Viessmann B1HE Series Installation And Service Instructions Manual Download Page 103

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103

6167 818 - 10

Vitodens 100-W, B1HE/B1KE Combi Installation/Service

Parts

Boiler Model No.

Serial No.

B1HE-85

7722772



B1HE-120

7722773



Ordering Parts:

Please provide Serial Number

when

ordering replacement parts. Order replacement

components from your Viessmann distributor.

Rating plate with serial number

Parts List

0001 Casing

0002 Cable Set

0003 Hydraulic System

0004 Heat Cell

0005 Other

0006 Electronic Equipment

0007 Programming Unit

0001

0006

0007

0003

0005

0002

0004

Summary of Contents for B1HE Series

Page 1: ...e instructions for future reference Product may not be exactly as shown IMPORTANT Vitodens 100 W B1HE Series and B1KE Combi Series Wall mounted gas fired condensing boiler with 3 5 inch black white display On demand domestic Hot Water with Combi Boilers For operation with natural gas or liquid propane gas Heating input 8 5 to 199 MBH 2 5 to 58 3 kW H ...

Page 2: ... Requirements Contaminated air Air contaminated by chemicals can cause by products in the combustion process which are poisonous to inhabitants and destructive to Viessmann equipment For a listing of chemicals which cannot be stored in or near the boiler room please see subsection entitled Combustion Air Supply Advice to owner Once the installation work is complete the heating contractor must fami...

Page 3: ...Junction Box 30 Fitting the Programming Unit and Front Panel 31 Adjusting pump Rate of Integral Pump 32 System Layout 1 33 System Layout 2 34 System Layout 3 35 System Layout 4 36 System Layout 5 37 System Layout 6 38 Boiler with Low Water Cut off remote mounted field supplied 39 Commission the System with the Commissioning Assistant 40 Filling the Heating System 42 Checking All Connections on the...

Page 4: ...9 Checking the CO2 Content Relay Tests 60 Clock Natural Gas Meter 60 Calling Up and Resetting the Maintenance Display 60 Instructing the System User 61 Calling Up Parameters 61 General 62 Boiler 63 DHW 65 Service Menu 67 Checking Outputs actuator test 67 Fault Display on the Programming Unit 69 Overview of Electronic Modules 71 Fault Messages 72 Repairs 82 Opening the Junction Box 89 Boiler Functi...

Page 5: ...or gas fitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professional for the installation of hard wired carbon mon...

Page 6: ...he heating contractor This includes low water cutoffs flow switches if used staging controls pumps motorized valves air vents thermostats etc Leave all literature at the installation site and advise the system operator ultimate owner where the literature can be found Contact Viessmann for additional copies This product comes with several safety instruction labels attached Do not remove Contact Vie...

Page 7: ...either serial number is sufficient Model No Serial No B1HE 85 7722772 B1HE 120 7722773 B1HE 150 7722774 B1HE 199 7722775 B1KE 120 7722776 B1KE 199 7722777 IMPORTANT General Information Boiler cross section Legend A Inox Radial stainless steel heat exchanger B Stainless steel MatrixPlus cylinder burner C Burner blower D Gas and hydronic connections E Black and white 3 5 inch boiler control display ...

Page 8: ... g as contained in paint solvents or cleaning fluids and excessive dust e g through grinding or polishing work Combustion air for the heating process and ventilation of the boiler room must be free of corrosive contaminants To that end any boiler must be installed in an area that has no chemical exposure The list below indicates the main currently known sources Avoid continuously high levels of hu...

Page 9: ...set up for operation with constant boiler water temperature By connecting an outdoor temperature sensor included with installation accessories the boiler can be operated in weather compensated mode The following are integrated closed loop hydraulic system with 2 connections for heating system supply and return and 2 connections for DHW tank heating B1HE or on demand DHW heating B1KE These boilers ...

Page 10: ... Venting System Installation Instructions Clearance to combustibles AL Alcove CL Closet Top Front Rear Left Right Vent pipe 1 0 0AL CL 0 0 0 0 1 Refer to the Installation Instructions of the Vitodens Venting System for details Recommended minimum boiler clearances to combustibles Recommended minimum boiler service clearances Fittings and Sealing Points All connections on the boiler must be fitted ...

Page 11: ...nt view Side view B1HE B1KE 85 and 120 Legend A Safety valve pressure gauge connection B Condensate drain C Heating system supply D For B1HE series DHW tank heating supply For B1KE series DHW E For B1HE series DHW tank heating return For B1KE series DCW F Heating system return G Fuel gas connection ...

Page 12: ...w Side view B1HE B1KE 150 and 199 Legend A Safety valve pressure gauge connection B Condensate drain C Heating system supply D For B1HE series DHW tank heating supply For B1KE series DHW E Fuel gas connection F For B1HE series DHW tank heating return For B1KE series DCW G Heating system return Dimensions ...

Page 13: ... suitable for 196 lb 86 kg loads Installation of mounting bracket on brick concrete wall 1 Mark out the rawl plug holes 2 Drill holes 7 e in 7 10 mm and insert the rawl plugs supplied 3 Fit the wall mounting bracket with the screws supplied CAUTION Whichever mounting method is used ensure that the bracket is tightly and securely fastened to wall Failure to secure boiler properly could cause boiler...

Page 14: ...ood stud Secure with bolts to wooden studs as shown Install mounting bracket on metal studs as per illustration Drill f in pilot holes to insert anchors Ensure that holes are located in the center of each metal stud Use fasteners to mount boiler mounting bracket to metal studs supplied Secure with bolts to metal studs as shown Ensure the mounting bracket is level Boiler mounting bracket installati...

Page 15: ...ts safe as they will be required for later installation Note To prevent dirt from entering the connections Do not remove the protective caps until you are about to fit the boiler 1 Mount the boiler on the wall mounting bracket Ensure that all four mounting tabs of the wall mountng bracket have locked into the boiler 2 Remove plastic shipping caps from the boiler connections 3 Remove the wooden blo...

