Viessmann Vitodens 100-W B1HA 125 Installation And Service Instructions Manual Download Page 1

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Installation and Service

Instructions

VITODENS 100-W

5784 568 - 18 04/2020

for use by heating contractor

Vitodens 100-W B1HA/B1KA

Models 26 to 125

Wall-Mounted, gas-fired condensing boilers

On demand domestic hot water with Combi

boiler

Read and save these instructions

for future reference.

IMPORTANT

Please file in Service Binder

Heating input: 21 to 125 MBH

6.2 to 36.6 kW

Summary of Contents for Vitodens 100-W B1HA 125

Page 1: ...ating contractor Vitodens 100 W B1HA B1KA Models 26 to 125 Wall Mounted gas fired condensing boilers On demand domestic hot water with Combi boiler Read and save these instructions for future referenc...

Page 2: ...tion 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...

Page 3: ...1HA with one heating circuit DHW tank and LLH 28 B1HA with one heating circuit and DHW tank 29 B1KA with one heating circuit 30 B1KA with one heating circuit and LLH 31 B1KA with one heating circuit w...

Page 4: ...the front Panel 52 Removing the Burner 53 Reinstall the Burner Assembly 53 Check Burner Gasket and Cylinder Assembly for Damage 53 Check and Adjust Ignition and Ionization Electrodes 54 Check Condens...

Page 5: ...ting of High Limit Switches for Vitodens boilers where required by law VIESSMANN IS NOT RESPONSIBLE FOR ANY DAMAGES THAT THE FOLLOWING TEST PROCEDURE MAY RESULT IN BY OVERHEATING THE SYSTEM The Vitode...

Page 6: ...e or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision can not...

Page 7: ...by the 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 advi...

Page 8: ...dition the Vitodens 100 W is set up for operation with constant boiler water temperature By connecting an outdoor temperature sensor included with installation accessories the boiler can be operated i...

Page 9: ...ogenated hydrocarbons e 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 boil...

Page 10: ...UL ULC listed CPVC gas vent material The zero inches vent clearance to combustibles for the Vitodens 100 W boiler supercedes the clearance to combustibles listing that appears on the special venting...

Page 11: ...sate drain plastic hose 1 in 22 mm B Boiler water supply NPT in male thread C Gas connection NPT in male thread D Boiler water return NPT in male thread E Combustion air opening for double pipe system...

Page 12: ...move caps For installations that do not require DHW tank connections leave caps installed Legend A DHW tank heating supply for B1HA boilers B DHW tank heating return for B1HA boilers C DHW for B1KA bo...

Page 13: ...to the installation instructions applicable to your installation requirements Installation of mounting bracket on brick concrete wall 1 Drill holes e in 10 mm 2 Align wall mounting boiler bracket and...

Page 14: ...ecure 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...

Page 15: ...mbi Installation Service Boiler Mounting continued Installation Mounting the boiler to the wall Note Prior to installing the boiler verify that the minimum mounting clearances are met 1 Mount boiler o...

Page 16: ...e field calculated Boiler mounting bracket and frame 1 Attach the wall mounting bracket supplied with the boiler to the boiler mounting frame using the supplied hardware Ensure that the wall mounting...

Page 17: ...ll roof or chimney taking the shortest possible route and at a rising angle min 3 Coaxial combustion air inlet cover shown installed For coaxial venting system remove the cover from the flue gas vent...

Page 18: ...CW connection NPT in male thread for B1KA E Boiler water return connection NPT in male thread 1 Make gas connection in accordance with codes CAN CSA B149 1 or 2 in Canada In the United States use the...

Page 19: ...be leak tested before placing the boiler in operation CAUTION Ensure that gas piping is large enough for all appliances in the residence No noticeable gas pressure drop in the gas line must occur when...

Page 20: ...ot used All plumbing must meet or exceed all local state and national plumbing codes WARNING The pressure gauge is a sensitive component and may be damaged if the boiler connections are not supported...

Page 21: ...lect a pump with an overflow 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 Connections Boiler Conn...

Page 22: ...ssure relief valve Removal of air from the system must occur via use of air vent s in the system supply To ensure the boiler can be purged of all air ensure supply return water lines do not contain re...

Page 23: ...Service Connections Safety Connections continued Hot water temperature and system pressure See page 44 for fill procedure The boiler water pressure reading is displayed on an analog gauge The boiler...

Page 24: ...stem flow and pressure drop calculations including DHW sizing A low loss header must be used when the system flow rate exceeds the maximum or minimum flow rate of the Vitodens 100 W boiler An alternat...

Page 25: ...strongly recommends and prefers the use of a low loss header over closely spaced tees Refer to the Technical Data manual for low loss header information Model B1HA 26 94 1 boiler Output NG LPG MBH 88...

