VIESSMANN VITODENS 100-W Heating Contractor Instruction Manual

Instruction Manual for VIESSMANN models including: VITODENS 100-W, Heating Contractor, VITODENS 100-W Heating Contractor, Contractor

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Installation and Service Instructions - Viessmann

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Installation and Service Instructions VITODENS 100-W

Installation and Service Instructions VITODENS 100-W 5600 332 - 13 02/2019 for use by heating contractor Vitodens 100-W WB1B Series Wall-Mounted, gas-fired condensing boiler

File Info : application/pdf, 100 Pages, 4.00MB

vitodens 100-wb1bc is

Installation and Service Instructions
for use by heating contractor
Vitodens 100-W WB1B Series Wall-Mounted, gas-fired condensing boiler with optional on demand hot water CombiPLUS Kit Heating input 37 to 118 MBH
10.8 to 34.5 kW
VITODENS 100-W

Vitodens 100-W, WB1B (with pre-installed coaxial vent pipe adaptor) and with CombiPLUS Kit installed.
5600 332 - 13 02/2019

IMPORTANT
Read and save these instructions for future reference.
Please file in Service Binder

Safety

Vitodens 100-W, WB1B CombiPlus Installation & Service

Safety, Installation and Warranty Requirements

Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).

Product documentation Read all applicable documentation before commencing installation. Store documentation near boiler in a readily accessible location for reference in the future by service personnel. For a listing of applicable literature, please see section entitled "Important Regulatory and Safety Requirements".
Warranty Information contained in this and related product documentation must be read and followed. Failure to do so renders the warranty null and void.
Licensed professional heating contractor The installation, adjustment, service and maintenance of this equipment must be performed by a licensed professional heating contractor. Please see section entitled "Important Regulatory and Installation Requirements".
Contaminated air Air contaminated by chemicals can cause by-products in the combustion process, which are poisonous to inhabitants and destructive to Viessmann equipment.
For a listing of chemicals which cannot be stored in or near the boiler room, please see subsection entitled "Combustion Air Supply".

Carbon monoxide Improper installation, adjustment, service and/or maintenance can cause flue products to flow into living space. Flue products contain poisonous carbon monoxide gas.
For information pertaining to the proper installation, adjustment, service and maintenance of this equipment to avoid formation of carbon monoxide, please see instructions supplied with burner.
Fresh air This equipment requires fresh air for safe operation and must be installed ensuring provisions for adequate combustion and ventilation air exist.
For information pertaining to the fresh air requirements of this product, please see subsection entitled "Combustion Air Supply".
Equipment venting Never operate boiler without an installed venting system. An improper venting system can cause carbon monoxide poisoning.
For information pertaining to venting and chimney requirements, please see section entitled "Venting Connection". All products of combustion must be safely vented to the outdoors.

Advice to owner Once the installation work is complete, the heating contractor must familiarize the system operator/ ultimate owner with all equipment, as well as safety precautions/requirements, shutdown procedure, and the need for professional service annually before the heating season begins.

WARNING
Installers must follow local regulations with respect to installation of carbon monoxide detectors. Follow manufacturer's maintenance schedule of the boiler.

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Vitodens 100-W, WB1B CombiPlus Installation & Service

Table of Contents
Page

Safety General Information Dimensions
Connections

Safety, Installation and Warranty Requirements..............2 Important Regulatory and Installation Requirements........5
CSD-1 Field Testing of High Limit Switches...............5 For installations on the Commonwealth of Massachusetts.....................................................6 About these Installation Instructions..............................7 Applicability. .............................................................8 Product Information.....................................................8 Mechanical Room. .....................................................9
Minimum Clearances. ................................................10 CombiPLUS Installation Options..................................10 Preparing the Connections..........................................11
Connections overview............................................11 Dimensions overview without bottom piping connections..12 CombiPLUS connections and piping connections.......13 Piping connections for Vitodens 100W, WB1B-26 and -35 (factory supplied).......................................14 Wall Mounting..........................................................15 Boiler and CombiPLUS installation............................15 Boiler mounting bracket and CombiPLUS installation..16 Mounting Vitodens 100-W boiler.............................17
Boiler Connections....................................................17 Vent connections...................................................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 Hot water temperature and system pressure.............23 Performing pressure test on the boiler......................23
Preparing the CombiPLUS Connections........................24 CombiPLUS Preparations for all Vitodens.....................25 Additional CombiPLUS Preparations for Vitodens 100-W, WB1B-26 only.................................26 Mounting the CombiPLUS..........................................27 CombiPLUS Installation Options.................................27 Connecting the CombiPLUS Piping................................28 Connecting the CombiPLUS Wiring..............................29 Accessing the Boiler Controls.....................................30 Preparing the Boiler Power Pump Module...................31 Connecting the CombiPLUS Cables to the Power Pump Module of the Boiler...............................32 Re-installing Covers...................................................33 Adding PRV and Label...............................................34 Programming............................................................35

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Table of Contents

Vitodens 100-W, WB1B CombiPlus Installation & Service

Connections (continued)
Venting Connections Control Connections Start-up, Inspection and Maintenance Troubleshooting
Additional Information
4

Page
Installation Examples.................................................36 General.................................................................36 Clearances...........................................................36 Pressure drop of Vitodens 100-W.............................36 Typical system flow rates........................................36 Heating circuit pumps.............................................36 CombiPLUS Built-in Pump.......................................37 System layout 1 to 4..............................................38 Vitodens and CombiPLUS Layout...............................44 Boiler in heating/cooling application..........................47 Boiler with low water cut-off (remote mounted, field supplied)........................................................48 Accessories for the Vitodens 100-W........................49 Low-loss header.....................................................49
Venting Connection...................................................50
Electrical Connections................................................50 Rotating the control unit and opening the power/pump module............................................50 Electrical connections to the power/pump module.....51 Optional operating control - OpenTherm...................51 Closing the power / pump module and reinstalling the control unit....................................................52 Reinstalling the front panel.....................................52
Necessary Tools.......................................................53 Testing/analysis equipment....................................53
Overview of Controls and Indicators............................53 Control and display elements.................................53
Overview of Boiler Components..................................54 Overview of CombiPLUS 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 Determining the boiler set-point..............................79 Check fixed high limit............................................80 Check flue gas temperature sensor..........................80 Check fuses.........................................................81 CombiPLUS Connection...........................................82 Check outlet temperature sensor.............................82 Replacing the flow limiter.......................................82 Checking or replacing the plate type heat exchanger...83
Electrical connections to the Terminal Strip for Accessories.............................................................84 Technical Data........................................................85
Call for heat priority logic table...............................85 Burner Program Sequence of Operation........................89 Wiring Diagram - Natural gas / Propane........................91 Service Function Overview.........................................92 Parts List................................................................93 Maintenance Record..................................................98 Lighting and Operating Instructions.............................99

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Vitodens 100-W, WB1B CombiPlus Installation & Service
Important Regulatory and Installation Requirements

Safety

Codes The installation of this unit shall be in accordance with local codes or, in the absence of local codes, use CAN/ CSA-B149.1 or .2 Installation Codes for Gas Burning Appliances for Canada. For U.S. installations use the National Fuel Gas Code ANSI Z223.1. Always use latest editions of codes.
In Canada all electrical wiring is to be done in accordance with the latest edition of CSA C22.1 Part 1 and/or local codes. In the U.S. use the National Electrical Code ANSI/ NFPA 70. The heating contractor must also comply with both the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, and the Installation Code for Hydronic Heating Systems, CSA B214-01, where required by the authority having jurisdiction.

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.
This product comes with several safety instruction labels attached. Do not remove! Contact Viessmann immediately if replacement labels are required.

CSD-1 Field Testing of High Limit Switches for Vitodens boilers where required by law.
VIESSMANN IS NOT RESPONSIBLE FOR ANY DAMAGES THAT THE FOLLOWING TEST PROCEDURE MAY RESULT IN BY OVERHEATING THE SYSTEM.
The Vitodens 100/200 boilers are equipped with flow switches that when activated disable or enable the burner to operate.
The fixed high limit, when tripped, produces a fault that will require manual reset of the boiler control.
Fixed High Limit fault simulation method #1: · Close the boiler valve and jump the flow switch. · Run the boiler at high fire and it will shut down by the coding card (in WB2B models, set coding address 06 to
max.) but should continue to stack the boiler temp until the fixed high limit is tripped. · Once the fixed high limit is tripped, slowly open the boiler valve to safely cool the boiler down.
Fixed High Limit fault simulation method #2: · Throttle the boiler valve to a point where the burner will run with as little flow as possible. · Run the boiler to high fire via relays test. · When the burner shuts down on the electronic limit, close the ball valve to stop the flow. · The boiler temp should continue to stack to trip the fixed high limit. · Once the fixed high limit is tripped, slowly open the boiler valve to safely cool the boiler down.
Fixed High Limit fault simulation method #3: · Remove one of the wires connected to limit switch, this will produce a fault in the boilers control that requires
manual reset.

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Safety

Vitodens 100-W, WB1B CombiPlus Installation & Service

Important Regulatory and Installation Requirements (continued)

For installations on the Commonwealth of Massachusetts, the following modifications to NFPA-54 chapter 10 apply:
Excerpt from 248 CMR 5-08: 2(a) For all side-wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used
in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side-wall exhaust vent termination is less than (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side-wall horizontal vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gas fitter 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 detectors.
a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard-wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
4. INSPECTION. The state or local gas inspector of the side-wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current edition of NFPA 54 as adopted by the Board; and
2. Product Approved side-wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

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Vitodens 100-W, WB1B CombiPlus Installation & Service

Safety/ General Information

Important Regulatory and Installation Requirements (continued)

Working on the equipment The installation, adjustment, service, and maintenance of this boiler must be performed by a licensed professional heating contractor who is qualified and experienced in the installation, service, and maintenance of hot water boilers. There are no user serviceable parts on the boiler, burners, or control.

The completeness and functionality of field supplied electrical controls and components must be verified by the heating contractor. This includes low water cutoffs, flow switches (if used), staging controls, pumps, motorized valves, air vents, thermostats, etc.

Ensure main power supply to equipment, the heating system, and all external controls has been deactivated. Close main gas supply valve. Take precautions in all instances to avoid accidental activation of power during service work.
Technical literature Literature for the Vitodens boiler: - Technical Data Manual - Installation and Service Instructions - Operating Instructions and User's Information Manual - Vitodens Venting System Installation Instructions - Instructions of other products utilized and installed - Installation codes mentioned
in this manual and as locally applicable

About these Installation Instructions

Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include "WARNING", "CAUTION", and "IMPORTANT". See below.

WARNING
Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury or substantial product/property damage.

Warnings draw your attention to the presence of potential hazards or important product information.

CAUTION
Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or product/ property damage.

Cautions draw your attention to the presence of potential hazards or important product information.

IMPORTANT

Helpful hints for installation, operation or maintenance which pertain to the product.
This symbol indicates that additional, pertinent information is to be found.
This symbol indicates that other instructions must be referenced. 7

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General Information
Applicability

Vitodens 100-W, WB1B CombiPlus Installation & Service

IMPORTANT

The boiler serial number must be provided when ordering replacement parts. Both the 16-digit serial number bar code label and the 12-digit ASME/NB serial number correlate to each other. Providing either serial number is sufficient.

Model No. WB1B 26 and WB1B 35

Serial No. 7457960
7457961

Note: Check the boiler rating plate on the Vitodens 100-W, models WB1B-26 or WB1B-35 to ensure it states compatibility with the CombiPLUS kit.