Page 16: ...e plug of the connecting cable from the bracket Note Incorrect routing of the cable can lead to heat damage and impairment of the EMC properties Do not change the position of the cable or its fixture fixing point on casing 5 Rotate the control housing 180 degrees 6 Insert the plug on the right hand side again 7 Re install the control housing into the up jacket 8 Install the clips provide into the ...

Page 17: ...alled from boiler supply to boiler the boiler return Piping Connections Proper piping practice Support piping by proper suspension method Piping must not rest on or be supported by boiler 2 imperfect threads Use moderate amount of dope Leave 2 threads bare See following page for details on gas connection and piping WARNING Do not damage the gas pipe The gas pipe must not come into contact with any...

Page 18: ...ore placing the boiler in operation CAUTION Ensure that gas piping is large enough for all boilers in the residence No noticeable gas pressure drop in the gas line must occur when any unit or combination of units lights or runs IMPORTANT IMPORTANT psig 14 w c 1 Isolate the boiler from the gas supply piping system using the individual manual shutoff valve during pressure tests equal to or less than...

Page 19: ...port piping by the boiler or its components Use isolation valves to isolate system components The B1HE DHW tank heating supply and return ports must be capped if the DHW tank is not used All plumbing must meet or exceed all local state and national plumbing codes IMPORTANT Max allowable working pressure MAWP B1HE KE 85 120 45 psig 3 bar B1HE KE 150 199 60 psig 4 bar WARNING Exposing the boiler to ...

Page 20: ... switch The drain connection must terminate into an open or vented drain as close to the boiler as possible to prevent siphoning of the boiler drain 1 Install the condensate drain pipe onto the boiler with a suitable gradient Ensure that there is no unnecessary bends are created inside the boiler Check tightness of siphon connection IMPORTANT Pipe ventilation must take place between the siphon tra...

Page 21: ...from the condensate drain Always fill the trap with water before commissioning IMPORTANT Note If there is a risk of frost only fill the trap just before commissioning Installation Condensate Connection continued Neutralization Unit with neutralizing granulate Neutralization Unit Neutralization Pellets 2 x 1 3 kg for refill or replacement purposes for models B1HE KE 150 199 for models B1HE KE 85 12...

Page 22: ...sensor WARNING If a DHW storage tank other than a Viessmann Vitocell 300 tank is used the installer must verify proper operation of the Viessmann DHW tank temperature sensor with original manufacturer of the tank Viessmann strongly recommends the installation of a temperature tempering valve in the DHW supply line Vitodens 100 W B1HE boilers can be used in conjunction with the stand alone DHW stor...

Page 23: ...elief discharge pipe extends to a floor drain and ends approximately 6 in 150 mm above the drain Ensure that there is no shutoff valve installed in the discharge pipe discharge pipe diameter is not reduced discharge is not piped to outdoors Minimum connection diameters Pressure relief valve in Discharge pipe in Install the approved factory supplied pressure relief valve Removal of air from the sys...

Page 24: ...s or an inadequate supply of combustion air can cause life threatening poisoning from carbon monoxide in the flue gas Ensure the flue system is in good working order Vents for supplying combustion air must be nonclosable Prevent condensate drainage via a wind protector 1 Do not damage the sealing lip on the outside ring of the sealing plug Carefully detach the inner part of the sealing plug prefer...

Page 25: ... the programming unit is located at the bottom Do not disconnect the plug from the mounting panel Do not change the position of the cable or its strain relief on the boiler jacketing Opening the junction box 4 Release junction box cover clamps 5 Lift the junction box cover Layout of the electrical connections Note For further information on the connections see the following chapters IMPORTANT fÖ P...

Page 26: ...e wiring panel See page 25 Note Alternatively a temperature switch Aquastat can be connected Legend A Circulation pump B Plug P1 P2 on the wiring panel Connecting the circulation pump to P1 and P2 Note Observe the priority of the connections Possible connections to P1 and priority of connections DHW pump or DHW recirculation pump Possible connections to P2 and priority of connections Circulation p...

Page 27: ...nections continued Routing connecting cables leads Bundle cables using cable ties Route low voltage cables separately from 120V cables Secure the cables on the underside using the supplied cable ties Do not route cables over sharp edges If connecting cables leads come into contact with hot components they will be damaged When routing and securing cables leads on site ensure that the maximum permis...

Page 28: ... S A the National Electrical Code NEC ANSI NFPA 70 and any other state local codes and or regulations In Canada the Canadian Electrical Code CEC CSA C22 1 Part 1 and any other province territory local codes and or regulations The Vitodens 100 W comes with a pre installed convience plug for the boiler power supply if required this convience plug can be removed in the junction box for field wiring o...

Page 29: ... following circumstances On their way between transmitter and receiver wireless signals are damped e g by air or when penetrating walls Wireless signals are reflected by metallic objects e g reinforcements embedded in walls metal foil of thermal insulation and thermal glazing with metallized thermal vapour deposit Wireless signals are isolated by service ducts and lift shafts Wireless signals are ...

Page 30: ...ng Unit and Front Panel Programming unit located at the bottom 1 Place the junction box lid on the junction box 2 Secure in place with latches Installation 1 Release the tabs on the boiler control base 2 Pull the control base straight out 3 Re install the control base into the base of the boiler Note steps 1 to 3 are only required if the control base is in the service position 4 Install the front ...

Page 31: ...secured fixing point of the cable tie 2 Pull Lightguide A out of all 4 detents at once and remove As you do so pull it upwards between 2 detents in the middle and at the same time Ensure that the locking tabs do not break off 3 Turn Lightguide A around and clip it into place at the bottom of the programming unit 4 Fit the front panel The front panel also serves to seal off the air box Ensure the f...

Page 32: ...s in B1HE 85 80 B1HE KE 120 100 B1HE 150 70 B1HE KE 199 85 Adjusting Pump Rate of Integrated Circulation Pump Installation Speed setting Parameter 1100 2 in the Boiler group Residual Head B1HE KE 85 120 Residual Head B1HE KE 150 199 Note Minimum adjustment of boiler pump speed setting is 50 for all models ...

Page 33: ...temperature sensor Note Refer to the residual head curves on page 32 The use of a low loss header is recommended if the water flow rate is above or below the operating range The low loss header is available as accessory part Maximum Flow Rates Ensure that a pressure activated by pass is installed if there are system component s in C that may isolate the flow to the pump IMPORTANT System Layout 1 M...

