Viessmann Vitodens 100-W Installation And Service Instructions Manual Download

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Installation and Service
Instructions

VITODENS

100-W

5600 332 v1.3 08/2012

for use by heating contractor

Vitodens 100-W
WB1B Series

Wall-Mounted, gas-fired condensing boiler
with optional on demand hot water Combi

PLUS

Kit

Read and save these instructions
for future reference.

IMPORTANT

Please file in Service Binder

Heating input

37 to 118 MBH

10.8 to 34.5 kW

Vitodens 100-W, WB1B (with pre-installed coaxial vent pipe adaptor)
and with

Combi

PLUS

Kit installed.

Summary of Contents for Vitodens 100-W

Page 1: ...ries Wall Mounted gas fired condensing boiler with optional on demand hot water CombiPLUS Kit Read and save these instructions for future reference IMPORTANT Please file in Service Binder Heating input 37 to 118 MBH 10 8 to 34 5 kW Vitodens 100 W WB1B with pre installed coaxial vent pipe adaptor and with CombiPLUS Kit installed ...

Page 2: ...rements Contaminated air Air contaminated by chemicals can cause by products in the combustion process which are poisonous to inhabitants and destructive to Viessmann equipment uFor 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 familiari...

Page 3: ...ns 17 Flue gas connection 17 Proper piping practice 18 Gas connection and piping 18 Gas piping pressure test 19 Heating water connections 20 Condensate connection 21 Fill siphon with water 21 Safety Connections and Pressure Testing 22 Installing safety devices on the boiler 22 Low water cut off 22 Performing pressure test on the boiler 23 Hot water temperature and system pressure 23 Preparing the ...

Page 4: ...iPLUS Components 55 Procedure Overview 56 Steps 57 Troubleshooting Steps 73 Changing Room Temperature 73 Diagnosis 74 Sequence of operation and potential faults during each start up cycle 74 Diagnostics table Faults with fault display on control unit 75 How to reset faults 76 Boiler Connection 77 Remove front panel 77 Check boiler temperature sensor 77 Check outdoor temperature sensor 78 Determini...

Page 5: ...tter 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 monoxide det...

Page 6: ...tor This includes low water cut offs flow switches if used staging controls pumps motorized valves air vents thermostats etc u 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 u This product comes with several safety instruction labels attached Do not remove Contact Viessmann immedi...

Page 7: ...g reliable on demand hot water without a DHW tank is available The Vitodens 100 W comes factory set for operation with natural gas Propane conversion kit is included with each boiler Boiler model must be selected based on an accurate heat loss calculation of the building Ensure boiler model is compatible with connected radiation Vitodens 100 W boilers are factory tested and calibrated Further gas ...

Page 8: ...echanical room where the boiler is located must not exceed 104 F 40 C Boiler operation in marine environments damp salty coastal areas The service life of the boiler s exposed metallic surfaces such as the casing and fan housing is directly influenced by proximity to damp and salty marine environments In such areas higher concentration levels of chlorides from sea spray coupled with relative humid...

Page 9: ...ants New building construction Swimming pools Remodelling areas hobby rooms Garages with workshops Furniture refinishing areas Dry cleaning laundry areas and establishments Auto body shops Refrigeration repair shops Metal fabrication plants Plastic manufacturing plants Photo processing plants Beauty salons Products containing contaminants Chlorine type bleaches detergents and cleaning solvents fou...

Page 10: ...clearance to combustibles listing that appears on the special venting system label Top clearance 12 30 cm See the Vitodens 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 Front Side Side Back Top 7 178mm 5 1 Refer to the Installation Instructions of the Vitodens Venting System for details CombiPLUS Instal...

Page 11: ... an overview only Refer to subsequent sections for detailed information on individual piping connections Piping connections for Vitodens 100 W WB1B 26 and 35 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 NPT National Pipe Thread VC Vent connection CAI Combustion air inlet connectio...

Page 12: ... b 15 400 mm c 2f 68 mm d 28 725 mm e 47 8 123 mm f 6d 156 mm g 14d 360 mm h 5 125 mm j 97 8 250 mm k 1a 31 mm m 77 8 200 mm n 3d 80 mm The maximum ambient temperature must not exceed 104º F 40º C g Heating water connections and gas connection to be made in the field See connection specific section for details g See subsection entitled Power supply connection for details regarding power supply to ...