ASME/NB stamp 12-digit serial number location (metallic plate riveted on the heat exchanger) H
Stainless steel Inox-Radial heat exchanger

Serial No. location (16-digit bar code white label located on the boiler as shown in this drawing)

Product Information
Natural / propane gas-fired wall-mounted hot water heating boiler for space heating. For operation with constant (set-point) and outdoor temperature responsive control in closed loop, forced circulation hot water heating circuits. An external controller is required for indirect storage tank DHW production (an optional CombiPLUS kit providing 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 valve adjustments are typically not required during field start-up. Follow the Vitodens Venting System Installation Instructions to vent this boiler.
8

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Vitodens 100-W, WB1B CombiPlus Installation & Service
Mechanical Room

General Information

During the early stages of new home design, we recommend that proper consideration be given to constructing a separate mechanical room dedicated to gas- or oil-fired equipment including domestic hot water storage tanks.
The boiler must be located in a heated indoor space, near a floor drain, and as close as possible to the wall.
Whenever possible, install boiler near an outside wall so that it is easy to duct the venting system to the boiler.
Locate boiler on walls capable of supporting the weight of the boiler filled with water (see section entitled "Technical Data" on page 86 for information required for total boiler weight calculation). Ensure that boiler location does not interfere with proper circulation of combustion and ventilation air of other fuel burning equipment (if applicable) within the mechanical room. The maximum room temperature of the mechanical room where the boiler is located must not exceed 104°F (40°C).
IMPORTANT
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 humidity, can lead to degradation of the exposed metallic surfaces mentioned above. Therefore, it is imperative that boilers installed in such environments not be installed using direct vent systems which draw outdoor air for combustion. Such boilers must be installed using room air dependent vent systems; i.e. using room air for combustion. The indoor air will have a much lower relative humidity and, hence, potential corrosion will be minimized.
WARNING
If you notice fire coming from the appliance, call the fire department immediately! Do not attempt to extinguish the fire unless qualified to do so.
WARNING
Fire causes a risk of burns and explosion! Shut down the boiler Close fuel shut-off valves Use a tested fire extinguisher, class ABC.
WARNING
Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk.

Installation area conditions
Ensure ambient temperatures are higher than 32°F (0°C) and lower than 104°F (40°C).
Prevent the air from becoming contaminated by halogenated hydrocarbons (e.g. as contained in paint solvents or cleaning fluids) and excessive dust (e.g. through grinding or polishing work). Combustion air for the heating process, and ventilation of the boiler room must be free of corrosive contaminants. To that end, any boiler must be installed in an area that has no chemical exposure. The list to the right indicates the main, currently known sources.
Avoid continuously high levels of humidity (e.g. through frequent drying of laundry).
Never close existing ventilation openings.
Sources of combustion and ventilation air contaminants. Areas likely to contain contaminants:
- 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 found in household laundry rooms
- Paint and varnish removers - Hydrochloric acid, muriatic acid - Chlorine-based swimming pool chemicals - Spray cans containing chlorofluorocarbons - Chlorinated waxes and cleaners - Cements and glues - Refrigerant leaks - Calcium chloride used for thawing - Sodium chloride used for water softening salt - Permanent wave solutions - Adhesives used to fasten building products and other
similar items - Antistatic fabric softeners used in clothes dryers
Before set-up
Before placing boiler in its installation location, ensure all necessary accessories are installed.
CAUTION
The boiler must be installed in such a way that gas ignition system components are protected from water (spraying, splashing, etc.) during boiler operation and service.

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Dimensions
Minimum Clearances

Front

Side Top *

Back

Side 5

Vitodens 100-W, WB1B CombiPlus Installation & Service
Recommended minimum service clearances Note:The Vitodens 100-W boiler has passed the zero
inches vent clearance to combustibles testing requirements dictated by the boiler Harmonized Standard ANSI Z21.13. CSA 4.9.2007 and therefore is listed for zero clearance to combustibles when vented with a single-wall special venting system (AL-29-4C material) or UL/ULC-listed CPVC gas vent material. The zero inches vent clearance to combustibles for the Vitodens 100-W boiler supercedes the clearance to combustibles listing that appears on the special venting system label.
Top clearance - 12" (30 cm).
See the Vitodens Venting System Installation Instructions.

*1 Refer to the Installation Instructions of the Vitodens Venting System for details.

Clearance to combustibles

Top Front

Rear Left

Right

0 AL,

Vent pipe*1
0

AL = Alcove CL = Closet

CombiPLUS Installation Options

7"/178mm
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Shown is the distance between the boiler and CombiPLUS with Viessmann supplied 7" flex piping connection fittings.

Note: The maximum distance between the boiler and the CombiPLUS is restricted by the communication cable to 36" (915 mm).
10

Shown is the maximum distance between the boiler and CombiPLUS using field supplied fittings and pipes.

Vitodens 100-W, WB1B CombiPlus Installation & Service
Preparing the Connections
Note: Use an approved pipe sealant or teflon tape when connecting the following installation fittings.
Connections overview

Dimensions

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)

Legend

BWR BWS BD BF GC PRV NPT VC CAI

Boiler water return, ¾" Boiler water supply, ¾" Boiler drain Boiler fill Gas connection, ¾" NPTM (male thread) Pressure relief valve National Pipe Thread Vent connection Combustion air inlet connection (optional)

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Dimensions
Preparing the Connections (continued)
Dimensions overview without bottom piping connections

Vitodens 100-W, WB1B CombiPlus Installation & Service

Front view

Side view

Top view

Connections Vitodens 100-W, WB1B 26, 35
Legend Connections A Condensate drain, plastic hose Ø 0.87" (22 mm) B Boiler water supply, NPT ¾" (male thread) C Gas connection, NPT ¾" (male thread) D Boiler water return, NPT ¾" (male thread) E Combustion air opening for double pipe system F Combustion air opening for coaxial system
Dimensions a 14" (355 mm) b 15¾" (400 mm) c 2f" (68 mm) d 28½" (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)

When preparing gas, water and electrical connections in the field, see section entitled "Wall Mounting" on page 15 of this manual for information regarding the installation of the wall mounting bracket.
IMPORTANT
The maximum ambient temperature must not exceed 104º F (40º C).
Heating water connections and gas connection to be made in the field. See connection-specific section for details.
See subsection entitled "Power supply connection" for details regarding power supply to the Vitodens 100-W boiler.

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Vitodens 100-W, WB1B CombiPlus Installation & Service
Preparing the Connections (continued)
CombiPLUS connections and piping connections

Dimensions

Front view

Side view

Top view
Legend A Boiler water supply, NPTM ¾" (male thread) B Boiler water return, NPTM ¾" (male thread) C System water supply, NPTM ¾" (male thread) D System water return, NPTM ¾" (male thread) E DHW, NPTM ½" (male thread) F DCW, NPTM ½" (male thread)

CE FD
Front view Shown is the distance between the boiler and CombiPLUS with Viessmann supplied 7" flex piping connection fittings.

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Dimensions
Preparing the Connections (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

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)

Legend

BWR BWS BD BF GC PRV PG VC CAI

Boiler water return, ¾" Boiler water supply, ¾" Boiler drain Boiler fill Gas connection, ¾" NPTM (male thread) Pressure relief valve Pressure gage Venting connection Combustion air inlet connection (optional)

Note: If using the optional CombiPLUS see page 10 and 24.

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Vitodens 100-W, WB1B CombiPlus Installation & Service
Wall Mounting

Dimensions

Boiler and CombiPLUS installation The Vitodens 100-W boiler and CombiPLUS can be wall-mounted on: - a brick/concrete wall - wood studs - metal studs
CAUTION
Whichever mounting method is used, ensure that the boiler bracket and CombiPLUS is tightly and securely fastened to wall. Failure to secure boiler or CombiPLUS properly could cause loosening, posing a severe safety hazard.

Following are the installation instructions for the mounting bracket on each material. Skip to the installation instructions applicable to your installation requirements.
Installation of mounting 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.

1. mm
2.

1. mm

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Legend

A Mounting template

B CombiPLUS mounting template

Dimensions
Wall Mounting (continued)
Installation on wood studs
Boiler bracket

Vitodens 100-W, WB1B CombiPlus Installation & Service
Boiler mounting bracket and CombiPLUS installation Install mounting bracket and CombiPLUS on wood studs as per illustration. Drill 3/16" pilot holes to insert mounting bolts. Ensure that holes are located in the center of each wood stud. Secure with bolts to wooden studs as shown.

Com biPLUS Installation on metal studs
Boiler bracket

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.

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Com biPLUS 16

Vitodens 100-W, WB1B CombiPlus Installation & Service
Wall Mounting (continued)

Dimensions/Connections

Mounting Vitodens 100-W boiler Note: Prior to installing the boiler, if a CombiPLUS kit
is also required, verify that the minimum mounting clearances are met.
1. Loosen the screws at the bottom of the boiler; do not remove completely.
2. Remove the front panel.
3. Mount boiler onto the mounting bracket.

For installation of the mounting bracket, see subsection entitled "Wall mounting installation" on page 16 of this manual.

Boiler Connections

Vent connections The Vitodens 100-W boiler comes with a preinstalled vent pipe adaptor (as shown). Run venting system, single-pipe, two-pipe or coaxial, through the side wall, roof or chimney, taking the shortest possible route and at a rising angle (min. 3º).
Refer to the Vitodens Venting System Installation Instructions.

When utilizing the combustion air inlet seal A for Vitodens 100 series boilers, remove the plastic center section and leave the rubber seal in place.

Legend A Combustion air intake B Flue vent

Coaxial combustion air inlet cover shown removed. 17

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Connections
Boiler Connections (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

2 imperfect threads

Use moderate amount of dope

Proper piping practice
Support piping by proper suspension method. Piping must not rest on or be supported by boiler.

Leave 2 threads bare

Gas connection and piping
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 and piping.

Legend A Water supply connection B Condensate drain connection C Gas connection D Water return connection
18

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Vitodens 100-W, WB1B CombiPlus Installation & Service
Boiler Connections (continued)

Connections

Legend A Gas connection B Accessible manual gas
shutoff (factory supplied) C Drip leg

Gas connection and piping (continued) 1. Refer to current 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 for gas piping requirements and sizing. Pipe size to the boiler must be determined based on: - pipe length - number of fittings - maximum input requirements of all gas appliances in
the residence.
IMPORTANT
Design piping layout in such a way that piping does not interfere with serviceable components.
2. Before connecting boiler to gas line, install ground joint union, capped drip leg and a manual equipment shutoff valve. Valves must be listed by a nationally recognized testing agency. Make boiler gas connection as shown on the left.
Gas connection (NPT).......... ¾"
3. Perform gas piping pressure test as described in the following subsection.
4. Identify shutoff valves as such with a tab and familiarize operator / ultimate owner of boiler with these valves.
WARNING
The gas supply piping must be leak tested before placing the boiler in operation.

IMPORTANT
Max. gas supply pressure: 14 "w.c.
Gas Piping Pressure Test

CAUTION
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.

1. Isolate the boiler from the gas supply piping system using the individual manual shutoff valve during pressure tests equal to or less than ½ psig (14 "w.c.)
2. The boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of ½ psig (14 "w.c.)
3. Perform leak test. Use approved liquid spray solution for bubble test. Ensure that no liquid is sprayed on any electrical components, wires or connectors. Do not allow leak detection fluid to contact gas valve regulator or regulator vent opening.
4. Correct any and all deficiencies.
5. Remove air from gas line.