Page 34: ...ailure to heed the above instructions may cause boiler short cycling and inadequate DHW supply Requires low loss header or closely spaced tees Legend PRV Pressure relief valve TPV Temperature and pressure relief valve A Vitodens 100 W gas fired condensing boiler B External boiler controller with room thermostat connection field supplied C Heating circuit D Heating circuit pump P2 E DHW storage tan...

Page 35: ...perform in addition to the above accurate calculations for DHW tank coil pressure drop versus boiler pump head to ensure sufficient water flow to the boiler heat exchanger Failure to heed the above instructions may cause boiler short cycling and inadequate DHW supply Note Refer to the residual head curves on page 32 The use of a low loss header is recommended if the water flow rate is above or bel...

Page 36: ...1KE 120 199 Output MBH 113 187 t 30ºF 17ºC rise GPM L h 7 5 1703 12 5 2839 35ºF 19 5ºC rise GPM L h 6 5 1476 10 7 2430 40ºF 22ºC rise GPM L h 5 7 1295 9 4 2135 Requires low loss header or closely spaced tees Legend PRV Pressure relief valve boiler DPRV Pressure relief valve DHW 150 psi WSE Water softener equipment DHW Domestic hot water DCW Domestic cold water A Vitodens 100 W gas fired condensing...

Page 37: ...of a low loss header is recommended if the water flow rate is above or below the operating range The low loss header is available as accessory part Legend PRV Pressure relief valve boiler DPRV Pressure relief valve DHW 150 psi WSE Water softener equipment DHW Domestic hot water DCW Domestic cold water A Vitodens 100 W gas fired condensing boiler B External boiler controller with room thermostat co...

Page 38: ...0 7 2430 40ºF 22ºC rise GPM L h 5 7 1295 9 4 2135 Note Refer to the residual head curves on page 32 The use of a low loss header is recommended if the water flow rate is above or below the operating range The low loss header is available as accessory part Legend PRV Pressure relief valve boiler DPRV Pressure relief valve DHW 150 psi WSE Water softener equipment DHW Domestic hot water DCW Domestic ...

Page 39: ...low water cut off manufacturer For low water cut off wiring information specific to your application refer to applicable wiring diagram on the boiler front panel Note The Vitodens 100 W boiler has a built in flow switch which may be accepted by local codes in lieu of a low water cut off Boiler below radiation Boiler above radiation LWCO LWCO Air Vent Air Vent Boiler with Low Water Cut off remote m...

Page 40: ...g correctly Start the actuator test IMPORTANT Commissioning assistant sequence Explanations and references Commissioning Language With app The boiler automatically switches on the WiFi access point Further commissioning steps according to the instructions of the Vitoguide mobile app Note Apps for commissioning and service are available for iOS and Android devices With programming unit If commissio...

Page 41: ... the low loss header Plug 96 Heat demand call for heat If a contact has been connected to plug 96 Maintenance Interval in burner hours run until next maintenance Interval adjustable in steps of 100 h Interval until next maintenance Interval adjustable to 3 6 12 18 or 24 months The boiler control carries out a restart Affix a further credentials label here so it can be found for subsequent use Affi...

Page 42: ...fusion barrier in order to prevent the diffusion of oxygen through tubing If plastic tubing without an oxygen diffusion barrier is used in underfloor heating systems Viessmann recommends that such systems be separated from the boiler with a heat exchanger Water Conditions for DHW B1KE Media pH value 6 5 to 12 glycol max 30 DHW max hardness Chloride up to 250 mg L Hardness up to 358 ppm max 0 278 k...

Page 43: ...return Vent flush until no more air noise is audible Note Required minimum flow rate for flushing 800 L h for B1HE KE 85 120 boilers 1100 L h for B1HE KE 150 199 boilers 7 Activate the filling function see commissioning assistant or following chapter 8 Close drain valve C and fill valve B Check the system pressure at pressure gauge The indicator must be in the green band 9 Open the shut off valves...

Page 44: ...able Ensure all connections are pressure tight Correct any leaks found on fittings pumps valves etc Checking the Gas Type 1 Verify that the fuel type listed on the boiler rating plate is the correct type for the installation being attempted 2 Once verified record the fuel type in Maintenance Record on page 99 The Vitodens 100 W boiler is for use with gases whose characteristics fall within the fol...

Page 45: ... Operation with LPG Removing the Front Panel 1 To change the gas type on the control unit see Commissioning the system with the commissioning assistant Note No mechanical adjustments are made to the gas solenoid valve 2 Affix labels as shown Legend A CSA Rating Plate B Field Conversion Label C Gas Type Label ...

Page 46: ...o the Maintenance Position To facilitate certain maintenance tasks move the programming unit up or down depending where it is located Do not disconnect the plug from the mounting panel Do not alter where and how the cable is secured fixing point of the cable tie HMI mounted at the bottom HMI mounted at the top ...

Page 47: ...ing on gas appliances to eliminate health risks and to guarantee the satisfactory condition of the system IMPORTANT WARNING Ensure that there is no open flame in the room WARNING Never purge a gas line into a combustion chamber Never use matches candles flame or other sources of ignition for purpose of checking leakage Use a soap and water solution to check for leakage A failure to follow this war...

Page 48: ...48 6167 818 10 Vitodens 100 W B1HE B1KE Combi Installation Service Commissioning Function Sequence and Possible Faults For further details regarding faults see Troubleshooting ...

Page 49: ... during boiler start up For this purpose it is sufficient to measure the CO2 concentration of the combustion air in the coaxial gap of the air intake pipe The vent pipe is considered sufficiently leak proof if a CO2 concentration in the combustion air no higher than 0 2 or an O2 concentration no lower than 20 6 is measured If higher CO2 values or lower O2 values are measured check venting system t...

Page 50: ... Disconnect cables and leads from Fan motor A 2 plugs Ionization electrode B Ignition unit C Ground D 4 Undo gas supply pipe fitting E 5 Undo screws F and remove the burner Note Cover gas connection E B1HE KE 85 120 so that no small parts can fall into it Always hold the fitting of the gas connection pipe with a suitable open ended wrench Use a two handed wrench method when tightening fittings and...