Page 13: ...e view Front view A B C D E F Front view Legend A Boiler water supply NPTM male thread B Boiler water return NPTM male thread C System water supply NPTM male thread D System water return NPTM male thread E DHW NPTM male thread F DCW NPTM male thread Shown is the distance between the boiler and CombiPLUS with Viessmann supplied 7 flex piping connection fittings ...

Page 14: ... GC Gas connection NPTM male thread PRV Pressure relief valve PG Pressure gage VC Venting connection CAI Combustion air inlet connection optional This section is an overview only Refer to subsequent sections for detailed information on individual piping connections Piping connections for Vitodens 100 W WB1B 26 and 35 factory supplied Note If using the optional CombiPLUS see page 10 and 24 ...

Page 15: ...g bracket on brick concrete wall 1 Drill holes Ø e 10 mm using mounting templates supplied with the boiler and the CombiPLUS 2 Align wall mounting boiler bracket and attach to wall with the screws and plastic anchors supplied The CombiPLUS is mounted directly to the wall with the screws and plastic anchors supplied CAUTION Whichever mounting method is used ensure that the boiler bracket and CombiP...

Page 16: ...e with bolts to wooden studs as shown Install mounting bracket and CombiPLUS on metal studs as per illustration Drill f pilot holes to insert anchors Ensure that holes are located in the center of each metal stud Use appropriate fasteners to mount CombiPLUS to metal studs not supplied Secure with bolts to metal studs as shown Boiler mounting bracket and CombiPLUS installation Installation on wood ...

Page 17: ... mounting bracket For installation of the mounting bracket see subsection entitled Wall mounting installation on page 16 of this manual The Vitodens 100 W boiler comes with a preinstalled vent pipe adaptor as shown Run venting system single pipe double pipe or coaxial through the side wall roof or chimney taking the shortest possible route and at a rising angle min 3º Installation Instructions Vit...

Page 18: ...Condensate drain connection C Gas connection D Water return connection 1 Make gas connection in accordance with codes CAN CSA B149 1 or 2 in Canada In the United States use the National Fuel Gas Code ANSI Z223 1 NFPA 54 as well as local codes where applicable 2 Close gas shutoff valve on boiler 3 Perform leak test 4 Bleed air from gas supply pipe See following page for details on gas connection an...

Page 19: ...wner of boiler with these valves CAUTION WARNING The gas supply piping must be leak tested before placing the boiler in operation 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 any unit or combination of units lights or runs IMPORTANT IMPORTANT Gas piping pressure test psig 14 w c 1 Isolate the boiler from ...

Page 20: ...ues stated is not covered by Viessmann warranty g Use a two hand wrench method when tightening fittings or piping onto the boiler connectors Use one wrench to prevent the boiler pipes from twisting and the second wrench to tighten the fitting or piping Failure to support the boiler connection could damage the boiler and its internal piping SUPPORT ALL PIPING USING HANGERS DO NOT support piping by ...

Page 21: ...p 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 Connections continued Condensate connection Fill siphon with water Legend A Flexible discharge tubing B Discharge tubing 1 Install the condensate drain pipe with a suitable gradient 2 Discharge condensate from the ...

Page 22: ... discharge is not piped to outdoors Minimum connection diameters Pressure relief valve Discharge pipe Piping to pre charged expansion tank Install the approved factory supplied 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 contain restrictive piping whe...

Page 23: ...ot leave boiler 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 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 and...

Page 24: ... 1015 16 265 16 406 17 431 117 16 291 when using 7 flex pipe 157 16 393 when using 12 flex pipe 913 16 249 Preparing the CombiPLUS Connections Note The flex pipes must be bent due to the offset in the fittings between the boiler and the CombiPLUS The nominal length of the 7 flex pipe after bending is 6b a The nominal length of the 12 flex pipe after bending is 10b a ...

Page 25: ...two hand wrench method when tightening fittings or piping onto the boiler and CombiPLUS connectors Use one wrench to prevent the boiler and CombiPLUS pipes from twisting and the second wrench to tighten the fitting or piping Failure to support the boiler or CombiPLUS connections could damage the boiler and or the CombiPLUS internal piping 5 Insert both heating circuit gaskets D into the female end...

