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Viessmann Vitodens 100-W WB1B Series User Manual

Viessmann Vitodens 100-W WB1B Series
100 pages
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Installation and Service
Instructions
VITODENS
d
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 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.

Table of Contents

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Viessmann Vitodens 100-W WB1B Series Specifications

General IconGeneral
Heat Exchanger MaterialStainless steel
TypeWall-mounted condensing boiler
EfficiencyUp to 98%
FuelNatural gas or LPG
Modulation Range1:6
Flue Gas Connection60/100 mm
NOx EmissionsLess than 40 mg/kWh
Warranty5 years
Water PressureMax. 3 bar

Summary

Installation and Service Instructions

Vitodens 100-W WB1B Series

Wall-Mounted, gas-fired condensing boiler with optional on demand hot water CombiPLUS Kit.

Safety

Safety, Installation and Warranty Requirements

Ensures understanding of instructions to prevent damage, injury, and loss of life.

General Information

About these Installation Instructions

Notes on symbols and notations for hazards and important product information.

Dimensions

Minimum Clearances

Details required clearances for installation and service of the boiler and CombiPLUS.

Venting Connections

Venting Connection

Instructions for proper venting installation and requirements.

Control Connections

Electrical Connections

Details on connecting electrical components for the power/pump module.

Start-up, Inspection and Maintenance

Necessary Tools

Lists essential tools for testing, analysis, and cleaning.

Troubleshooting

Troubleshooting Steps

Guides through identifying and resolving faults using diagnostic tables.

Additional Information

Technical Data

Provides specifications, ratings, and connection details for the boiler.

Important Regulatory and Installation Requirements

Safety / General Information

About these Installation Instructions

Explains symbols and notations for hazards and product information.

General Information

Applicability

Details boiler serial number requirements and compatibility checks.

Product Information

Describes boiler type, operation, and factory settings.

General Information

Mechanical Room

Specifies requirements for the installation location and ambient conditions.

General Information

Before Set-up

Ensures all necessary accessories are installed before placing the boiler.

Dimensions

Minimum Clearances

Details required clearances for installation and service of the boiler and CombiPLUS.

CombiPLUS Installation Options

Illustrates different installation configurations for the CombiPLUS unit.

Dimensions

Preparing the Connections

Overview of piping connections for the boiler.

Dimensions

Dimensions overview without bottom piping connections

Provides detailed dimensional drawings of the boiler.

Dimensions

CombiPLUS connections and piping connections

Details piping and connection points for the CombiPLUS unit.

Dimensions

Piping connections for Vitodens 100-W, WB1B 26 and 35 (factory supplied)

Diagrams showing factory supplied piping connections for specific models.

Dimensions

Wall Mounting

Instructions for mounting the boiler and CombiPLUS on various wall types.

Dimensions

Boiler mounting bracket and CombiPLUS installation

Details on installing mounting brackets for wood and metal studs.

Dimensions/Connections

Mounting Vitodens 100-W boiler

Steps for mounting the boiler onto the wall bracket.

Boiler Connections

Overview of boiler connections, starting with flue gas.

Connections

Boiler Connections (continued)

Details on proper piping practices and gas connection.

Connections

Gas piping pressure test

Procedures for performing a leak test on the gas supply piping.

Connections

Heating water connections

Instructions for flushing and connecting the boiler to the heating system.

Connections

Condensate connection

Details on connecting the condensate drain and filling the siphon.

Connections

Safety Connections and Pressure Testing

Covers installation of safety devices and pressure testing procedures.

Connections

Performing pressure test on the boiler

Step-by-step guide for hydrostatically pressure testing the boiler.

Connections

Preparing the CombiPLUS Connections

Diagrams showing CombiPLUS connections and pipe lengths.

Connections

CombiPLUS Preparations for all Vitodens

Instructions for installing fittings and system connections to the CombiPLUS.

Connections

Additional CombiPLUS Preparations for Vitodens 100-W, WB1B-26 only

Procedure for exchanging the flow restrictor for specific models.

Connections

Mounting the CombiPLUS

Steps for preparing the wall and mounting the CombiPLUS unit.

Connections

Connecting the CombiPLUS Piping

Instructions for connecting the CombiPLUS to the boiler using flex pipes.

Connections

Connecting the CombiPLUS Wiring

Details on routing control and pump cables for the CombiPLUS.

Connections

Accessing the Boiler Controls

Steps for removing covers to access boiler and power pump module controls.

Connections

Preparing the Boiler Power Pump Module

Procedure for preparing the power pump module for CombiPLUS wiring.

Connections

Connecting the CombiPLUS Cables to the Power Pump Module of the Boiler

Guide for connecting CombiPLUS cables to the boiler's power pump module.

Connections

Re-installing Covers

Instructions for reassembling covers of the power pump module, boiler, and CombiPLUS.