Page 51: ...ert thermal insulation ring F and flame body assembly D with gasket E Observe correct installation position Align the tab as per the diagram 7 Align the hole in flame body assembly D with the burner door pin Secure flame body assembly D and gasket E with Torx screw C Torque 27 lb in 3 0 Nm 8 Check thermal insulation ring F for firm seating 9 Fit electrodes B Check clearances see following chapter ...

Page 52: ...rt points of the retaining clips Secure the thermal insulation ring with 3 hex head screws Torque 35 lb in 4 Nm Check thermal insulation ring F for firm seating 9 Fit electrodes B Check clearances see following chapter Torque 40 lb in 4 5 Nm Check flame body assembly D electrodes B thermal insulation ring F and gasket G for damage Only remove and replace components if they are damaged or worn Note...

Page 53: ...king and Adjusting the Ignition and Ionization Electrodes Legend A Ignition electrodes B Ionization electrode C Ionization electrode gap B1HE KE 85 120 0 40 in 0 02 in 10 mm 0 5 B1HE KE 150 199 0 47 in 0 02 in 12 mm 0 5 D Ignition electrode gap B1HE KE 85 120 0 25 in 0 02 in 6 5 mm 0 5 B1HE KE 150 199 0 24 in 0 02 in 6 mm 0 5 1 Check the electrodes for wear and contamination 2 Clean the electrodes...

Page 54: ...ll upon completion of service work as per the instructions on page 50 in this manual 2 Clean the combustion chamber A by vacuuming loose debris out 3 Remove embedded sediment from the stainless steel heat exchanger surface by thoroughly rinsing with water or cleaning agents such as Axiom Industries Clean F Steel Follow Axiom handling and application instructions when using cleaning agent Avoid get...

Page 55: ...to the maintenance position 3 Remove the supply hose 4 Pull siphon trap upwards out of the drain hose 5 Hold siphon trap as straight as possible and remove Ensure that no condensate runs out 6 Clean the siphon trap 7 Fill the siphon trap with water and refit it on the drain hose WARNING Risk of electric shock from escaping condensate Check the connections for leaks and check that the siphon trap i...

Page 56: ...ket Torque 22 lb ft 30 Nm 4 Check the gas connections for leaks 5 Connect the cables leads Fan motor A 2 plugs Ionization electrode B Ignition unit C Ground D WARNING Escaping gas leads to a risk of explosion Check all fittings and the gas shut off valve for gas leaks WARNING Do not damage the gas pipe The gas pipe must not come into contact with any other components in the appliance Keep the gas ...

Page 57: ...er inlet and the union nut on the upper side of the flow sensor Pull the pipe out 3 Remove the DHW flow sensor 4 Check flow limiter A and filter sieve B Replace in case of excessive scaling or damage Reinsert 5 Install the DHW flow sensor with new gaskets in the reverse order 18 lb ft 24 Nm torque for the union nuts WARNING Risk of electric shock from escaping heating water or DHW Check all water ...

Page 58: ...ping must be leak tested before placing the boiler in operation 3 Top up with water until filling pressure is higher than the inlet pressure of the diaphragm expansion tank Note With the system cold the filling pressure must be approximately 3 psig higher than the static pressure B1HE KE 85 120 Maximum operating pressure 45 psig Minimum operating pressure 12 psig B1HE KE 150 199 Maximum operating ...

Page 59: ... value deviates from the permissible ranges implement steps listed above 5 Enter the value into the report 6 Set the upper heating output See the following chapter 7 Check the CO2 content If the actual value deviates from the permissible ranges by more than 1 implement steps listed above 8 Enter the value into the report 9 Re seal test port A The electronic combustion controller automatically ensu...

Page 60: ... simultaneously for approx 4 sec then release 2 Use to select Reset service messages 3 OK Clock Natural Gas Meter For example A Vitodens 100 W 150 boiler 150 000 Btu h input requires 240 seconds to use 10 cu ft of natural gas After contacting the local utility you find the heating value is e g 1000 Btu per cu ft Therefore 3600 x 10 240 x 1000 150 000 Btu h input Therefore the boiler input is corre...

Page 61: ... function B1HE only The DHW can be heated to a specified higher target DHW temperature for a period of one hour To activate the function see the operating instructions Inform the system user what DHW temperatures should be set and the risks associated with having a raised outlet temperature at the draw off points Calling Up Parameters Note All parameters are accessible via a software tool such as ...

Page 62: ...eover from winter to summertime Setting Explanations 25 1 to 31 Changeover from 02 00 h to 03 00 h occurs on the Sunday after or on this set date Day of changeover adjustable from 1st to 31st of the month 912 2 Month of changeover from winter to summertime Setting Explanations 3 1 to 12 Month of changeover March Month of changeover adjustable from January to December 912 3 Earliest day of changeov...

Page 63: ...l see parameter 508 0 2241 0 Source outside temperature sensor Setting Explanations 1 Hardwired 521 0 Interval in burner hours run until next maintenance Setting Explanations 0 0 to 25500 Number of burner hours to run until next service Burner hours until next service adjustable from 0 to 25500 522 3 Interval until next maintenance Setting Explanations 0 1 2 3 4 5 Interval until next maintenance N...

Page 64: ... been performed Maintenance messages are active if present Clear maintenance messages once 1503 0 Minimum heating output Setting Explanations 5 to 100 A limit can be set on the minimum heating output for heating operation Factory settings defined by settings specific to the boiler Adjustable from 5 to 100 1606 0 Minimum burner pause time Setting Explanations 0 1 The minimum burner pause time can b...

Page 65: ...witched on during DHW heating 497 3 Number of cycles DHW recirculation pump Setting Explanations 0 1 2 3 4 5 Number of cycles per hour for 5 minutes each during the selected time phase 1 cycle 2 cycles 3 cycles 4 cycles 5 cycles 6 cycles 503 0 Scald protection Setting Explanations Off On 0 1 The adjustable water temperature is limited to a maximum value Scald protection switched off Risk of injury...

