background image

Initial Start-up, Inspection and Maintenance

54

Steps

(continued)

12. Remove burner (continued)

S

ervice

Maintenance

6.

Disconnect electrical cables from gas
valve

, and ignition transformer

unit

.

7.

Remove connection hose

from air

pressure switch.

8.

Loosen the fitting

on the gas

connection pipe.

9.

Loosen four Torx (T-30) screws

,

remove burner and disconnect all
electrical cables from blower motor

.

5

5

8

1

7

7

5

1

.3

To avoid damage to the burner, do
not lay burner on its cylindrical
burner tube.
Failure to heed this caution may
cause damage to the burner tube,
which may lead to improper
operation.

CAUTION

Summary of Contents for Vitodens 100 WB1A 8-24

Page 1: ...B1A Series Wall mounted natural gas fired condensing boiler For natural gas Heating input 29 to 100 MBH 8 5 to 29 3 kW Read and save these instructions for future reference IMPORTANT Vitodens 100 W WB...

Page 2: ...Important Regulatory and Installation Requirements in the Installation Instructions H Advice to owner Once the installation work is complete the heating contractor must familiarize the system operator...

Page 3: ...ons 18 Flue gas connection 18 Proper piping practice 19 Gas connection and piping 19 Gas piping pressure test 21 Heating water connections 22 Condensate connection 23 Fill siphon with water 23 Safety...

Page 4: ...ture 61 Diagnosis 62 Sequence of operation and potential faults during each start up cycle 62 Diagnostics table Faults with fault display on control unit 63 Correction 65 Remove front cover panel 65 C...

Page 5: ...rt for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than 7 feet above finished grade in the area of the venting i...

Page 6: ...structure used in whole or in part for residential purposes c MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented ga...

Page 7: ...ed electrical controls and components must be verified by the heating contractor This includes low water cut offs flow switches if used staging controls pumps motorized valves air vents thermostats et...

Page 8: ...tial hazards or important product information Helpful hints for installation operation or maintenance which pertain to the product This symbol indicates that additional pertinent information is to be...

Page 9: ...rcuits An external controller is required for outdoor responsive control and DHW production The Vitodens 100 W comes factory set for operation with natural gas with no option of conversion to liquid p...

Page 10: ...air of other fuel burning equipment if applicable within the mechanical room The maximum room temperature of the mechanical room where the boiler is located must not exceed 104 F 40 C Boiler operatio...

Page 11: ...y areas and establishments H Auto body shops H Refrigeration repair shops H Metal fabrication plants H Plastic manufacturing plants H Photo processing plants H Beauty salons Products containing contam...

Page 12: ...al or 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 ven...

Page 13: ...o subsequent sections for detailed information on individual piping connections Piping connections for Vitodens 100 W WB1A 8 24 and 8 30 factory supplied Legend BWR Boiler water return BWS Boiler wate...

Page 14: ...m h 5 125 mm Vitodens 100 W WB1A side view When preparing gas water and electrical connections in the field see section entitled Wall Mounting on page 16 of this manual for information regarding the i...

Page 15: ...Piping connections for Vitodens 100 W WB1A 8 24 and 8 30 factory supplied Legend BWR Boiler water return BWS Boiler water supply BD Boiler drain BF Boiler fill GC Gas connection NPTM male thread PRV...

Page 16: ...to the installation instructions applicable to your installation requirements Installation of mounting bracket on brick concrete wall 1 Drill holes 3 8 10 mm using mounting template supplied with the...

Page 17: ...metal studs install mounting bracket on wall as shown on previous page Refer to drawings on the left and below for more detailed installation information Install mounting bracket on wood studs as per...

Page 18: ...of the mounting bracket see subsection entitled Wall mounting bracket installation on page 16 of this manual Connections Flue gas connection Combustion air Flue gases The Vitodens 100 W boiler comes...

Page 19: ...connection Water return connection 1 Make gas connection in accordance with codes CAN CSA B149 1 or National Fuel Gas Code ANSI Z223 1 NFPA 54 as well as local codes where applicable 2 Close gas shut...

Page 20: ...ts 2 Before connecting boiler to gas line install ground joint union capped drip leg and a manual equipment shutoff valve Valves must be listed by a nationally recognized testing agency Make boiler ga...

Page 21: ...supply piping system during any pressure testing of that system at test pressures in excess of psig 14 w c 3 Perform leak test Use approved liquid spray solution for bubble test Ensure that no liquid...

Page 22: ...from pressure exceeding those values stated is not covered by Viessmann warranty H Use a two hand wrench method when tightening fittings or piping onto the boiler connectors Use one wrench to prevent...

Page 23: ...for condensing boiler applications To avoid condensate spillage select a pump with an overflow switch The drain connection must terminate into an open or vented drain as close to the boiler as possib...

Page 24: ...is not piped to outdoors Minimum connection diameters Pressure relief valve Discharge pipe Piping to precharged expansion tank Install the approved factory supplied pressure relief valve Removal of a...

Page 25: ...akage All leaks must be repaired 5 After 15 minutes release water pressure from boiler by opening boiler drain valve slowly remove caps from supply and return connections as well as cap from 2 nipple...