Page 26: ...t and set aside Remove the factory installed 14L min flow restrictor a small flat screw driver maybe required to unseat the restrictor and discard 2 Install the new flow restrictor H for the WB1B 26 model only supplied with the installation fittings Color Specification WB1B 26 black on white 10L min WB1B 35 brown on white 14L min 3 Reinstall the flow tube cap ensure not to pinch or damage the gask...

Page 27: ...ition when connecting the 7 flex piping 2 Drill a hole through the top mounting hole as shown on the template x2 Drill a hole in the centre of the slot as shown on the template x2 Remove the template 3 Install the supplied anchors K into the wall if required 4 Install the supplied washers J on to the lag bolts I Install the lag bolts washers into the wall anchors if used and through the slots of t...

Page 28: ...nding is 10b a Slide the CombiPLUS A up and install the flex pipes L or M to the extension fittings of the CombiPLUS A Note L is a 7 pipe and M is a 12 pipe 2 Tighten the two lag bolts located in the CombiPLUS A mounting bracket slots Install the supplied washers J on to the lag bolts I Install the lag bolts washers through the upper mounting holes of the CombiPLUS A mounting bracket and into the ...

Page 29: ...ne knock out and the pump cable R through the other Note There are optional knock outs on the front left side of the CombiPLUS A if required Secure the cables inside the CombiPLUS A using the locknuts provided 2 Connect the electrical connectors in the CombiPLUS A as shown Connections A Q R A A Pump connection Diverting valve motor connection Flow sensor connection Water Temperature sensor connect...

Page 30: ...ousing captive screws located at the bottom front of the boiler Remove the cover by pulling straight out from the boiler and set aside 2 Release and hold the boiler control locks located on both sides of the boiler and rotate forward and down 3 Release the four captive screws on the power pump module cover by rotating them 90 degrees with a Phillips screw driver Set the cover aside Connections 2 1...

Page 31: ...ck X4 terminals 3 4 room thermostat connection of the power pump module and discard for room thermostat connection only 3 Remove the second and fourth hole plug from the base of the power pump module and discard Note Once the CombiPLUS is installed and the jumper pin is removed if not programmed for use with the CombiPLUS the boiler will provide DHW heating based on the built in resistors DHW inpu...

Page 32: ...own Connect wire BK2 to the power pump line of terminal block X3 as shown Connect the green yellow ground wire to terminal block X2 any open terminal 3 The control cable Q has two connectors Connect the DHW temperature sensor flow sensor five pin connector to terminal plugin X7 Connect the diverter valve six pin connector to terminal plugin X10 Note For additional wiring details see the wiring dia...

Page 33: ...th a Phillips screw driver 2 Rotate the boiler controls up and in Ensure that the locking clips are engaged 3 Install the boiler cover by inserting it straight on from the front 4 Tighten the boiler housing captive screws located at the bottom front of the boiler 5 Install the CombiPLUS A cover by inserting it straight on from the front 6 Using a Phillips screw driver install and tighten all four ...

Page 34: ...stitute the valve supplied by the manufacturer The heat exchanger is approved for a max operating pressure of 150 psig The DHW pressure relief valve must be installed in vertical position in the domestic hot water supply as close to the CombiPLUS heat exchanger as possible Drain pipe of same diameter as valve outlet must be routed to safe place of disposal and must be installed with a downward slo...

Page 35: ...reen Note If one or both of the rotary selector dials are already in the central position take it or them out of the central position and then simultaneously turn both rotary selectors back to the central position 3 Turn the rotary selector to the control range on the right will appear on the display 4 Adjust the control by turning the rotary selector tr The display shows 0 or 1 flashing 1 boiler ...

Page 36: ...per waterside boiler friction loss calculations Pump selection must be based on accurate system flow and pressure drop calculations incl 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 alternative method may be used such as primary secondary piping using closely spaced tees A low loss header offers additio...