When performing the gas piping pressure test, ensure the following requirements are met.
WARNING
Never check for gas leaks with an open flame.
WARNING
Exposing boiler gas pressure regulator and gas valve to extreme pressures renders warranty null and void.
IMPORTANT
½ psig = 14 "w.c. 19

5600 332 - 13

Connections
Boiler Connections (continued)

Legend

BWR Boiler water return, ¾"

BWS Boiler water supply, ¾"

Boiler drain

Boiler fill

Gas connection, ¾" NPTM

PRV Pressure relief valve

NPT National Pipe Thread

Pressure gage

Vitodens 100-W, WB1B CombiPlus Installation & Service
Heating water connections 1. Thoroughly flush heating system (particularly before
connecting the boiler to an existing system).
2. Connect boiler to the heating system.
Max. operating pressure.......................3 bar (45 psig) Test pressure......................................4 bar (60 psig)
IMPORTANT
Damage resulting from pressure exceeding those values stated is not covered by Viessmann warranty.
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.
WARNING
The pressure gage is a sensitive component and may be damaged if the boiler connections are not supported by using a second wrench when tightening fittings and/or piping.
All plumbing must meet or exceed all local state and national plumbing codes.
IMPORTANT
SUPPORT ALL PIPING USING HANGERS. DO NOT support piping by the unit or its components.
Use isolation valves to isolate system components.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Boiler Connections (continued)

Connections

Legend A Flexible discharge tubing B Discharge tubing

Condensate connection The Vitodens 100-W boiler comes with a built-in condensate trap. An external trap is not required when connecting the field drain to flexible discharge tubing. Discharge tubing (field supplied) must be of 1" diameter. Use CPVC, PVC or other material approved by codes listed below. In the U.S. the drain pipe and fittings must conform to ANSI standards and ASTM D1785 or D2846. CPVC or PVC cement and primer must conform to ASTM D2564 or F493. In Canada use CSA or ULC listed schedule 40 CPVC or PVC drain pipe, fittings and cement. If the condensate outlet of the Vitodens 100-W boiler is lower than the drain, a condensate pump must be installed. Select a pump which is approved for condensing boiler applications. To avoid condensate spillage, select a pump with an overflow switch. The drain connection must terminate into an open or vented drain as close to the boiler as possible to prevent siphoning of the boiler drain.
1. Install the condensate drain pipe with a suitable gradient. 2. Discharge condensate from the boiler into the drainage
system, either directly or (if required) via a neutralization unit (accessory).
Installation Instructions of Neutralization Unit (if applicable)
IMPORTANT
Pipe ventilation must take place between the siphon trap and the neutralization unit (if applicable).
IMPORTANT
Do not connect the drain pipe from any other appliance, such as water softener backwash pipe, to Vitodens condensate drain pipe.

Fill siphon with water Fill a minimum of 10 fl. oz. (0.3 liters) of water into the boiler adaptor.
WARNING
At initial start-up, flue gases may be emitted from the condensate drain. Fill the siphon with water before start-up.

5600 332 - 13

Connections

Vitodens 100-W, WB1B CombiPlus Installation & Service

Safety Connections and Pressure Testing

Installing safety devices on the boiler

1. Remove loosely pre-assembled combination pressure relief valve and drain valve assembly.
2. Apply sufficient amount of pipe sealant to both ends of all pipe fittings B, C, and E, and install onto tees D, F.
3. Install pressure relief valve A and tighten.

Legend A Pressure relief valve (30 psig),¾" NPT B Brass nipple, length 2" x ¾" C Drain valve connection, ¾" D Tee, ¾"x¾"x¾" E Brass nipple, length 3" x ¾" F Tee, ¾"x¾"x¾" L Boiler supply connection
Minimum connection diameters: Pressure relief valve..........................¾" Discharge pipe .................................¾" Piping to pre-charged expansion tank...¾"
IMPORTANT
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 where air could be trapped.

4. Install discharge pipe on pressure relief valve in such a way that... - the end of the pipe is not threaded. - the pressure relief discharge pipe extends to a floor drain and ends approximately 6" (150 mm) above the drain. Ensure that... - there is no shutoff valve installed in the discharge pipe. - discharge pipe diameter is not reduced. - discharge is not piped to outdoors.
WARNING
Do not install an isolation valve between boiler and pressure relief valve. The discharge pipe for the pressure relief valve must be oriented to prevent scalding of attendants. Pipe pressure relief valve discharge pipe close to floor drain. Never pipe discharge pipe to the outdoors.
Low water cut-off A low water cut-off may be required by local codes. Do not install an isolation valve between boiler and low water cutoff (see subsection entitled "Boiler with low water cutoff" on page 48 in these instructions).

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Safety Connections and Pressure Testing (continued)

Connections

Hot water temperature and system pressure

Performing pressure test on the boiler
The boiler must be leak tested before being placed in operation. Before boiler is connected to piping or electrical power supply, it must be hydrostatically pressure tested.

The hot water reading is constantly displayed during operation.

1. Cap supply and return connections (¾" NPT Male).
2. Connect a ½" garden hose to boiler drain valve at the bottom of the boiler and fill boiler slowly until pressure gage indicates max. 4 bar (60 psig).
3. Maintain pressure for 15 minutes. During time of pressure testing, do not 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 ¾" cap from 2" nipple, and install pressure relief valve immediately instead of ¾" cap.

After boiler has passed the pressure test, proceed with the installation.

The boiler water pressure reading is displayed on an analog gauge.

WARNING
Exposing the boiler to pressures and temperatures in excess of those listed will result in damage, and will render warranty null and void.
See page 57 for fill procedure.

5600 332 - 13

Connections

Vitodens 100-W, WB1B CombiPlus Installation & Service

Preparing the CombiPLUS Connections

15c" (400)

1315/16" (355)

507/16" (1280) when using 7" flex pipe. 547/16" (1382) when using 12" flex pipe.
117/16" (291) when using 7" flex pipe. 157/16" (393) when using 12" flex pipe.

8c" ( 223)
16" (406) 17" (431)

1015/16" (265)
913/16" (249)
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 optional 12" flex pipe after bending is 10b" a".

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
CombiPLUS Preparations for all Vitodens

Connections

B
4. C C
2. A

6. 5.

3. B
A 1.
D E

Installing the extension fitttings B and system connections D, E, F and G to the CombiPLUS A.
1. Using a Phillips screw driver, remove all four screws holding the CombiPLUS A cover and set aside.
2. Remove the cover by pulling straight out from the CombiPLUS A and set aside.
3. Lubricate both extension fitting B O-rings with supplied lubricant and install each O-ring to the lower portion of the extension fittings B. Insert each of the extension fittings B on a slight angle through the rubber grommets and into the main supply/return connections of the CombiPLUS A. Ensure that the extension fittings B are fully seated.
4. Insert a locking clip C into the lower portion of each extension fitting B.
Note: Pull up on each extension fitting B to ensure that they are locked in place.
See page 34 for water flow directions in piping and fittings.
Note: Use a 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 heating circuit gaskets D into the female end of each heating circuit adaptor E. Install the assembled heating circuit adaptors E to the system water supply/return connections on the CombiPLUS A.
6. Insert DHW gaskets F into the female end of each DHW adaptor G. Install the assembled DHW adaptors G to the DHW/ DCW connections on the CombiPLUS A.
IMPORTANT
DO NOT overtighten the adaptor fittings.
Legend A CombiPLUS B Extension fitting (x2) C Locking clip (x2) D Heat circuit gasket c" (x2) E DHW gasket b" (x2) F c" Heating circuit adaptor (x2) G b" DHW adaptor (x2)
25

5600 332 - 13

Connections

Vitodens 100-W, WB1B CombiPlus Installation & Service

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

A 2.

1.
H Gasket

The CombiPLUS A flow restrictor must be exchanged when used with the Vitodens 100-W, WB1B-26.
1. Remove the two 4 mm hex head cap screws from the flow tube cap and set aside. Gently remove the flow tube cap by pulling straight up (ensure not to damage the gasket) 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 gasket).
4. Reinstall the two 4 mm hex head cap screws securing the flow tube cap. Torque screws to 4.5 Nm (40 lb/in)
Legend A CombiPLUS H 26kW flow restrictor

A 4. 26

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Mounting the CombiPLUS

Connections

J I 4.

CombiPLUS Installation Options

Prepare the wall and mount the CombiPLUS A using the supplied template and mounting hardware.
1. Pull the bottom of the boiler away from the wall approximately 1/2" (12 mm) and slide the top of the CombiPLUS mounting template T between the wall and the boiler. Release the boiler and allow the weight of the boiler to hold the template in place.
The top outline on the template shows the lower imprint of the boiler (shown in dotted lines). Adjust the template to the boiler in this position when connecting the 12" flex piping.
The second outline on the template shows the lower imprint of the boiler (shown in solid lines). Adjust the template to the boiler in this position 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 the CombiPLUS A.
Note: Leave the lag bolts loose enough to allow up and down adjustments in the slot.
Note: Refer to the installation Instructions for additional mounting options.
Legend A CombiPLUS I Lag bolt (x4) J 1/4" plain washer (x4) K Anchor (x4) T Template

Shown is the maximum distance between the boiler and CombiPLUS using field supplied fittings and pipes.
Note: The maximum distance between the boiler and the CombiPLUS is restricted by the communication cable to 36" (915 mm).

5600 332 - 13

Connections
Connecting the CombiPLUS Piping

N 1.
L

N L

Vitodens 100-W, WB1B CombiPlus Installation & Service
Connecting the CombiPLUS A using the supplied piping, adaptors and mounting hardware.
1. Install the adaptors N to the tees at the bottom of the boiler. Install the flex pipes L to the adaptors N. Carefully form the flex pipes L to align with the extension fittings on the top of the CombiPLUS A. Note:The flex pipes L 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". Slide the CombiPLUS A up and install the flex pipes L to the extension fittings of the CombiPLUS A.
IMPORTANT
DO NOT overtighten the flex pipe fittings. When connecting the flexible pipes do not overtighten the hex nuts. This is a gasketed design and should be hand tightened plus b turn with a wrench.

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 wall anchors (if used) and tighten.

Legend A CombiPLUS L 7" flex pipe (x2) N c" Adaptor (x2)

A IJ

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Connecting the CombiPLUS Wiring

Connections

Diverting valve motor connection

1. A

Connecting the CombiPLUS A wiring using the supplied control and pump cables.

Q 1. Remove both standard knock-outs from the rear right side of the CombiPLUS A.

Route the control cable Q through one 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.

Pump connection

Legend A CombiPLUS Q Control cable R Pump cable

To remove, push to unlock

Water Temperature sensor connection

Flow sensor connection

5600 332 - 13

Connections
Accessing the Boiler Controls

Vitodens 100-W, WB1B CombiPlus Installation & Service
Removing the boiler and power pump module covers to provide access to the power pump module.
1. Loosen the boiler housing 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.

5600 332 - 13

3. 30

Vitodens 100-W, WB1B CombiPlus Installation & Service
Preparing the Boiler Power Pump Module

Connections

Jumper pin

Preparing the power pump module for connection to the CombiPLUS wiring.
When handling static sensitive components, avoid damage caused by static discharge by following Electro-Static Discharge safety procedures.
1. Remove the jumper pin from terminal X8 (CombiPLUS) of the power pump module and discard.
2. Remove the jumper cable from terminal block 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 input connections of the power pump module). If the jumper pin is not removed the boiler will not provide on demand hot water via the CombiPLUS. For programming see page 35.

Jumper pin 1.
Hole plug
2.

3. Hole plug
Jumper cable

5600 332 - 13

Connections

Vitodens 100-W, WB1B CombiPlus Installation & Service

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

Connecting the CombiPLUS cables to the power pump module.
1. Route the control cable Q through the fourth hole of the power pump module base and route the pump cable R through the second hole of the power pump module base.
Secure the cables inside the power pump module using the locknuts provided.

2. There are three wires to connect on the power pump cable R.

Connect wire BK1 to the power pump neutral of terminal block X3 (as shown).

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.

Q 4.

Note: For additional wiring details see the wiring diagram.
4. Install the supplied anchors V into the wall behind the cables. Install the conduit clip U with the supplied screw W into the wall anchor V. Press cables Q and R into the conduit clip U.

BK1

BK2

Neutral Line

Ground (green/yellow)

DHW Temperature Sensor / Flow Sensor

Diverter Valve
Cable 3.

Legend BK1 - Black 1 (Neutral)
(BK1 with blue shrink sleeve on pump side) BK2 - Black 2 (Line)

Note: See page 29 for CombiPLUS connections.

Legend Q Control cable R Pump cable U Conduit clip V #10 Anchor W #10 Screw

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Re-installing Covers

Connections

1. 2.