Page 26: ...consumption W max 130 W min 80 Built in pump Grundfos UPS15 78 three speed heating circuit DHW production pump for Vitodens 100 W B1HA 26 35 94 125 and B1KA 35 125 boilers in the factory setting the p...

Page 27: ...Outdoor temperature sensor OTS Note The use of a low loss header is recommended if the water flow rate is less than 1 7 GPM 400 L h or more than 6 2 GPM 1400 L h The low loss header is available as ac...

Page 28: ...1400 L h The low loss header is available as accessory part DHW supply and return piping between boiler DHW connections and the Viessmann DHW tank connections shall be a minimum of 1 in nominal pipe d...

Page 29: ...ommended if the water flow rate is less than 1 7 GPM 400 L h or more than 6 2 GPM 1400 L h The low loss header is available as an accessory part DHW supply and return piping between boiler DHW connect...

Page 30: ...ens 100 W B Room thermostat C Heating circuit D Outdoor temperature sensor OTS Note The use of a low loss header is recommended if the water flow rate is less than 1 7 GPM 400 L h or more than 6 2 GPM...

Page 31: ...ler B External boiler system controller with room thermostat connection field supplied C Heating circuit D Heating circuit pump field supplied E Low loss header there is no LLH temperature sensor avai...

Page 32: ...h room thermostat connection field supplied E Closely spaced tees 4x pipe or 12 in 305 mm 1 F Outdoor temperature sensor OTS 1 A low loss header offers additional benefits not provided by a pair of cl...

Page 33: ...piped in parallel to the boiler with appropriate valves to prevent the chilled medium from entering the boiler The boiler piping system of a hot water heating boiler connected to heating coils located...

Page 34: ...des in lieu of a low water cut off Boiler below radiation Boiler above radiation LWCO LWCO Air Vent Air Vent Venting For detailed installation information and specific venting requirements reference t...

Page 35: ...mary Heat supplied by boiler Qsecondary Heat consumed by system Vprimary Vsecondary T1 T3 T2 T4 Qprimary Qsecondary T1 176 F 80 C Vsecondary Vprimary Vbypass When installing a low loss header system m...

Page 36: ...own 3 Release the 4 boiler cover retaining clips and pull cover off 4 Terminal block for OpenTherm or room thermostat s and outdoor temperature sensor Connectors for DHW tank temperature sensor or tan...

Page 37: ...B Connection for Viessmann supplied DHW tank temperature sensor or field supplied aquastat to a factory installed connection Location of terminal block and temperature sensor connections A B B1HA mod...

Page 38: ...continued Control Connections Legend Viessmann DHW tank temperature sensor supplied Note see wiring diagram on page 77 Legend A Viessmann DHW tank temperature sensor supplied B Viessmann DHW tank temp...

Page 39: ...er on B1HA only e g Honeywell Aquastat or others A Legend A Tank temperature controller field supplied Note see wiring diagram on page 77 1 Cut off and discard the 2 red connectors labelled 5 See page...

Page 40: ...om thermostat 24VAC field supplied B Switching relay field supplied Note When using the operating methods operation without room temperature thermostat or weather compensated operation without room te...

Page 41: ...the boiler The boiler will adjust the heat input accordingly low high modulation Follow the installation instructions of the field supplied operating controls Refer to the OpenTherm accessory manual...

Page 42: ...tructions of all labels and stickers attached to boiler surfaces Do not remove any of these instructions Contact Viessmann if any replacement labels are required 1 Connect the electrical accessories a...

Page 43: ...splay unit C Power switch ON OFF Overview of Controls and Indicators Legend A Display value or F fault B Temperature in F C in conjunction with the display value C Heating mode D DHW heating E Display...

Page 44: ...High fire 100 3 Altitude setting see page 49 0 or 5000 ft 1500 m Adjusts the boiler for high altitude operation 0 1 5 Do Not Adjust 6 5000 ft 1500 m 4 Do not adjust 0 5 Fuel Type 0 Natural Gas The ga...

Page 45: ...the antifreeze manufacturer Do not use automotive silicate based antifreeze Please observe that an antifreeze water mixture may require a backflow preventer within the automatic water feed and influe...

Page 46: ...e burner cover panel as per the removal instructions on page 42 2 Close gas shutoff valve 3 Loosen screw in test nipple A on the gas combination valve do not remove completely Connect calibrated manom...

Page 47: ...mum resolution of 0 04 w c for measuring the running pressure 9 Enter gas type into Maintenance Record on page 90 in this manual 10 Switch off the heating system ON OFF service switch boiler is shut d...

Page 48: ...to a minimum of 0 4 under the value for high fire as shown in the flue gas CO2 content table 7 Should the actual CO2 value deviate from the values shown in the flue gas CO2 content table check the se...