Page 37: ...US built in pump Grundfos UPS15 78 three speed heating circuit DHW production pump for Vitodens 100 WB1B 26 35 boilers in the factory setting the pump speed is preset to speed three Speed One Speed Three Speed Two Flow Q gpm Head H ft of wc Performance chart courtesy of Grundfos CombiPLUS built in pump Grundfos UPS15 78 residual head pressure Residual head of built in three speed pump used with Vi...

Page 38: ... Pressure relief valve A Vitodens 100 W B Room thermostat C Heating circuit D Heating circuit pump field supplied E Expansion tank F Pressure Activated By Pass Note Heating circuit C in the examples should be designed to 30º F to 40º F 16 7º C to 22 2º C For a lesser t design the system layout designer must use one of the examples 3 or 4 on the following pages Ensure that a pressure activated by p...

Page 39: ...age tank F DHW tank temperature aquastat or sensor G DHW circulating pump field supplied H Low loss header K Expansion tank L Primary pump boiler circuit field supplied with low loss header only Maximum Flow Rates Model WB1B 26 35 t Output Btu h 83 000 108 000 30º F rise GPM 5 5 35º F rise GPM 4 7 6 2 40º F rise GPM 4 2 5 4 Primary pump L must pump into the boiler as illustrated Note The use of a ...

Page 40: ... relief valve A Vitodens 100 W gas fired condensing boiler B External boiler DHW controller field supplied C Heating circuit D Heating circuit pump field supplied E DHW storage tank F DHW tank temperature aquastat or sensor G DHW circulating pump field supplied H Closely spaced tees 4x pipe Ø or 12 305 mm K Expansion tank L Primary pump boiler circuit field supplied A low loss header offers additi...

Page 41: ...ature sensor J Limit thermostat optional See note 1 K DHW tank aquastat Honeywell Part No L4008A1031 Vi Part No 9560 985 M Mixing valve motor control N Mixing valve supply temperature sensor O Viessmann mixing valve P Room thermostat optional See note 2 Q Vitodens 100 boiler R Expansion tank System Layout 4 Vitodens 100 W WB1B 26 35 with DHW storage tank Low loss header one high temperature heatin...

Page 42: ...g circuit pump logic output of Vitotronic 2 The heating circuit pump logic output of Vitotronic 3 DHW has priority over heating circuit 3 DHW has priority over heating circuit 3 DHW has priority over heating circuit see also 4 see also 4 see also 4 4 If no priority is required for DHW demand supply 4 If no priority is required for DHW demand supply 4 If no priority is required for DHW demand suppl...

Page 43: ...pplied 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 accessory part See page 49 in this manual for details on the low loss header Note 1 Optional high limit safety control of heating circuit E During DHW production with DHW terminal activated the boiler supply temperature will b...

Page 44: ...ner equipment A Vitodens 100 W B Room thermostat C Heating circuit D CombiPLUS E Expansion tank 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 accessory part Built in pump residual head for the heating system side is 6 0 ft of water column at the boiler maximum flow rate of 6 2 G...

Page 45: ...heating circuit Legend AV Air vent PRV Pressure relief valve boiler PRV Pressure relief valve DHW 150 psi WSE Water softner equipment A Vitodens 100 W gas fired condensing boiler B External boiler system controller field supplied C Heating circuit D Heating circuit pump field supplied E CombiPLUS F LLH G Expansion tank Note The use of a low loss header is recommended if the water flow rate is less...

Page 46: ...ng boiler B External system controller field supplied C Heating circuit D Heating circuit pump field supplied E CombiPLUS F Closely spaced tees 4x pipe Ø or 12 305 mm G Expansion tank A low loss header offers additional benefits not provided by a pair of closely spaced tees Viessmann strongly recommends and prefers the use of a low loss header over closely spaced tees See page 49 for details Note ...

Page 47: ...the chilled medium is 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 in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation...

Page 48: ...tances at the highest point of the piping system 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 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 acc...

Page 49: ...eating circuit flow rate Vbypass Bypass flow rate 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 system mixed supply temperature T3 must be calculated as follows For maximum boiler flow rates see the table on page 87 in this manual Viessmann strongly ...

Page 50: ...ining important information Read and follow their respective instructions The ON OFF switch located on the boiler does not disconnect power to power pump module therefore the main service switch or breaker must be turned off For other required installation steps please reference the Installation Instructions for the accessory part Note on connection of accessories CAUTION Under certain climatic co...

