Vitodens 100w

Installation and service VIESMANN
instructions
for contractors
Vitodens 100-W
Type B1HA, B1KA, 6.5 to 35.0 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
Gas Council Number: 41-819-36 - 39, 47-819-33 - 35
For applicability, see the last page
VITODENS 100-W
5677 216 GB 3/2015 Please keep safe.

Safety instructions
Safety instructions
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained ■ Codes of practice of the relevant trade

associations
Danger ■ All current safety regulations as
This symbol warns against the defined by DIN, EN, DVGW, TRGI,
risk of injury. TRF, VDE and all locally applicable
standards
!
Please note a ÖNORM, EN, ÖVGW-TR Gas,
This symbol warns against the ÖVGW-TRF and ÖVE
risk of material losses and envi- c SEV, SUVA, SVGW, SVTI,
ronmental pollution. SWKI, VKF and EKAS guideline
1942: LPG, part 2
Note
Details identified by the word "Note" con- Safety instructions for working on the
tain additional information. system
Target group Working on the system
These instructions are exclusively inten- ■ Where gas is used as the fuel, close
ded for authorised contractors. the main gas shut-off valve and safe-
■ Work on gas installations must only be guard it against unintentional reopen-
carried out by a registered gas fitter. ing.
■ Work on electrical equipment must ■ Isolate the system from the power sup-
only be carried out by a qualified elec- ply, e.g. by removing the separate fuse
trician. or by means of a mains isolator, and
■ The system must be commissioned by check that it is no longer 'live'.
the system installer or a qualified per- ■ Safeguard the system against recon-
son authorised by the installer. nection.
Regulations to be observed Danger

Hot surfaces can cause burns.
■ National installation regulations ■ Before maintenance and serv-
■ Statutory regulations for the preven- ice work, switch OFF the appli-
tion of accidents ance and let it cool down.
■ Statutory regulations for environmen- ■ Never touch hot surfaces on
tal protection the boiler, burner, flue system
or pipework.
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Safety instructions
Safety instructions (cont.)
!
Please note Safety instructions for operating the
Electronic assemblies can be system
damaged by electrostatic dis-
charge. If you smell gas
Prior to commencing work, touch
earthed objects such as heating Danger
or water pipes to discharge static Escaping gas can lead to explo-
loads. sions which may result in serious
injury.
Repair work ■ Never smoke. Prevent naked
flames and sparks. Never
!
Please note switch lights or electrical appli-
Repairing components that fulfil a ances on or off.
safety function can compromise ■ Close the gas shut-off valve.
the safe operation of the sys- ■ Open windows and doors.
tem. ■ Evacuate any people from the
Replace faulty components only danger zone.
with genuine Viessmann spare ■ Notify your gas or electricity
parts. supply utility from outside the
building.
Auxiliary components, spare and ■ Have the power supply to the
wearing parts building shut off from a safe
place (outside the building).
!
Please note
Spare and wearing parts that If you smell flue gas
have not been tested together
with the system can compromise Danger
its function. Installing non-author- Flue gas can lead to life threat-
ised components and making ening poisoning.
non-approved modifications or ■ Shut down the heating system.
conversions can compromise ■ Ventilate the installation site.
safety and may invalidate our ■ Close doors to living spaces to
warranty. prevent flue gases from
For replacements, use only orig- spreading.
inal spare parts supplied or
approved by Viessmann.
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Safety instructions
Safety instructions (cont.)
What to do if water escapes from the Danger

appliance The simultaneous operation of
the boiler and appliances that
Danger extract air to the outside can
When water escapes from the result in life threatening poison-
appliance there is a risk of elec- ing due to reverse flow of the flue
trocution. gas.
Switch off the heating system by Fit an interlock circuit or take suit-
means of an external isolator (for able steps to ensure an adequate
example fuse box, domestic supply of combustion air.
power distribution).
Flue systems and combustion air
Ensure that flue systems are clear and

cannot be sealed, for instance due to
accumulation of condensate or other
causes. Ensure an adequate supply of
combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems,
or an inadequate supply of com-
bustion air can cause life threat-
ening poisoning from carbon
monoxide in the flue gas.
Ensure the flue system is in good
working order. Apertures for sup-
plying combustion air must be
non-closable.
Extractors
Operating appliances that extract air to

the outside (cooker hoods, extractors, air
conditioning units, etc.) can create neg-
ative pressure. If the boiler is operated at
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the same time, this can lead to reverse

flow of the flue gas.
4
Index
Index
Installation instructions
Information
Disposal of packaging.......................................................................................... 7
Symbols................................................................................................................ 8
Intended use......................................................................................................... 9
Product information.............................................................................................. 9
Preparing for installation................................................................................... 11
Installation sequence
Mounting the boiler and making the connections................................................. 14
Opening the control unit enclosure....................................................................... 20
Electrical connections........................................................................................... 21
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 28
Further details regarding the individual steps....................................................... 30
Troubleshooting
Function sequence and possible faults................................................................ 61
Fault display......................................................................................................... 62
Repairs................................................................................................................. 66
Gas type conversion

Converting from LPG to natural gas..................................................................... 76
Control unit
Functions and operating conditions in weather-compensated mode................... 78
Designs
Connection and wiring diagram............................................................................ 79
Parts lists
Ordering parts...................................................................................................... 81
Overview of assemblies....................................................................................... 82
Sheet metal parts assembly................................................................................. 83
Heat cell assembly............................................................................................... 85
Burner assembly.................................................................................................. 87
Hydraulic assembly.............................................................................................. 89
Hydraulic assembly, system boiler....................................................................... 91
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Hydraulic assembly, combi boiler......................................................................... 92
5
Index
Index (cont.)
Control unit assembly........................................................................................... 94

Miscellaneous....................................................................................................... 95
Specification....................................................................................................... 97
Disposal
Final decommissioning and disposal.................................................................... 99
Certificates
Declaration of conformity...................................................................................... 100
Keyword index.................................................................................................... 101
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Information
Disposal of packaging
Please dispose of waste packaging in

line with statutory regulations.
Installation
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Information
Symbols
Sym- Meaning
bol
Reference to other document
containing further information
Step in a diagram:
1. The numbers correspond to the
order in which the steps are car-
ried out.
Warning of material losses and

environmental pollution
Live electrical area
Pay particular attention.
■ Component must audibly

click into place.
or
■ Acoustic signal
■ Fit new component.
or
■ In conjunction with a tool:
Clean the surface.
Dispose of component correct-
ly.
Dispose of component at a suit-

able collection point. Do not
dispose of component in do-
mestic waste.
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Information
Intended use
The appliance is only intended to be Any usage beyond this must be

installed and operated in sealed unven- approved by the manufacturer in each
ted heating systems that comply with individual case.
EN 12828, with due attention paid to the
associated installation, service and Incorrect usage or operation of the appli-
operating instructions. It is only designed ance (e.g. the appliance being opened
for the heating of water that is of potable by the system user) is prohibited and will
water quality. result in an exclusion of liability. Incorrect
usage also occurs if the components in
Intended use presupposes that a fixed the heating system are modified from
installation in conjunction with permissi- their intended use (e.g. if the flue gas and
Installation
ble, system-specific components has ventilation air paths are sealed).
been carried out.
Commercial or industrial usage for a pur-

pose other than heating the building or
DHW shall be deemed inappropriate.
Product information
Vitodens 100-W, type B1HA, B1KA
Preset for operation with natural gas. Product description

Conversion to LPG P requires a gas con-
version kit. The Vitodens 100-W is available as a
gas condensing boiler for the connection
Conversion for other countries of one DHW cylinder and as a gas con-
densing combi boiler with an integral
The Vitodens 100-W must only be deliv- plate heat exchanger for DHW heating.
ered to the countries specified on the For the connection of heating circuits
type plate. For deliveries to alternative and the DHW cylinder or the DHW line,
countries, an approved contractor must see from page 13.
arrange individual approval on his/her In the delivered condition, the
own initiative and in accordance with the Vitodens 100-W is set up for operation
law of the country in question. with constant boiler water temperature.
By connecting an outside temperature
sensor (accessories), the boiler can be
operated in weather-compensated
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mode.
9
Information
Product information (cont.)
The following are integrated: one sealed Connecting accessories

unvented hydraulic system with 2 con-
nections for heating flow and return, and Cylinder temperature sensor, outside
2 connections for cylinder heating (gas temperature sensor and time switch are
condensing boiler) or DHW heating (gas connected to the control unit with low
condensing combi boiler). voltage.
These boilers are only intended for
installation in sealed unvented heating
systems. Boilers for open vented heating
systems are also available.
If the Vitodens 100-W is installed in an S
plan or Y plan system, the DHW primary
connections are not used and must be
capped off.
The following components are integra-

ted into the hydraulic system:
■ Circulation pump
■ 3-way diverter valve
■ Safety valve
■ Diaphragm expansion vessel
■ Plate heat exchanger for DHW heating
(gas condensing combi boiler)
DHW heating with DHW cylinder
If a Viessmann Vitocell is connected, a

cylinder temperature sensor will issue
the heat demand (accessories). The cyl-
inder temperature sensor is connected
to the boiler control unit. A 230 V cylinder
temperature controller is not required.
If a different DHW cylinder is connected,
the cylinder temperature sensor (acces-
sories) may also be used on this cylin-
der. Alternatively, a 230 V cylinder tem-
perature controller should be connected
via the cylinder demand junction box
(part of the boiler standard delivery).
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Preparing for installation
Preparing for boiler installation
Dimensions and connections
350
400
250
156
5
68
Installation
860
700
A B CD E
F
58 58 34
150
123 123 125
A Heating flow E Heating return