Connections

Adding PRV and Label

Procedure for installing the DHW pressure relief valve and scald danger label.

Connections

Programming

Steps for programming the boiler control for operation with or without CombiPLUS.

Connections

Installation Examples

Provides schematics and guidelines for system layouts.

Clearances

Specifies minimum clearances from non-insulated pipes to combustible construction.

Pressure drop (primary circuit) of Vitodens 100-W

Graph showing pressure drop in the primary circuit based on flow rate.

Heating circuit pumps

Recommended heating pumps for Vitodens 100-W models.

Connections

CombiPLUS built-in pump

Details on the Grundfos UPS15-78 pump performance and specifications.

Connections

System Layout 1

Diagram for a single heating circuit system with Vitodens 100-W.

Connections

System Layout 2

Diagram for a system with DHW storage, low-loss header, and one heating circuit.

Connections

System Layout 3

Diagram for a system with DHW storage, closely spaced tees, and one heating circuit.

Connections

System Layout 4

Diagram for a complex system with multiple circuits and controllers.

Connections

Wiring diagram for system layout 4

Detailed wiring schematic for System Layout 4.

Connections

System Layout 4 (Installation of heating circuits)

Details on heating circuits, DHW production, and low-loss header use.

Connections

System Layout 4 (Vitodens 100-W, WB1B 26, 35 with one heating circuit and the CombiPLUS)

Diagram for a system with CombiPLUS and one heating circuit.

Connections

Vitodens 100-W, WB1B 10-26, 10-35 with CombiPLUS Kit, low-loss header, one heating circuit

System layout with CombiPLUS, low-loss header, and one heating circuit.

Connections

Vitodens 100-W, WB1B 10-26, 10-35 with CombiPLUS and one heating circuit without LLH

System layout with CombiPLUS, no low-loss header, and one heating circuit.

Connections

Boiler in heating/cooling application

Instructions for connecting the boiler in a heating/cooling system.

Connections

Boiler with low water cut-off (remote-mounted, field supplied)

Diagrams for installing a low water cut-off device for the boiler.

Connections

Accessories for the Vitodens 100-W

Details on optional accessories like neutralization units and low-loss headers.

Low-Loss Header

Information on low-loss header types, benefits, and installation principles.

Venting / Control Connections

Venting Connection

Guidance on vent termination and protection against environmental effects.

Electrical Connections

Steps to open the control unit and power/pump module.

Control Connections

Electrical connections to the power pump module (room thermostat and DHW)

Wiring details for room thermostat, DHW, and pump connections.

Optional operating control - OpenTherm

Explanation of OpenTherm protocol and its connection to the boiler.

Control Connections

Closing the power pump module and reinstalling the control unit

Procedures for closing modules and reinstalling the control unit.

Reinstalling the front panel

Steps for reattaching the front panel to the boiler.

Start-up, Inspection and Maintenance

Necessary Tools

Lists essential tools for testing, analysis, and cleaning.

Overview of Controls and Indicators

Identifies and explains the boiler's controls, indicators, and display elements.

Start-up, Inspection and Maintenance

Overview of Boiler Components

Diagram identifying major components within the boiler assembly.

Start-up, Inspection and Maintenance

Overview of CombiPLUS Components

Diagram identifying major components within the CombiPLUS unit.

Start-up, Inspection and Maintenance

Procedure Overview

Outlines the sequence for start-up, inspection, and maintenance procedures.

Start-up, Inspection and Maintenance

Filling and bleeding heating system

Detailed steps for filling and venting the heating system with water.

Start-up, Inspection and Maintenance

Check power supply connection

Ensures correct 120 VAC power supply and neutral conductor connection.

Select appropriate gas type

Guides selection of gas type (natural gas or LPG) based on specifications.

Start-up, Inspection and Maintenance

Measure static pressure and running pressure

Procedures for measuring gas static and running pressure.

Start-up, Inspection and Maintenance

Measure running gas supply pressure

Details on measuring running gas pressure at the test nipple.

Start-up, Inspection and Maintenance

How the Vitodens 100-W boiler operates

Explanation of the premix combustion system and burner operation.

Start-up, Inspection and Maintenance

Relay tests (burner tests)

Procedure for performing relay tests and checking CO2 levels.

Start-up, Inspection and Maintenance

Adjusting the CO2 content

Steps for adjusting high-fire and low-fire CO2 content.

Start-up, Inspection and Maintenance

High altitude setting

Procedure for setting the boiler for operation at high altitudes.

Start-up, Inspection and Maintenance

Set maximum heating input

Procedure for limiting the maximum heating input or output.

Start-up, Inspection and Maintenance

Clock natural gas meter

Method for verifying input by timing the natural gas meter.

Check all primary and secondary circuit connections for leaks

Ensuring all system connections are pressure-tight and leak-free.

