrostatic dis-charge.Prior to commencing work,touch earthed objects such asheating or water pipes to dis-charge static loads.

Repair work

! Please noteRepairing components that fulfila safety function can compro-mise the safe operation of thesystem.Replace faulty components onlywith genuine Viessmann spareparts.

Auxiliary components, spare andwearing parts

! Please noteSpare and wearing parts thathave not been tested togetherwith the system can compro-mise its function. Installing non-authorised components andmaking non-approved modifica-tions or conversions can com-promise safety and may invalid-ate our warranty.For replacements, use only orig-inal spare parts supplied orapproved by Viessmann.

Safety instructions

Safety instructions (cont.)

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Safety instructions for operating the system

If you smell gas

DangerEscaping gas can lead to explo-sions which may result in seri-ous injury.■ Do not smoke. Prevent naked

flames and sparks. Neverswitch lights or electrical appli-ances on or off.

■ Close the gas shut-off valve.■ Open windows and doors.■ Evacuate any people from the

danger zone.■ Notify your gas or electricity

supply utility from outside thebuilding.

■ Have the power supply to thebuilding shut off from a safeplace (outside the building).

If you smell flue gas

DangerFlue gas can lead to life threat-ening poisoning.■ Shut down the heating sys-

tem.■ Ventilate the installation site.■ Close doors to living spaces

to prevent flue gases fromspreading.

What to do if water escapes from theappliance

DangerIf water escapes from the appli-ance there is a risk of electrocu-tion.Switch OFF the heating systemat the external isolator (e.g. fusebox, domestic distributionboard).

DangerIf water escapes from the appli-ance there is a risk of scalding.Never touch hot heating water.

Condensate

DangerContact with condensate can beharmful to health.Never let condensate touch yourskin or eyes and do not swallowit.

Flue systems and combustion air

Ensure that flue systems are clear andcannot be sealed, for instance due toaccumulation of condensate or otherexternal causes.Avoid continuous condensate disposalwith a wind protector.Ensure an adequate supply of combus-tion air.Inform system users that subsequentmodifications to the building character-istics are not permissible (e.g. cable/pipework routing, cladding or parti-tions).

Safety instructions


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DangerLeaking or blocked flue sys-tems, or an inadequate supplyof combustion air can cause lifethreatening poisoning from car-bon monoxide in the flue gas.Ensure the flue system is ingood working order. Vents forsupplying combustion air mustbe non-sealable.

Extractors

Operating appliances that exhaust airto the outside (extractor hoods, extrac-tors, air conditioning units, etc.) cancreate negative pressure. If the boiler isoperated at the same time, this canlead to a reverse flow of flue gas.

DangerThe simultaneous operation ofthe boiler and appliances thatexhausts air to the outside canresult in life threatening poison-ing due to a reverse flow of fluegas.Fit an interlock circuit or takesuitable steps to ensure an ade-quate supply of combustion air.

Safety instructions


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Service instructionsInformationSymbols................................................................................................................ 7Intended use......................................................................................................... 8Product information.............................................................................................. 8

Installation instructionsPreparing for installation................................................................................... 9

Installation sequenceMounting the boiler and making connections....................................................... 13Opening the control unit enclosure....................................................................... 18Electrical connections........................................................................................... 19

Service instructionsCommissioning, inspection, maintenanceSteps - commissioning, inspection and maintenance.......................................... 23Further details regarding the individual steps....................................................... 24

TroubleshootingFunction sequence and possible faults................................................................ 38Fault display......................................................................................................... 39Repairs................................................................................................................. 44

Gas type conversionChanging from LPG to natural gas....................................................................... 50

Control unitFunctions and operating conditions in weather-compensated mode................... 53

DesignsConnection and wiring diagram............................................................................ 55

Parts lists............................................................................................................ 57

Specification....................................................................................................... 61

CertificatesDeclaration of conformity...................................................................................... 63

Keyword index.................................................................................................... 64

Index

Index

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Symbol MeaningReference to other document containing further information

1.Step in a diagram:The numbers correspond to the order in which the steps are car-ried out.

Warning of material losses and environmental pollution Live electrical area Pay particular attention. ■ Component must audibly click into place.

or■ Acoustic signal■ Fit new component.

or■ In conjunction with a tool: Clean the surface.Dispose of component correctly. Dispose of component at a suitable collection point. Do not dis-pose of component in domestic waste.

Information

Symbols53

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The appliance is intended solely forinstallation and operation in open ven-ted and sealed unvented heating sys-tems that comply with EN 12828, withdue attention paid to the associatedinstallation, service and operatinginstructions. It is only designed for heat-ing up heating water that is of potablewater quality.

Intended use presupposes that a fixedinstallation in conjunction with permissi-ble, system-specific components hasbeen carried out.

Commercial or industrial usage for apurpose other than heating the buildingor DHW shall be deemed inappropriate.

Any usage beyond this must beapproved by the manufacturer in eachindividual case.

Incorrect usage or operation of theappliance (e.g. the appliance beingopened by the system user) is prohibi-ted and will result in an exclusion of lia-bility. Incorrect usage also occurs if thecomponents in the heating system aremodified from their intended use (e.g. ifthe flue gas and ventilation air pathsare sealed).