B Gas condensing boiler: F Condensate drain/ drain safety
Cylinder flow valve: Plastic hose 7 22 mm
Gas condensing combi boiler:
DHW
C Gas connection
D Gas condensing boiler:
Cylinder return
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Cold water
11
Preparing for installation (cont.)
Fitting the wall mounting bracket
250
145
Ø10
A Vitodens installation template

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1. Position the supplied installation tem- 2. Mark out the rawl plug holes.
plate on the wall.
12
Preparing for installation (cont.)
3. Drill 7 10 mm holes and insert the

rawl plugs supplied.
4. Fit wall mounting bracket with screws

supplied.
Fitting the pre-plumbing jig or mount-

ing frame
Pre-plumbing jig or mounting

frame installation instructions
Installation
Preparing the connections
!
Please note
To prevent appliance damage,
connect all pipework free of load
and torque stress.
1. Prepare the water connections. Flush

the heating system.
2. Prepare the gas connection.
3. Prepare the electrical connections.

■ Power cable:
Flexible cable 3 x 1.5 mm2
Leave the earth conductor (PE)
longer than the 'live' conductors L1
and N.
■ Accessory cables:
NYM-O 2-core min. 0.5 mm2.
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Mounting the boiler and making the connections
Removing the front panel and mounting the boiler
3.
2.
1.
2x
1. Undo the screws at the bottom of the 3. Hook the boiler onto the wall mount-
boiler; do not remove completely. ing bracket.
2. Remove the front panel.

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Mounting the boiler and making the connections (cont.)
Making the connections on the water side
For installation of fittings on the Gas condensing boiler

heating water side and DHW
side, see separate installation
instructions.
Installation
A B C D E
z z E
C
A
¨
A Heating flow
B Gas condensing boiler:
Cylinder flow
DHW
C Gas connection
D Gas condensing boiler:
Cylinder return
Cold water
E Heating return
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Gas condensing combi boiler Permiss. DHW operating pressure:

10 bar (1.0 MPa)
Note
Install a pressure reducer if required.
D
E
F B
A
C
F Filling loop
Gas connection
1. Connect gas shut-off valve to con-

nection A.
A
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2. Carry out a tightness test.
Note
Only use suitable and approved leak
detection agents (EN 14291) and
devices for the tightness test. Leak
detection agents with unsuitable con-
stituents (e.g. nitrides, sulphides) can
result in material damage.
Remove leak detection agent resi-
dues after testing.
Installation
!
Please note
Excessive test pressure will
damage the boiler and the gas
train.
Max. test pressure 150 mbar.
If a higher pressure is
required for tightness tests,
disconnect the boiler and the
gas train from the main supply
pipe (undo the fitting).
3. Purge the gas line.

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Connecting the safety valve and condensate drain
■ If the condensate pipe is routed out-

side the building, use a pipe with at
least 7 30 mm and protect this pipe
from frost. Avoid long external pipe
runs.
!
Please note
A frozen condensate pipe can
result in faults and damage to
the boiler.
Always protect condensate
pipes against frost.
■ Observe local building regulations.

A Connect condensate pipe A to the pub-
lic sewage system with a constant fall
and a pipe vent.
Observe the local waste water regula-
tions.
■ The condensate pipe is connected to Note

the discharge pipe of the safety valve. Fill the trap with water before commis-
The supplied condensate hose meets sioning.
the temperature requirements for CE
certification.
■ We recommend connecting the con-
densate pipe to the internal domestic
waste water system, either directly or
via a tundish.
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Filling the trap with water
Pour at least 0.3 l of water into the flue

outlet.
!
Please note
During commissioning, flue gas
may escape from the condensate
drain.
Always fill the trap with water
before commissioning.
Installation
Balanced flue connection
Note
Only use the "System certificate" and
"Skoberne GmbH flue system" labels in
conjunction with the Viessmann flue sys-
tem made by Skoberne.
Connect the balanced flue.

During installation and positioning of the
flue system, observe Building regula-
tions Part L and BS 5440.
Flue system installation instruc-

tions.
Connecting several Vitodens 100-W Do not carry out commissioning until

to a shared flue system the following conditions are met:
■ Free passage through the flue gas
Adjust the burner setting of each con- pipes.
nected boiler to match the flue system: ■ Flue system with positive pressure is
■ For shared connection, see gas-tight.
page 40.
■ For flue gas cascade, see page 47.
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■ Apertures for ensuring sufficient com- Danger

bustion air supply are open and cannot Leaking or blocked flue systems
be closed off. or an insufficient supply of com-
■ Applicable regulations on installing bustion air cause life threatening
and commissioning flue systems have poisoning due to carbon monox-
been followed. ide in the flue gas.
Ensure the flue system functions
correctly. Apertures for combus-
tion air supply must not be able to
be closed off.
Opening the control unit enclosure
2.
3.
4x 2x 1.
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Opening the control unit enclosure (cont.)
!
Please note Prior to commencing any work,
Electronic assemblies can be touch earthed objects such as
damaged by electrostatic dis- heating or water pipes to dis-
charge. charge static loads.
Electrical connections
Installation
D
? L
C E F
%
4 3 2 1
A B
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Electrical connections (cont.)
% Gas condensing boiler: C Connecting cable

■ For Viessmann DHW cylinders: D Jumper
Cylinder temperature sensor E Power supply (230 V, 50 Hz).
(plug on the cable harness out- See page 26.
side the control unit) F Vitotrol 100 or on-site room temper-
■ In the case of alternative DHW ature controller (230 V switched
cylinders compliant with the G3 input)
Directive: Remove jumper D when making
Cylinder demand junction box (for this connection.
connection of a cylinder tempera-
ture controller and a 2-way shut- Separate installation instruc-
off valve) tions
■ Without DHW cylinder:
For operation without a DHW cyl-
inder, set rotary selector "tw" to Information on connecting
"0". accessories
A Only for weather-compensated When connecting accessories
mode: observe the separate installation
Outside temperature sensor (acces- instructions provided with them.
sories)
B OpenTherm device
Remove jumper D when making
this connection.
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Connection of room temperature controller and DHW cylinder with 230 V cyl-
inder temperature controller
Installation
% C
A E D
A Cylinder demand junction box D 230 V cylinder temperature control-

B Jumper, remove when making this ler
connection E Room temperature controller
C Power supply (230 V, 50 Hz).
See page 26.
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Connection of room temperature controller with time switch and DHW cylinder
with 2-way valve and 230 V cylinder temperature controller
% C
A H
M
1~
G E
A Cylinder demand junction box E 2-way shut-off valve

B Jumper, remove when making this F High limit safety cut-out
connection G Time switch
C Power supply (230 V, 50 Hz). H Room temperature controller
See page 26.
D 230 V cylinder temperature control-
ler
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Cable entry
Installation
A Power cable, remote control con-
necting cable
B LV leads (sensor leads)
Outside temperature sensor (accessories)
1. Fit outside temperature sensor. 2. Connect the outside temperature

sensor to terminals 3 and 4 of the
Installation site: power cable (see page 21).
■ North or north-westerly wall, 2 to
2.5 m above ground level; in multi
storey buildings, in the upper half of
the 2nd floor
■ Not above windows, doors or vents
■ Not immediately below balconies
or gutters
■ Never render over
■ Connection:
2-core lead, length up to 35 m with
1.5 mm2 cross-section
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Vitotrol 100 connection (accessories)
C
B X1
1 LN
A NO
NC
COM
Example: Vitotrol 100, type UTDB
A Vitotrol 100, type UTDB C Jumper, remove when making this