Reinstalling the covers for the boiler, power pump module and the CombiPLUS A.
1. Align and install the cover of the power pump module and lock into place by rotating the four captive screws 90 degrees with 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 screws holding the CombiPLUS A cover.
Legend A CombiPLUS

4.
3. A

5600 332 - 13

Connections
Adding PRV and Label

Boiler Supply

Boiler Return

Heating Circuit Supply DHW

Heating Circuit DCW Return

P O

S 2.

Vitodens 100-W, WB1B CombiPlus Installation & Service
Installing the PRV P and tee O to the CombiPLUS A and label S to the boiler.
Note: The system must be leak tested. Refer to the boiler Installation Instructions.
The DHW pressure relief valve is designed to relieve excessive pressure in the system, produced during domestic hot water heating.
Model: Watts No. 3L Size: ¾" NPT Max. Operating Pressure: 150 psig Input Rating: 200 MBH
The installation of the DHW pressure relief valve must be in accordance with local codes. The DHW pressure relief valve must be installed in the domestic hot water supply by a heating contractor. If local codes require a different relief valve, substitute 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 slope from the valve. Do not install a shutoff valve between the DHW pressure relief valve and the heat exchanger, or in the drain pipe.
1. Install the 150 psi PRV P and tee O to the installed field supplied piping from the CombiPLUS A.
2. Apply the scald danger label S as shown. Note: This label must be installed as required by national code.
Legend A CombiPLUS O ¾" Tee P ¾" PRV, 150 psi S Danger label

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Programming

Connections

1. 2.

Programming the boiler control for operation with or without the CombiPLUS.
Note: If an optional CombiPLUS is used, the boiler control must be programmed.
Note: For additional programming refer to the boiler Operating, Installation and Service Instructions.
1. Lift flap and pull control unit cover down. All boiler controls are located behind the control unit cover.
2. Simultaneously turn rotary selectors " " and "tr" to their central position. " and SERV" will appear on the screen. 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 with the optional CombiPLUS (right control range). "0" boiler without optional CombiPLUS (left control range) (factory default setting).
Note: After programming the boiler control to accept the CombiPLUS, wait until the boiler temperature is displayed, then switch the control OFF then ON. ECO will be displayed on the screen.

5600 332 - 13

4. 35

Connections
Installation Examples

Vitodens 100-W, WB1B CombiPlus Installation & Service

General The schematics on the following pages are to be seen as guidelines only. They further do not display all system varieties, safety devices, or concepts possible. Specific system layouts may be further discussed with the local Viessmann sales representative office.
Clearances A minimum of 2" (51 mm) circumferential clearance from non-insulated hot water pipes to combustible construction must be maintained. In cases where the pipes are insulated with pipe insulation of appropriate and sufficient thickness and insulation values, the above clearance may be reduced to 0" (refer to local gas codes).
CAUTION
For underfloor heating applications, an additional immersion or strap-on aquastat must be installed in the low temperature underfloor loop (downstream of the mixing valve) to de-energize the pump and/or boiler to prevent overheating. High water temperatures can damage concrete slabs.
Pressure drop (primary circuit) of Vitodens 100-W
The Vitodens 100-W is designed only for closed loop, forced circulation hot water heating systems.
ft. m

Heating circuit pumps
Recommended heating pumps with Vitodens 100-W, WB1B 26, 35.
Grundfos 15-58 (3-speed) Taco 00R
or equivalent
Refer to the graph above for the proper waterside boiler friction loss calculations.
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 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.
Use standard friction loss method for pipe sizing. Observe boiler maximum and minimum flow rate limitations. If system flow rate exceeds boiler maximum flow rate (as stated on page 86) or if system flow rate is unknown, Viessmann strongly recommends the installation of a lowloss header. See page 49 for low-loss header information or refer to the Vitodens Venting System Installation Instructions.

IMPORTANT

Pump selection must be based on accurate system flow and pressure drop calculations (incl. DHW sizing).

Pressure Drop
5600 332 - 13

Flow rate Typical system flow rates

Model WB1B t Output Btu/h 30ºF (17ºC) rise (GPM) 35ºF (19.5ºC) rise (GPM) 40ºF (22ºC) rise (GPM)

26
83,000 5.5 4.7 4.2

USGPM L/h
35
108,000 ---6.2 5.4

Vitodens 100-W, WB1B CombiPlus Installation & Service
Installation Examples (continued)

Connections

CombiPLUS 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 Three Speed Two

Speed One

Head H (ft of wc)

Flow Q (gpm)
Performance chart courtesy of Grundfos

Pump Model Rated voltage Rated current
Capacitor Power consumption

Grundfos UPS15-78

VAC

115

A max.

1.15

A min.

0.8

W max.

130

W min.

CombiPLUS built-in pump, Grundfos UPS15-78, residual head pressure Residual head of built-in three speed pump used with Vitodens 100 WB1B 26, 35

Head H (ft of wc)

5600 332 - 13

Flow Q (gpm) 37

Connections
Installation Examples (continued)
System Layout 1 Vitodens 100-W, WB1B 26, 35 with...
- one heating circuit
AV PVR
System Layout 1 - Alternate Option
AV PVR

Vitodens 100-W, WB1B CombiPlus Installation & Service

Legend AV Air vent PRV 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 30ºF to 40ºF (16.7ºC to 22.2ºC). For a lesser t design, the system layout designer must use one of the examples (3 or 4) on the following pages.
IMPORTANT
Ensure that a pressure activated by-pass is installed if there are system component(s) in C that may isolate the flow to the pump D.

Maximum Flow Rates

Model WB1B t Output Btu/h 30ºF (17ºC) rise (GPM) 35ºF (19.5ºC) rise (GPM) 40ºF (22ºC) rise (GPM)

26
83,000 5.5 4.7 4.2

35
108,000 ---6.2 5.4

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 an accessory part.
38

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Installation Examples (continued)

Connections

System Layout 2 Vitodens 100-W, WB1B 26, 35 with... - DHW storage tank - low-loss header - one heating circuit
AV
PRV

Legend AV Air vent PRV Pressure relief valve TPV Temperature and pressure 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 Low-loss header K Expansion tank L Primary pump (boiler circuit, field supplied) with
low-loss header only

Maximum Flow Rates

Model WB1B

TPV

Output Btu/h

83,000

108,000

30ºF (17ºC) rise (GPM) 5.5

----

35ºF (19.5ºC) rise (GPM) 4.7

6.2

40ºF (22ºC) rise (GPM) 4.2

5.4

IMPORTANT
Primary pump L must pump into the boiler (as illustrated).
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 an accessory part. See page 49 in this manual for details on the lowloss header.

5600 332 - 13

Connections
Installation Examples (continued)
System Layout 3 Vitodens 100-W, WB1B 26, 35 with... - DHW storage tank - one heating circuit

PRV

4xpipe Ø or 12" / 305 mm

TPV

Vitodens 100-W, WB1B CombiPlus Installation & Service

Legend
AV Air vent PRV Pressure relief valve TPV Temperature and pressure 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 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. Please see page 36 for details.

Maximum Flow Rates

Model WB1B t Output Btu/h 30ºF (17ºC) rise (GPM) 35ºF (19.5ºC) rise (GPM) 40ºF (22ºC) rise (GPM)

26
83,000 5.5 4.7 4.2

35
108,000 ---6.2 5.4

IMPORTANT
Primary pump L must pump into the boiler (as illustrated)
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 lowloss header.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Installation Examples (continued)
System Layout 4 Vitodens 100-W, WB1B 26, 35 with...
- DHW storage tank - Low-loss header - one high-temperature heating circuit

Connections

120V POWER

SUPPLY

4-7 GPM FLOW
GRUNDFOS UPS-15-58FC 3-SPEED CIRCULATOR OR EQUIVALENT RECOMMENDED

max. 17.5 GPM or 35 GPM (SEE LOW LOSS HEADER)

OPTIONAL LIMIT THERMOSTAT

SEE NOTE 1

LOW LOSS HEADER (for max. 19.5 GPM) (for max. 35.2 GPM)

120V POWER SUPPLY

SEE NOTE 1

See page 43 for notes and explanation of this drawing.

Legend A Boiler power pump module A1 Primary pump (boiler power / pump module control)
(field supplied) B Honeywell switching relay for B1 Heating circuit pump (field supplied) C Honeywell switching relay for DHW H control C1 DHW circulating pump (field supplied) D Radiator heating circuit E Low loss header
-Max. flow 19.5 USGPM Model No. 80/60 -Max. flow 35.2 USGPM Model No. 120/80 F DHW indirect storage tank G Limit thermostat (optional) See note 1 H DHW tank aquastat, Honeywell Part No. L4008A1031, Vi. Part No. 9560 985 I Vitodens 100 boiler J Expansion tank
41

5600 332 - 13

To boiler/burner control unit GC1

Connections
Installation Examples (continued)
Wiring diagram for system layout 4
A Power Pump Module
RT DHW

Vitodens 100-W, WB1B CombiPlus Installation & Service
1PH

Honeywell Aquastat L4008A1031 Vi.PN. 9560985 for DHW Control
TANK AQUASTAT

120 VAC/ 1PH

(OPTIONAL)
DOMESTIC HOT WATER PUMP

HONEYWELL SWITCHING RELAY RA889A-1001

1 Power Supply. Provide disconnect means and overload protection as required
2 DHW has priority over heating circuit E (see also 3 )
3 If no priority is required for DHW demand, supply power to terminals L1, L2 of RA889A relay of heating circuit EB

(OPTIONAL)

Honeywell Switching
Relay RA889A-1001 for heating circuit E

HIGH TEMP HEATING CIRCUIT PUMP
24V Field Wiring 120V Field Wiring Factory Wiring

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Installation Examples (continued)

Connections

System Layout 4
Installation of heating circuits: - radiator heating circuit (high temperature circuit) - DHW production with the following flow conditions:
The flow rate of the heating circuits is greater than the maximum possible water flow rate of the Vitodens 100 boiler.
The use of a low-loss header is therefore recommended. A low-loss header is available as an accessory part.
The radiator heating circuit is supplied by a circulation pump (field supplied). The DHW pump is field supplied.

Note 1 Optional high limit safety control of heating circuit E. [During DHW production with DHW terminal activated, the boiler supply temperature will be set automatically to 172ºF (78ºC)]. The heating system must be protected from excessive temperature if no automatic mixing valves are used or no DHW priority is required. After the DHW call for heat is satisfied, there is a 20 second pump post-purge time.

Maximum Flow Rates

Model WB1B t Output Btu/h 30ºF (17ºC) rise (GPM) 35ºF (19.5ºC) rise (GPM) 40ºF (22ºC) rise (GPM)

26
83,000 5.5 4.7 4.2

35
108,000 ---6.2 5.4

5600 332 - 13

Connections
Installation Examples (continued)
Vitodens 100-W, WB1B 26, 35 with one heating circuit and the CombiPLUS

Vitodens 100-W, WB1B CombiPlus Installation & Service

Maximum Flow Rates

Model WB1B t Output Btu/h 30ºF (17ºC) rise (GPM) 35ºF (19.5ºC) rise (GPM) 40ºF (22ºC) rise (GPM)

26
83,000 5.5 4.7 4.2

35
108,000 ---6.2 5.4

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 GPM.
Note: Heating circuit C in the examples should be designed to 30ºF to 40ºF (16.7ºC to 22.2ºC). For lesser delta T design, system layout designer must use one of the examples (5 or 6) on the following pages.

Legend
AV Air vent PRV Pressure relief valve (boiler) PRV* Pressure relief valve (DHW 150 psi) WSE Water softner equipment
A Vitodens 100-W B Room thermostat C Heating circuit D CombiPLUS E Expansion tank

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Vitodens 100-W, WB1B CombiPlus Installation & Service
Installation Examples (continued)

Connections

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

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.

Maximum Flow Rates

Model WB1B t Output Btu/h 30ºF (17ºC) rise (GPM) 35ºF (19.5ºC) rise (GPM) 40ºF (22ºC) rise (GPM)

26
83,000 5.5 4.7 4.2

35
108,000 ---6.2 5.4

5600 332 - 13

Connections
Installation Examples (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

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

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 an accessory part.