Page 51: ...1 on page 38 GAS PUMP FAN Note Boilers are factory shipped with a wiring diagram 11 x17 sheet inside a pouch attached to the inside of the front cover The wiring diagram shipped with the boiler supercedes the wiring information in this manual Provide a main power disconnect service switch as per local code requirements Also refer to wiring diagram on page 91 What is OpenTherm The OpenTherm OT prot...

Page 52: ...e safety instructions 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 Reinstall power pump module cover plate 2 Install control cover if previously removed 3 Flip control upward and lock into position CAUTION Electrical cables may become damaged if in contact with hot components When running a...

Page 53: ... to calculate standard non condensing efficiency g Carbon monoxide measuring equipment 0 to 400 ppm Control and display elements The control unit is preset at the factory for standard operation Your heating system is ready for use The factory presets may be individually adjusted to suit your specific requirements Legend A Pressure gage B LCD display C Selector dial for DHW temperature D tr Selecto...

Page 54: ...J Flue gas temperature sensor 230º F 110º C K Test port caps x2 L Burner mounting flange assembly N Radial fan O Air gas inlet Venturi L Burner mounting flange assembly M Boiler temperature sensor N Radial fan O Air gas inlet Venturi T Heat exchanger flue gas collector U Control console flame safeguard with ignition transformer unit V ASME NB plate W Inlet air Venturi extension X Terminal strip lo...

Page 55: ... Legend A Boiler water supply B Diverting valve C Expansion tank D Outlet temperature sensor E System water supply F DHW G Boiler water return H Air vent valve I Plate type heat exchanger J Flow sensor K Circulation pump L System water return M DCW Fig 46 Start up Inspection and Maintenance ...

Page 56: ...measurement for sealed combustion coaxial vent only 67 13 Removing front panel 67 14 Remove burner 68 15 Check burner gasket and cylinder assembly for damage 68 16 Check and adjust ignition and ionization electrodes 69 17 Check condensate drain and clean siphon P trap 69 18 Check neutralization unit if applicable 70 19 Clean combustion chamber heat exchanger surfaces 70 20 Check diaphragm expansio...

Page 57: ...ackflow preventer within the automatic water feed and influence components such as diaphragm expansion tanks radiation etc A 30 antifreeze content will provide freeze up protection to 10 F 23 C Do not use antifreeze other than specifically made for hot water heating systems System also may contain components which might be negatively affected by antifreeze Check total system frequently when filled...

Page 58: ... outer conductor L and the neutral conductor N must not be interchanged See wiring diagram on page 91 entitled Additional Information in this manual A power module is supplied with the Vitodens 100 W boiler which requires 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 1 Verify that the ...

Page 59: ...nd after working on gas appliances to eliminate health risks and to guarantee the satisfactory condition of the system The burner is automatically ignited and starts operation after a safety time has elapsed During initial start up the unit may indicate a fault F4 because of air in the gas supply pipe After fault F4 is displayed reset the burner see page 76 The ignition procedure is repeated This ...

Page 60: ...e over 14 w c 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 warning could result in fire explosion personal injury or death 9 Enter gas type into Maintenance Record ...

Page 61: ...t of a forced draft design The benefits of forced draft systems are lower component temperatures direct air fuel connection premix for improved mixing and longer service life of the boiler due to mild to moderate ambient conditions The matrix cylinder burner blower and the combination gas valve are factory calibrated and pre adjusted for optimum boiler performance at all firing rates through a pne...

Page 62: ...ane see the separate instructions The CO2 value lies within the range of 7 5 to 10 5 for natural gas and 10 to 12 for liquid propane gas The CO2 value measured must be compared with the above CO2 value Note When the boiler is initially turned on a self diagnostic check is initiated Wait until the temperature display is stabilized and the boiler s actual temperature is displayed Note If step 14 is ...

Page 63: ... test burner in operation A and r pump operation low fire range 1 and below Control range low fire Note Once in a low high fire test range you can switch back and forth between the high and low by simply positioning the control range for the required test Note The heat generated by the boiler during the high low fire relay test must be removed The heating load must be imposed on the boiler DHW or ...