Product information

Vitodens 100-W, type WB1B

Preset for operation with natural gas.Conversion to LPG P requires a gasconversion kit.

Conversion for other countries

The Vitodens 100-W may only be deliv-ered to countries listed on the typeplate. For deliveries to other countries,approved contractors must arrangeindividual approval on their own initia-tive and in accordance with the law ofthe country in question.

Information

Intended use

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Preparing for boiler installation

Dimensions and connections

119

600

43

26

151

a9347

25

375

b

A B

C

D

510

025

0

A Heating flow 7 22 mmB Heating return 7 22 mmC Condensate drain: Plastic hose

7 22 mm

D Gas connection R ½

Preparing for installation

Preparing for installation53

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Rated heating outputrange

kW 7.9 - 13 7.9 - 16 7.9 - 19 7.9 - 26 11.0 - 35

a mm 285 285 285 285 340b mm 123 123 123 123 171


Preparing for installation (cont.)

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Fitting the wall mounting bracket

25

150Ø10

≥250

A

B

A Vitodens installation template B Opening for the balanced flue pipe



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1. Position the supplied installationtemplate on the wall.

2. Mark out the rawl plug holes.

3. Drill 7 10 mm holes and insert therawl plugs supplied.The rawl plugs are suitable for thefollowing materials:■ Concrete■ Vertically perforated bricks■ Hollow concrete breeze blocks■ Hollow brick and concrete ceil-

ings■ Perforated sand lime bricks■ Solid sand lime bricks■ Natural stone with dense struc-

ture■ Porous concrete■ Solid gypsum panels■ Solid concrete breeze blocks■ Solid bricks

4. Fit the wall mounting bracket withthe screws supplied.

Preparing the connections

! Please noteTo prevent appliance damage,connect all pipework free of loadand torque stress.

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

2. Prepare the gas connection.

3. Prepare the electrical connections.Observe applicable IEEE stand-ards.■ A 1.5 m power cable is fitted in

the delivered condition.■ A 1.5 m connecting cable for the

circulation pump is provided sep-arately.

■ Cables for accessories:NYM-O 2-core min. 0.5 mm2.



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Removing the front panel and mounting the boiler

3.

2.

1.

2x

1. Undo the screws on the undersideof the boiler; do not remove themcompletely.

2. Remove front panel.

3. Hook the boiler into the wall mount-ing bracket.

NoteAlign the boiler vertically and hori-zontally on all 3 axes.

Installation sequence

Mounting the boiler and making connections53

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Fitting the connections on the water side

A BA B

A Heating water flow B Heating water return

NoteInstall a shut-off valve and drain & fillvalve on site in the heating waterreturn.

Y-plan system

AB

E

F FC

D

A CylinderB Vitodens 100-WC Circulation pump

D Feed and expansion tankE 3-way diverter valveF Radiators


Mounting the boiler and making connections (cont.)

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Gas connection

A

1. Connect the gas shut-off valve toconnection A.

2. Carry out a tightness test.

NoteOnly use suitable and approvedleak detection agents (EN 14291)and devices for the tightness test.Leak detection agents with unsuita-ble constituents (e.g. nitrides, sul-phides) can cause material dam-age.Remove leak detection agent resi-dues after testing.

! Please noteExcessive test pressure willdamage the boiler and thegas train. Max. test pressure150 mbar. If a higher pres-sure is required for tightnesstests, disconnect the boilerand the gas train from themain supply pipe (undo thefitting).

3. Purge the gas line.



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Condensate connection

A

Note■ Connect condensate pipe A with a

pipe vent to the domestic wastewater system, routing it inside thebuilding as far as possible.

■ If the condensate pipe is routed out-side the building, use a pipe withmin. 7 30 mm and protect it fromfrost. Avoid long external pipe runs.

! Please noteA frozen condensate pipe canresult in faults and damage tothe boiler.Always protect condensatepipes against frost.

■ Observe local building regulations.

1. Pull condensate pipe A out of theappliance far enough to preventunnecessary bends inside theappliance. Ensure that the trap isproperly connected.

2. Connect condensate pipe A to thepublic sewage system with a con-stant fall and a pipe vent.Observe local waste water regula-tions.



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Filling the condensate connection trap with water

! Please noteDuring commissioning, flue gasmay escape from the conden-sate drain.Therefore fill the trap with waterbefore commissioning.

Pour a minimum of 0.3 l of water intothe flue gas connection.

Balanced flue connection

AB

A Flue gasB Supply air

Connect the balanced flue pipe.During installation and positioning ofthe flue system, observe Building Reg-ulations Part L and BS 5440.

Flue system installation instruc-tions

! Please noteWhen using the Viessmann fluesystem, please read the instruc-tions.The flue system must be free toexpand and contract. Thereforeno screws are required unlessthese are specifically mentionedin the instructions.The flue system must be sup-ported in accordance with theflue instructions. Different manu-facturers have different joiningsystems.Do not mix pipes, fittings or join-ing systems from different man-ufacturers.



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Do not carry out commissioning untilthe following conditions are met:■ Free passage through the flue gas

pipes.■ Flue system with positive pressure is

gas-tight.■ Inspection port covers checked for

secure and tight seating.■ Apertures for ensuring sufficient com-

bustion air supply are open and can-not be closed off.

■ Applicable regulations on installingand commissioning flue systemshave been followed.