Page 66: ...K 5 F above the target DHW temperature 1087 0 Max duration DHW heating Setting Explanations 60 0 1 to 240 After a set period of time has elapsed DHW heating ends even though the target DHW temperature has not yet been reached Not adjustable on gas condensing combi boilers Factory setting 60 min No time limit for DHW heating Duration of DHW heating adjustable from 1 to 240 min in 1 min increments 1...

Page 67: ...mixing valve can only be called up if such components are installed in the system Note If a called up sensor is faulty appears on the display Calling up operating data Tap the following buttons 1 and OK simultaneously for approx 4 sec then release 2 Use to select Diagnostics 3 OK 4 Use to select the required group 5 OK 6 Use to select the required information Service Active messages Reset maintena...

Page 68: ...ating Heating group Primary circuit pump speed 3 way valve target position Heating circuit 1 pump speed Target value Heating Middle DHW Target value Internal circulation pump speed in 3 way diverter valve set to heating operation 3 way diverter valve in central position filling draining 3 way diverter valve set to DHW heating Speed heating circuit pump heating circuit 1 without mixing valve in DHW...

Page 69: ...ssage list 1 and OK simultaneously for approx 4 sec then release 2 Message history 3 OK 4 Use to select Delete message list 5 OK 6 OK to confirm the prompt If there is a fault the display shows Burner fault or Active messages Note If a central fault message facility is connected this is started If Connection error appears on the display Check connecting cable and plug between HMU heat management u...

Page 70: ...nd ionization electrode If the condensate has reached the flame body assembly also replace the gasket of the flame body assembly A 19 Temperature limiter has responded A 20 Service interval could not be activated Check the time and date settings Information Messages on the display Meaning I 56 External demand active I 57 External blocking active I 59 Parameters were restored parameter set was flas...

Page 71: ... 100 W B1HE B1KE Combi Installation Service Overview of Electronics Modules Troubleshooting Legend A BCU burner control unit B HMU heat management unit with wiring panel C HMI programming unit with WiFi communication module ...

Page 72: ...Check storage tank temperature sensor plug 5 wires 3 and 4 Replace faulty component if necessary F 13 Regulates as if the out side temperature were 32 F 0 C Lead break outside temperature sensor Check the operating mode setting in the commissioning assistant and correct if necessary Check outside temperature sensor and connection to sensor external plug contacts 1 and 2 Measure voltage at sensor i...

Page 73: ...r in a fault state Ionization current lies outside the permissible range Check gas supply gas pressure and gas flow switch check gas solenoid valve and inlet strainer Check ionization electrode Clearance to flame body assembly Check electrode flame body assembly for contamination If specified measures don t help replace fan unit Reset the boiler F 68 Burner in a fault state Flame signal is already...

Page 74: ...target system pressure and range F 77 Burner in a fault state Data memory burner control unit Reset the boiler If fault recurs replace BCU burner control unit See page 89 F 89 No central heating and no DHW heating Internal circulation pump blocked Check circulation pump Replace if necessary F 142 Burner in a fault state Communication error CAN bus Check the fan unit for correct function For this c...

Page 75: ...the boiler F 299 Time date incorrect Real time clock setting incorrect Set the time and date F 342 No central heating no DHW heating Communication error BCU burner control unit Check connecting cable to the burner control unit plug X4 on BCU Check all plug in connections and cables of the internal CAN Remove all plugs except X4 X2 X16 and X18 from the BCU burner control unit Check whether fault pe...

Page 76: ... state CO limit within boiler exceeded Check entire flue gas path for the following Flue gas recirculation Leaks Flue gas back pressure caused by water pocket if flue system fall is insufficient Constrictions Blockages Repair flue system if necessary Reset the boiler F 353 Burner shutdown with restart if demand exists Insufficient gas supply burner output reduced Check the gas supply Optically che...

Page 77: ...e loss immediately after flame formation during safety time Check gas supply gas pressure and gas flow switch Check balanced flue system for flue gas recirculation Check ionization electrode Clearance to flame body assembly Contamination on electrode Reset the boiler F 370 Burner in a fault state Fuel valve or modulation valve will not close Reset the boiler If fault occurs repeatedly replace fan ...

Page 78: ...ue system for flue gas recirculation Check ionization electrode and flame body assembly Clearance to flame body assembly Contamination on electrode Reset the boiler F 382 Burner in a fault state Error counter has exceeded limit Reset the boiler Work through fault analysis using fault history F 383 F 384 Burner in a fault state Possible contamination of gas line Check gas line for contamination Che...

Page 79: ...ntrol unit faulty Check IO electrode for ground fault If fault persists replace BCU burner control unit See page 89 Reset the boiler F 404 Burner in a fault state BCU burner control unit faulty Replace BCU burner control unit See page 89 Reset the boiler F 405 Burner in a fault state Ionization electrode ground fault BCU burner control unit faulty Check IO electrode for ground fault If fault persi...

Page 80: ... and flue gas recirculation Clean flue system if necessary Reset the burner Note Deposits on the electrodes indicate foreign bodies in the combustion air Check the installation room and flue system for causes of the deposits For example Laundry detergents cleaning agents toiletries deposits in the ventilation air supply chimney If flame body assembly and ionization electrode have been replaced als...

Page 81: ...ion air supply chimney If flame body assembly and ionization electrode have been replaced also clean fan unit gas air channel and Venturi extension F 471 No call for heat Lead break or short circuit Check system plug dD Check lead and plug in connection Measure to see if supply voltage to sensor is 5V No call for heat HMU heat management unit communication error Check connecting cable between BCU ...

Page 82: ...are the resistance with the value for the currently recorded temperature from the following diagram In the event of severe deviation 10 replace the sensor 5 Rotate sensor clockwise by turn to install it 6 Reconnect leads flue gas temperature sensor C 7 If the permissible flue gas temperature has been exceeded the flue gas temperature sensor locks out the boiler Reset the burner on the programming ...