Page 26: ...from non insulated hot water pipes to combustible construction must be maintained In cases where the pipes are insulated with pipe insulation of appropriate and sufficient thickness and insulation val...

Page 27: ...r equipped with Viessmann System Technology Please note that the examples below are simplified conceptual drawings only Piping and necessary componentry must be field verified A low water cut off LWCO...

Page 28: ...ump field supplied Expansion tank Ensure that a pressure activated by pass is installed Refer to the table for the DIP switch setting on page 38 Please note The use of a low loss header is recommended...

Page 29: ...tr h The low loss header is available as accessory part See page 36 in this manual for details on the low loss header Model No Vitodens 100 W Max flow rate GPM ltr h WB1A 8 24 6 2 1400 WB1A 8 30 6 2 1...

Page 30: ...ommended if the water flow rate is less than 1 7 GPM 400 ltr h or more than 6 2 GPM 1400 ltr h The low loss header is available as accessory part See page 36 in this manual for details on the low loss...

Page 31: ...Boiler Connections 31 Installation Examples continued Wiring diagram for system layout 4 5581 775 1 3...

Page 32: ...p field supplied C Honeywell switching relay for DHW H control DHW circulating pump field supplied D Vitotronic 050 Model HK1M Digital indoor outdoor heating circuit control unit pump control Vi Part...

Page 33: ...xcessive temperature if no automatic mixing valves are used or no DHW priority is required After the DHW call for heat is satisfied there is a 80 seconds pump post purge time Model No Vitodens 100 W M...

Page 34: ...appropriate valves to prevent the chilled medium from entering the boiler See illustration on the left The boiler piping system of a hot water heating boiler connected to heating coils located in air...

Page 35: ...ystem Do not install an isolation valve between boiler and low water cut off Follow the installation instructions of the low water cut off manufacturer For low water cut off wiring information specifi...

Page 36: ...right for an illustration of the principle of operation The low loss header is available in the following sizes Select the size based on the maximum system flow rate of your application Model No Max...

Page 37: ...y to the building before attaching the vent termination It is strongly recommended to install the vent termination on the leeward side of the building Electrical Connections Removing the control unit...

Page 38: ...oller external heat demand Room temperature thermostat Anticipator setting 0 2A DIP switch settings S1 Remove short factory test leads from terminal L N and Ground before connecting main power supply...

Page 39: ...nt cover panel until it locks into position 3 Screw in screw at top part of boiler Read and follow where applicable the safety instructions of all labels and stickers attached to boiler surfaces Do no...

Page 40: ...arach fluid samplers or suitable electronic flue gas analyzer H Manometer to measure gas pressure 0 to 11 w c accurately and up to 28 w c gas pressure or a non electric Magnehelic manometer may also b...

Page 41: ...lve Pressure gage Opening the control unit Controls and indicators are located behind the hinged front cover Control and display elements The control unit is preset at the factory for standard operati...

Page 42: ...isplay value or fault code Heating mode Burner in operation Current burner firing rate Boiler water temperature in F combined with display value Fault System pressure combined with display value Emiss...

Page 43: ...ow switch VK315M P trap Air pressure switch Condensate hose 400mm Water pressure sensor Vent pipe adaptor Test port cap Burner mounting flange assembly Boiler temperature sensor Radial fan RG130 120 1...

Page 44: ...nections for leaks 52 I M 10 Perform combustion analysis 52 I 11 Check venting system for leaks circular air gap measurement for sealed combustion coaxial vent only 53 S I M 12 Remove burner 53 I M 13...

Page 45: ...g tap slowly to fill the boiler with water Isolation valves not shown to isolate system components must be closed during fill bleed process H Flush the boiler heat exchanger via the boiler supply and...

Page 46: ...quires a 120 VAC power supply The voltage at connector X3 must be 120 V see wiring diagram Neutral conductor The electrical power supply must have a neutral conductor In Canada all electrical wiring i...

Page 47: ...nd or running pressure remove burner cover panel as per the removal and reinstallation instructions on page 18 in these instructions 2 Close gas shutoff valve 3 Loosen screw in test nipple A on the ga...

Page 48: ...to decrease pressure Boiler valve must not be exposed to pressure over 14 w c 9 Enter gas type into Maintenance Record on page 74 in this manual 10 Switch off the heating system on off service switch...

Page 49: ...for optimum boiler performance at all firing rates through a pneumatic link between combustion air and gas flows Blower speed is automatically increased or decreased based on heat demand thereby regul...

Page 50: ...between 12 00 and 4 00 o clock See top illustration on left Turning the selector dial tr counter clockwise between the 12 00 and 8 00 o clock position will bring the boiler to the low fire position Se...

Page 51: ...boiler input is correct Burner input formulas up to 4500 ft INPUT 3600 t x 1000 where t TIME sec for 1 ft 3 INPUT 3600 x 01 x 1000 x 35 31 T where T TIME sec for 01 m3 natural gas A boiler underfired...