Maximum Flow Rates

Model WB1B t Output Btu/h 30ºF (17ºC) rise (GPM) 35ºF (19.5ºC) rise (GPM) 40ºF (22ºC) rise (GPM)

26
83,000 5.5 4.7 4.2

35
108,000 ---6.2 5.4

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 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.
46

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Installation Examples (continued)
Boiler in heating/cooling application

Connections

Legend A Heating/Cooling unit B Spring-loaded flow check valve C Circulation pump D Expansion tank E Water chiller F Boiler circuit pump (field supplied)

IMPORTANT
Viessmann strongly suggests that the valves pictured above be labelled "v1" and "v2".
The boiler, when used in connection with a refrigeration system, must be installed ensuring 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 of the boiler water during the cooling cycle.
Check installation instructions of the chiller manufacturer carefully for additional requirements. Cooling season starts: Close valve v1 and open valve v2. Heating season starts: Close valve v2 and open valve v1.

5600 332 - 13

Connections
Installation Examples (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

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

Hi-Vent

LWCO

A low water cut-off may be required by local codes. 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 accepted by local codes in lieu of a low water cut-off.

Boiler below radiation

Boiler above radiation

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Installation Examples (continued)
Accessories for the Vitodens 100-W Neutralization Unit for Single-Boiler Applications with neutralizing granulate for Vitodens 100-W, WB1B 26, 35

Connections

Vprimary

Vbypass

Vsecondary

Low-Loss Header - Type 80/60
[max. flow rate 19.5 GPM (4.4 m3/h)] - Type 120/80
[max. flow rate 35.2 GPM (8 m3/h)]
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. When used in conjunction with the Vitodens 100-W boiler, the low-loss header acts as hydraulic break, decoupling boiler and system circuits from each other (no sensor required). It is recommended to use the low-loss header in applications in which the total system flow rate exceeds the maximum or falls below the minimum flow rate of the Vitodens 100-W boiler. For maximum boiler flow rates, see the table on page 87 in this manual. Viessmann strongly recommends the use of a low-loss header in cases where the system head and flow rates are unknown. In addition, the low-loss header helps eliminate air and debris [D] from the heating system. See illustrations for Low-loss header design and the principle of operation. Product may not look exactly as illustrated.
T1 T3
T4 T2

Principal of operation
The low-loss header is available in the following sizes. Select the size based on the maximum system flow rate of your application.

Model No. Type 80/60 Type 120/80

Max. system flow rate 19.5 GPM (4.4 m3/h) 35.2 GPM (8 m3/h)

Legend
AB Air Bleed BR Boiler Return BS Boiler Supply BY Bypass
(with laminar flow) D Debris and/or air T1 Boiler supply temp. T2 Boiler return temp.

DV Drain Valve SR System Return SS System Supply TS Viessmann Temp.
Sensor (not used) SW Sensor Well T3 System supply temp. T4 System return temp.

Vprimary
Vsecondary
Vbypass Qprimary
Qsecondary

Boiler circuit flow rate Heating circuit flow rate
Bypass flow rate Heat supplied by boiler Heat consumed by system

Vprimary < Vsecondary T1 > T3 T2 = T4 Qprimary = Qsecondary

T1 176°F (80°C) Vsecondary=Vprimary+Vbypass

IMPORTANT
When installing a low-loss header, system mixed supply temperature (T3) must be calculated as follows

Low-loss header design

Product may not look exactly as illustrated.

5600 332 - 13

Venting / Control Connections
Venting Connection

Vitodens 100-W, WB1B CombiPlus Installation & Service

CAUTION
Under certain climatic conditions some building materials may be affected by flue products expelled in close proximity to unprotected surfaces. Sealing or shielding of the exposed surfaces with a corrosion resistant material (e.g. aluminum sheeting) may be required to prevent staining or deterioration. The protective material should be attached and sealed (if necessary) to the building before attaching the vent termination. It is strongly recommended to install the vent termination on the leeward side of the building.

For detailed installation information and specific venting requirements, reference the Vitodens Venting System Installation Instructions supplied with the boiler.

Electrical Connections
Rotating the control unit and opening the power/pump module
1. Loosen the screws underneath the boiler but do not remove them. Remove the cover (as shown on page 17).
2. Pull tabs outwards. 3. Flip control unit down. 4. Remove cover by releasing tabs if necessary. 5. Unlock 4 spring-loaded lock screws B and remove
cover plate of the power pump module.

IMPORTANT
Both the control unit and the power pump module have labels and stickers containing important information. Read and follow their respective instructions.
IMPORTANT
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. Note on connection of accessories
For other required installation steps, please reference the Installation Instructions for the accessory part.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Electrical Connections (continued)

Control Connections

IMPORTANT
Remove short factory test leads from terminal L, N and Ground before connecting main power supply to boiler A.
IMPORTANT
Ensure that pressure activated by-pass is installed with system layout 1 on page 38.

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

120V PUMP

DHW RT

Legend
A Main power supply (120V, 60Hz, 1 PH).
B Heating circuit pump (or boiler pump for low-loss header application or CombiPLUS pump).
C DHW tank temperature controller / external heat demand (field supplied) (not used with the CombiPLUS kit).
D Room temperature thermostat (Anticipator setting 0.2A) (field supplied).

Boiler control base GAS PUMP FAN
Diverting valve DHW / flow sensor

Optional operating control - OpenTherm
What is OpenTherm? The OpenTherm (OT) protocol is a point-to-point communication system, which connects a boiler with a room controller or other devices. The room unit calculates a heating demand (water temperature request) and transmits it to the boiler. The boiler will adjust the heat input accordingly (low-high modulation).
Legend A Viessmann outdoor temperature sensor (field wiring) B OpenTherm (field wiring) C Connection cable terminal D Power pump module
Follow the installation instructions of the field supplied operating controls.

5600 332 - 13

Control Connections
Electrical Connections (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service
Closing the power pump module and reinstalling the control unit 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 and securing connecting cables on site, ensure that the maximum permissible temperatures of the cables are not exceeded.

Reinstalling the front panel 1. Set front panel on the guide rails and push in place. 2. Tighten screws at the bottom.
IMPORTANT
Read and follow, where applicable, the 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.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Necessary Tools

Start-up, Inspection and Maintenance

Testing/analysis equipment (use only calibrated equipment)
Multimeter to measure 0 - 12A, 120V and resistances Flue gas analyzer to measure % CO2 or O2
(i.e. Bacharach fluid samplers or suitable electronic flue gas analyzer)
Manometer to measure gas pressure 0 to 11 "w.c. (accurately) and up to 28 "w.c. gas pressure (or a non-electric Magnehelic® manometer may also be utilized)
Stack thermometer 0 to 500°F (0 to 260°C)
Bacharach calculator or suitable tables to calculate standard (non-condensing) efficiency
Carbon monoxide measuring equipment 0 to 400 ppm.

Special items Approved leak detection fluid for natural gas Pipe joint sealant Garden hose for bleeding boiler heat exchanger
and pressure testing
Cleaning supplies Plastic hand brush Rags

Overview of Controls and Indicators
Lift flap and pull control unit cover down. All boiler controls are located behind the control unit cover.

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" Selector dial for boiler water temperature E ON / OFF switch F Gas shut-off valve

Legend A Heating mode pump output "ON" (when RT is closed) B DHW mode pump output "ON" (when DHW is closed) C Boiler water temperature in °F or fault code D Units for boiler water temperature measurement E Service mode F Current burner firing power rate G Burner in operation indicator H Fault indicator I Comfort function started J Comfort function stopped
53

5600 332 - 13

Start-up, Inspection and Maintenance
Overview of Boiler Components

Vitodens 100-W, WB1B CombiPlus Installation & Service

Fig. 45 Legend A Fixed high limit, 210°F (99°C) B Ignition / ionization electrode C Flow switch, VK315M D P-trap F Condensate hose, 16" (400 mm) G Water pressure gage H Vent pipe adaptor J Flue gas temperature sensor 230ºF (110ºC) K Test port caps (x2) L Burner mounting flange assembly N Radial fan
54

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 (low voltage wiring)

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Overview of CombiPLUS Components

Start-up, Inspection and Maintenance

Fig. 46 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
55

5600 332 - 13

Start-up, Inspection and Maintenance
Procedure Overview

Vitodens 100-W, WB1B CombiPlus Installation & Service

Start-up steps Inspection steps Maintenance steps

S I M 1. Fill and vent the heating system ......................................................................................57

2. Check power supply connection.......................................................................................58

3. Select appropriate gas type..............................................................................................58

I M 4. Measure static pressure and running pressure.....................................................................59

S I M 5. How the Vitodens 100-W boiler operates...........................................................................61

6. Relay tests (burner tests).................................................................................................62

7. High altitude testing........................................................................................................64

M 8. Set maximum input.........................................................................................................65

S I M 9. Clock natural gas meter...................................................................................................66

I M 10. Check all primary and secondary circuit connections for leaks...............................................66

I M 11. Perform combustion analysis............................................................................................66

12. Check venting system for leaks (circular air gap measurement)

for sealed combustion, coaxial vent only ..........................................................................67

S I M 13. Removing front panel......................................................................................................67

S I M 14. Remove burner...............................................................................................................68

I M 15. Check burner gasket and cylinder assembly for damage ......................................................68

I M 16. Check and adjust ignition and ionization electrodes.............................................................69

I M 17. Check condensate drain and clean siphon (P-trap)...............................................................69

I M 18. Check neutralization unit (if applicable)..............................................................................70

I M 19. Clean combustion chamber/heat exchanger surfaces...........................................................70

M 20. Check diaphragm expansion tank and system pressure........................................................71

21. Check functioning of safety valves....................................................................................71

22. Check gas pipes and fittings for leaks................................................................................72

23. Reinstall burner...............................................................................................................72

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Steps

Start-up, Inspection and Maintenance

Start-up

1. Filling and bleeding heating system

CAUTION
Unsuitable fill water increases the level of deposits and corrosion, and may lead to damage to the equipment. Thoroughly flush the entire heating system prior to
filling with water. Only use fill water of potable quality. Soften fill water harder than 150 ppm temporary
hardness. Inhibitors or antifreeze additives suitable for heating
systems may be added manually.
During fill and removal of air, the boiler pump can be activated. To activate the pump, in less than 2 seconds turn selector dial to stand-by position 1 from a control range (counter-clockwise) and then right back into the control range 2 (clockwise). The pump will run for 30 minutes and cancel the request automatically or after the ON/OFF switch is turned OFF.
2

1. Open system isolation valves (if installed).
Note: Before filling the heating system with water, check that all necessary flow check valves are installed.
2. Check inlet pressure of the diaphragm expansion tank.
Note: If the nitrogen pressure of the precharged expansion tank is less than the static pressure of the system, inflate membrane pressure to slightly exceed pressure of system. The static pressure required at the tank is based upon the static height of the system. The system fill pressure value must be equal to the expansion tank pressure value at approx. 60ºF (15.6ºC).
3. To remove debris and/or sludge ensure that the system piping is flushed out. Failure to do so may cause sediment in the boiler causing overheating and damage not covered by warranty.
Note: System fill pressure must be approximately 3 psig higher than the static head when the system is cold.
4. Optional: Fill the heating system with water at the boiler filling tap A and drain air completely from the drain tap B.
Note: Water treatment should be considered in areas where it is known that boiler feed water contains a high mineral content and hardness. In areas where freezing might occur, an antifreeze may be added to the system water to protect the system. Please adhere to the specifications given by the antifreeze manufacturer. Do not use automotive silicatebased antifreeze. Please observe that an antifreeze/ water mixture may require a backflow 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 with antifreeze.
To remove air from the heat exchanger: Connect a hose to the boiler filling tap A and connect
the other end to fresh water supply (or heating medium).
Open the fresh water supply valve and then open the boiler filling tap A slowly to fill the boiler with water. Isolation valves (not shown) to isolate system components must be closed during fill/bleed process.
Flush the boiler heat exchanger via the boiler supply and return (for at least 10 mins.) until all air has been removed from the boiler.
When the drain tap B begins to bleed water, close the boiler drain valve and open system isolation valves.