Page 83: ...eviation 10 replace the sensor Outside temperature sensor 1 Check the cable and plug of the outside temperature sensor 2 Disconnect wires 1 and 2 from terminal on the wiring panel 3 Check the sensor resistance Compare the resistance with the value for the current temperature from the following diagram If the results are very different from the curve 10 disconnect the wires from the sensor Repeat t...

Page 84: ...e shutoff valves and isolate boiler water from both heating system and domestic cold water in 3 Pour approximately 5 gallons of new food grade white vinegar or citric acid into a pail 4 Place the discharge hose D and hose E connected to the pump inlet into the pail of cleaning solution 5 Attach other end of the hoses D and E to the heat exchanger 6 Open both drain valves 7 Operate the pump and all...

Page 85: ...KE Combi Installation Service Fault Messages continued Troubleshooting Fault Messages continued Repairs continued Checking the plate heat exchanger B1KE 120 Legend A Heating water supply B Heating water return C Cold water D DHW B1KE 199 ...

Page 86: ... and drain the boiler on the heating water and DHW sides 2 Undo screws 3 Remove plate heat exchanger Note During and after removal small amounts of water may trickle from the plate heat exchanger 4 Remove gaskets and dispose of them 5 Check connections on the DHW side for scaling Clean or replace the plate heat exchanger as required 6 Check connections on the heating water side for contamination C...

Page 87: ... place with an open ended wrench to prevent damage to the gas pipe use the two handed method 3 Remove the burner 4 Remove the clips push the pipe upwards and pivot it backwards Then remove the pipe downwards 5 Pull the clip off the supply pipe new cable ties must be installed when securing the clips 6 Pull off the clips Push the supply pipe upwards Note If necessary the safety valve with drain mus...

Page 88: ... the two handed method 3 Remove the burner 4 Pull off the clip and remove the flow switch 5 Pull off the clips and remove the supply pipe toward the front When refitting the pipes new cable ties must be used to secure the clips 6 Remove the screws on the hydraulic plate at the bottom of the boiler 7 Undo the union nut of the boiler pump 8 Remove the hydraulic unit 9 The hydraulic unit is installed...

Page 89: ...nd wiring diagram WARNING Incorrect or improperly fitted fuses can lead to an increased risk of fire Insert fuses without using any force Position fuses correctly Only use structurally identical types with the specified response characteristics Fault Messages continued Fault Messages continued Opening the Junction Box 1 Folding down the red clips to open the front cover of the junction box 2 Open ...

Page 90: ...pwards out of the lateral guides to its left and right 6 The cables are now exposed and can be pulled off the pcbs 7 The rear cover can then be removed and the circuit boards are fully visible The interlock must be observed 8 Lift up Refit in reverse order When assembling the separation wall in addition to the lateral guides pay attention to the latching with the rear cover WARNING Errors in assem...

Page 91: ...after 20 min Heating curve The heating curves represent the relationship between the outside temperature and the supply temperature Simplified The lower the outside temperature the higher the supply temperature must be in order to reach the target room temperature Factory settings Slope 1 4 Level 0 Slope setting ranges Infloor heating systems 0 2 to 0 8 Low temperature heating systems 0 8 to 1 6 H...

Page 92: ...ture If the actual tank temperature exceeds the target tank temperature by 2 5 K 5 F the burner shuts down and circulation pump run on begins Fault Messages continued Fault Messages continued Call for Heat WARNING Risk of injury due to increased DHW temperature Inform the system user of the risk from the raised outlet temperature at the draw off points If necessary provide on site scald protection...

Page 93: ...tion Service Fault Messages continued Wiring Diagram Fault Messages continued Overview of the Modules Legend A1 HMU heat management unit A2 Wiring panel A3 BCU burner control unit A5 HMI programming unit with communication module TCU 200 A6 ON OFF switch ...

Page 94: ...ule TCU 200 A8 Power supply unit Outside temperature sensor for weather compensated operation Tank temperature sensor fÖ Power supply jF PlusBus lA CAN bus lH Input 120VAC function configurable through K1 relay on WP board aBH No function P1 Output 120V 60 Hz P2 Output 120V 60 Hz A To wiring panel X10 B To the BCU burner control unit C To the BCU burner control unit D PlusBus connection E Wiring p...

Page 95: ...eat management unit plug 156 B HMU heat management unit terminal X4 C Flue gas temperature sensor D Boiler water temperature sensor 1 and 2 E Gas solenoid valve and fan motor with PWM switching and feedback F Boiler flow switch G Ignition unit and flame monitoring H DHW flow switch B1KE only K Internal circulation pump primary pump L 3 way diverter valve M DHW outlet temperature sensor B1KE only ...

Page 96: ...tput 120VAC 60 Hz max 36 Watts P1 Optional DHW pump P2 Circulation pump zone 1 lH Connecting the temperature controller function of plug 96 Tank temperature sensor or temperature switch Aquastat B1HE only Outside temperature sensor lA No function jF No function F1 Fuse 6 3A slow 120V A HMU heat management unit connection 120VAC B CAN plug 91 HMU heat management unit C HMU heat management unit extr...

Page 97: ...97 6167 818 10Vitodens 100 W B1HE B1KE Combi Installation Service B1HE Models 85 120 150 199 Wiring Diagram ...

Page 98: ...98 6167 818 10 Vitodens 100 W B1HE B1KE Combi Installation Service B1KE Models 120 199 Wiring Diagram ...

Page 99: ...99 6167 818 10Vitodens 100 W B1HE B1KE Combi Installation Service Maintenance Record Service Reports Fuel type altitude venting and other site parameters may change ...

Page 100: ...218 99 146 66 229 104 Boiler water content USG L 1 02 3 88 1 02 3 88 2 5 9 50 2 5 9 50 1 02 3 88 2 5 9 50 Boiler max flow rate 4 GPM L h 4 8 1090 6 2 1408 8 8 1999 10 6 2408 6 2 1408 10 6 2408 Max operating pressure max allowable working pressure at 210ºF 99ºC psig bar 45 3 45 3 60 4 60 4 45 3 60 4 Boiler water temperature Adjustable high limit AHL range space heating steady state DHW tank heating...