DangerLeaking or blocked flue systemsor an insufficient supply of com-bustion air cause life threateningpoisoning due to carbon monox-ide in the flue gas.Ensure the flue system functionscorrectly. Apertures for combus-tion air supply must not be ableto be closed off.Prevent condensate drainagevia a wind protector.

Opening the control unit enclosure

! Please noteElectronic assemblies can bedamaged by electrostatic dis-charge.

Prior to commencing any work,touch earthed objects such asheating or water pipes to dis-charge static loads.

4x

3.

1.

2.



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Information on connectingaccessoriesWhen connecting accessoriesobserve the separate installationinstructions provided with them.

PUMPX21

L N 1 L N?

GAS EX7 FAN

X20

A

4 3 2 1

B GF5

X1

CDM

1~

BN BU GN

/YE

A Only for weather-compensatedmode:Outside temperature sensor(accessories).

B Connecting cable (accessories).C Cylinder demand terminal box

(accessories; see separate installa-tion instructions).

D Circulation pump connecting cable(supplied).

NoteIf the circulation pump is not con-nected to the control unit, connectan external frost stat.

E Jumper (1 - L).

F Power supply (230 V, 50 Hz).

DangerIncorrect core allocation canresult in serious injury anddamage to the appliance.Never interchange cores"L1" and "N".

The power supply must be from afused spur with a 2-pole isolatorswitch, fitted with a 3 A fuse.


Electrical connections53

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Wire the power supply with a neu-tral conductor. Connect water pipesto the earth bonding of the buildingin question.

G Connections for external 230 Vcontrols:■ Vitotrol 100 (room temperature

controller)

Separate installationinstructions

■ On-site room temperature con-

troller■ Input for Y-plan or S-plan heating

systems

Remove jumper E (1 - L) whenconnecting a 230 V control, leavingthe capacitor in place.Take power for external controlsfrom "L" and "N". The switched liveto start the boiler goes into "1".Please note that if there are twocircuits connected, e.g. heatingand hot water, you cannot use aplug-in timer or programmableroom thermostat receiver. Twochannel switching must be externalto the boiler.The only exception is if weathercompensation is also fitted.

Power supply

Regulations and directives

DangerIncorrectly executed electricalinstallations can result in injuriesfrom electrical current and appli-ance damage.

Connect the power supply andimplement all safety measures(e.g. RCD circuit) in accordancewith the following regulations:■ VDE regulations■ Connection requirements

specified by your local powersupply utility

Install an isolator in the power cablewhich simultaneously isolates all non-earthed conductors from the mains withcontact separation of at least 3 mm.

We also recommend the installation ofan AC/DC-sensitive RCD (RCD class B

) for DC (fault) currents that canoccur with energy efficient equipment.Protect the power cable with afuse/MCB of up to 16 A.

DangerIncorrect core assignment canresult in serious injury and dam-age to the appliance.Take care not to interchangewires "L1" and "N".

DangerThe absence of system compo-nent earthing can lead to seri-ous injury from electric current ifan electrical fault occurs.The appliance and pipeworkmust be connected to the equi-potential bonding of the building.


Electrical connections (cont.)

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Outside temperature sensor (accessories)

1. Fit the outside temperature sensor.

Installation location:■ North or north-westerly wall, 2 to

2.5 m above ground level. Inmulti storey buildings, in theupper half of the second floor

■ Not above windows, doors orvents

■ Not immediately below balconiesor gutters

■ Never render over■ Connection:

2-core lead, length up to 35 mwith a cross-section of 1.5 mm2

2. Plug the connecting cable suppliedwith the outside temperature sen-sor into slot "X21".

3. Connect the outside temperaturesensor to terminals 3 and 4 (seepage 19).



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Routing connecting cables and closing the control unit enclo-sure

! Please noteConnecting cables/leads will bedamaged if they touch hot com-ponents.

When routing and securingcables/leads on site, ensure thatthe maximum permissible tem-perature for these is not excee-ded.

2.

3.

1.



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For further information regarding the individual steps, see the page indicated

Commissioning steps

Inspection steps

Maintenance steps Page

• • • 1. Filling the heating system.............................................. 24

• 2. Venting the boiler............................................................ 25

• • • 3. Converting to operation with LPG................................ 26

• • • 4. Checking the static pressure and supply pressure.... 26

• 5. Checking the CO2 or O2 content.................................... 28

• • 6. Removing the burner ..................................................... 30

• • 7. Checking the burner gasket and burner gauzeassembly......................................................................... 31

• • 8. Checking and adjusting the electrode.......................... 32

• • 9. Cleaning the heat exchanger......................................... 33

• • 10. Checking the condensate drain and cleaning thetrap................................................................................... 34

• • 11. Installing the burner ...................................................... 35

• • • 12. Checking all connections on the heating water andDHW sides for leaks

• • • 13. Checking the flue system for unrestricted flow andtightness

• • • 14. Checking the firm seating of electrical connections • • • 15. Checking all gas equipment for tightness at

operating pressure ........................................................ 36

• • 16. Fitting the front panel..................................................... 37

• 17. Instructing the system user........................................... 37

Commissioning, inspection, maintenance

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Filling the heating system

! Please noteUnsuitable fill water increasesthe level of deposits and corro-sion and may lead to boilerdamage.■ Flush the heating system thor-

oughly before filling.■ Only fill with water of potable

quality.■ Soften fill water harder than

300 ppm.■ Special antifreeze suitable for

heating systems can beadded to the fill water.