B Terminals "X1" on the control unit connection
Recommended connecting cable

■ 2-core cable with 1.5 mm² cross-sec-
tion for 230 V~
Power supply
Regulations and directives Install an isolator in the power cable that

simultaneously isolates all non-earthed
Danger conductors from the power supply with at
Incorrectly executed electrical least 3 mm contact separation.
installations can result in injuries We also recommend installing an AC/
from electrical current and in DC-sensitive RCD
appliance damage. (RCD class B ) for DC (fault) cur-
rents that can occur with energy efficient
Connect the power supply and equipment.
implement all safety measures Protect the power cable with an external
(e.g. RCD circuit) in accordance 3 A fuse to BS 1362.
with the following regulations:
■ IEC 60364-4-41
■ VDE regulations
■ Connection requirements
specified by your local power
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supply utility
26
Danger Danger
Incorrect core assignment can The absence of component
result in serious injury and dam- earthing can lead to serious injury
age to the appliance. from electric current if an electri-
Take care not to interchange cal fault occurs.
cores "L1" and "N". The appliance and pipework
must be connected to the equi-
potential bonding of the building.
Routing connecting cables and closing the control unit enclo-

sure
Installation
!
Please note
Connecting cables will be dam-
aged if they touch hot compo-
nents.
When routing and securing
cables/leads on site, ensure that
the maximum permissible tem-
perature for these cables/leads is
not exceeded.
3.
2.
1.
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Steps - commissioning, inspection and maintenance
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
• • • 1. Filling the heating system.............................................. 30

• • • 2. Venting the boiler by flushing....................................... 32
• • • 3. Converting to operation with LPG................................ 33
• • • 4. Checking the static and supply pressure..................... 34
• 5. Reducing the maximum heating output....................... 35
• 6. Adjusting the circulation pump rate to the heating
system............................................................................. 37
• 7. Burner adjustment when connecting multiple flues to
a shared flue system...................................................... 39
• 8. Adjust the burner setting if several boilers are
connected to a shared flue (flue gas cascade)............ 47
• 9. Checking the CO2 content............................................. 50
• • 10. Burner removal .............................................................. 53
• • 11. Checking the burner gasket and burner gauze
assembly......................................................................... 54
• • 12. Checking and adjusting the electrode.......................... 55
• • 13. Cleaning the heat exchanger......................................... 55
• • 14. Checking the condensate drain and cleaning the trap 56
• • 15. Installing the burner ...................................................... 57
• • 16. Checking the diaphragm expansion vessel and
system pressure............................................................. 58
• • • 17. Checking the connections on the heating water and
the DHW side................................................................... 58
• • • 18. Checking flue system for unrestricted flow and
tightness
• • • 19. Checking firm seating of electrical connections
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Steps - commissioning, inspection and… (cont.)
Commissioning steps
Inspection steps
Maintenance steps Page
• • • 20. Checking all gas equipment for tightness at operating

pressure .......................................................................... 59
• • 21. Fitting the front panel..................................................... 59
• 22. Instructing the system user........................................... 60
Service
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Further details regarding the individual steps
Filling the heating system
!
Please note ■ Soften fill water with a hard-
Unsuitable fill water increases ness above 300 ppm.
the level of deposits and corro- ■ Antifreeze suitable for heating
sion and may lead to boiler dam- systems can be added to the fill
age. water.
■ Flush the heating system thor-
oughly before filling.
■ Only fill with water of potable
quality.
1. Close the gas shut-off valve.
2. Switch ON the power supply.
3. Turn rotary selector "rt" anticlock-

wise for less than 2 s and then clock-
wise back into the r. h. section of the
control range.
"SERV", "r" and "w" will appear
on the display. Filling function is ena-
bled.
This function terminates automati-
cally after 20 min or when the ON/
OFF switch is switched off.
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30
Further details regarding the individual steps (cont.)
Gas condensing boiler
B C A 1. Open shut-off valves A and (if fitted)

B.
2. Connect fill hose to valve C and

open valve C.
3. Fill the heating system. [a removable

filling loop with double check valve
must be used in UK] (system pres-
sure 0.8 to 1.2 bar).
4. Close valve C.
close
open
Gas condensing combi boiler
1. Open shut-off valves A and (if fitted)

B.
2. Open valves C and D.
Note
The cold water supply must be
Service
open.
3. Fill the heating system (system pres-

sure 0.8 to 1.2 bar).
4. Close valves C and D.
5. Remove the connection line between

valves C and D. In operation the
B D CA
connection must be interrupted.
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Venting the boiler by flushing
A 1. Connect the drain hose on shut-off

valve A to a drain.
2. Close shut-off valve B.
3. Open valves A and C and flush at

mains pressure, until no sound of
escaping air can be heard.
4. First close valve A and then valve

C.
5. Adjust the operating pressure

≥ 0.8 bar (80 kPa) with valve C.
6. Open shut-off valve B.
7. Disconnect drain hose and keep

safe.
CB
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A 1. Connect the drain hose on shut-off

valve A to a drain.
2. Close shut-off valve B.
3. Open valves A, C and D and

flush at mains pressure, until no
sound of escaping air can be heard.
4. First close valve A and then valves

C and D.
5. Adjust the operating pressure

≥ 0.8 bar (80 kPa) with valves C and
D.
6. Open shut-off valve B.
7. Disconnect drain hose and keep

safe.
D CB
Converting to operation with LPG
In the delivered condition, the boiler is Separate installation instruc-

Service
set up for operation with natural gas. For tions.

operation with LPG, change the gas noz-
zle and switch to the correct gas type in Conversion from LPG to natural gas, see
the control unit. page 76.
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Checking the static and supply pressure
Danger 4. Check the static pressure.

CO formation as a result of incor- Set value: max. 57.5 mbar
rect burner adjustment can have (5.75 kPa)
serious health implications.
Carry out a CO test before and 5. Start the boiler.
after work on gas appliances.
Note
Operation with LPG During commissioning, the boiler can
Purge the LPG tank twice during com- enter a fault state because of airlocks
missioning or replacement. Vent the tank in the gas line. After approx. 5 s,
and gas connection line thoroughly after press Reset to reset the burner.
purging.
6. Check the supply (flow) pressure.
A
Set value:
■ Natural gas: 20 mbar (2.0 kPa)
■ LPG: 37 mbar (3.7 kPa)
Note
Use a suitable tester with a resolution
of at least 0.1 mbar (10 Pa) to check
the supply pressure.
7. Proceed as indicated in the following

table.
8. Shut down the boiler, close the gas

shut-off valve and remove the pres-
sure gauge. Close test connec-
tor A with the screw.
1. Close the gas shut-off valve.
2. Undo screw A inside test connector

"IN" on the gas train but do not
remove it, and connect the pressure
gauge.
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3. Open the gas shut-off valve.
34
9. Open the gas shut-off valve and start Note

the appliance. The maximum pressure drop
between the gas shut-off valve and
Danger test connector A at the gas train is
Gas escaping from the test 0.5 mbar (50 Pa).
connector leads to a risk of
explosion.
Check gas tightness at test
connector A.
Supply pressure (flow pressure) Measures

For natural gas For LPG
below 17.4 mbar below 25 mbar Do not start the boiler. Notify your gas
(1.74 kPa) (2.5 kPa) supply utility or LPG supplier.
17.4 to 25 mbar 25 to 47 mbar Start the boiler.
(1.74 to 2.5 kPa) (2.5 to 4.7 kPa)
above 25 mbar above 47 mbar Install a separate gas pressure governor
(2.5 kPa) (4.7 kPa) upstream of the system and regulate the
flow pressure to 20 mbar (2.0 kPa) for
natural gas or 37 mbar (3.7 kPa) for LPG.
Notify your gas supply utility or LPG sup-
plier.
Reducing the maximum heating output
The maximum heating output can be

reduced according to system require-
ments.
1. Switch ON the ON/OFF switch. Service

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35
2. Turn rotary selector "tr" for less

than 2 s fully clockwise and then back
into the r.h. section of the control
range.
"SERV" and "A" appear on the dis-
play.
3. Select the required maximum heating

output with rotary selector "tr".
Bars for the selected heating output
flash on the display.
°C
60
A
■ Position 1 (1 bar) = lower heating

output.
■ Position 6 (5 bars) = upper heating
output.
4. Test selected heating output by

checking the gas throughput.
5677 216 GB
36
5. Accept set heating output:

Turn rotary selector "tw" for less
than 2 s fully clockwise and then back
into the r. h. section of the control
range.
During acceptance, the display
shows "– . – . –".
6. Shut down the boiler.
Adjusting the circulation pump rate to the heating system
In its delivered condition the circulation

pump is set to the following pump rate:
■ For DHW heating: Speed 100 %
■ For heating mode without outside
temperature sensor:
Rated heating output in kW 19 26 30 35

Speed in % 72 80 86 100
The speed cannot be changed.
■ For heating mode with outside tem-

perature sensor:
Rated heating output in kW 19 26 30 35

Min. speed in % 72 72 72 72 Service
Max. speed in % 72 80 86 100
The maximum speed can be changed.

