Viessmann WB1A Series Installation And Service Instructions Manual Download Page 43 | Manualshive

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Start-up, Inspection and Maintenance

43

Overview of Components

Legend

Fixed high limit, 210°F/99°C
Ignition transformer module
ZIG 2/12
Flow 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, 120/1/60

Air + gas inlet venturi

P

Gas valve VK4115V, 120/1/60

R

Air vent w/shutoff base,

3

/

8

”

S

Power pump module

U

Control console

5

5

8

1

7

7

5

1

.3

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Summary of Contents for WB1A Series

Page 1: ...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 WB1A with preinstalled coaxial vent p...

Page 2: ...d Installation Requirements in the Installation Instructions H Advice to owner Once the installation work is complete the heating contractor must familiarize the system operator ultimate owner with al...

Page 3: ...ion 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 Connections and Pressur...

Page 4: ...quence 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 Check boiler temperature...

Page 5: ...oses 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 including but not limite...

Page 6: ...for residential purposes c MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting syst...

Page 7: ...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 etc Technical literature...

Page 8: ...nt product information Helpful hints for installation operation or maintenance which pertain to the product This symbol indicates that additional pertinent information is to be found in column three T...

Page 9: ...roller 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 propane Boiler model mus...

Page 10: ...ing 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 operation in marine environment...

Page 11: ...ody shops H Refrigeration repair shops H Metal fabrication plants H Plastic manufacturing plants H Photo processing plants H Beauty salons Products containing contaminants H Chlorine type bleaches det...

Page 12: ...C 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 system label Clear...

Page 13: ...or 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 water supply BD Boiler drai...

Page 14: ...00 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 installation of the wall...

Page 15: ...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 Pressure relief valve P...

Page 16: ...pplicable 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 boiler 2 Align wall mounting brack...

Page 17: ...unting 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 illustration Drill 3 1...

Page 18: ...t 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 with a preinstalled ven...

Page 19: ...n 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 shutoff valve on boiler 3 P...

Page 20: ...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 gas connection as shown o...

Page 21: ...ssure 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 is sprayed on any electrical compon...

Page 22: ...g 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 the boiler pipes from...

Page 23: ...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 possible to prevent siphoning...

Page 24: ...rs Minimum connection diameters Pressure relief valve Discharge pipe Piping to precharged expansion tank Install the approved factory supplied pressure relief valve Removal of air from the system must...

Page 25: ...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 and install pressure re...

Page 26: ...to combustible construction must be maintained In cases where the pipes are insulated with pipe insulation of appropriate and sufficient thickness and insulation values the above clearance may be redu...

Page 27: ...nn 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 must be installed wher...

Page 28: ...nsion 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 if the water flow rate...

Page 29: ...r 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 1400 DHW supply and retu...

Page 30: ...low 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 header Model No Vitode...

Page 31: ...Boiler Connections 31 Installation Examples continued Wiring diagram for system layout 4 5581 775 1 3 All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 32: ...ywell 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 No 7134 627 Heating cir...

Page 33: ...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 Max flow rate GPM ltr h...

Page 34: ...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 handling units where t...

Page 35: ...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 specific to your application r...

Page 36: ...rinciple 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 system flow rate Type 80 50 17 6 GP...

Page 37: ...e 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 and opening the power p...

Page 38: ...and 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 to boiler Ensure that p...

Page 39: ...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 not remove any of these i...

Page 40: ...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 be utilized H Stack ther...

Page 41: ...ol 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 operation Your heating system is ready for...

Page 42: ...ode 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 Emissions test activated onl...

Page 43: ...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 60 Air gas inlet ventu...

Page 44: ...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 Check burner gasket an...

Page 45: ...e 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 return for at least 10...

Page 46: ...oltage 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 is to be done in accordance with the...

Page 47: ...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 gas combination valve do...

Page 48: ...iler 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 boiler is shut down clo...

Page 49: ...ormance 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 regulating the amount of com...

Page 50: ...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 See illustration on botto...

Page 51: ...ut 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 by 5 is still acceptable Do not ov...

Page 52: ...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 working on gas applianc...

Page 53: ...2 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 frequency of servicing...

Page 54: ...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 1 3 To avoid damage to...

Page 55: ...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 wrench 14 Check and adjust...

Page 56: ...ome 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 refractory or replace it Installation Instru...

Page 57: ...sits 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 CitriSurft 3050 by Stel...

Page 58: ...e 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 first time mark this value...

Page 59: ...n 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 valve and ignition transfor...

Page 60: ...ls 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 the hinged front cover...

Page 61: ...room temperature will be adjusted using this device Make adjustments using the appropriate operating instructions only Please also note lf thermostatic radiator valves are installed in the room where...

Page 62: ...em 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 s plug in connections C...

Page 63: ...e 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 ionization elec trodes and l...

Page 64: ...set 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 the fault is not removed...

Page 65: ...stance 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 sensor 5581 775 1 3 A 10...

Page 66: ...rox 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 fixed high limit 4 Coat the replacemen...

Page 67: ...ate 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 Remove cover 4 Check fus...

Page 68: ...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 6 2 1400 Max operating...

Page 69: ...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 tion 7 hose nozzle in...

Page 70: ...e 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 purge period expected blow...

Page 71: ...Additional Information 71 Wiring Diagram 5581 775 1 3 PUMP PUMP DHW All manuals and user guides at all guides com a l l g u i d e s c o m...

Page 72: ...G130 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 081 Control housing rea...

Page 73: ...ue 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 Boiler water supply 412 G...

Page 74: ...pm 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 input range high fire Oxy...

Page 75: ...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 any gas control which ha...

Page 76: ...nn 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 775 1 3 Printed on environmentally f...

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