Fill and vent the heating system.


Further details regarding the individual steps

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Venting the boiler

B

A

1. Close shut-off valve in heatingwater return.

2. Remove cover panel.

3. Connect the drain hose on air ventvalve A to a drain.

4. Open air vent valve A and on-sitefill valve in heating water return B.Vent (flush) under mains pressureuntil no more air noise can beheard.

NoteIf the heating system has not beencompletely vented, the heatingwater flow rate can be too low. Thiscan lead to the burner beingswitched off by internal safetyequipment before the specified setboiler water temperature is ach-ieved.

5. First close air vent valve A andthen fill valve in heating waterreturn B.

6. ■ Sealed unvented heating system:Adjust operating pressure to≥ 0.8 bar with fill valve B.

■ Open vented heating system:The static head must be at least0.2 bar.

7. Open shut-off valve in heatingwater return.


Further details regarding the individual steps (cont.)

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Converting to operation with LPG

In the delivered condition, the boiler isset up for operation with natural gas.For operation with LPG, change thegas nozzle and switch to the correctgas type at the control unit.

Separate installation instructions

For conversion from LPG to naturalgas, see page 50.

Checking the static pressure and supply pressure

DangerCO formation as a result ofincorrect burner adjustment canhave serious health implications.Always carry out a CO testbefore and after work on gasappliances.

Operation with LPGPurge the LPG tank twice on commis-sioning or replacement. Vent the tankand gas connection line thoroughlyafter purging.

A



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1. Close the gas shut-off valve.

2. Undo screw in test connector A onthe gas train, but do not remove it.Connect the pressure gauge.

3. Open the gas shut-off valve.

4. Check the static pressure.Set value: max. 57.5 mbar

5. Start the boiler.

NoteDuring commissioning, the appli-ance can enter a fault statebecause of airlocks in the gas line.After approx. 5 s, press RESET toreset the burner.

6. Check the supply (flow) pressure.

Set value:■ Natural gas: 20 mbar■ LPG: 37 mbar

NoteUse a suitable measuring devicewith a resolution of at least0.1 mbar to check the supply pres-sure.

7. Take measures as described in thetable below.

8. Shut down the boiler, close the gasshut-off valve, remove the pressuregauge and tighten the screw in testconnector A.

9. Open the gas shut-off valve andstart the appliance.

DangerGas escaping from the testconnector leads to a risk ofexplosion.Check gas tightness at testconnector A.

NoteThe maximum pressure drop betweenthe gas shut-off valve and test connec-tor A at the gas train is 0.5 mbar.

Supply pressure (flow pressure) StepsFor natural gas For LPGBelow 17.4 mbar Below 25 mbar Do not commission the boiler. Notify the

gas supply utility or LPG supplier.17.4 to 25 mbar 25 to 47 mbar Start the boiler.Above 25 mbar Above 47 mbar Install a separate gas pressure governor

upstream of the system and regulate thepre-charge pressure to 20 mbar for nat-ural gas or 37 mbar for LPG. Notify yourgas supply utility or LPG supplier.



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Checking the CO2 or O2 content

The Vitodens 100-W is factory-set fornatural gas. During commissioning ormaintenance, the CO2 and CO have tobe measured at the boiler flue adaptortest port to check the flue integrity. Sub-ject to the Wobbe index, the CO2 con-tent fluctuates between 7.4 % and10.5 %. A CO level of up to 500 ppmduring start-up is acceptable.We recommend measuring the O2, asthe value is unmistakable regardinglambda (air/gas). The O2 content fluctu-ates between 7.5 % and 3.2 %. TheCO/CO2 ratio has to be less than 0.004.

If the actual CO2 or O2 and CO valuesdeviate from the stated range, checkthe balanced flue systems for leaks. Ifthe flue installation is OK, change thegas valve.

NoteOperate the appliance with uncontami-nated combustion air to prevent operat-ing faults and damage

A

1. Connect a flue gas analyser at fluegas port A on the boiler flue con-nection.

2. Start the boiler.



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rr

3. Turn rotary selector "tr" clock-wise for less than 2 s and then anti-clockwise back to the control rangeon the right.The display shows "SERV" and theboiler water temperature is shown.

4. Adjust the upper output:Turn rotary selector "tr" to thecontrol range on the right.The display shows 5 bars for upperoutput.

5. Measure the CO2 content for upperoutput.The CO2 content must be between7.4 and 10.5 %.

6. Adjust the lower output:Turn rotary selector "tr" to thecontrol range on the left.The display shows 1 bar for loweroutput.

7. Test the CO2 content for lower out-put.The CO2 content must be between7.4 and 10.5 %.

8. If the CO2 content is not within thegiven range, check the flue gas/ventilation air system for tightness.Remedy any leaks.



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9. Shut the boiler down, remove fluegas analyser and close flue gasport A.