See the following chapter.
5677 216 GB
37
100
D
90 C
B
Circulation pump in %
80
E
70
A
60
Speed
50
-25 -20 -15 -10 -5 0 5 10 15 20 25
Outside temperature in °C
A Max. speed 19 kW D Max. speed 35 kW

B Max. speed 26 kW E Min. speed
C Max. speed 30 kW
Changing the maximum speed
Only when operating with an outside

temperature sensor.
1. Switch ON the ON/OFF switch.
2. Turn both rotary selectors "tw" and

"tr" simultaneously to their central
positions.
The display shows "SERV".
r
5677 216 GB
38
3. Within 2 s, turn rotary selector "tr"

to the top right range.
"r" appears on the display and the
set value in % of maximum speed
flashes.
4. Change the maximum speed with

rotary selector "tw".
5. The change has been programmed

when the value stops flashing. The
control unit returns to standard
mode.
6. Reset both rotary connectors to their

required set values.
Burner adjustment when connecting multiple flues to a shared

flue system
When connecting several ■ Minimum shaft cross-section

Vitodens 100-W to a shared flue system: – Square 175 x 175 mm
– Round 7 195 mm Service
Adjust the burner setting of each con- ■ Minimum height between floors 2.5 m
nected boiler by a correction factor to ■ Max. 6 boilers with the same rated
match it to the flue system. heating output connected to the
shared flue system
System conditions:
■ Shared flue in shaft 7 100 mm
■ Balanced flue connection line from
boiler to shaft 7 80/125 mm
5677 216 GB
39
1. At terminal block A insert jumper

B across terminals 3 and 4.
X21 X7
X20
4 3 2 1

positions.
r 4. Refer to the following table for the

correction factor required for the flue
system.
5. Within 2 s, turn rotary selector "tw"

to the top left range.
The display shows "r", "A", and
the selected correction factor
flashes.
In the delivered condition, factor 0
has been set.
6. Within 15 s, set rotary selector

"tr" to the required correction fac-
tor.
7. The set correction factor is program-

med when the value stops flashing,
r
and the control unit returns to stand-
ard mode.
8. Remove jumper B from terminal

5677 216 GB
block A.
40
One boiler per floor
Rated heating output 19 kW

Number of boilers 2 3 4 5 6
Correction factor (set Flue length a (m)
value)
0
1 ≤ 25 ≤ 12
2 – > 12 ≤ 25 ≤ 17 ≤ 14 ≤ 13
3 – – > 17 ≤ 25 > 14 ≤ 19 > 13 ≤ 17
4 – – – > 19 ≤ 24 > 17 ≤ 20
5 – – – > 24 ≤ 25 > 20 ≤ 23
6 – – – – > 23 ≤ 25

value)
0
1 ≤ 17
2 > 17 ≤ 25 ≤ 17
3 – > 17 ≤ 25 ≤ 17 ≤ 14 ≤ 13
4 – – > 17 ≤ 21 > 14 ≤ 17 > 13 ≤ 15
5 – – > 21 ≤ 25 > 17 ≤ 20 > 15 ≤ 17
6 – – – > 20 ≤ 22 > 17 ≤ 19

value)
Service
0
1 ≤ 13
2 > 13 ≤ 25 ≤ 14
3 – > 14 ≤ 21 ≤ 14
4 – > 21 ≤ 25 > 14 ≤ 17 ≤ 14 ≤ 13
5 – – > 17 ≤ 21 > 14 ≤ 16 > 13 ≤ 15
6 – – > 21 ≤ 24 > 16 ≤ 18 > 15 ≤ 16
5677 216 GB
41

value)
0
1 ≤ 10
2 > 10 ≤ 25 ≤ 11
3 – > 11 ≤ 17
4 – > 17 ≤ 22 ≤ 14 ≤ 13
5 – > 22 ≤ 25 > 14 ≤ 17 > 13 ≤ 14 ≤ 13
6 – – > 17 ≤ 20 > 14 ≤ 16 > 13 ≤ 15
Note
The correction factor changes the boiler
modulation range.
5677 216 GB
42
a
2.5 m
3m
Service
5677 216 GB
43
Two boilers per floor

Number of boilers 2 4 6
Correction factor (set value) Flue length a (m)
0
1 ≤ 15 ≤5 ≤5
2 – > 5 ≤ 12 >5≤8
3 – > 12 ≤ 15 > 8 ≤ 12
4 – – > 12 ≤ 15
5 – – –
6 – – –

0
1 ≤ 25
2 – ≤8 ≤6
3 – > 8 ≤ 13 >6≤8
4 – > 13 ≤ 15 > 8 ≤ 10
5 – – > 10 ≤ 12
6 – – > 12 ≤ 14

0
1 ≤ 11
2 > 11 ≤ 15 ≤7 ≤5
3 – > 7 ≤ 10 >5≤7
4 – > 10 ≤ 14 >7≤8
5 – > 14 ≤ 15 > 8 ≤ 10
6 – – > 10 ≤ 11

0
5677 216 GB
1 ≤9
2 > 9 ≤ 15 ≤6 ≤5
44
3 – >6≤8 >5≤6
4 – > 6 ≤ 11 >6≤7
5 – > 11 ≤ 14 >7≤8
6 – > 14 ≤ 15 >8≤9
Note
modulation range.
Service
5677 216 GB
45
a
2.2 m
3m
0.3 m
5677 216 GB
46
Adjust the burner setting if several boilers are connected to a

shared flue (flue gas cascade)
Adjust the burner setting of each con- System conditions:

nected boiler by a correction factor to ■ Shared flue gas header 7 100 mm
match it to the flue system. ■ Up to 4 boilers with the same rated
heating output connected to the
shared flue system
1. At terminal block A insert jumper

B across terminals 3 and 4.
X21 X7
X20
4 3 2 1

positions.
r 4. Refer to the following table for the

correction factor required for the flue Service
system.
5. Within 2 s, turn rotary selector "tw"

to the top left range.
The display shows "r", "A", and
the selected correction factor
flashes.
In the delivered condition, factor 0
has been set.
5677 216 GB
47
6. Within 15 s, set rotary selector

"tr" to the required correction fac-
tor.
7. The set correction factor is program-

r
ard mode.
8. Remove jumper B from terminal

block A.

0
1 ≤ 25 ≤9 ≤4
2 – > 9 ≤ 25 > 4 ≤ 13
3 – – > 13 ≤ 22
4 – – > 22 ≤ 25
5 – – –
6 – – –

0
1 ≤ 17 ≤5
2 > 17 ≤ 25 > 5 ≤ 15 ≤7
3 – > 15 ≤ 25 > 7 ≤ 13
4 – – > 13 ≤ 18
5 – – > 18 ≤ 24
6 – – > 24 ≤ 25

0
1 ≤ 12 ≤4 ≤2
2 > 12 ≤ 25 > 4 ≤ 11 >2≤5
5677 216 GB
3 – > 11 ≤ 19 > 5 ≤ 10
48
4 – > 19 ≤ 25 > 10 ≤ 13
5 – – > 13 ≤ 18
6 – – > 18 ≤ 21

0
1 ≤ 10
2 > 10 ≤ 25 ≤8
3 – > 8 ≤ 15 ≤7
4 – > 15 ≤ 21 > 7 ≤ 10
5 – > 21 ≤ 25 > 10 ≤ 13
6 – – > 13 ≤ 16
Note
modulation range.
Service
5677 216 GB
49
Checking the CO2 content
The Vitodens 100-W is factory-set for If the actual CO2 or O2 and CO values
natural gas. During commissioning or deviate from the stated range, check the
maintenance, the CO2 and CO have to balanced flue system for leaks. If flue
be measured at the boiler flue adaptor installation is OK, change the gas
test port to check the flue integrity. Sub- valve.
ject to the Wobbe index, the CO2 content
fluctuates between 7.4 % and 10.5 %. Note
CO of up to 500 ppm during start-up is Operate the appliance with uncontami-
acceptable. nated combustion air to prevent operat-
We recommend measuring O2 as the ing faults and damage.
value is unmistakable regarding lambda
(air/gas). The O2 content fluctuates
between 7.5 % and 3.2 %. The CO/CO2
ratio has to be less than 0.004.
5677 216 GB
50
01. Connect a flue gas analyser at flue

gas port A on the boiler flue con-
nection.
02. Start the boiler and check for

leaks.
Danger
Escaping gas leads to a risk
of explosion.
A Check all gas equipment for
tightness.
03. Turn rotary selector "tr" for less

than 2 s fully clockwise and then
back into the r.h. section of the con-
trol range.
The display shows "SERV", "A"
and the boiler water temperature.
04. Set the upper heating output:

Turn rotary selector "tr" into the
r.h. section of the control range until
the display shows 5 bars for the
upper heating output. Service
05. Check the CO2 content for the upper

heating output.
The CO2 content must be between
7.0 and 10.5 %.
5677 216 GB
51
06. Set the lower heating output:

Turn rotary selector "tr" into the
l.h. section of the control range until
the display shows 1 bar for the lower
heating output.
07. Check the CO2 content for the lower

heating output.
The CO2 content must be between
0.3 and 0.9 % below the value of the
upper heating output.
08. ■ If the CO2 content is within the

given range, continue with point
10.
■ If the CO2 content lies outside the
given range, check the flue gas/
ventilation air system for tight-
ness; remedy any leaks.
Replace gas train if required.
09. Re-check the CO2 content for the

upper and lower heating output.
10. Shut down the boiler, remove the

flue gas analyser and close flue gas
test port A.