Page 64: ...ly turn both rotary selectors back to the central position 2 Turn selector dial tr clockwise all the way to the U Reset position 3 r appears on display along with flashing set value i or 2 4 With selector dial set the value to 2 for operation above 5 000 ft 1 500 m Turn the selector dial from the center position to the right or left 5 Do not adjust the selector dials for at least 15 seconds The se...

Page 65: ...wise all the way to U Reset and then back again into the middle position range in less than 2 seconds and back to 6 The display shows SERV the boiler water temperature five flashing bars for high fire burner in operation A and r heating system pump operation 3 With selector dial select the max input or output for heating operation by selecting number from 1 to 6 on selector dial tr for required va...

Page 66: ... 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 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 CAUTION Always contact your gas utility to obtain the correct heating value before clocking the meter IMPORTANT Start up Inspection and Maintenance ...

Page 67: ...ment and one for flue gas measurement Note This test is not applicable for single wall venting systems non sealed combustion Legend A Flue gas measurement port B Combustion air 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 the particular installatio...

Page 68: ...ere is a gasket between the gas valve and this connection 6 Loosen four Torx T 30 screws F and remove burner 15 Check burner gasket and cylinder assembly for damage Maintenance Check the burner gasket A and burner cylinder 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 i...

Page 69: ...in and clean siphon P trap Maintenance Start up and Maintenance IMPORTANT 1 Check the siphon to ensure unimpeded drainage of condensate 2 Remove 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 siphon A with water by pouring 10 fl oz 0 3L of water int...

Page 70: ...nt manufacturer s safety instructions and wear appropriate protective equipment 1 Remove burner cover panel as per the removal instructions on page 67 in this manual and reinstall panel upon completion of service work 2 If necessary clean the combustion chamber A and heat exchanger surfaces B with a brush and or rinse with water Use solvent free cleaning agents to remove residues Remove combustion...

Page 71: ...ssure is higher than the inlet pressure of the diaphragm expansion tank Note With the system cold the filling pressure must be approx 3 psig higher than the static pressure Max boiler operating pressure 45 psig Min boiler operating pressure 14 to 23 psig Pressure 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 N...

Page 72: ...ket and tighten the fitting E on the gas connection pipe to a torque of 15 Nm 132 lb in 3 Plug the Venturi extension D into the fan 4 Replace electrical cables from gas valve B and electrode block C 5 Open gas shutoff valve and switch on power supply 6 Check the gas connection for tightness 7 Install front panel as shown on page 52 CAUTION Ensure all joints of gas line are pressure tight and that ...

Page 73: ...mperature 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 appropriate operating instructions only Note lf thermostatic radiator valves are installed in the room where the control is installed they must be fully open In case the room temperature setting on the separate room tem...

Page 74: ... boiler pump operation Check cabling and plug in connectors of the blower as well as the blower itself Check proper power supply to the blower Check ignition transformer unit and its plug in connections Check gas combination valve 104VRAC DC between brown and blue must be present during start up plug 35 Check gas supply pressure Check electrode settings purge gas supply line Check condensate line ...

Page 75: ... Outlet temperature sensor shorted out Check sensor see pages 29 and 82 52 Burner blocked with CombiPLUS only Flow sensor shorted out in CombiPLUS Check connections and wire replace sensor if required 58 No DHW heating used with storage tanks Jumper connection shorted out removed or missing Check PPM jumper see page 31 59 No DHW heating with CombiPLUS only Outlet temperature sensor wire broken Che...

Page 76: ...loses too late Check the gas train Check both control paths Reset control f9 Burner in fault mode Blower speed too low at burner start Check the blower check the blower cables and supply check the blower control Reset control fa Burner 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 ...

Page 77: ...ly 2 Remove the front panel Resistance in KΩ Boiler water temperature 1 Disconnect cables from boiler temperature sensor A 2 Measure resistance of the boiler temperature sensor and compare with resistance boiler water temperature curve shown 3 If the value measured differs significantly replace the sensor WARNING The boiler temperature sensor is immersed in the heating water risk of scalding Drain...

Page 78: ...boiler water temperature is regulated subject to the outside temperature Frost protection function Built in automatic frost protection allows the boiler to be shut off for an extended period of time while protecting it against freeze up Frost protection is continually active The burner is switched ON when the boiler water temperature reaches 41º F 5º C and is switched OFF again when the boiler wat...