Removing the burner

E B A D4x C

1. Switch off the power supply.

2. Shut off the gas supply.

3. Disconnect the power cables fromfan motor A and gas train B.

4. Open control unit enclosure (seepage 18) and disconnect the cableto ignition electrode C.

5. Disconnect the venturi extensionfrom fan A.

6. Undo gas supply pipe fitting D.

7. Undo 4 screws E and remove theburner.

! Please noteTo prevent damage, never rest the burner on theburner gauze assembly.



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Checking the burner gasket and burner gauze assembly

Check burner gasket A and burnergauze assembly D for damage andreplace if necessary.

4x

B

ACDE

1. Remove electrode B.

2. Undo 3 cheese head screws andremove thermal insulation ring C.

3. Undo 4 Torx screws and removeburner gauze assembly D withgasket E.

4. Insert and secure new burnergauze assembly D with new gas-ket E.

! Please noteTighten the screws suffi-ciently to ensure the compo-nents do not suffer damageand will function correctly.



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5. Mount thermal insulation ring C.


6. Fit electrode B.


Checking and adjusting the electrode

1. Check the electrode for wear andcontamination.

2. Clean the electrode with a smallbrush (not a wire brush) or emerypaper.

8+2

4+0,5

3. Check the electrode gaps. If thegaps are not as specified or theelectrode is damaged, replace theelectrode and gasket and align.




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Cleaning the heat exchanger

! Please noteScratches to the surfaces of theheat exchanger that come intocontact with hot gas can resultin corrosion damage. Brushingcan cause deposits to becomelodged in the gaps between thecoils.Never use brushes to cleanthe heating surfaces.

! Please notePrevent damage due to cleaningwater.Cover the control unit with suita-ble watertight material.

NoteDiscolouration on the heat exchangersurface is a normal sign of use. It hasno bearing on the function and servicelife of the heat exchanger.The use of chemical cleaning agents isnot required.

A

1. Use a vacuum cleaner to removecombustion residues from heatingsurface A of the heat exchanger.

2. Flush heating surface A withwater.

3. Check condensate drain. Clean thetrap: See the following chapter.

4. Flush the heating surface againwith water. This will also fill the trapwith water.



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Checking the condensate drain and cleaning the trap

B A

1. Check at trap A that the conden-sate can drain freely.

2. Place an appropriate drip panbelow trap A.

3. Remove locking cap B and drainthe content of trap A into the drippan.

4. Replace locking cap B with gas-ket.

5. Fill trap A with water. For this,pour approx. 0.3 l of water into thecombustion chamber.



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Installing the burner

A D C B4x E

1. Fit the burner and tighten 4 screwsA diagonally.


2. Insert new gasket and tighten thefittings on gas supply pipe B (Tor-que approx. 30 Nm).

3. Plug the venturi extension intofan C.

4. Attach electrical cables from fanmotor C and gas train D.

5. Plug ignition electrode cable Einto the control unit and close thecontrol unit enclosure.

6. Reopen the gas supply and switchon the power supply.



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7. Check the gas connections fortightness.

DangerEscaping gas leads to a riskof explosion.Check the fitting for gastightness.

Checking all gas equipment for tightness at operating pressure

DangerEscaping gas leads to a risk ofexplosion.Check all gas equipment fortightness.

NoteOnly use suitable and approved leakdetection agents (EN 14291) and devi-ces for the tightness test. Leak detec-tion agents with unsuitable constituents(e.g. nitrides, sulphides) can causematerial damage.Remove leak detection agent residuesafter testing.



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Fitting the front panel

2.

3.

1.

2x

4.

Instructing the system user

The system installer should hand theoperating instructions to the systemuser and instruct the user in operatingthe system.



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Display Action Control unit is-

sues a heat de-mand

No Increase set valueand ensure heat isdrawn off

Yes

Fan starts No No fault display Heating water flowrate too low. In-crease flow rateand ensure heat isdrawn off.Check flow sensorand connectingcable.

Fault F9 after ap-prox. 51 s

Check the fan, fanconnecting ca-bles, fan powersupply and fancontrol

Yes

Ignition No Fault F4 Check the ignitionmodule connec-tion

Yes

Gas train opens No Fault F4 Check the gastrain (control volt-age 230 V); checkthe gas supplypressure

Troubleshooting

Function sequence and possible faults

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Yes

Ionisation currentbuilds (above2 µA)Symbol A

No Fault F4 Check the ionisa-tion current andelectrode adjust-ment, check thecondensate drainand check the gasline for airlocks.

Yes

Burner in opera-tion

No Shuts down belowthe set boiler watertemperature andrestarts immediate-ly

Check the fluesystem for tight-ness (flue gas re-circulation), checkthe condensatedrain, check thegas flow pressure

Fault display

2fFaults are indicated on the display by aflashing fault message with fault symbol"U".For fault message explanations see thefollowing table.■ Flashing fault symbol "U": To reset,

press "U RESET" (see page 43)after the fault has been remedied

■ Constantly displayed fault symbol "U":Automatic reset after the fault hasbeen remedied

Troubleshooting

Function sequence and possible faults (cont.)

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Fault codedisplayed

System character-istics

Cause Measures

10 Continuous opera-tion

Short circuit, out-side temperaturesensor

Check the outside tem-perature sensor and lead(see page 45).

18 Continuous opera-tion

Lead break, out-side temperaturesensor

Check the outside tem-perature sensor and lead(see page 45).

30 Burner blocked Short circuit, boilerwater temperaturesensor

Check the boiler watertemperature sensor (seepage 46).