Page 101: ...verage condensate flow rate 6 with natural gas TS TR 122 86ºF 50 30ºC USG day L day 20 3 76 8 27 9 105 6 34 9 132 0 46 9 177 6 27 9 124 8 46 9 196 8 Condensate connection 7 hose nozzle Ø in c in c in c in c in c in c in Boiler flue gas connection 8 Ø in mm 3 80 3 80 3 80 3 80 3 80 3 80 Combustion air supply coaxial outer connection 8 single Ø in mm 5 125 3 80 5 125 3 80 5 125 3 80 5 125 3 80 5 125...

Page 102: ...90 DHW supply temperature ºF ºC 140 60 140 60 Continuous draw rate 1 at t 77ºF 43K USG min L h 3 3 757 4 7 1070 Max flow through heat exchanger USG min L h 3 7 840 5 3 1200 Maximum allowable working pressure potable water psi 150 150 Test pressure psi 300 300 1 DCW and DHW temperature rise would be proportional Maximum DHW supply temperature is 140ºF 60ºC B1KE on demand hot water operation Specifi...

Page 103: ...ring Parts Please provide Serial Number A when ordering replacement parts Order replacement components from your Viessmann distributor A Rating plate with serial number Parts List 0001 Casing 0002 Cable Set 0003 Hydraulic System 0004 Heat Cell 0005 Other 0006 Electronic Equipment 0007 Programming Unit 0001 0006 0007 0003 0005 0002 0004 ...

Page 104: ...2776 Ordering Parts Please provide Serial Number A when ordering replacement parts Order replacement components from your Viessmann distributor 0001 Casing 0002 Cable Set 0003 Hydraulic System 0004 Heat Cell 0005 Other 0006 Electronic Equipment 0007 Programming Unit A Rating plate with serial number 0001 0006 0007 0003 0005 0002 0004 ...

Page 105: ... 199 7722775 Ordering Parts Please provide Serial Number A when ordering replacement parts Order replacement components from your Viessmann distributor A Rating plate with serial number 0001 Casing 0002 Cable Set 0003 Hydraulic System 0004 Heat Cell 0005 Other 0006 Electronic Equipment 0007 Programming Unit 0001 0006 0007 0003 0005 0002 0004 ...

Page 106: ...2777 Ordering Parts Please provide Serial Number A when ordering replacement parts Order replacement components from your Viessmann distributor A Rating plate with serial number 0001 Casing 0002 Cable Set 0003 Hydraulic System 0004 Heat Cell 0005 Other 0006 Electronic Equipment 0007 Programming Unit 0001 0006 0007 0003 0005 0002 0004 ...

Page 107: ...ring Parts Please provide Serial Number when ordering replacement parts Order replacement components from your Viessmann distributor Parts List continued Casing 0001 Front cover 0002 Seal cover 0003 Seal profile 0004 Hinge 0005 Hinge bottom 2 pcs 0006 Diaphragm grommet 88 9 mm 0007 Diaphragm grommet 80 mm 0008 Ventilation cover 0009 Center clip 2 pcs 0010 Cable inlet grommets 2 pcs 0011 Screw EJOT...

Page 108: ...r Parts List continued Heat Cell 0001 Heat exchanger 0002 Connection elbow HV 0003 Connection elbow HR 0004 Gasket set connection elbow 0005 Insulation block 0006 Boiler flue connection 80 125 0007 Flow sensor Duplex 0008 Flue gas sensor 0009 Flue gas gasket DN80 0010 Flue duct and gaskets 0011 Grommet DN80 0012 Cap plug boiler flue connection 0013 O ring connected piping 0014 Ventilation cover 00...

Page 109: ...der replacement components from your Viessmann distributor Heat Cell 0001 Connection elbow 0002 Gasket set connection elbow 0003 Thermal insulation block separation plate 0004 Boiler flue connection 80 125 0005 Temperature sensor 0006 Flue gas temperature sensor 0007 Flue gas gasket DN80 0008 Grommet DN80 0009 Cap plug boiler connection 0010 Gasket set pipework 0011 Ventilation cover 0012 Burner d...

Page 110: ...ement components from your Viessmann distributor Burner 0001 Cylinder flame body Matrix Plus 0002 Thermal insulation ring with Mutlitherm 0003 Gasket set incl screws 0004 Burner door 0005 Ignition transformer 0006 Blade terminal 5 pcs 0007 Ignition electrode gasket 0008 Ignition electrode 0009 IO electrode gasket 0010 IO electrode 0011 Diaphragm backflow protection 0012 Radial fan 120V 0013 Gasket...

Page 111: ...ement parts Order replacement components from your Viessmann distributor Burner 0001 Flame body assembly 0002 Thermal insulation ring 0003 Burner door 0004 Ignition transformer 0005 Ignition IO electrode gasket 3 pcs 0006 Ignition electrode block 0007 FK gasket 0008 Ionization electrode 0009 Membrane non return device 0010 Radial Fan 120V 0011 Blade terminal 5 pcs 0012 Seal rings pack 9 pcs 0013 V...

Page 112: ...phragm grommet 0002 Hydraulics flow pipe 0003 VT flow pipe with O rings 0004 Connection pipe return CA 0005 Condensate hose 0006 Meander Siphon 0007 Siphon holder 0009 Hydraulics connection pipe 0010 Air box hydraulics gasket 4 pcs 0011 Screw PT 50 x 14 5 pcs 0012 Gasket A 17 x 24 5 pcs 0013 Spring clip d 25 0014 Connector fittings 2 pcs 0015 Self tapping screw 5 pcs 0016 Round head screw 5 pcs 00...

Page 113: ...iaphragm grommet 0002 Hydraulics flow pipe 0003 VT flow pipe with O rings 0004 Connection pipe return 0005 Condensate hose WT 0006 Meander Siphon 0007 Siphon holder 0009 Hydraulics connection pipe 0010 Air box hydraulics gasket 4 pcs 0011 Screw 5 pcs 0012 Gasket 5 pcs 0013 Spring clip d 25 0014 Connector fittings 2 pcs 0015 Self tapping screw 5 pcs 0016 Round head screw 5 pcs 0017 Pump Module 0018...