"tr" to their respective original
positions.
5677 216 GB
52
Burner removal
F4x E D
C B A Service
1. Switch off the power supply. 5. Undo gas supply pipe fitting E.
2. Shut off the gas supply. 6. Undo 4 screws F and remove the
burner.
3. Pull the power cables from fan motor
!
A, gas train B and electrodes C. Please note
Prevent damage.
4. Pull venturi extension D from the Never rest the burner on the
fan. burner gauze assembly.
5677 216 GB
53
Checking the burner gasket and burner gauze assembly
Check burner gasket A for damage and Replace the burner gauze assembly if it
replace if required. is damaged.
E D C A
2x
1. Remove electrode B. 4. Insert and secure new burner gauze

assembly D with new gasket E.
2. Undo the 2 Torx screws and remove
!
thermal insulation ring C. Please note
Tighten screws just enough
3. Undo the 2 Torx screws and remove to ensure the components do
burner gauze assembly D with gas- not suffer damage and will
5677 216 GB
ket E. function correctly.
54
5. Mount thermal insulation ring C. 6. Fit electrode B.
! !
Please note Please note
Tighten screws just enough Tighten screws just enough
to ensure the components do to ensure the components do
not suffer damage and will not suffer damage and will
function correctly. function correctly.
Checking and adjusting the electrode
1. Check the electrode for wear and

contamination.
2. Clean the electrode with a small

brush (not with a wire brush) or emery
paper.
8+2
3. Check the electrode gaps. If the gaps

are not as specified or the electrode
is damaged, replace electrode and
4+0,5 gasket and realign the electrode.
Tighten the electrode fixing screws.
!
Please note
to ensure the components do
not suffer damage and will
function correctly.
Cleaning the heat exchanger Service
!
Please note Note
Do not damage the surfaces of Discolouration on the heat exchanger
the heat exchanger that come surface is a normal sign of use. It has no
into contact with hot gas. This can bearing on the function and service life
lead to corrosion damage. of the heat exchanger.
Never use brushes to clean the The use of chemical cleaning agents is
heat exchanger. not required.
Brushing can cause deposits to
become lodged in the gaps
between the coils.
5677 216 GB
55
1. Use a vacuum cleaner to remove

combustion residues from heating
surface A of the heat exchanger.
A
2. Flush heating surface A with
water.
3. Check condensate drain and clean

siphon. See the following chapter.
4. Flush the heating surface again with

water (the siphon is also filled with
water in the process).
Checking the condensate drain and cleaning the trap
1. Pull trap A upwards out of the drain

connection.
2. Pull supply hose B off trap A.
3. Clean trap A.
B
4. Reconnect supply hose B.
5. Refit trap A to the drain connec-

A tion.
6. Fill trap A with water. For this, pour

approx. 0.3 l of water into the com-
bustion chamber.
7. Check that condensate can drain

freely and that the connections are
tight.
5677 216 GB
56
Installing the burner
A4x B C
F E D Service
1. Fit burner and tighten 4 screws A 3. Plug venturi extension C onto the
diagonally. fan.
!
Please note 4. Fit electrical cables to fan motor D,
Tighten screws just enough gas train E and ignition unit F.
not suffer damage and will 5. Reopen gas supply and switch on
function correctly. power supply.
5677 216 GB
2. Insert new gasket and tighten the fit-

ting on gas supply pipe B.
57
!
6. Check gas connections for tight- Please note
ness. The use of leak detection
spray can result in faulty oper-
Danger ation.
Escaping gas leads to a risk of Leak detection spray must not
explosion. come into contact with electri-
Check the fitting for gas tight- cal contacts or seal the dia-
ness. phragm opening on the gas
valve.
Checking the diaphragm expansion vessel and system pressure
Note 2. If the pre-charge pressure of the

The expansion vessel can lose some of expansion vessel is lower than the
its charge pressure after some time in static system pressure, top up with
use. When the boiler heats up, the pres- nitrogen until the pre-charge pres-
sure gauge will indicate a higher pressure is 0.1 to 0.2 bar (10 to 20 kPa)
sure of 2 or 3 bar (0.2 or 0.3 MPa). The higher than the static system pres-
safety valve can respond and discharge sure.
excess pressure.
For this reason, check the expansion 3. Top up with water until the charge
vessel pre-charge pressure annually. pressure of the cooled system is at
least 1.0 bar (0.1 MPa), and is 0.1 to
Check whether the installed expansion 0.2 bar (10 to 20 kPa) higher than the
vessel is adequate for the system water pre-charge pressure of the expan-
volume (GB only). sion vessel.
Carry out this test on a cold system. Permiss. operating pressure: 3 bar
(0.3 MPa)
1. Drain the system until the pressure
gauge shows "0".
Alternatively, close the cap valve on
the expansion vessel and reduce the
pressure until the pressure gauge
indicates "0".
Checking the connections on the heating water and the DHW

side
Check all connections and lines on the

heating water and DHW side (including
inside the appliance) for tightness and
5677 216 GB
possible damage.
58
Checking all gas equipment for tightness at operating pressure
!
Danger Please note
Escaping gas leads to a risk of The use of leak detection spray
explosion. can result in faulty operation.
Check all gas equipment for tight- Leak detection spray must not
ness. come into contact with electrical
contacts or seal the diaphragm
opening on the gas valve.
Fitting the front panel
1.
Service
2.
2x
5677 216 GB
1. Hook the front panel into place. 2. Tighten screws on the underside.
59
Instructing the system user
The system installer should hand the

operating instructions to the system user
and instruct the user in operating the
system.
5677 216 GB
60
Troubleshooting
Function sequence and possible faults
Display Measures
Control unit issues No Increase set value
a heat demand and ensure heat is
drawn off
Yes
Fan starts No After approx. 1 min Check the fan, fan

fault F9 connecting cables,
power at the fan
and fan control
Yes
Ignition No Fault F4 Check the ignition

module connec-
tion
Yes
Gas train opens No Fault F4 Check the gas

train (230 V control
voltage) and gas
supply pressure
Yes
Ionisation current No Fault F4 Check the ionisa-

builds (higher than tion current, check
Service
2 µA) the electrode ad-

Symbol A justment, conden-
sate drain and the
gas line for air-
locks
5677 216 GB
61
Troubleshooting
Function sequence and possible faults (cont.)
Yes
Burner in opera- No Stops below the set Check the flue sys-
tion boiler water tem- tem for tightness
perature and re- (flue gas recircula-
starts immediately tion); check the
gas flow pressure
Fault display
Faults are indicated by a flashing fault

code with fault symbol "U" on the dis-
f2 play.
For an explanation of the fault codes,
see the following table.
Displayed System characteris- Cause Measures

fault code tics
10 Constant tempera- Short circuit, out- Check the outside tem-
ture mode side temperature perature sensor and lead
sensor (see page 66).
18 Constant tempera- Lead break, out- Check the outside tem-
ture mode side temperature perature sensor and lead
sensor (see page 66).
30 Burner blocked Short circuit, boiler Check boiler water tem-
water temperature perature sensor (see
sensor page 68).
38 Burner blocked Lead break, boiler Check boiler water tem-
water temperature perature sensor (see
sensor page 68).
50 No DHW heating Short circuit, cylin- Check sensor (see
der temperature page 69).
sensor
5677 216 GB
62
Troubleshooting
Fault display (cont.)