38 Burner blocked Lead break, boilerwater temperaturesensor

Check the boiler watertemperature sensor (seepage 46).

50 No DHW heating Cylinder demandterminal box fault

Check terminal box con-nections and replace theterminal box if required.

58 No DHW heating Cylinder demandterminal box fault

Check terminal box con-nections and replace theterminal box if required.

60 Burner blocked Short circuit, re-turn temperaturesensor

Check the return temper-ature sensor (seepage 46).

68 Burner blocked Lead break, returntemperature sen-sor

Check the return temper-ature sensor (seepage 46).

A9 Control mode with-out OpenTherm de-vice

Communicationerror, OpenThermdevice

Check connections andlead; replace OpenThermdevice if required.

b0 Burner blocked Short circuit, fluegas temperaturesensor

Check the sensor (seepage 47).

b8 Burner blocked Lead break, fluegas temperaturesensor

Check the sensor (seepage 47).

E5 Burner blocked Internal fault Check the ionisationelectrode and connectingcables.Press "Reset" (seepage 43).

F0 Burner blocked Internal fault Replace control unit.

Troubleshooting

Fault display (cont.)

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Fault codedisplayed


Cause Measures

F1 Burner in a faultstate

Max. flue gas tem-perature exceeded

Check heating system filllevel. Check circulationpump. Vent the system.Press "Reset" (seepage 43).


Temperature limit-er has responded.

Check heating system filllevel. Check circulationpump. Vent the system.Check temperature limit-er and connecting ca-bles. Press "Reset" (seepage 43).


Flame signal is al-ready present atburner start.

Check ionisation elec-trode and connecting ca-ble. Press "Reset" (seepage 43).


No flame signal. Check ignition/ionisationelectrodes and connect-ing cables, gas pressure,gas train, ignition, ignitionmodule and condensatedrain.Press "Reset" (seepage 43).


Fuel valve closestoo late.

Check gas train. Checkboth control paths.Press "Reset" (seepage 43).


Fan speed too lowduring burner start

Check fan, fan connect-ing cables and powersupply to fan; check fancontrol.Press "Reset" (seepage 43).

Troubleshooting


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Fault codedisplayed


Cause Measures

FA Burner in a faultstate

Fan idle state notreached

Check fan, fan connect-ing cables and fan con-trol.Press "Reset" (seepage 43).

FC Burner blocked Electrical fan con-trol (control unit)faulty

Check fan connecting ca-bles; if required, replaceor replace control unit.

Fd Burner blocked Burner control unitfault

Check ignition electrodesand connecting cables.Check whether a stronginterference (EMC) fieldexists near the appliance.

Press "Reset" (seepage 43).Replace control unit iffault persists.

FF Burner blocked Burner control unitfault

Check ignition electrodesand connecting cables.Check whether a stronginterference (EMC) fieldexists near the appliance.

Press "Reset" (seepage 43).Replace control unit iffault persists.

Troubleshooting


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Initiating a reset

NoteOnly press RESET if fault symbol "U" is flashing.

r

Turn rotary selector "rt" to"U RESET" for between 1 s and 2 s,then back to the control range.

Troubleshooting


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Removing the front panel and pivoting the control unit down-wards

2x

4.

2.

3.

1.

Troubleshooting

Repairs

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Outside temperature sensor

X21 X7

X20

4 3 2 1

1. Open the control unit enclosure.See page 18.

2. Disconnect leads from outside tem-perature sensor.

100

10

-15-10

-5 10 20 30

Temperature in °C

468

20

406080

Res

ista

nce

in k

Ω

0

3. Check sensor resistance and com-pare it to the curve.

4. In the event of severe deviationreplace the sensor.

Troubleshooting

Repairs (cont.)

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Checking the boiler water temperature sensor and return tem-perature sensor

B

A

1. Disconnect the leads from boilerwater temperature sensor A orreturn temperature sensor B andcheck the resistance.

Troubleshooting

Repairs (cont.)

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10

1

10 30 50 70 90 110Temperature in °C

0.40.60.8

2

468

20

Res

ista

nce

in k

Ω


3. In the case of severe deviation,drain the boiler on the heatingwater side and replace the sensor.

DangerThe boiler water tempera-ture sensor is directlyimmersed in the heatingwater (risk of scalding).Drain the boiler beforereplacing the sensor.

Checking the flue gas temperature sensor

A

1. Disconnect the leads from flue gastemperature sensor A and checkthe resistance.

Troubleshooting

Repairs (cont.)

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10

1

10 30 50 70 90 110Temperature in °C

0.40.60.8

2

468

20

Res

ista

nce

in k

Ω


3. In the event of severe deviationreplace the sensor.

Checking the temperature limiter

If the burner control unit cannot bereset after a fault shutdown althoughthe boiler water temperature is belowapprox. 95 °C, check the temperaturelimiter.

A

1. Disconnect the leads from tempera-ture limiter A.

2. Check the continuity of the temper-ature limiter with a multimeter.

3. Remove faulty temperature limiter.

4. Install a new temperature limiter.

5. Reset by pressing "Reset" on thecontrol unit (see page 43).

Troubleshooting

Repairs (cont.)