Page 79: ...outdoor reset calculated Adjusting the tr dial will select the heating curve corresponding with the heating curve chart The set point will be calculated from the design boiler water temperature associated with the heating curve selected and reset from the actual outdoor air temperature Setting the dial between 1 and 6 will select the corresponding curve from the chart The dot between 4 and 5 is th...

Page 80: ...approx 203 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 fixed high limit with heat conducting paste and install 5 To reset refer to page 76 1 Pull the leads from flue gas temperature sensor A 2 Check the sensor resistance and compare it with the cur...

Page 81: ...pump module cover plate B 4 Check fuse F1 T6 3A slow blow Replacements fuses are available from Viessmann in packs of 10 Part No 7815 580 The ON OFF switch located on the boiler does not disconnect power to power pump module therefore the main service switch or breaker must be turned off IMPORTANT Control unit fuse 1 Switch off main power supply 2 Flip down control unit 3 Remove cover A 4 Check fu...

Page 82: ... in KW Temperature Replacing the flow limiter Note Water can leak when replacing the outlet temperature sensor Shut off the cold water supply Drain the DHW line and the plate type heat exchanger DHW side 1 Drain the boiler and combiPLUS 2 Remove screws from the cover and remove cover 3 Undo screws A 4 Remove the cap B 5 Remove faulty flow limiter C 6 Select new flow limiter C corresponding to boil...

Page 83: ...ds 4 Turn the three way valve B with drive A 1 8 turn counterclockwise and remove 5 Remove two screws C from the plate type heat exchanger and remove the plate type heat exchanger D with gaskets Note During removal small amounts of water may trickle out and escape from the removed plate type heat exchanger 6 Check the DHW side for scaling and if required clean or replace the plate type heat exchan...

Page 84: ... the boiler The boiler will adjust the heat input accordingly low high modulation The Viessmann Input Module is designed to accept a 0 10 DC modulating input signal from a boiler reset module controller and send this signal to the Vitodens 100 with OpenTherm communication GAS PUMP FAN Terminal strip for accessories connections Legend A Viessmann outdoor temperature sensor field wiring B OpenTherm ...

Page 85: ...78º C non adjustable On 20 seconds 5 Outdoor temperature sensor 2 Temperature dial tr setting RT contact closed or OT connection terminals 1 2 shorted On 4 minutes 240 seconds 6 Room thermostat RT terminal Close RT contact in power pump module On 4 minutes 240 seconds The Vitodens 100 W WB1B boiler has several operating control options The following table provides the priority levels of each of th...

Page 86: ...gas supply pressure Natural gas LPG w c w c 4 10 4 10 Max gas supply pressure 3 Natural gas and LPG w c 14 14 A F U E 95 2 95 2 Weight lbs kg 78 34 1 78 34 1 Shipping weight lbs kg 95 43 95 43 Boiler water content USG L 0 87 3 3 0 87 3 3 Boiler max flow rate 4 GPM L hr 6 2 1400 6 2 1400 MAWP max allowable working pressure at 210º F 99º C psig bar 45 3 45 3 Boiler water temperature Adjustable high ...

Page 87: ... Average condensate flow rate 6 with natural gas TS TR 122 86º F 50 30º C USG day L day 1 95 2 3 8 9 2 5 2 8 9 4 10 5 Condensate connection 7 hose nozzle Ø in 1 1 Boiler flue gas connection 8 Ø in mm 2e 60 2e 60 Combustion air supply connection 8 outer Ø in mm 4 100 4 100 Noise level at 1 meter at full load at partial load dB dB 47 40 49 42 High altitude factory set 9 ft m 0 5 000 0 1 500 0 5 000 ...

Page 88: ...nnections to boiler supply return and to heating supply return NPTM male c c Dimensions Overall depth Overall width Overall height Height with pipe connector inches mm inches mm inches mm inches mm 9 8 250 17 432 8 7 223 13 331 9 8 250 17 432 8 7 223 13 331 Integrated pump flow rate DHW production 23 ft 9 8 m Head pressure Heating system operation with system side additional drop in pressure of ma...