fault code tics
51 No DHW heating Short circuit, outlet Check sensor (see
temperature sen- page 71).
sor
52 Burner blocked Short circuit, flow Check connections and
sensor lead; replace sensor if re-
quired.
58 No DHW heating Lead break, cylin- Check sensor (see
der temperature page 69).
sensor
59 No DHW heating Lead break, outlet Check sensor (see
temperature sen- page 71).
sor
5A Burner blocked Lead break, flow Check connections and
sensor lead; replace sensor if re-
quired.
A9 Control mode without Communication er- Check connections and
OpenTherm device ror, OpenTherm lead; replace OpenTherm
device device if required.
b0 Burner blocked Short circuit, flue Check sensor (see
gas temperature page 72).
sensor
b8 Burner blocked Lead break, flue Check sensor (see
gas temperature page 72).
sensor
E3 Burner in a fault Fault in safety Check the temperature
state chain limiter and connecting ca-
bles (see page 70).
Check the control unit, Service
and replace if required.
E5 Burner blocked Internal fault Check the ionisation elec-
trode and connecting ca-
bles.
Press "Reset" (see
page 65).
F0 Burner blocked Internal fault Replace control unit.
F1 Burner in a fault Max. flue gas tem- Check heating system fill
state perature exceeded level. Check circulation
pump. Vent the system.
5677 216 GB
Press "Reset" (see

page 65).
63
Troubleshooting

fault code tics
F2 Burner in a fault Temperature limit- Check heating system fill
state er has responded level. Check circulation
pump. Vent the system.
Check the temperature
limiter and connecting ca-
bles (see page 70).
Press "Reset" (see
page 65).
F3 Burner in a fault Flame signal is al- Check ionisation elec-
state ready present at trode and connecting ca-
burner start ble.
Press "Reset" (see
page 65).
F4 Burner in a fault No flame signal de- Check the ignition/ionisa-
state tected tion electrode and con-
necting cables, check the
gas pressure, check the
gas train, ignition, ignition
module and condensate
drain.
Press "Reset" (see
page 65).
F8 Burner in a fault Fuel valve closes Check gas train. Check
state too late both control paths.
Press "Reset" (see
page 65).
F9 Burner in a fault Fan speed too low Check fan, fan connecting
state during burner start cables and power supply;
check fan control.
Press "Reset" (see
page 65).
FA Burner in a fault Fan idle state not Check fan, fan connecting
state reached cables and fan control.
Press "Reset" (see
page 65).
FC Burner blocked Electrical fan con- Check fan connecting ca-
trol (control unit) ble; replace if required, or
faulty replace control unit.
5677 216 GB
64
Troubleshooting

fault code tics
Fd Burner blocked Burner control unit Check ignition electrodes
fault and connecting cables.
Check whether a strong
interference (EMC) field
exists near the appliance.
Press "Reset" (see

page 65).
Replace control unit if
fault persists.
FF Burner blocked Burner control unit Check ignition electrodes
fault and connecting cables.
Check whether a strong
interference (EMC) field
exists near the appliance.
Press "Reset" (see

page 65).
Replace control unit if
fault persists.
Initiating a reset
Turn rotary selector "rt" to "U

RESET" for less than 2 s, then back into
the control range section.
Service
r
5677 216 GB
65
Troubleshooting
Repairs
Removing the front panel
2.
1.
2x
1. Undo screws at the bottom of the 2. Remove the front panel.

boiler; do not remove completely.
Outside temperature sensor
1. Open the control unit enclosure. See

page 20.
5677 216 GB
66
Troubleshooting
Repairs (cont.)
2. Disconnect outside temperature sen-

sor leads.
X21 X7
X20
4 3 2 1
100 3. Check the sensor resistance and

80 compare it with the curve.
60
40
4. In the event of severe deviation
Resistance in kΩ
replace the sensor.

20
10
8
6
4
-15 -5 0 10 20 30
-10
Temperature in °C
Service
5677 216 GB
67
Troubleshooting
Repairs (cont.)
Boiler water temperature sensor
1. Pull the leads from boiler water tem-

perature sensor A and check the
resistance.
20 2. Check the sensor resistance and

compare it with the curve.
10
8
6 3. In the case of severe deviation, drain
4 the boiler on the heating water side
Resistance in kΩ
and replace the sensor.

2
Danger
1
0.8 The boiler water temperature
0.6 sensor is in direct contact with
0.4 the heating water (risk of
10 30 50 70 90 110
scalding).
5677 216 GB
Temperature in °C
Drain the boiler before replac-
ing the sensor.
68
Troubleshooting
Repairs (cont.)
Checking the cylinder temperature sensor (gas condensing

boiler)
1. Remove plugs % from the cable har-

ness and check the resistance.
X21 X7
X20
20 2. Compare the sensor resistance with

the curve.
10
8
6 3. In the event of severe deviation
4 replace the sensor.
Resistance in kΩ
1
0.8
0.6
0.4
10 30 50 70 90 110
Temperature in °C
Service
5677 216 GB
69
Troubleshooting
Repairs (cont.)
Checking the temperature limiter
If the burner control unit cannot be reset

after a fault shutdown, although the
boiler water temperature is below
A approx. 95 °C, check the temperature
limiter.
1. Pull the cables from temperature lim-

iter A.
2. Check the continuity of the tempera-

ture limiter with a multimeter.
3. Remove the faulty temperature lim-

iter.
4. Install a new temperature limiter.
5. Reset by pressing "Reset" on the

control unit to (see page 65).
5677 216 GB
70
Troubleshooting
Repairs (cont.)
Checking the outlet temperature sensor (gas condensing combi

boiler)
1. Pull leads from outlet temperature

sensor A.
2. Check the sensor resistance and

A

replace the sensor.
10
8
6 Note
4 Water can leak when replacing the
Resistance in kΩ
outlet temperature sensor. Shut off

2 the cold water supply. Drain the DHW
line and the plate heat exchanger (on
1
Service
0.8 the DHW side).
0.6
0.4
10 30 50 70 90 110
Temperature in °C
5677 216 GB
71
Troubleshooting
Repairs (cont.)
Check flue gas temperature sensor
1. Pull leads from flue gas temperature

sensor A.
A
2. Check the sensor resistance and

replace the sensor.
10
8
6
4
Resistance in kΩ
1
0.8
0.6
0.4
10 30 50 70 90 110
5677 216 GB
Temperature in °C
72
Troubleshooting
Repairs (cont.)
Replacing the flow limiter (gas condensing combi boiler)
A 1. Drain the boiler on the DHW side.
2. Pivot the control unit downwards.

B
3. Undo screws A.
C
4. Remove cap B.
5. Remove faulty flow limiter C.
6. Select new flow limiter C according

to the boiler serial no. (see type plate)
and the following table.
7. Insert new flow limiter C.
8. Mount new cap B provided.
Serial no. Flow rate Colour

(type plate) l/min
7543422 10 Black
7543424 12 Red
7543426 14 Brown
Service
5677 216 GB
73
Troubleshooting
Repairs (cont.)
Checking or replacing the plate heat exchanger (gas condensing

combi boiler)
B B
C D
F E
C Heating water flow E Cold water

D Heating water return F DHW
1. Shut off and drain the boiler on the 3. Undo 2 screws A on plate heat
heating water and the DHW side. exchanger B and remove plate heat
exchanger with gaskets.
2. Pivot the control unit downwards.
Note
During and after removal, small
amounts of water may trickle from the
plate heat exchanger.
5677 216 GB
74
Troubleshooting
Repairs (cont.)
4. Check the connections on the DHW 6. Install in reverse order using new
side for scaling; clean or replace the gaskets.
plate heat exchanger if required.
Note
5. Check the connections on the heat- During installation, ensure the fixing
ing water side for contamination; holes are aligned and the gaskets are
clean or replace the plate heat seated correctly. Mount the plate
exchanger if required. heat exchanger with the correct ori-
entation.
Checking the fuse
F4
Service
1. Switch off the power supply.
2. Open control unit enclosure (see

page 20).
3. Check fuse F4.

5677 216 GB
75
Gas type conversion
Converting from LPG to natural gas
Removing the gas restrictor
F A
C ED
1. Pull cable from gas train A. 6. Remove or void gas type sticker on
the top of the boiler (next to the type
2. Undo union nut B. plate).
3. Undo 2 screws C and remove gas 7. Start the boiler and check for leaks.
train A.
Danger
4. Remove gas restrictor D from gas Escaping gas leads to a risk of
train A. explosion.
Check all gas equipment for
5. Mount gas train A with new gaskets tightness.
E and F.
!
Please note
not suffer damage and will
function correctly.
5677 216 GB
76
Gas type conversion
Converting from LPG to natural gas (cont.)
Changing the gas type at the control unit

positions.
3. Turn rotary selector "tr" within 2 s

fully anticlockwise.
The set value and "A" flash on the
display.
4. Change the control unit setting to nat-

ural gas or LPG by turning rotary
selector "tw".
The display shows:
■ "0" for operation with natural gas
or
■ "1" for operation with LPG Service
5. The set operating mode is program-

ard mode.
Checking the CO2 content
See page 50.