Page 114: ...m 0001 Connection pipe 0002 Diaphragm grommet 0003 Connection pipe 0004 Connection pipe HR circulation 0005 Connection pipe HV circulation bottom 0006 Angle piece G1 1 4 G1 1 4 0007 Condensate hose 0008 Meander Siphon 0009 Siphon holder 0010 Screw 5 pcs 0012 Self tapping screw 5 pcs 0013 Spring clip d 25 0014 Gaskets and O rings 0015 Gasket set 1 1 4 5 pcs 0016 Pump Module 0017 Seal set O Ring 5 p...

Page 115: ...1 Connection pipe 0002 Diaphragm grommet 0003 Connection pipe 0004 Connection pipe HR combi 0005 Connection pipe HV combi bottom 0006 Angle piece G1 1 4 G1 1 4 0007 Condensate hose 0008 Meander Siphon 0009 Siphon holder 0010 Screw 5 pcs 0012 Self tapping screw 5 pcs 0013 Spring clip d 25 0014 Gaskets and O rings 0015 Gasket set 1 1 4 5 pcs 0016 Pump Module 0017 Seal set O Ring 5 pcs 0018 O Ring 00...

Page 116: ...utor Pump Module 0001 Round seal ring 5 pcs 0002 O Rings 5 pcs 0003 Screw 5 pcs 0004 Valve insert 0005 O Ring 5 pcs 0006 Connector G3 4 0007 Fuse clip nipple connection 0008 Compact carrier sheet hydraulics 0009 Circulation adapter 0010 Circulation adapter return flow side 0011 Clip D 24 5 pcs 0012 Screw EJOT 5 pcs 0013 Plug D 8 D 10 0014 Clip D 8 small 5pcs 0015 Return flow housing with cap and p...

Page 117: ...3 O Rings 5 pcs 0004 Screw 5 pcs 0005 Valve insert 0006 Flow sensor 0007 O Ring 5 pcs 0008 Safety pin 2 pcs 0009 NTC temperature sensor VA 30 125 C 0010 Plate heat exchanger 0011 Profile seal 0012 Flow regulator 0013 Connector G3 4 0014 Fuse clip nipple connection 0015 Compact carrier sheet hydraulics 0016 Adapter PWT compact 0017 Clip D 24 5 pcs 0018 Screw EJOT 5 pcs 0019 Round head screw 5 pcs 0...

Page 118: ... 7722774 B1HE 199 7722775 Ordering Parts Please provide Serial Number when ordering replacement parts Order replacement components from your Viessmann distributor Pump Module 0001 3 Way Diverter valve 0002 Gasket set 5 pcs 0003 Gasket set 5 pcs 0004 Pump 115V 0005 Circulation pump motor 115V 0006 Flow switch 0007 Hydraulic module ...

Page 119: ...nents from your Viessmann distributor Pump Module 0001 Flow sensor DN15 0002 3 Way diverter valve 0003 Gasket set 5 pcs 0004 Gasket 5 pcs 0005 Gasket set 2 pcs 0006 Gasket set 5 pcs 0007 RV cartridge non return valve 0008 Flow regulator 0009 Potable water sensor short Clip D 8 0010 Clip D 8 5 pcs 0011 Pump 115V 0012 Circulation pump motor 115V 0013 PWT B10TH16 with threaded bolt 0014 Profile seal ...

Page 120: ...2774 B1HE 199 7722775 B1KE 120 7722776 B1KE 199 7722777 Ordering Parts Please provide Serial Number when ordering replacement parts Order replacement components from your Viessmann distributor Electronic Equipment 0001 BCU 0002 Cover 0003 Rear cover 0004 Base enclosure 0005 Cable 0006 Cable set 0007 Front Cover 0008 Divider 0009 Plug Sset 0010 Clip 0011 Power switch ...

Page 121: ...7722773 B1HE 150 7722774 B1HE 199 7722775 B1KE 120 7722776 B1KE 199 7722777 Ordering Parts Please provide Serial Number when ordering replacement parts Order replacement components from your Viessmann distributor Cable Set 0001 Wiring harness low voltage 0002 Wiring harness 120V 0003 Power cable 0004 Cable gland 0005 Cable 10 pin twisted L 1300 ...

Page 122: ...B1HE 150 7722774 B1HE 199 7722775 B1KE 120 7722776 B1KE 199 7722777 Ordering Parts Please provide Serial Number when ordering replacement parts Order replacement components from your Viessmann distributor Programming Unit 0001 Human Machine Interface HMI P 3 5 450 0002 Telemetric Control Unit TCU200 0003 Ribbon cable Wifi module 0004 Fiber optic HMI 450 ...

Page 123: ... 120 7722773 B1HE 150 7722774 B1HE 199 7722775 B1KE 120 7722776 B1KE 199 7722777 Ordering Parts Please provide Serial Number when ordering replacement parts Order replacement components from your Viessmann distributor Other 0001 Technical Documentation 0002 Lubricant 0003 Vitowhite spray paint 150 ml can 0004 Touch up paint stick Vitowhite ...

Page 124: ...6 B1KE 199 7722777 Ordering Parts Please provide Serial Number when ordering replacement parts Order replacement components from your Viessmann distributor Accessories 0001 Pressure Gauge 0002 Boiler Pressure Relief Valve 0003 Locking Clip 0004 O Ring 0005 Adaptor 0006 Label 0007 Boiler Drain Fill Valve 0008 DHW Pressure Relief Valve B1KE Only 0009 Outdoor Temperature Sensor 0013 Wall Mounting Bra...

Page 125: ...ire or explosion D Do not use this boiler if any part has been under water Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above 2 Set thermostat or other operating control to lowest setting 3 Turn off all electric power to the...

Page 126: ...126 6167 818 10 Vitodens 100 W B1HE B1KE Combi Installation Service ...

Page 127: ...127 6167 818 10Vitodens 100 W B1HE B1KE Combi Installation Service ...

Page 128: ... Vitodens 100 W B1HE B1KE Combi Installation Service Technical information subject to change without notice Printed on environmentally friendly recycled and recyclable paper Scan for digital copy of this document ...

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Viessmann B1HE Series, Installation And Service Instructions Manual

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