5600 332 - 13

Start-up, Inspection and Maintenance
Steps (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

Start-up

1. Fill and vent heating system (continued)
5. Check system pressure.
6. Ensure proper / adequate fuel supply exists. Open gas shutoff valve. Max. boiler operating pressure.......................45 psig Min. boiler operating pressure...............14 to 23 psig Pressure relief valve.....................................30 psig

Start-up

2. Check power supply connection
A power module is supplied with the Vitodens 100-W boiler, which requires a 120VAC power supply. The voltage at connector X3 must be 120V (see wiring diagram). Neutral conductor The electrical power supply must have a neutral conductor.

IMPORTANT
In Canada all electrical wiring is to be done in accordance with the latest edition of CSA C22.1 Part 1 and/or local codes. In the U.S. use the National Electrical Code ANSI/ NFPA 70. The heating contractor must also comply with both the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI, ASME CSD-1.

Note: The outer conductor "L" and the neutral conductor "N" must not be interchanged. See wiring diagram on page 91 entitled "Additional Information" in this manual.

Start-up and Maintenance

3. Select appropriate gas type

Heating value (gross)

Btu/ft3

Specific gravity

Ultimate carbon dioxide (CO2)

Natural gas 970 to 1100 0.57 to 0.70 11.7 to 12.2

The Vitodens 100-W boiler is for use with gases whose characteristics fall within the following ranges. Do not use any other types of gas.
Liquid Propane gas 2466 to 2542 1.522 to 1.574 13.73 to 13.82
1. Verify that the fuel type listed on the boiler rating plate is the correct type for the installation being attempted.
2. Once verified, record the fuel type in Maintenance Record on page 98.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Steps (continued)

Start-up, Inspection and Maintenance

Start-up and Maintenance

3. Select appropriate gas type (continued)

To verify the fuel type
1. Simultaneously turn selector dial " " and "tr" to their center position as shown. "SERV" appears in the display. (To do the following step, "SERV" must still be shown in the display).

2. Turn selector dial "tr" counter clockwise to the "O" position within 2 seconds as shown. "A" and the setpoint value will flash on the display.

3. Adjust the control unit to natural gas or LPG by

turning the selector dial "

" counter clockwise

or clockwise. The display shows:

"0" for operation with natural gas

"1" for operation with LPG.

4. Do not adjust the selector dials for 15 seconds. The set operating mode is then saved and the control unit returns to standard mode.

Start-up and Maintenance

4. Measure static pressure and running pressure

Legend A Inlet gas pressure measurement port B Outlet pressure port C Low-fire adjustment screw / cover D Hi-fire adjustment screw
IMPORTANT
A CO2 measurement (see page 62) must be taken before and after working on gas appliances to eliminate health risks and to guarantee the satisfactory condition of the system.

Static pressure 1. To measure static and/or running pressure remove
burner cover panel as per the removal instructions on page 67.
2. Close gas shutoff valve. 3. Loosen screw in test nipple A on the gas combination
valve, do not remove completely. Connect calibrated manometer.
4. Open the gas shutoff valve.
5. Measure static pressure. Values must be: - 14 "w.c. max. for NG - 14 "w.c. max. for LPG
6. Enter measured value into Maintenance Record on page 98 in this manual.
7. Start up boiler, using the on/off service switch (field supplied).
IMPORTANT
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 boiler employs a direct spark ignition system with 3 trials for ignition.

5600 332 - 13

Start-up, Inspection and Maintenance
Steps (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

Start-up and Maintenance
Measuring running gas supply pressure, using test nipple A

4. Measure static pressure and running pressure (continued)

8. All measurements must be made under high-fire conditions.
Note: Use suitable measuring instruments calibrated with a minimum resolution of 0.04 "w.c. for measuring the running pressure.

Measure the running pressure; value must be:

Running supply pressure with Natural gas under 4 "w.c.
4 to 14 "w.c. over 14 "w.c.

Running

Corrective action

supply

pressure with

Liquid propane

gas

under 10 "w.c.

Do not attempt adjustment. Call local gas utility to increase pressure.

10 to 14 "w.c.

Start up boiler.

over 14 "w.c.

Do not attempt adjustment. Call local gas utility to decrease pressure. Boiler valve must not be exposed to pressure over 14 "w.c.

9. Enter gas type into Maintenance Record on page 98 in this manual.
10. Switch off the heating system ON/OFF service switch (boiler is shut down), close the gas shut-off valve, remove the manometer and re-tighten the screw in the test nipple A.
11. Open gas shutoff valve and check that the test nipple A and all gas connections are gas-tight.

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.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Steps (continued)

Start-up, Inspection and Maintenance

Start-up and Maintenance

5. How the Vitodens 100-W boiler operates...

Start-up and Maintenance
Legend
A Inlet gas pressure measurement port B Outlet pressure port C Low-fire adjustment screw / cover D Hi-fire adjustment screw

The Vitodens 100-W boiler uses a premix combustion system, which is designed to deliver a measured air-gas mixture to the burner for complete combustion.
The gas is injected upstream of the blower. The burner and heat exchanger are part 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 pneumatic link between combustion air and gas flows.
Blower speed is automatically increased or decreased based on heat demand, thereby regulating the amount of combustion air drawn. The pneumatic link between air and gas introduces the required amount of gas for correct combustion to meet the current heat demand, based on a linear relationship between P air and P gas.

5600 332 - 13

Start-up, Inspection and Maintenance
Steps (continued)
Start-up and Maintenance
A Flue gas measuring port
Legend A Heating mode pump output on B Heating mode C Boiler water temperature in °F or fault code D Water temperature unit in °F E Service mode F Current burner firing rate G Burner in operation H Fault I Comfort function started J Comfort function stopped

Vitodens 100-W, WB1B CombiPlus Installation & Service

6. Relay tests (burner tests)

The Vitodens 100-W boiler is factory preset for operation with natural gas. It is recommended that a CO2 check be performed at the boiler vent pipe adaptor as part of the initial start-up/maintenance procedure. For high altitude operation above 5,000 ft (1,500 m), refer to page 64 first.
For conversion to propane, see the separate instructions. The CO2 value lies within the range of;
- 7.5 to 11.0 % for natural gas and 10 to 12% for liquid propane gas. The CO2 value measured must be compared with the above CO2 value.

NG range Target value LPG range Target value

CO2 high-fire 7.5-11.0%
9.0% 10.0-12.0%
10.8%

low-fire 7.5-11.0% 8.7% 10.0-12.0% 10.5%

Note: When the boiler is initially turned on, a selfdiagnostic check is initiated. Wait until the temperature display is stabilized and the boiler's actual temperature is displayed.
Note: If step 14 is not performed, the process will end automatically after 30 minutes.
If the CO2 value measured lies more than 1% outside the stated range, perform the following step: - Check the venting system for leaks (refer to the
Vitodens Venting System Installation Instructions).
1. Bring the boiler to a high-fire test position by turning the selector dial "tr" clockwise all the way to "U Reset" and then back again into the high-fire control range (in less than 2 seconds). The display shows "SERV", the boiler water temperature, five bars "<<<<<" for high-fire test, burner in operation "A" and "r" pump operation.

high-fire range (6 and above)
5600 332 - 13

Control range - high-fire 62

Vitodens 100-W, WB1B CombiPlus Installation & Service
Steps (continued)

Start-up, Inspection and Maintenance

Start-up and Maintenance

6. Relay tests (burner tests) (continued)

Note: During the relay test (if required) the selector dial "tr" position can limit the boiler input according to the following table;

Dial setting 1 & below between 1 & 6 6 & above

Input setting low fire between low & high fire high fire

Display flashing
<
<<<
<<<<<

2. Check the flue gas CO2 content. Should the actual value deviate by more than 1% from the range shown in the table, check the seals in the balanced flue system. Adjust if necessary.
3. Enter actual values into the service report.
4. Bring the boiler to a low-fire test position by turning the selector dial "tr" clockwise all the way to "U Reset" and then back again into the low-fire test control range
St(ainrtl-euspsatnhdanM2aisnetecnoanndcse). If the selector dial is in the high-fire position, turn the dial to the low-fire position. The display shows "SERV", the boiler water temperature, one bar "<" for low-fire test, burner in operation "A" and "r" pump operation.

IMPORTANT
Steady state conditions must be established before measuring flue gases.
7. Check the CO2 content for high- and low-fire again. If the CO2 content is still not within the given range (refer page 62), adjust the CO2 content.
8. Adjusting the CO2 content. See CO2 table on page 62.
9. Adjust the high-fire (natural gas or liquid propane gas). With the adjusting screw B, using a hex head wrench (4 mm), adjust the high-fire CO2 content to 9% for NG or 10.8% for LPG. Clockwise rotation decreases gas flow and counter-clockwise rotation increases gas flow.
High-fire increase gas flow

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 heating) during the duration of the test. Boiler temperature is automatically adjusted to a maximum of 178ºF (81ºC).
5. Check the flue gas CO2 content. Should the actual value deviate by more than 1% from the above range, check the seals in the balanced flue system.
6. Enter actual values into the service report.

Low-fire increase gas flow
10. Adjust the low-fire (natural gas or liquid propane gas). Remove cover C from the gas valve. With the adjusting screw under the cover and using a T40 size Torx head wrench, set the low-fire CO2 content to 8.7% for NG or 10.5% for LPG. Clockwise rotation increases gas flow and counter-clockwise rotation decreases gas flow.
11. Reinstall cover C.
12. Shut the boiler down, remove flue gas analyzer and close flue gas measurement port A.
13. Return selector dial " " and "tr" to the original positions.
14. To cancel the relay test, switch the boiler OFF then back ON. If not cancelled, the relay test is automatically deactivated after 30 minutes.

5600 332 - 13

Start-up, Inspection and Maintenance
Steps (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

Start-up and Maintenance

7. High altitude setting

Note: When the boiler is initially turned on, a selfdiagnostic check is initiated. Wait until the temperature display is stabilized and the boiler's actual temperature is displayed.

1. Simultaneously turn selector dials " " and "tr" to their center position. "SERV" appears in the display. (To do the following step, "SERV" must still be shown in the display.) 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.
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.

Value

Operation

Altitude < 5,000 ft. (1,500 m)

Altitude > 5,000 ft. (1,500 m)

5. Do not adjust the selector dials for at least 15 seconds. The set value " 1" or "2" is then saved and the control unit returns to standard mode.
6. Turn ON/ /OFF switch OFF and then ON. When completed, it will activate the designated setting

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Steps (continued)

Start-up, Inspection and Maintenance

Start-up and Maintenance Control range

8. Set maximum heating input

- The maximum input (or output) for heating operation can be limited (does not affect DHW heating). The limit is set via the modulation range. The maximum adjustable heating input (or output) may be limited by programming.

1. Start up the boiler.

2. Bring the boiler to a high-fire test position by turning the selector dial "tr" clockwise 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 value in % of the rated input (or output).
Note: For example, if the selector dial is set at "1" only one bar will be flashing on the display and the input will be reduced to 40% of max input.

4. Turn the water temperature selector dial " "

clockwise (in less than 2 seconds and back again into

operation range. The icon

will appear for a

moment on display, the control accepted the setting.

5. Press the ON/OFF switch.

6. Start the boiler and the maximum input will be set.

Note: When the boiler is initially turned on, a selfdiagnostic check is initiated. Wait until the temperature display is stabilized and the boiler's actual temperature is displayed.
65

5600 332 - 13

Start-up, Inspection and Maintenance
Steps (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

Start-up and Maintenance

9. Clock natural gas meter

IMPORTANT
A boiler under fired by 5% is still acceptable. Do not over fire the boiler.
CAUTION
Always contact your gas utility to obtain the correct heating value before clocking the meter.