5677 216 GB
77
Control unit
Functions and operating conditions in weather-compensated mode
In weather-compensated mode, the

boiler water temperature is regulated
according to the outside temperature.
Heating curve for weather-compensated control
90
G
80 F
70 E
D
flow temperature in °C
60
C
50
Boiler water or
B
40
A
30
20
10
0
20 15 10 5 0 -5 -10 -15 -20
Outside temperature in °C
Setting of rotary selector "tr" Frost protection function

A =1
B =2 The frost protection function requires an
C =3 outside temperature sensor to be con-
D =4 nected. The frost protection function
E = delivered condition becomes active at outside temperatures
F =5 of < 5 °C. The burner starts and the boiler
G =6 water temperature is held at 20 °C.
5677 216 GB
78
Designs
Connection and wiring diagram
E
B
F
A
G
H
Service
K
L
M
A Diverter valve stepper motor C Vitotrol 100 type UTA or on-site

5677 216 GB
B Ignition/ionisation room temperature controller

(switched 230 V input)
79
Designs
Connection and wiring diagram (cont.)
D Vitotrol 100, type RT or on-site % Gas condensing boiler:

room temperature controller ■ For Viessmann DHW cylin-
(switched 230 V input) ders: Cylinder temperature
E Vitotrol 100, type UTDB or on-site sensor
room temperature controller ■ In the case of alternative DHW
(switched 230 V input) cylinders compliant with the G3
F Power supply 230 V/50 Hz Directive:
G Remote control (OpenTherm Cylinder demand junction box
device) (for connection of a 230 V cyl-
H Outside temperature sensor inder temperature controller
(accessories) and a 2-way shut-off valve)
K Time switch (accessories) aG Flue gas temperature sensor
L Gas pressure switch (accesso- sÖ Circulation pump 230 V~
ries) dG Gas solenoid valve
M PCB inside the control unit fJ Temperature limiter
X ... Electrical interface a-Ö Fan motor 230 V~
§ Boiler water temperature sensor a-ÖA Fan control
$ Outlet temperature sensor (gas aVL Flow sensor
condensing combi boiler)
5677 216 GB
80
Parts lists
Ordering parts
The following information is required: Standard parts are available from your
■ Serial no. (see type plate A) local supplier.
■ Assembly (from this parts list)
■ Position number of the individual part
within the assembly (from this parts
list)
Service
5677 216 GB
81
Parts lists
Overview of assemblies
B C
E F
A Type plate D Control unit assembly

5677 216 GB
B Sheet metal parts assembly E Miscellaneous

C Heat cell assembly F Hydraulic assembly
82
Parts lists
Sheet metal parts assembly
0007
0002
0001
0002
0009
0008
0005
0006
0006
0009
Service
0004
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83
Parts lists
Sheet metal parts assembly (cont.)
Pos. Part
0001 Front panel
0002 Profiled seal
0004 Strain relief upper part
0005 Air box floor
0006 Diaphragm grommets (set)
0007 Wall mounting bracket
0008 Control flap
0009 Vitodens 100 logo
5677 216 GB
84
Parts lists
Heat cell assembly
0005 0001
0002
0003 0001
0003
0004
0014
0015
0006
0013 0004
0013
0014
0012 0015
0007
0008
0011 0009
0010
0011
0016
Service
0017
5677 216 GB
85
Parts lists
Heat cell assembly (cont.)
Pos. Part
0001 Gasket DN 60
0002 Boiler flue connection
0003 Boiler flue connection plug
0004 Flue gasket
0005 Flue gas temperature sensor
0006 Heat exchanger
0007 Condensate hose
0008 Splash trap
0009 Tee union
0010 Gas connection
0011 Gasket A 17 x 24 x 2 (5 pce)
0012 Burner (see burner assembly)
0013 Thermal insulation block
0014 Heat exchanger mounting (set)
0015 O-ring 20.63 x 2.62 (5 pce)
0016 Condensate hose 400
0017 Corrugated hose 19 x 800 with ferrule/bend
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86
Parts lists
Burner assembly
0003 0002 0011 0001

0004 0011
0007 0006 0005 0004

0006 0001
0004
0006
0008
0013
0011
0010
0013
0013 0014
0008
0009
0008
0012
0013
0014
Service
0014
0013
0015
0013
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87
Parts lists
Burner assembly (cont.)
Pos. Part
0001 Burner gasket 7 187 (wearing part)
0002 Thermal insulation ring
0003 Cylinder burner gauze assembly
0004 Burner gauze assembly gasket
0005 Burner door
0006 Gasket, ionisation electrode (5 pce)
0007 Ignition/ionisation electrode
0008 Gasket, burner door flange (wearing part)
0009 Radial fan NRG 118
0010 Gas valve GB-ND 055 E01
0011 Mounting plate, thermal insulation ring (2 pce)
0012 Venturi extension
0013 Gasket A 17 x 24 x 2 (5 pce)
0014 Gasket set
0015 Conversion kit G31
5677 216 GB
88
Parts lists
Hydraulic assembly
0002
0001
0003
0005
0010 0007
0010
0007
0003
0006
0012
0007
0018
0021 0010
0007 0004
0010 0020 0003
0018 0011 0009
0013
0009
0007
0013
0014
0007
0007
0019
0015 0007
0007
Service
0016 0015
0016
0019
0007 0015
0015 0016
0016
0022
0008
0017
0008
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89
Parts lists
Hydraulic assembly (cont.)
Pos. Part
0001 Diaphragm expansion vessel CRI 8
0002 Cushion
0003 Gasket A 10 x 15 x 1.5 (5 pce)
0004 DEV connection line G 3/8
0005 Connection elbow HR brass
0006 Profile hose HR
0007 Spring clip DN 25 (5 pce)
0008 Clip 7 10 (5 pce)
0009 Clip 7 8 narrow (5 pce)
0010 O-ring 20.63 x 2.62 (5 pce)
0011 Air vent valve G 3/8
0012 Temperature sensor
0013 Circular seal washer 8 x 2 (5 pce)
0014 Profile hose HF
0015 Clip 7 18 (5 pce)
0016 O-ring 17 x 4 (5 pce)
0017 Pressure gauge
0018 Clip 7 8 (5 pce)
0019 Hose connector adaptor
0020 Thermal circuit breaker
0021 Connection elbow HF
0022 Hydraulics (see hydraulic assembly, system or combi boiler)
5677 216 GB
90
Parts lists
Hydraulic assembly, system boiler
0009
0007 0006 0001 - 0011 0002
0011 0007 0003 0014 0006 0013 0001
0002
0004
0009
0008
0005
0003
0006 0008
0009
0009
0009
0006 0008
0012
0010
Pos. Part
0001 Air vent valve
0002 O-ring 34 x 3 (5 pce)
0003 Check valve
0004 O-ring 23.7 x 3.6 (5 pce)
Service
0005 Bypass cartridge

0006 Clip 7 16 (5 pce)
0007 Stepper motor adaptor
0008 O-ring 19.8 x 3.6 (5 pce)
0009 O-ring 16 x 3 (5 pce)
0010 Clip 7 18 (5 pce)
0011 Linear stepper motor
0012 Circulation pump motor UPM3 15-75
0013 Safety valve 3 bar
5677 216 GB
0014 Hydraulic assembly, system boiler
91
Parts lists
Hydraulic assembly, combi boiler
0024 0017 0022

0001 - 0019 0017
0004 0007 0014

0007
0013
0001
0002
0015
0016
0016
0005 0012
0006 0006
0009 0009 0003
0012 0002
0009
0026
0006 0025
0019
0008 0023
0011
0018
0020 0011
0025 0019
0026
0006
0008
0009
0021
0009
0008
0010
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92
Parts lists
Hydraulic assembly, combi boiler (cont.)
Pos. Part
0001 Air vent valve
0002 O-ring 34 x 3 (5 pce)
0003 O-ring 23.7 x 3.6 (5 pce)
0004 Linear stepper motor
0005 Bypass cartridge
0006 Clip 7 16 (5 pce)
0007 Stepper motor adaptor
0008 O-ring 19.8 x 3.6 (5 pce)
0009 O-ring 16 x 3 (5 pce)
0010 Clip 7 18 (5 pce)
0011 Clip 7 10 (5 pce)
0012 Check valve
0013 Temperature sensor
0014 Clip 7 8 narrow (5 pce)
0015 Water volume controller
0016 Oval cap seal (5 pce)
0017 Gasket set, plate heat exchanger
0018 Flow sensor
0019 O-ring 9.6 x 2.4 (5 pce)
0020 Expansion vessel
0021 Circulation pump motor UPM3 15-75
0022 Plate heat exchanger
0023 Safety valve 3 bar
0024 Hydraulic assembly, combi boiler
0025 Clip 7 8 (5 pce)
0026 Circular seal washer 8 x 2 (5 pce)
Service
5677 216 GB
93
Parts lists
Control unit assembly
0001
0002
0003
0010
0004 0002
0010
0003
0002
0011
0012
0005 0006 0007 0008 0009 0013
Pos. Part
0001 Cover, wiring chamber
0002 Clip hinge
0003 Profiled seal
0004 Control unit VBC113-C11.xx
0005 Cable harness X20
0006 Ignition cable with angled plug 5 kΩ
0007 Gas valve connecting cable 35
5677 216 GB
0008 Fan connecting cable 100