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Checking the fuse

F4

1. Switch off the power supply.

2. Open the control unit enclosure(see page 18).

3. Check fuse F4.

Troubleshooting

Repairs (cont.)

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Replacing the gas restrictor

E

C

D

B

A

1. Remove the burner (see page 30).

2. Undo 3 screws A and remove gastrain B.

3. Remove gas restrictor C (if fitted)from gas train B. Insert new gasrestrictor C in gas train B.

4. Mount gas train B with new gasketD.


Gas type conversion

Changing from LPG to natural gas

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5. Refit the burner with a new gasketE and tighten the union nuts. ! Please note

Tighten the union nuts suffi-ciently to ensure the compo-nents do not suffer damageand will function correctly.

Changing the gas type at the control unit

1. Turn on the ON/OFF switch.

r

2. Turn both rotary selectors "à" and"tr" simultaneously into theirrespective central positions."SERV" appears on the display.

rr

3. Turn rotary selector "tr" fully anti-clockwise within 2 s.The display shows "A" and theset value flashes.

4. Change the control unit to naturalgas or LPG by turning rotary selec-tor "à".The display shows:■ "0" for operation with natural gas

or■ "1" for operation with LPG

Gas type conversion

Changing from LPG to natural gas (cont.)

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5. Do not adjust the rotary selectorsfor at least 15 s. The set operatingmode is then saved and the controlunit returns to standard mode.

6. Turn the ON/OFF switch off and onagain. The selected gas type isnow enabled

Checking the CO2 content

See page 28.

Gas type conversion

Changing from LPG to natural gas (cont.)

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In weather-compensated mode, theboiler water temperature is regulatedsubject to the outside temperature.

NoteY-plan and S-plan systems cannot beoperated in weather-compensatedmode.For further information, see separateinstallation instructions for the cylinderdemand terminal box (accessories).

Heating curve for weather-compensated control

Outside temperature in °C

Boile

r wat

er o

rflo

w te

mpe

ratu

re in

°C

90

80

70

60

50

40

30

0 -5 -10 -15 -205101520

20

10

0

A

B

C

D

E

F

G

Setting of rotary selector "tr"A = 1B = 2C = 3D = 4E = delivered conditionF = 5G = 6

Frost protection function

The frost protection function requiresan outside temperature sensor to beconnected.The frost protection function is active atoutside temperatures of < 5 ºC. Theburner starts and the boiler water tem-perature is held at 20 ºC.

Control unit

Functions and operating conditions in weather-compensated mode53

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NoteThe frost protection function is onlyenabled if the circulation pump is con-nected to the boiler control unit. Other-wise install an external frost stat.

Control unit

Functions and operating conditions in… (cont.)

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A Ignition/ionisation

Designs

Connection and wiring diagram53

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B Vitotrol 100, type UTA or on-siteroom temperature controller(switched 230 V input)

C Vitotrol 100, type RT or on-siteroom temperature controller(switched 230 V input)

D Vitotrol 100, type UTD or on-siteroom temperature controller(switched 230 V input)

E Power supply 230 V/50 HzF OpenTherm connection (remote

control, if installed)Max. cable length 30 m

G Outside temperature sensor(accessories)

H Time switch (accessories)

K Gas pressure switch (accesso-ries)

L PCB inside the control unitX ... Electrical interface§ Boiler water temperature sensor% Cylinder demand terminal box

(accessories)aG Flue gas temperature sensoraJ Return temperature sensorsÖ Circulation pumpdD Flow switchdG Gas solenoid valvefJ Temperature limitera-Ö Fan motor 230 V~a-ÖA Fan control

Designs

Connection and wiring diagram (cont.)

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When ordering spare parts:Quote the part and serial numbers (seetype plate) and the position numbers ofthe required part (as per this parts list).

Standard parts are available from yourlocal supplier.

Parts lists

Parts lists53

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VIESMANN

020

026

034

025

015

014

016

017

022

019

018024

021

004

012040

Parts lists

Parts lists (cont.)

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043

046

A

005039

008

027

010

006

011

003013

028007002029013

028

009

001

001 Heat exchanger002 Connection pipe, heating water

flow

003 Connection pipe, heating waterreturn

004 Gas supply pipe

Parts lists

Parts lists (cont.)

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005 Boiler flue connection with gasket006 Trap007 Flue gasket008 Plug for boiler flue connection009 Thermal insulation block010 Condensate pipe011 Condensate hose012 Fixing clips013 Clip 7 8 (5 pce)014 Burner gasket015 Thermal insulation ring016 Burner gauze assembly017 Burner gauze assembly gasket018 Ignition and ionisation electrodes019 Ignition and ionisation electrode

gasket (5 pce)020 Fan021 Gas train022 Burner door024 Venturi extension025 Control unit026 Cover, wiring chamber027 Thermal circuit breaker028 Boiler water temperature sensor029 Flow control switch034 Fuse 2.5 A (slow) (10 pce)

039 Wall mounting bracket040 Front panel043 Flue gas temperature sensor046 Air vent valve

Wearing parts018 Ignition and ionisation electrodes

Parts not shown023 Conversion kit G 31030 Gas solenoid valve cable harness

35031 Fan cable harness 100032 Cable harness X20033 Connecting cable, auxiliary earth035 Cable fixing036 Touch-up spray paint, white037 Touch-up paint stick, white038 Special grease041 Installation and service instruc-

tions042 Operating instructions044 Power cable045 Circulation pump connecting cableA Type plate

Parts lists

Parts lists (cont.)