Clock natural gas meter to verify input
1. Ensure all other gas equipment served by the meter is turned off during timing of gas input to the Vitodens 100-W boiler.
2. Measure the time in seconds it takes for the boiler to use 10 cu. ft. of gas. Divide 3600 x 10 by the number of seconds and you get the number of cu. ft. of gas used per hour. Multiply this number by the heating value of the gas to obtain Btu per hour input.
For example: A Vitodens 100-W boiler (118 000 Btu/h input) requires 305 seconds to use 10 cu. ft. of natural gas. After contacting the local utility, you find the heating value is e.g. 1000 Btu per 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

Start-up and Maintenance

10. Check all primary and secondary circuit connections for leaks
Check heating system and domestic hot water connections (if applicable). Ensure all connections are pressure tight. Correct any leaks found on fittings, pumps, valves, etc.

Start-up and Maintenance

11. Perform combustion analysis

IMPORTANT
A CO2 measurement (see page 62) must be taken before and after working on gas appliances to eliminate health risks and to guarantee the satisfactory condition of the system.
Record the measured combustion values in the sequence stated in the Maintenance Record on page 98 in this manual.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Steps (continued)

Start-up, Inspection and Maintenance

Start-up and Maintenance
Legend A Flue gas measurement port B Combustion air measurement port

12. Check venting system for leaks (circular air gap measurement) For sealed combustion, coaxial vent only
Viessmann strongly recommends that the heating contractor perform a simplified leak test during boiler start-up. For this purpose it is sufficient to measure the CO2 concentration of the combustion air in the coaxial gap of the air intake pipe. The vent pipe is considered sufficiently leak-proof if a CO2 concentration in the combustion air no higher than 0.2% or an O2 concentration no lower than 20.6% is measured. If higher CO2 values or lower O2 values are measured, check venting system thoroughly.
Note: The vent pipe adaptor comes with two measurement ports, one for combustion air intake measurement and one for flue gas measurement.
Note: This test is not applicable for single-wall venting systems (non-sealed combustion).

MStaairntt-uenpaanncde Maintenance

13. Removing front panel
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 installation conditions and usage but in general once a year should be adequate. Any service work must be carried out by a licensed professional heating contractor.
The boiler incorporates a flue gas measurement port. The flue gases can be analyzed (if required). The push fit cap may be removed and a sample tube installed. The push fit cap must be refitted after use. The flue gas sample will enable the heating contractor to judge whether any adjustments are required. Before commencing any service operation, isolate and secure the main power supply against accidental reactivation, and turn off the main gas supply.
1. Loosen the screws at the bottom of the boiler; do not remove completely.
2. Remove the front panel.

5600 332 - 13

Start-up, Inspection and Maintenance
Steps (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

Maintenance Start-up and Maintenance

14. Remove burner
1. Switch the burner OFF (shut off main service switch). 2. Shut off the gas supply. 3. Pull power cables from fan motor A, gas valve B
and electrode block C. 4. Pull the Venturi extension D from the fan.
CAUTION
To avoid damage to the burner, do not lay burner on its cylindrical burner tube. Failure to heed this caution may cause damage to the burner tube, which may lead to improper operation.
5. Release gas supply pipe fitting E. Note: There is a gasket between the gas valve and this connection.
6. Loosen four Torx (T-30) screws F and remove burner.

Maintenance

15. Check burner gasket and cylinder assembly for damage
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 insulation ring C.
3. Loosen the four Torx screws and remove burner cylinder assembly D and assembly gasket E.
4. Fit and secure new burner cylinder assembly D and new assembly gasket E. Tighten to a torque of 3.5 Nm (31 lb.in.) using a calibrated torque wrench.
5. Reinstall thermal insulation ring C.
6. Reinstall electrode block B. Tighten to a torque of 3.5 Nm (31 lb.in.) using a calibrated torque wrench.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Steps (continued)

Start-up, Inspection and Maintenance

SMtaairntt-uenpaanncde Maintenance

16. Check and adjust ignition and ionization electrodes
1. Check ignition and ionization electrode for wear, contamination or warping.
2. Clean electrodes with a small brush or emery paper. 3. Check clearances. If clearances are not satisfactory
or the electrodes are damaged, replace electrode block and gasket and align. Tighten fastening screws for the electrodes to a torque of 3.5 Nm (31 lb.in.) using a calibrated torque wrench. 4. Reinstall grounding wire.

Legend
A Ignition ionization electrode B Ground

Maintenance Start-up and Maintenance

17. Check condensate drain and clean siphon (P-trap)
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 into the combustion chamber.
IMPORTANT
If the condensate does not drain freely, condensate will accumulate in bottom part of boiler resulting in a burner shut-down (fault message F4). The combustion chamber refractory will also become wet at the bottom. Do not restart the boiler immediately with a wet combustion chamber refractory. This will damage the refractory. Either dry the refractory (i.e. using a hairdryer) or replace it.
Installation Instructions Neutralization Unit (if applicable)
69

5600 332 - 13

Start-up, Inspection and Maintenance
Steps (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

Maintenance

18. Check neutralization unit (if applicable)

Accessory

1. Check the pH value of the condensate with a pH measuring strip. If the pH value is less than 6.5, replace granulate.
2. If contaminated: Rinse neutralization unit with tap water. 3. Add granulate as marked on the cartridge.
IMPORTANT
pH measuring strip is field supplied.

IMPORTANT
The granulate is consumed as it neutralizes the condensate. The red marking indicates the min. filling level.
Installation Instructions Neutralization Unit

Maintenance

19. Clean combustion chamber/heat exchanger surfaces
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 by-product deposits with alkaline agents containing tenside. - Remove coatings and (yellowish brown) surface discoloration with phosphoric acid-based "Antox 75 E Plus", or citric acid-based CitriSurf 3050 or CitriSurf 77 by Stellar Solutions Inc. - Rinse thoroughly with water. Note: Be careful not to scratch parts which are in contact with flue gas. Use plastic brushes, not wire brushes! The cleaning agents must not contain hydrocarbon-based solvents or potassium.
3. Connect electrical cables to corresponding parts.
WARNING
Follow cleaning agent manufacturer's safety instructions and wear appropriate protective equipment.

IMPORTANT
Perform leak test.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Steps (continued)

Start-up, Inspection and Maintenance

Start-up and Maintenance Start-up and Maintenance

20. Check diaphragm expansion tank and system pressure
Perform check on the system when cold.
1. Drain boiler/system and reduce pressure until the manometer reading is "0".
2. If the nitrogen pressure of the pre-charged expansion tank is less than the static pressure of the system, inflate membrane pressure to slightly exceed pressure of system. The static pressure required at the tank is based upon the static height of the system. The system fill pressure value must be equal to the expansion tank pressure value at approx. 60ºF (15.6ºC).
Note: Static head of 33 ft. (10 m) (distance between boiler and topmost heat emitter surface) corresponds to a static pressure of 1 bar (15 psig).
3. Top up with water until filling pressure 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.
Note: A lower manometer reading usually indicates loss of water due to leakage. All leaks must be repaired.

Start-up and Maintenance

21. Check functioning of safety valves
Ensure proper operation of low water cut-off(s) (if applicable), pressure relief valve, and pump(s). Check pressure gage, air vent and pressure relief valve. Ensure that pressure relief valve does not leak and that it operates in accordance with information provided by the original manufacturer.
Refer to maintenance instructions supplied with low water cut-offs, pumps, etc.
Flush float water type low water cut-offs (if used). Follow local regulations with respect to backflow preventers. If oil-lubricated pumps are used, ensure proper lubrication. If motorized zone valves are used, refer to maintenance instructions provided with zone valves.

5600 332 - 13

Start-up, Inspection and Maintenance
Steps (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

Start-up and Maintenance

22. Check gas pipes and fittings for leaks

WARNING
The gas supply piping must be leak tested before placing the boiler in operation.
CAUTION
Ensure all joints of gas line are pressure tight and that gas valves do not leak when under normal operating pressure (use approved leak detection liquid). Do not use open flame.

Start-up and Maintenance Start-up and Maintenance

23. Reinstall burner
1. Replace electrical cables from fan motor A, mount burner, and diagonally tighten 4 Torx T-30 screws F to a torque of 4 Nm (35 lb.in.).
2. Insert new supplied gasket 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.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Troubleshooting Steps

Troubleshooting

Diagnosis Correction

1. Establish fault message or diagnose behavior of system.
2. Look for corresponding cause of fault in the diagnostics table.
3. Find corrective measures in the table. 4. Perform corrective measures (page 74 to 76).
Note: See page 54 and 55 for an overview of controls, indicators and system components.

Changing Room Temperature

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 temperature controller is not sufficient to achieve the desired room temperature (e.g. during a particularly cold winter), the boiler water temperature can be adjusted accordingly using the boiler water temperature selector dial tr.

5600 332 - 13

Troubleshooting
Diagnosis

Vitodens 100-W, WB1B CombiPlus Installation & Service

Sequence of operation and potential faults during each start-up cycle
Call for heat by control (boiler water set-point temperature is 9ºF (5ºC) above current boiler water temperature).
yes
Water flow switch activates plug 33.

yes
Blower starts up.

Ignition.

yes

Display message

Fault F9 after

approximately

51 seconds.

Fault F4
no

Corrective action Increase boiler water set-point
temperature and ensure that there is heat demand.
Check water flow switch. Replace
if necessary (min. flow 1.8 USG/m (400 L/h). Check 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.

yes
Gas combination valve opens.

Fault F4
no

yes
Ionization current builds up / flame established (symbol A appears).

Fault F4
no

yes
Burner is operating.

Burner shuts off when the boiler temperature is below the selected boiler set-point temperature and immediately starts up again(cycles).

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 and flue gas system for leaks. Check ignition cable resistance (4.5K to 5K Ohms).
Check flue gas system for leakage
(flue gas recirculation), check running gas pressure.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Diagnosis (continued)

Troubleshooting

Faults are indicated by a flashing fault code with fault code symbol "U" on the display. For fault code explanations see the following table.

Diagnostics table: Faults with fault display on control unit

Fault code in

System

display window characteristics*1

Start-up10and MaintCenoannsctaent mode

Constant mode

Burner blocked

No DHW tank

heating or external

heat demand

No DHW heating

with CombiPLUS

only

Burner blocked (with

Start-up and MaintCenoamnbciePLUS only)

No DHW heating (used

with storage tanks)

No DHW heating (with

CombiPLUS only)

Burner blocked

Regulated operation

without OpenTherm

device

Burner blocked

Cause
Outside temperature sensor shorted out Outside temperature sensor wire broken Boiler water temperature sensor shorted out Boiler water temperature sensor wire broken Jumper connection shorted out, removed or missing
Outlet temperature sensor shorted out
Flow sensor shorted out (in CombiPLUS) Jumper connection shorted out, removed or missing Outlet temperature sensor wire broken Flow sensor wire broken
Communication fault OpenTherm device
Flue gas temperature sensor shorted out Flue gas temperature sensor wire broken Internal fault
Internal fault

Corrective measures
Check the optional outside temperature sensor and wiring (see page 78). Check the outside temperature sensor and wiring (see page 78). Check the boiler water temperature sensor (see page 77). Check the boiler water temperature sensor (see page 77). Install PPM jumper (see page 31)
Check sensor (see pages 29 and 82).
Check connections and wire; replace sensor if required. Check PPM jumper. (see page 31)
Check the sensor (see page 29).
Check connections and wire; replace sensor if required. Check connections and wire; replace OpenTherm device if required.
Check sensor (see page 80). Check sensor (see page 80) Check the ionization electrode and connecting cable. Press reset (see page 69). Replace the control unit.

*1 Constant mode: Boiler operates based on "tr" temperature setting Burner blocked: If fault cause is corrected, burner resumes operation. Burner in fault mode: Boiler control requires manual reset before burner can resume operation.