Page 89: ... 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 for next call for heat Start up and Maintenance 1500 rpm 1500 rpm Transition Modulation range Call for heat Fan control Fan required signal Ignition Combination gas valve Flame signal Sequence time O S t a n d...

Page 90: ...t 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 modulation signal high low is processed eg boiler actual water temperature Phase 8 Burner operation At the end of the flame stabilization period 5 sec a release for modulation occurs and the burner temperature con...

Page 91: ...91 5600 332 v1 3Vitodens 100 W WB1B Installation Service Additional Information Wiring Diagram Natural gas Propane ...

Page 92: ...Activated Relay Test w Selector Dial Right w Control Range SERV A Static Flashing Flash Eco w Selector Dial Left w Control Range SERV ECO momentary Static Comfort w Selector Dial Right w Control Range SERV COMFORT momentary Static Boiler with or without Combi Plus r w Mid Position w Right Control Range r Left Control Range Without Combi Plus SERV w 0 Static Static Flashing Right Control Range With...

Page 93: ...ization electrode block 055 Gasket for electrode block 056 Radial fan NRG118 CVI 120 1 60 057 Gas valve Venturi assembly 120 1 60 058 Burner mounting flange assembly 059 Venturi extension 060 Gasket for radial fan 061 Gasket set for gas connection pipe 062 Gasket set for gas valve Venturi assembly 087 Flip down cover Other Parts not illustrated 090 Hinges for control housing set of 10 107 Touch up...

Page 94: ... mount bracket 016 Combustion chamber refractory 017 Condensate pipe 018 Condensate hose 019 Gasket for air intake 020 Guide rails set of 2 021 Clip d 8 set of 5 023 Connector retaining clip set of 2 024 Sealing grommet DN60 025 O ring set for heat exchanger 21 x 3 mm 026 Sealing grommet set 027 Air vent with shut off base e 028 Supply return o ring set 18 x 3 mm 029 Support bracket setfor heat ex...

Page 95: ... 35 for gas valve 103 Connecting cable No 100 for radial fan 104 Connecting cable for ignitor 105 Strain relief 106 Grounding wire for ignition electrode 107 Wire harness X21 Installation fittings Parts 401 Pressure relief valve 402 Nipple c x 2 403 Sediment fauset 404 Tee c 405 Nipple c x 3b 406 Gas ball valve c 407 Extension c x 2a Other Parts not illustrated 410 Accessory pack metal stud mount ...

Page 96: ...2 105 Sealing grommet 106 Accessory pack anchors set of 4 107 Pressure relief valve c 150 psig 108 Tee c brass 109 Gaskets assortmentof b c 110 Adaptor G c F x NPT c M 111 Adaptor G b F x NPT b M 112 0 ring 17x4 113 Clip d 18 200 Harness for sensors 201 Harness for pump 202 Accessory pack conduit clips set of 2 Other Parts not illustrated 100 Installation fittings items 101 to 111 and 390 complete...

Page 97: ...placement powerhead UPS15 78 120 1 60 331 Plate heat exchanger 20 plates 332 Gasket set PWT 333 Step motor linear 334 Flow sensor 335 Air vent 337 Bypass cartridge 339 Clip d 8 set of 5 340 Clip d 10 set of 5 342 Clip d 16 set of 5 344 Clip SIV special set of 5 348 Expansion pipe 383 Sensor 3 boiler 390 Flow regulator 10L for use with WB1B 26 only 391 Flow regulator 14L for use with WB1B 35 only ...

Page 98: ... w c 4 14 w c o Liquid Propane gas w c 10 14 w c Carbon dioxide content CO2 n at lower end of rated input range low fire vol n at upper end of rated input range high fire vol Oxygen content O2 n at lower end of rated input range low fire vol n at upper end of rated input range high fire vol Carbon monoxide content CO n at lower end of rated input range ppm Never exceed 50 ppm air free n at upper e...

Page 99: ...e 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 under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label 2 Set thermostat or other operating control to lowest setting 3 Turn off all electric power to the appliance 4 This appli...

Page 100: ...Vitodens 100 W WB1B Operating User s Information 5600 332 v1 3 Technical information subject to change without notice Printed on environmenally friendly recycled and recyclable paper ...

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