Perform combustion analysis

Guidance on taking CO2 measurements before and after gas appliance work.

Start-up, Inspection and Maintenance

Check venting system for leaks (circular air gap measurement)

Performing a simplified leak test on the venting system.

Maintenance

Removing front panel

Steps for removing the front panel for access to measurement ports.

Start-up, Inspection and Maintenance

Remove burner

Procedure for safely removing the burner assembly.

Maintenance

Check burner gasket and cylinder assembly for damage

Instructions for inspecting and replacing burner gasket and cylinder assembly.

Start-up, Inspection and Maintenance

Check and adjust ignition and ionization electrodes

Guidance on checking, cleaning, and adjusting ignition and ionization electrodes.

Maintenance

Check condensate drain and clean siphon (P-trap)

Procedure for checking and cleaning the condensate drain and siphon.

Start-up, Inspection and Maintenance

Check neutralization unit (if applicable)

Procedure for checking pH and replacing granulate in the neutralization unit.

Maintenance

Clean combustion chamber/heat exchanger surfaces

Instructions for cleaning combustion chamber and heat exchanger surfaces.

Start-up, Inspection and Maintenance

Check diaphragm expansion tank and system pressure

Procedures for checking expansion tank pressure and system fill pressure.

Check functioning of safety valves

Ensures proper operation of safety valves, pressure relief valve, and pump(s).

Start-up, Inspection and Maintenance

Check gas pipes and fittings for leaks

Ensures gas supply piping and fittings are leak-tight.

Reinstall burner

Steps for reinstalling the burner assembly after service.

Troubleshooting

Troubleshooting Steps

General steps to diagnose and correct system faults.

Changing Room Temperature

Adjusting room temperature settings and boiler water temperature.

Troubleshooting

Sequence of operation and potential faults during each start-up cycle

Flowchart detailing start-up sequence and common faults.

Troubleshooting

Diagnostics table: Faults with fault display on control unit

Table listing fault codes, causes, and corrective measures.

Troubleshooting

How to reset faults

Procedure for resetting faults using the control unit selector dial.

Troubleshooting

Boiler Connection

Steps for removing the front panel and checking the boiler temperature sensor.

Troubleshooting

Check outdoor temperature sensor

Procedure for checking the outdoor temperature sensor and frost protection function.

Troubleshooting

Determining the boiler set-point

Guides for setting boiler water temperature based on controls.

Troubleshooting

Check fixed high limit

Procedure for checking and replacing the fixed high limit safety device.

Check flue gas temperature sensor

Procedure for checking and replacing the flue gas temperature sensor.

Troubleshooting

Check fuses

Instructions for checking and replacing fuses in the control and power pump modules.

Troubleshooting

CombiPLUS Connection

Troubleshooting steps specific to the CombiPLUS unit.

Check outlet temperature sensor

Procedure for checking the CombiPLUS outlet temperature sensor.

Replacing the flow limiter

Steps for replacing the flow limiter in the CombiPLUS unit.

Troubleshooting

Checking or replacing the plate type heat exchanger

Procedure for checking and replacing the plate type heat exchanger.

Additional Information

Electrical Connections to the Terminal Strip for Accessories

Details on connecting accessories like outdoor sensors and OpenTherm to terminal strips.

Additional Information

Technical Data

Provides technical specifications and data for the boiler and CombiPLUS.

Call for heat priority logic table

Table detailing priority levels for different operating controllers.

Additional Information

Technical Data (continued)

Contains detailed specifications, dimensions, and connection sizes.

Additional Information

Technical Data (continued)

Provides flue gas values, condensate rates, and noise levels.

Additional Information

Technical Data (continued)

Lists DHW supply temperatures, draw rates, pressures, and dimensions.

Additional Information

Burner Program Sequence of Operation

Diagram and table outlining the burner's operational sequence.

Additional Information

Burner Program Sequence of Operation (continued)

Detailed explanation of each phase in the burner's operational sequence.

Additional Information

Wiring Diagram - Natural gas / Propane

Comprehensive wiring diagram for natural gas and propane operation.

Additional Information

Service Function Overview

Table detailing activation sequences for service functions like filling and relay tests.

Additional Information

Parts List

Lists parts for the Vitodens 100-W boiler and ordering information.

Additional Information

Parts List

Diagram and list of boiler components and their part numbers.

Additional Information

Parts List

Lists control unit parts, wiring harnesses, and installation fittings.

Additional Information

Parts List

Lists CombiPLUS Kit parts, accessories, and installation fittings.

Additional Information

Parts List

Lists parts for the CombiPLUS unit, including regulators and bypass cartridges.

Additional Information

Maintenance Record

Template for recording static pressure, gas pressure, and CO2 measurements.

Additional Information

Lighting and Operating Instructions

Safety instructions and steps for lighting and operating the appliance.

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