Page 49: ...lected value is adopted The maximum heating output can be reduced according to the system requirements 1 Tap MODE 2 until CONFI flashes 3 OK to confirm P appears in the left hand display area The righ...

Page 50: ...4 1 appears in the left hand display area and flashes Select 13 using and confirm with OK 5 The right hand display area flashes Here the unit of measurement temperature unit can be adjusted 0 C 1 F Ta...

Page 51: ...utility you find the heating value is e g 1000 Btu per cu ft Therefore 3600 x 10 288 x 1000 125 000 Btu h input Therefore the boiler input is correct Burner input formulas up to 4500 ft INPUT 3600 t x...

Page 52: ...gas measurement port To ensure continued efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals The frequency of servicing will depend on...

Page 53: ...der assembly D for damage and replace if necessary Replace the cylinder burner assembly if damaged 1 Remove electrode block B 2 Loosen the three Torx screws and remove the thermal insulation ring C 3...

Page 54: ...ve all hoses from siphon A 3 Release locking tabs at opening B from underneath and remove siphon A upwards 4 Clean siphon A and reinstall 5 Refit all hoses Secure drain hose with cable ties 6 Fill the...

Page 55: ...cuuming loose debris out 3 Remove embedded sediment from the stainless steel heat exchanger surface B by thoroughly rinsing with water or cleaning agents such as Axiom Industries Clean F Steel Follow...

Page 56: ...ssure relief valve 30 psig 4 When starting up the system for the first time mark this value as the minimum filling pressure on the manometer Note A lower manometer reading usually indicates loss of wa...

Page 57: ...e fitting B on the gas connection pipe to a torque of 132 lb in 15 Nm 3 Plug the Venturi extension C into the radial fan D 4 Replace electrical cables from gas valve E and electrode block F 5 Open gas...

Page 58: ...he 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 dis...

Page 59: ...hanging Room Temperature In case a separate external room temperature controller thermostat is installed the desired room temperature will be adjusted using this device Make adjustments using the appr...

Page 60: ...heat demand Fan starts Ignition Gas valve opens Ionization current builds higher than 2 A Symbol A Burner in operation After approx 1 min fault 9 Fault F4 Fault F4 Fault F4 Stops below the set boiler...

Page 61: ...rted out Check sensor see page 68 52 Burner blocked Flow sensor shorted out Check connections and wire replace sensor if required 58 No DHW heating Tank temperature sensor wire broken Check sensor see...

Page 62: ...r in fault mode Blower not at stand still Check the blower blower connecting cables and blower control Reset control FC Burner blocked Electrical fan control control unit faulty Check fan connecting c...

Page 63: ...e fully removed 2 Remove the front panel Resistance in K Boiler water temperature 1 Disconnect cables from boiler temperature sensor A 2 Measure resistance of the boiler temperature sensor and compare...

Page 64: ...er water temperature is regulated subject to the outdoor temperature Frost protection function Built in automatic frost protection allows the boiler to be shut off for an extended period of time while...

Page 65: ...m The selected value is adopted Setting the heating curve Heating curves illustrate the relationship between the out door temperature the set room temperature and the boiler water temperature or suppl...

Page 66: ...3 OK to confirm Note When adjusting this setting bear in mind that your heating system requires some time to heat the home to the required temperature Legend A Boiler water temperature B Outdoor temp...

Page 67: ...Pull the leads from fixed high limit A 2 Check the continuity of the fixed high limit with a multimeter 3 Remove faulty fixed high limit 4 Coat the replacement fixed high limit with heat conducting p...

Page 68: ...1 Pull the leads from outlet temperature sensor A 2 Check the sensor resistance and compare it with the curve 3 Replace the sensor in case of severe deviation Note Water can leak when replacing the o...

Page 69: ...control unit downwards 3 Remove two screws A from the plate type heat exchanger and remove the plate type heat exchanger B with gaskets Note During removal small amounts of water may trickle out and e...

Page 70: ...connections refer to information starting on page 36 Electrical Connections to the Terminal Strip for Accessories Additional Information Follow the installation instructions of field supplied operati...

Page 71: ...nal room thermostat On 20 seconds 3 Combi B1KA only DHW flow sensor temp sensor On none 4 DHW B1HA only DHW temperature sensor reading drops below set point Close DHW contact in control aquastat boile...

Page 72: ...88 1 02 3 88 1 02 3 88 Boiler max flow rate 4 GPM L h 6 2 1400 6 2 1400 6 2 1400 Max operating pressure max allowable working pressure at 210 F 99 C psig bar 45 3 45 3 45 3 Boiler water temperature A...

Page 73: ...on 8 in mm 2e 60 2e 60 2e 60 Combustion air supply coaxial connection 8 single outer in mm 4 100 2e 60 4 100 2e 60 4 100 2e 60 Noise level at 1 meter at full load at partial load dB dB 46 9 41 1 51 6...