Page 52: ...ons are pressure tight Correct any leaks found on fittings pumps valves etc 10 Perform combustion analysis Service Start up and Maintenance A CO measurement see page 50 must be taken before and after...

Page 53: ...non sealed combustion 12 Remove burner Service Maintenance To ensure continued efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals The...

Page 54: ...e connection hose from air pressure switch 8 Loosen the fitting on the gas connection pipe 9 Loosen four Torx T 30 screws remove burner and disconnect all electrical cables from blower motor 5581 775...

Page 55: ...to a torque of 2 5 lb ft 3 5 Nm using a calibrated torque wrench 5 Reinstall thermal insulation ring 6 Reinstall electrode block Tighten to a torque of 1 8 lb ft 2 5 Nm using a calibrated torque wren...

Page 56: ...on chamber refractory will also become wet at the bottom portion Do not restart the boiler immediately with a wet combustion chamber refractory This will damage the refractory Either dry the refractor...

Page 57: ...residues H Remove deposits of soot with alkaline agents containing tenside H Remove coatings and yellowish brown surface discoloration with phosphoric acid based Antox 75 E Plus or citric acid based...

Page 58: ...With the system cold the filling pressure must be approx 3 psig higher than the static pressure Max operating pressure 45 psig Min operating pressure 14 psig 4 When starting up the system for the firs...

Page 59: ...t new gasket and tighten the fitting on the gas connection pipe 3 Insert air pressure switch connection pipe onto the gas valve OUT connector P2 on the switch 4 Replace electrical cables from gas valv...

Page 60: ...e 65 Overview of Controls and Indicators Legend tr boiler water temperature selector dial Display fault and reset button LCD display Opening the control unit Controls and indicators are located behind...

Page 61: ...hermostat is installed the desired room temperature will be adjusted using this device Make adjustments using the appropriate operating instructions only Please also note lf thermostatic radiator valv...

Page 62: ...no Check flue gas system and differential air pressure switch Differential air pressure switch enables start up Close contacts between terminals X8 7 and X8 8 104VRAC DC symbol A appears unit and it...

Page 63: ...e Internal fault Replace control unit e4 Burner blocked Fault with the supply voltage power pump module Check connections Replace control unit e5 Burner blocked Internal fault Check ignition and ioniz...

Page 64: ...blower control Press Reset fd Burner blocked Burner control unit fault Check the ignition electrodes and leads Check whether a strong inter ference EMC field exists near the equipment Press reset If t...

Page 65: ...sensor A 2 Measure resistance of the boiler temperature sensor and compare with resistance boiler water temperature curve shown on the left 3 If the value measured differs significantly replace the se...

Page 66: ...iler water temperature is below approx 203 F 95 C check the fixed high limit 1 Pull the leads from fixed high limit 2 Check the continuity of the fixed high limit with a multimeter 3 Remove faulty fix...

Page 67: ...er pump module cover plate 4 Check fuse F1 T6 3A slow blow Replacements available form Viessmann package of 10 PN 7815 580 Control unit fuse 1 Switch off main power supply 2 Flip down control unit 3 R...

Page 68: ...Natural gas w c 4 4 Max gas supply pressure 3 Natural gas w c 14 14 A F U E 95 1 95 1 Weight lbs kg 95 43 95 43 Boiler water content USG ltr 0 82 3 1 0 82 3 1 Boiler max flow rate 4 GPM ltr h 6 2 1400...

Page 69: ...h kg h Pa mbar 79 2 36 0 33 0 15 0 100 1 0 100 1 45 5 33 0 15 0 100 1 0 Average condensate flow rate 6 with natural gas TS TR 122 86 F 50 30 C USG day ltr day 1 8 2 1 7 8 2 1 2 4 8 9 Condensate connec...

Page 70: ...period Phase 3 Pre purge Pre purge cycle starts within the pre programmed timing If air proving switch opens during this period the burner will revert back to Phase 1 Also if at the end of the pre pur...

Page 71: ...Additional Information 71 Wiring Diagram 5581 775 1 3 PUMP PUMP DHW...

Page 72: ...lapper 059 Radial fan RG130 120 1 60 060 Air gas inlet venturi Type 002 061 Gas valve VK4115V 120 1 60 062 Burner mounting flange assembly 063 Ignition transformer module ZIG 2 12 080 Control console...

Page 73: ...for supply pipe 031 Flue gasket 60mm 032 Flue gasket 100mm 033 Flow switch VK315M 084 Power pump module 120 1 60 302 Wall mount bracket 408 Boiler drain 409 Boiler fill 410 Boiler water return 411 Bo...

Page 74: ...c vol vol vol vol ppm ppm Measurements Static pressure Running pressure supply pressure j Natural gas Carbon dioxide content CO2 H at lower end of rated input range low fire H at upper end of rated in...

Page 75: ...e or explosion D Do not use this 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 a...

Page 76: ...ssmann ca info viessmann ca Viessmann Manufacturing Company U S Inc 45 Access Road Warwick Rhode Island 02886 USA Tel 401 732 0667 Fax 401 732 0590 www viessmann us com info viessmann us com 76 5581 7...

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