0009 Cable harness, stepper motor AMP-X
94
Parts lists
Control unit assembly (cont.)
Pos. Part
0010 Fuse, 2.5 A (slow), 250 V (10 pce)
0011 Outside temperature sensor NTC 5 K
0012 Lead, outside temperature sensor
0013 Connecting cable, heating circuit pump 20
Miscellaneous
0001
0002
0003
Service
0004
0005
5677 216 GB
95
Parts lists
Miscellaneous (cont.)
Pos. Part
0001 Touch-up spray paint, white, 150 ml

0002 Touch-up paint stick, white
0003 Special grease
0004 Operating instructions
0005 Installation and service instructions
5677 216 GB
96
Specification
Specification
Rated voltage: 230 V~ Temperature limiter

Rated frequen- setting: 100 °C (fixed)
cy: 50 Hz Backup fuse (power
Rated current: 2.0 A~ supply): 3A
Safety category: I
IP rating: IP X4 to EN 60529
(only for room sealed
operation)
Permissible ambient temperature

■ During operation: 0 to +40 °C
■ During storage
and transport: -20 to +65 °C
Gas boiler, category II 2H3P

Rated heating output
range in heating mode
TF/TR 50/30 °C kW 6.5 – 19 6.5 – 26 8.8 – 30 8.8 – 35
TF/TR 80/60 °C kW 5.9 – 5.9 – 8.0 – 8.0 – 31.9
17.3 23.7 27.3
range 5.9 – 5.9 – 8.0 –
kW 8.0 – 35.0
for DHW heating (gas con- 17.3 26.0 30.0
densing combi boiler)
6.1 – 6.1 – 8.2 –
Rated heat input range kW 8.2 – 36.5
17.8 27.1 31.3
Connection values *1
Relative to max. load with:
- Natural gas E m3/h 1.9 2.6 3.0 3.5
- LPG P kg/h 1.4 1.9 2.2 2.6
Service
Power consumption
(max.)
- Gas condensing boiler W 84 92 98 108
- Gas condensing combi
W — 97 105 119
boiler
Weight
- Gas condensing boiler kg 35 36 37 37
*1 The connection values are only for reference (e.g. in the gas contract application)
or for a supplementary, rough estimate to check the volumetric settings. Due to
5677 216 GB
factory settings, the gas pressure must not be altered from these values. Refer-
ence: 15 °C, 1013 mbar.
97
Specification
Specification (cont.)

range in heating mode
TF/TR 50/30 °C kW 6.5 – 19 6.5 – 26 8.8 – 30 8.8 – 35
TF/TR 80/60 °C kW 5.9 – 5.9 – 8.0 – 8.0 – 31.9
17.3 23.7 27.3
- Gas condensing combi
kg — 36 38 38
boiler
Gas condensing combi
boiler (DHW heating)
Permiss. operating pres- bar — 10 10 10
sure MPa — 1 1 1
Nominal water flow rate l/min — 10.6 12.3 14.3
at ΔT 35 K (to EN 13203)
Set flow rate (max.) l/min — 10.0 12.0 14.0
Product ID _-0085BT0029
5677 216 GB
98
Disposal
Final decommissioning and disposal
Viessmann products can be recycled.

Components and substance from the
system are not part of ordinary house-
hold waste.
For decommissioning the system, iso-
late the system from the power supply
and allow components to cool down
where appropriate.
All components must be disposed of cor-
rectly.
Service
5677 216 GB
99
Certificates
Declaration of conformity
Declaration of Conformity for the Vitodens 100-W
We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, confirm as sole respon-
sible body that the product Vitodens 100-W complies with the following standards:
EN 297 EN 55 014-2
EN 483 EN 60 335-1
EN 625 EN 60 335-2-102
EN 677 EN 61 000-3-2
EN 806 EN 61 000-3-3
EN 12 897 EN 62 233
EN 55 014-1
In accordance with the following Directives and regulations, this product is designated
_-0085:
92/42/EEC 2009/125/EC*2
2004/108/EC 2010/30/EU*2
2006/95/EC 811/2013*2
2009/142/EC 813/2013*2
This product complies with the requirements of the Efficiency Directive

(92/42/EEC) for condensing boilers.
Allendorf, 01 March 2015 Viessmann Werke GmbH & Co KG
Authorised signatory Manfred Sommer

5677 216 GB
*2 Valid from September 2015

100
Keyword index
Keyword index
A Gas train ...........................................34

Adjusting the pump rate.....................37 Gas type conversion..........................76
– LPG................................................33
B – Natural gas.....................................76
Boiler water temperature sensor .......68
Burner gasket.....................................54 H
Burner gauze assembly.....................54 Heat exchanger cleaning...................55
Burner installation..............................57 Heating curve.....................................78
Burner removal..................................53
I
C Ignition...............................................55
Combustion chamber cleaning..........55 Ignition electrode................................55
Commissioning..................................30 Ionisation electrode............................55
Condensate........................................18
Condensate drain.........................18, 56 M
Connection diagram...........................79 Max. Heating output...........................35
Connections.......................................15
Control unit, opening..........................20 O
Cylinder temperature sensor .............69 Outlet temperature sensor.................71
Output adjustment
D – Multiple connection.........................39
Declaration of conformity.................100 Output matching
– Flue gas cascade...........................47
E Outside temperature sensor .............66
Electrical connections........................21
P
F Plate heat exchanger.........................74
Fault code..........................................62 Power supply.....................................26
Fault display.......................................62
Filling function....................................30 R
Filling the system...............................31 Reducing the heating output..............35
Flow limiter.........................................73 Reset..................................................65
Flue gas cascade...............................47
Flue gas temperature sensor.............72 S
Flue pipe............................................19 Safety chain ......................................70
Frost limit...........................................78 Safety valve.......................................18
Frost protection..................................78 Shared flue system connection..........39
Function sequence.............................61 Specification ......................................97
Fuse...................................................75 Static pressure...................................34
Supply pressure.................................34
G System filling......................................30
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Gas connection..................................16 System pressure................................31

Gas supply pressure..........................34
101
Keyword index
Keyword index (cont.)
T W
Temperature limiter............................70 Wall mounting....................................12
Trap..............................................19, 56 Water side connections......................15
Troubleshooting.................................66 Weather-compensated mode.............78
V
Ventilation air pipe.............................19
Venting...............................................32
Vitotrol 100
– Connection.....................................26
5677 216 GB
102
5677 216 GB
103
Subject to technical modifications.
Applicability
Serial No.:
7543420 7543421 7543422 7543423
7543424 7543425 7543426
Viessmann Werke GmbH&Co KG Viessmann Limited

D-35107 Allendorf Hortonwood 30, Telford
Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB
5677 216 GB
Fax: +49 6452 70-2780 Telephone: +44 1952 675000

www.viessmann.com Fax: +44 1952 675040
E-mail: [email protected]
104

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Installation and service VIESMANN

For applicability, see the last page

5677 216 GB 3/2015 Please keep safe.

Safety instructions explained ■ Codes of practice of the relevant trade

Target group Working on the system

Regulations to be observed Danger

Safety instructions (cont.)

Safety instructions (cont.)

What to do if water escapes from the Danger

Flue systems and combustion air

Ensure that flue systems are clear and

Operating appliances that extract air to

the same time, this can lead to reverse

Preparing for installation................................................................................... 11

Gas type conversion

Hydraulic assembly, combi boiler......................................................................... 92

Control unit assembly........................................................................................... 94

Keyword index.................................................................................................... 101

Please dispose of waste packaging in

Warning of material losses and

Live electrical area

Pay particular attention.

■ Component must audibly

Dispose of component at a suit-

The appliance is only intended to be Any usage beyond this must be

Commercial or industrial usage for a pur-

Vitodens 100-W, type B1HA, B1KA

Preset for operation with natural gas. Product description

Product information (cont.)

The following are integrated: one sealed Connecting accessories

The following components are integra-

DHW heating with DHW cylinder

If a Viessmann Vitocell is connected, a

Preparing for installation

Preparing for boiler installation

Dimensions and connections

123 123 125

A Heating flow E Heating return

Preparing for installation (cont.)

Fitting the wall mounting bracket

A Vitodens installation template

Preparing for installation (cont.)

3. Drill 7 10 mm holes and insert the

4. Fit wall mounting bracket with screws

Fitting the pre-plumbing jig or mount-

Pre-plumbing jig or mounting

1. Prepare the water connections. Flush

2. Prepare the gas connection.

3. Prepare the electrical connections.

Mounting the boiler and making the connections

Removing the front panel and mounting the boiler

2. Remove the front panel.

Mounting the boiler and making the connections (cont.)

Making the connections on the water side

For installation of fittings on the Gas condensing boiler

Mounting the boiler and making the connections (cont.)

Gas condensing combi boiler Permiss. DHW operating pressure:

1. Connect gas shut-off valve to con-