Page 74: ...sure potable water psi 150 Test pressure psi 300 Integrated pump flow rate DHW production 23 ft 9 8 m Head pressure Heating system operation with system side additional drop in pressure of max 6 ft of...

Page 75: ...Continue or if FHL tripped 15 minute forced fan operation 9 Post purge Continue to next phase 10 Combination gas valve proof of closure test Continue to next phase 0 Boiler shutdown stand by Waiting f...

Page 76: ...lock out and will require a manual reset Phase 6 Flame stabilization Controller required time for flame stabilization Phase 7 Forced low fire The controller will go into low fire until required modula...

Page 77: ...ture Sensor 5 DHW Tank Temperature Sensor or tank temperature controller 15 Flue Gas temperature Sensor 20 Boiler Pump internal 33 Flow Switch 35 Gas Valve 47 Fixed High Limit 100 Fan Motor 100A Fan M...

Page 78: ...ply Temperature Sensor 15 Flue Gas temperature Sensor 20 Boiler Pump internal 33 Flow Switch 35 Gas Valve 47 Fixed High Limit 100 Fan Motor 100A Fan Motor Control 149 Flow Sensor DHW WARNING DISCONNEC...

Page 79: ...embly D Control Assembly E Hydraulic and Combi Block Assembly F Other Parts 1 Serial number is located inside main enclosure assembly behind boiler cover panel on left hand side Other Parts not illust...

Page 80: ...not illustrated 0100 Installation Set 2 0125 Technical literature set 0128 Installation Service Instructions 0130 Operating Instructions 0132 Installation Instructions Venting System 0133 Parts List V...

Page 81: ...26 94 Boiler 7560853 B1HA 35 125 Boiler 7560854 B1KA 35 125 Boiler 7560855 Parts for Main Enclosure Assembly 0001 Cover panel boiler 0002 Profile gasket for cover panel 0003 Nameplate Viessmann 0004 S...

Page 82: ...0004 Sealing grommet DN60 0005 Sensor for flue gas 0006 Heat exchanger assembly ASME 0007 Condensate pipe 0008 Condensate P trap 0009 Extension P trap 0010 Fuel connection pipe NG LP 0011 Gasket set A...

Page 83: ...54 B1KA 35 125 Boiler 7560855 Parts for Burner Assembly 0001 Burner gasket 187x5 5 mm 0002 Insulating ring 0003 Burner tube 0004 Gasket for burner tube 0005 Burner mounting flange assembly 0006 Gasket...

Page 84: ...urn 0002 Clip d 10 set of 5 0003 Clip d 8 set of 5 0004 O ring set for heat exchanger 21x3 mm 0005 Air bleed valve G3 8 0006 Sensor 3 boiler 0007 O ring 8x2 mm set of 5 0008 Connection pipe for heatin...

Page 85: ...O ring set for heat exchanger 21x3 mm 0005 Air bleed valve G3 8 0006 Sensor 3 boiler 0007 O ring 8x2 mm set of 5 0008 Connection pipe for heating supply 0009 Clip d 18 set of 5 0010 O ring 17x4 mm set...

Page 86: ...r vent 0002 O ring 34 x 3 mm 5 pieces 0003 Circulation pump head Grundfos UPS15 78 0004 Bypass cartridge 0005 Clip D 16 set of 5 0006 Adaptor for step motor 0007 Step motor linear 0008 Hydraulic pumpi...

Page 87: ...r step motor 0008 O ring 19 8 x 3 6 mm 5 pieces 0009 O ring 16 x 3 mm 5 pieces 0010 Clip d 18 set of 5 0011 Clip d 10 set of 5 0012 Clip plate D8 slim 5 pieces 0013 Flow regulator WHT BRN Type A 14L 0...

Page 88: ...r Control Assembly 0001 Control console cover 0002 Clip hinge 2 pieces 0003 Profile gasket 0004 Control console VBC115 F50 0005 Harness X20 X7 0006 Ignition cable 5kOhm 0007 Harness 35 for expanded fu...

Page 89: ...llation Service Additional Information Parts List continued Model No Serial No B1HA 26 94 Boiler 7560853 B1HA 35 125 Boiler 7560854 B1KA 35 125 Boiler 7560855 Other Parts 0001 Touch up spray paint Vit...

Page 90: ...ptor for pressure relief valve 0103 Sediment faucet in 0104 Extension in x 3 in 0105 Tee in 0106 Gas ball valve in 0107 Thermometer 1 0108 DHW pressure relief valve 150 psi 2 Other Parts not illustrat...

Page 91: ...pressure supply pressure Natural gas w c 4 14 w c Liquid Propane gas w c 10 14 w c Carbon dioxide content CO 2 at lower end of rated input range low fire vol at upper end of rated input range high fir...

Page 92: ...technician to inspect the appliance 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 on this...

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