Viessmann Vitodens 100-W B1HA 26Vitodens 100-W B1HA 35Vitodens 100-W B1KA 35 Installation And Service Instructions Manual Download Page 1

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Installation and Service

Instructions

VITODENS



100-W

5784 568 - 03 06/2017

for use by heating contractor

Vitodens 100-W

B1HA Series and B1KA Combi Boiler

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 26Vitodens 100-W B1HA 35Vitodens 100-W B1KA 35

Page 1: ...g contractor Vitodens 100 W B1HA Series and B1KA Combi Boiler Wall Mounted gas fired condensing boilers On demand domestic hot water with Combi boiler Read and save these instructions for future refer...

Page 2: ...on 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 o...

Page 3: ...Performing pressure test on the boiler 23 Installation Examples 24 General 24 Clearances 24 Heating circuit pumps 24 Waterside flow 25 Built in pump 26 B1HA with one heating circuit 27 B1HA with one h...

Page 4: ...bustion Analysis 47 Check Venting System for Leaks 48 Removing the front Panel 48 Removing the Burner 49 Check Burner Gasket and Cylinder Assembly for Damage 49 Check and Adjust Ignition and Ionizatio...

Page 5: ...ng 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 Vitodens...

Page 6: ...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 be...

Page 7: ...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 advise...

Page 8: ...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 in weath...

Page 9: ...enated 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 boiler...

Page 10: ...es when vented with a single wall special venting system AL 29 4C material or UL ULC listed CPVC gas vent material The zero inches vent clearance to combustibles for the Vitodens 100 W boiler superced...

Page 11: ...nsate 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 syste...

Page 12: ...ve 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 boil...

Page 13: ...o 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 a...

Page 14: ...od 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 e...

Page 15: ...i 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 ont...

Page 16: ...st be 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 mount...

Page 17: ...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 ad...

Page 18: ...W 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 N...

Page 19: ...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 a...

Page 20: ...ng by the boiler or its components Use isolation valves to isolate system components The B1HA DHW tank heating supply and return ports must remain capped if the DHW tank is not used All plumbing must...

Page 21: ...ect 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 Conne...

Page 22: ...plied pressure 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 c...

Page 23: ...unattended 4 Inspect all pipe joint connections and safety devices with a flashlight for leaks A lower manometer reading than 4 bar 60 psig usually indicates loss of water due to leakage All leaks mu...

Page 24: ...tem 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 alternati...

Page 25: ...ann therefore 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 1 boiler Output NG...

Page 26: ...wer 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 and B1KA 35 boilers in the factory setting the pump spe...

Page 27: ...tdoor 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 acce...

Page 28: ...00 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 dia...

Page 29: ...mmended 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 connecti...

Page 30: ...B Room thermostat C Heating circuit D Expansion tank E 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...

Page 31: ...rnal 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 available for...

Page 32: ...rmostat connection field supplied E Closely spaced tees 4x pipe or 12 in 305 mm 1 F Expansion tank G Outdoor temperature sensor OTS 1 A low loss header offers additional benefits not provided by a pai...

Page 33: ...iped 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: ...s 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 the...

Page 35: ...Qprimary 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 syst...

Page 36: ...rol unit and opening the power pump module 1 Press in the control retaining tabs 2 With retaining tabs pressed in rotate the control forward and down 3 Release the 4 boiler cover retaining clips and p...

Page 37: ...rs labelled 5 Operation without DHW tank Set the set DHW temperature to OFF Note When connecting accessories observe the separate installation instructions provided with them Legend A Viessmann outdoo...

Page 38: ...ructions 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 as...

Page 39: ...lay 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 v...

Page 40: ...heating output should be tested by measuring the gas throughput 00 26 99 Modulation Range 26 99 100 High fire 100 3 Altitude setting see page 45 0 or 5000 ft 1500 m Adjusts the boiler for high altitu...

Page 41: ...se automotive silicate based antifreeze Please observe that an antifreeze water mixture may require a backflow preventer within the automatic water feed and influence components such as diaphragm expa...

Page 42: ...tion valve do not remove completely Connect calibrated manometer 4 Open the gas shutoff valve 5 Measure static pressure Values must be 14 w c max for NG 14 w c max for LPG 6 Enter measured value into...

Page 43: ...m resolution of 0 04 w c for measuring the running pressure 9 Enter gas type into Maintenance Record on page 85 in this manual 10 Switch off the heating system ON OFF service switch boiler is shut dow...