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Rated heatingoutput range

TF/TR 50/30 °C(Pcond(50/30))

kW 7.9 - 13 7.9 - 16 7.9 - 19 7.9 - 26 11 - 35

TF/TR 80/60 °C(Pn(80/60))

kW 7.2 - 11.9 7.2 -14.6

7.2 -17.3

7.2 -23.7

10 - 31.9

Rated heating in-put range

kW 7.4 -12.2

7.4 -15.0

7.4 -17.8

7.4 -24.3

10.3 -32.7

Supply values Relative to themax. load with

natural gas H m3/h 1.3 1.6 1.9 2.6 3.5LPG P kg/h 0.9 1.1 1.4 1.9 2.6Min. static head (open vented sys-tems)

bar 0.1 0.1 0.1 0.1 0.1

Min. flow rate(heating water)

l/h 200 200 200 200 200

Rated voltage V 230Rated frequency Hz 50Rated current A 2.0Backup fuse (max.) A 16Power consump-tion (max.)

W 45 50 55 60 65

Weight withoutfront panel (instal-lation)

kg 24 24 24 24 32

Flue gas mass flowrate G20

kg/h 12.4 -20.4

12.4 -25.1

12.4 -29.8

12.4 -40.7

17.2 -54.8

Flue gas mass flowrate G31

kg/h 11.5 -18.9

11.5 -23.3

11.5 -27.6

11.5 -37.7

16.0 -50.7

CO2 content % 7.4 - 10.5CO2 content at rat-ed heating output

% 9.1

Permissible ambi-ent temperature

- during operation °C 0 to +40- during storageand transport

°C -20 to +65

Nominal flue gastemperature

°C 70

Specification

Specification53

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Rated heatingoutput range

TF/TR 50/30 °C(Pcond(50/30))

kW 7.9 - 13 7.9 - 16 7.9 - 19 7.9 - 26 11 - 35

TF/TR 80/60 °C(Pn(80/60))

kW 7.2 - 11.9 7.2 -14.6

7.2 -17.3

7.2 -23.7

10 - 31.9

Flue gas super-heating temp.

°C 110

Minimum flue gastemperature

°C 35

IP rating IP X4 to EN 60529 (only for room sealed operation)Protection class ITemperature limit-er setting

°C 100 (fixed)

Product ID CE-0085 BT 0029

NoteThe supply values are only for reference (e.g. in the gas contract application) or fora supplementary, rough estimate to check the volumetric settings. Due to the fac-tory settings, the gas pressure must not be altered from these values. Reference:15 °C, 1013 mbar (101.3 kPa).

Specification

Specification (cont.)

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We, Viessmann WerkeGmbH & Co. KG, D-35107 Allendorf,declare as sole responsible body thatthe named product complies with theEuropean directives and supplementarynational requirements in terms of itsdesign and operational characteristics.

Conformity has been verified with theCE designation. Using the serial num-ber, the full Declaration of Conformitycan be found on the following website:

www.viessmann.co.uk/eu-conformity

Manufacturer's declaration

This product meets the requirements of the Efficiency Directive (92/42/EEC) forcondensing boilers.

Certificates

Declaration of conformity53

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BBoiler water temperature sensor........46Burner gasket.....................................31Burner gauze assembly..................... 31Burner installation.............................. 35Burner removal.................................. 30

CCombustion chamber cleaning.......... 33Commissioning.................................. 24Condensate connection..................... 16Condensate drain...............................34Connection diagram...........................55Connections.......................................14Connections on the water side...........14Control unit, opening..........................18

EElectrical connections........................ 19

FFault code.......................................... 39Fault display.......................................39Filling the system............................... 24Flue gas temperature sensor............. 47Flue pipe............................................ 17Frost limit........................................... 53Frost protection.................................. 53Function sequence.............................38Fuse...................................................49

GGas connection..................................15Gas supply pressure.......................... 27Gas train ........................................... 27Gas type conversion– LPG................................................ 26– Natural gas..................................... 50

HHeat exchanger cleaning................... 33Heating curve.....................................53

IIgnition............................................... 32Ignition electrode................................32Ionisation electrode............................32

OOutside temperature sensor.............. 45

PPower supply..................................... 20

RReset..................................................43

SSafety chain ...................................... 48Spare parts........................................ 57Specification ......................................61Static pressure................................... 27Supply pressure.................................26

TTemperature limiter............................ 48Trap..............................................17, 34Troubleshooting................................. 44

VVentilation air pipe..............................17Venting...............................................25

WWall mounting.....................................11Weather-compensated mode.............53

Keyword index

Keyword index

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Viessmann LimitedHortonwood 30, TelfordShropshire, TF1 7YP, GBTelephone: +44 1952 675000Fax: +44 1952 675040E-mail: [email protected]

Viessmann Werke GmbH & Co. KGD-35107 AllendorfTelephone: +49 6452 70-0Fax: +49 6452 70-2780www.viessmann.com

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http://www.viessmann.com

for contractors Natural gas and LPG version Type WB1B VIESMANN

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Transcript of for contractors Natural gas and LPG version Type WB1B VIESMANN