Page 44: ...al gas and 10 to 12 for liquid propane gas The CO2 value measured must be compared with the above CO2 value Checking the CO2 Content Relay Tests 1 Connect a flue gas analyzer at flue gas port A on the...

Page 45: ...e selected 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...

Page 46: ...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 Tapi...

Page 47: ...ity you find the heating value is e g 1000 Btu per cu ft Therefore 3600 x 10 305 x 1000 118 000 Btu h input Therefore the boiler input is correct Burner input formulas up to 4500 ft INPUT 3600 t x 100...

Page 48: ...s 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 t...

Page 49: ...here is a gasket between the gas valve and this connection 6 Loosen four Torx T 30 screws F and remove burner Check the burner gasket A and burner cylinder assembly D for damage and replace if necessa...

Page 50: ...e 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 51: ...ner cover panel as per the removal instructions on page 38 in this manual and reinstall panel upon completion of service work 2 If necessary clean the combustion chamber A and heat exchanger surfaces...

Page 52: ...sure 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 wat...

Page 53: ...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 54: ...anging 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 appro...

Page 55: ...unit issues a 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...

Page 56: ...ure sensor see page 58 38 Burner blocked Boiler water temperature sensor wire broken Check the boiler water temperature sensor see page 58 50 No DHW heating Tank temperature sensor shorted out Check s...

Page 57: ...lve ignition ignition module and condensate drain Reset control Check ignition cable resistance 4 5K to 5K ohms f8 Burner in fault mode The combination gas valve closes too late Check the gas valve Ch...

Page 58: ...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 with resistance...

Page 59: ...ional the boiler 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...

Page 60: ...requires an outside temperature sensor to be connected The frost protection function becomes active at outside temperatures of 41 F 5 C The burner starts and the boiler water temperature is held at 6...

Page 61: ...3 F 95 C check the fixed high limit 1 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 fi...

Page 62: ...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 ou...

Page 63: ...ntrol 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 esc...

Page 64: ...rating instructions Electrical Connections to the Terminal Strip for Accessories Additional Information Follow the installation instructions of field supplied operating controls What is OpenTherm OT T...

Page 65: ...quastat boiler set point temp 172 F 78 C non adjustable On 20 seconds 5 Outdoor temperature sensor OTS 2 Temperature wr setting 96 plug terminals dual L and I jumpered On 4 minutes 240 seconds 6 Set p...

Page 66: ...8 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 Adj...

Page 67: ...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 41 1 51...

Page 68: ...tion only MBH kW 149 43 7 Max boiler temperature during DHW production F C 176 80 DHW supply temperature F C 140 60 Continuous draw rate 1 at t 77 F 43K USG min L h 3 3 750 Max flow through heat excha...

Page 69: ...ed 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 for next call for heat St...

Page 70: ...ck 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 modulati...

Page 71: ...ler Temperature Sensor 5 DHW Tank 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 WARNING...

Page 72: ...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 Additional Informati...

Page 73: ...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 illustrated...

Page 74: ...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 75: ...1HA 26 Boiler 7560853 B1HA 35 Boiler 7560854 B1KA 35 Boiler 7560855 Parts for Main Enclosure Assembly 0001 Cover panel boiler 0002 Profile gasket for cover panel 0003 Nameplate Viessmann 0004 Strain r...

Page 76: ...rt cap set of 2 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 0...

Page 77: ...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 for electrode block 0007 Igni...

Page 78: ...ting return 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 fo...

Page 79: ...f 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 heating supply 0009 Clip d 18 set of 5 0010 O ring 17...

Page 80: ...t 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 pumping bl...

Page 81: ...ep 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 0014...

Page 82: ...ol 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 functions...

Page 83: ...nstallation Service Additional Information Parts List continued Model No Serial No B1HA 26 Boiler 7560853 B1HA 35 Boiler 7560854 B1KA 35 Boiler 7560855 Other Parts 0001 Touch up spray paint Vitowhite...

Page 84: ...30 psi 0102 Adaptor 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 Par...

Page 85: ...essure 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 fire...

Page 86: ...appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been und...

Page 87: ...87 5784 568 03Vitodens 100 W B1HA series B1KA Combi Installation Service...

Page 88: ...hnical information subject to change without notice Printed on environmentally friendly recycled and recyclable paper Scan for digital copy of this document Vitodens 100 W B1HA series B1KA Combi Insta...

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Summary of Contents for Vitodens 100-W B1HA 26Vitodens 100-W B1HA 35Vitodens 100-W B1KA 35

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