5600 332 - 13

Troubleshooting
Diagnosis (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

Diagnostics table: Faults with fault display on control unit (continued)

Fault code in

System

display window characteristics*1

Cause

Burner in fault mode Maximum flue gas temperature

exceeded

Burner in fault mode Fixed high limit tripped

Burner in fault mode Flame signal is already present

at burner start

Burner in fault mode No flame signal is present

Burner in fault mode The combination gas valve

closes too late

Burner in fault mode Blower speed too low at

burner start

Burner in fault mode Blower not at stand-still

Burner blocked

Electrical fan control (control

unit) faulty

Burner blocked

Burner control unit fault

Corrective measures
Check the flue gas system. Reset control.
Check the heating system water level. Check the circulation pump. Bleed the system. Check the fixed high limit and connecting cables. Reset control.
Check the ionization electrode and connecting cable. Reset control.
Check ignition electrodes and wires. Measure the ionization current, check the gas pressure, check the gas train, ignition, ignition module and condensate drain. Reset control. Check ignition cable resistance (4.5K to 5K ohms).
Check the gas train. Check both control paths. Reset control.
Check the blower, check the blower cables and supply; check the blower control. Reset control.
Check the blower, blower connecting cables and blower control. Reset control.
Check fan connecting cable; if required replace cable or replace control unit. Reset control.
Check ignition electrodes and connecting cables. Check whether a strong interference (EMC) field exists near the equipment (correct if applicable). Reset control. Replace control unit if the fault persists.

How to reset faults
Turn rotary selector "tr" to "U Reset", pause until "SERV" appears on the screen and then immediately (within 2 seconds) turn "tr" back into the control range. This operation will put the boiler in relay test mode if no fault is present (turn boiler off then back on to start again).

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Boiler Connection

Troubleshooting

Remove front panel 1. Loosen the screws at the bottom of the boiler; do not
remove completely.
2. Remove the front panel.

Start-up and Maintenance

Check boiler temperature sensor
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.

5600 332 - 13
Resistance in K

WARNING
The boiler temperature sensor is immersed in the heating water (risk of scalding). Drain the boiler before replacing the sensor.

Boiler water temperature 77

Troubleshooting
Boiler Connection (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service
Check outdoor temperature sensor
1. Disconnect cables from outdoor sensor. 2. Measure resistance of the outdoor sensor and
compare with resistance / outdoor sensor curve shown below. 3. If the value measured differs significantly, replace the sensor. In weather-compensated mode (optional), the 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 41ºF (5ºC) and is switched OFF again when the boiler water temperature reaches at least 59ºF (15ºC) [but not more than 68ºF (20ºC)].
For details on the control, please refer to the Vitodens 100-W Operating Instructions.

Resistance in K
5600 332 - 13

Temperature 78

Vitodens 100-W, WB1B CombiPlus Installation & Service
Boiler Connection (continued)

Troubleshooting

Boiler water or supply temperature

Outside temperature
Legend A Selector dial "tr" setting: 1 B Selector dial "tr" setting: 2 CStaSrte-luepctaonrddiMala"inttr en"ansceetting: 3 D Selector dial "tr" setting: 4 E Factory default F Selector dial "tr" setting: 5 G Selector dial "tr" setting: 6

Determining the boiler set-point
Room dependent control: Outdoor temperature sensor not connected
With no outdoor sensor installed, the "tr" dial will provide a constant temperature set-point for the boiler based on the dial position selected. Setting the dial between 1 and 6 will provide a set-point value of 81ºF to 178ºF (27ºC to 81ºC) respectively. The dot between 4 and 5 represents the factory default setpoint value of 140ºF (60ºC).
Weather dependent control: Outdoor temperature sensor connected
With the outdoor sensor connected, the boiler will automatically recognize the sensor and switch the setpoint dial operation from constant temperature calculated to outdoor reset calculated.
Adjusting the "tr" dial will select the heating curve corresponding with the heating curve chart. The setpoint 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 the factory default curve.
Note: Both the room dependent control and the outdoor reset control strategies require a closed contact at terminals RT to generate a call for heat to the boiler. Setting the dial to "0" places the boiler in freeze protection mode regardless of the control option selected or the contact position at RT.

Factory default

5600 332 - 13

Troubleshooting
Boiler Connection (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service
Check fixed high limit If the burner control unit cannot be reset after a fault shutdown (F2), even though the boiler water temperature is below 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.

Check flue gas temperature sensor 1. Pull the leads from flue gas temperature sensor A. 2. Check the sensor resistance and compare it with the
curve. 3. Replace the sensor in case of severe deviation.
Temperature 80

Resistance in K
5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Boiler Connection (continued)

Troubleshooting

Check fuses
Control unit fuse 1. Switch off main power supply.
2. Flip down control unit. 3. Remove cover A.
4. Check fuse F4 T 2.5A (slow blow). Replacements fuses are available from Viessmann in packs of 10 (Part No. 7404 396).

Start-up and Maintenance

Power pump module fuse 1. Switch off main power supply. 2. Flip down and remove control unit A.
Also refer to pages 50 and 52. 3. Remove power 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).
IMPORTANT
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.
81

5600 332 - 13

Troubleshooting
CombiPLUS Connection

Vitodens 100-W, WB1B CombiPlus Installation & Service
Check outlet temperature sensor 1. Pull the leads from outlet temperature sensor A. 2. Check the sensor resistance and compare it with
the curve. 3. Replace the sensor in case of severe deviation.

Resistance in K

Temperature
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).
Replacing the flow limiter 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 boiler
size (see boiler rating plate). See page 26. 7. Insert new flow regulator C. 8. Fit new cap B provided.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
CombiPLUS Connection (continued)

Troubleshooting

Checking or replacing the plate type heat exchanger 1. Shut off and drain the boiler on the heating water
and the DHW side.
2. Disconnect diverting valve motor connection
3. Push the three-way drive A slightly upwards.
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 platetype heat exchanger.
6. Check the DHW side for scaling and if required, clean or replace the plate-type heat exchanger.
7. Check the heating water side for contamination and if required, clean or replace the plate-type heat exchanger.
8. Install in reverse order with new gaskets. Note: Refer to the installation Instructions for additional mounting options.

Legend A Three-way valve drive B Three-way valve C Screws D Plate-type heat exchanger E Heating water supply F Heating water return G DCW H DHW

To remove, push to unlock

5600 332 - 13

Additional Information

Vitodens 100-W, WB1B CombiPlus Installation & Service

Electrical Connections to the Terminal Strip for Accessories

Boiler control

Boiler reset module (0-10V controller)
OT-Devices

Follow the installation instructions of field supplied operating controls.
What is OpenTherm? The OpenTherm (OT) protocol is a point-to-point communication system, which connects a boiler with a room controller or other devices. The room unit calculates a heating demand (water temperature request) and transmits it to 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.

Boiler control base

GAS PUMP FAN
Diverting valve DHW / flow sensor

Legend A Viessmann outdoor temperature sensor (field wiring) B OpenTherm (field wiring) C Connection cable terminal D Power pump module
Follow the installation instructions of the field supplied operating controls.

5600 332 - 13

Terminal strip for accessories connections. 84

Vitodens 100-W, WB1B CombiPlus Installation & Service
Technical Data

Additional Information

Call for heat priority logic table
The Vitodens 100-W, WB1B boiler has several operating control options. The following table provides the priority levels of each of the different operating controllers.

Priority 1 2 3 4
5
6

Control operating mode Freeze protection OpenTherm CombiPLUS DHW / external heat demand
Outdoor temperature sensor*2
Room thermostat (RT terminal)

Required signal *1
Boiler temperature < 41ºF (5ºC)
OT signal
DHW flow sensor / temp. sensor
Close DHW contact in power / pump module - boiler set-point temp. = 172ºF (78ºC)
(non-adjustable)
- Temperature dial "tr" setting - RT contact closed or OT
connection terminals 1 & 2 shorted.
Close RT contact in power / pump module.

Pump output Pump off delay

4 minutes (240 seconds)

20 seconds

none

20 seconds

4 minutes (240 seconds)

*1 Boiler control will adjust the boiler water temperature set-point to the highest of all input signals. *2 Priority #6 (outdoor temperature sensor / RT contact) not functional when OT inputs are recognized by the boiler control.

5600 332 - 13

Additional Information
Technical Data (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

Rated voltage:.................................................120VAC Rated frequency:.................................................60 Hz Rated current:...................................................6.0 A~
Max. ambient temperature - at operation:.................32º to 104ºF (0º to +40ºC) - when storing and transporting:...........-4º to +149ºF
(-20º to +65ºC)

Setting of adjustable electronic high limit:.....176ºF (80ºC)
Setting of fixed high limit safety cut-out (fixed setting):......................210ºF (99ºC)
Main fuse:.....................................................max. 15A
Power consumption - Burner:.................................................max. 105 W - Control unit:..........................................max. 10 VA

Boiler Model Natural gas and LPG SCtSaArt-iunppuatnd Maintenance
CSA output/DOE*1 heating capacity Net I=B=R rating*2 Heat exchanger surface area
Min. gas supply pressure Natural gas LPG Max. gas supply pressure*3 Natural gas and LPG A.F.U.E. Weight
SSthairptp-uinpgawndeigMhatintenance
Boiler water content
Boiler max. flow rate*4
MAWP (max. allowable working pressure) at 210ºF (99ºC) Boiler water temperature - Adjustable high limit (AHL) range
space heating (steady state) DHW production (set-point)
- Fixed high limit (FHL) Boiler connections Boiler heating supply and return Pressure relief valve Drain valve

Model No.
MBH kW
MBH kW
MBH ft.2 m2
"w.c. "w.c.
"w.c. % lbs kg lbs kg
USG L
GPM L/hr.
psig bar
ºF (ºC) ºF (ºC)
ºF (ºC)
NPTM (male) " NPTF (female) " (male thread) "

WB1B 26
37-91 10.8-26.7
34-83 9.9-24.3
72 10.23
0.95
4 10
14 94.0
78 34.1
95 43 0.87 3.3 6.2 1400
45 3

Standard heating boiler WB1B 35
37-118 10.8-34.6
34-108 9.9-31.6
94 10.23
0.95
4 10
14 94.0
78 34.1
95 43 0.87 3.3 6.2 1400
45 3

86 to 176 (30 to 80) 176 (80)
210 (99)

*1 Output based on 140ºF (60ºC), 120ºF (49ºC) system supply / return temperature. *2 Net I=B=R rating based on piping and pick-up allowance of 1.15. *3 If the gas supply pressure exceeds the maximum gas supply pressure value, a separate gas pressure regulator must
be installed upstream of the heating system. *4 See "Typical System Flow Rates" on page 36 in this manual.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Technical Data (continued)

Additional Information

Boiler Model Dimensions Overall depth
Overall width
Overall height
Gas supply connection
Flue gas*5 Temperature at boiler return temperature of 86ºF (30ºC) - at rated full load - at rated partial load Temperature at boiler return temperature of 140ºF (60ºC) Flue gas value Mass flow rate (of flue gas)

Model No.
inches mm
inches mm
inches mm
NPTF (female)"
ºF (ºC) ºF (ºC)
ºF (ºC)

WB1B 26
14d 360 15c 400 28b 725
c"

Standard heating boiler WB1B 35
14d 360 15c 400 28b 725
c"

127 (53) 90 (32)
167 (75)

131 (55) 90 (32)
172 (78)

- at rated full load - at rated partial load

lbs/h kg/h lbs/h kg/h

79.2 36.0 33.0 15.0

100.1 45.5 33.0 15.0

Available draught
Flue gas temperature sensor limit Average condensate flow rate*6 with natural gas - TS/TR =122 / 86ºF (50 / 30ºC)
Condensate connection*7
Boiler flue gas connection*8 Combustion air supply connection*8 Noise level (at 1 meter) - at full load - at partial load High altitude (factory set)*9

Pa mbar
ºF (ºC)
USG/day L/day hose nozzle Ø in. Ø
in. (mm) outer
Ø in (mm)
(dB) (dB) ft. (m)

100 1.0 230 (110)
1.95-2.3 8-9
1" 2e (60) 4 (100)
47 40 0-5,000 (0-1,500)

100 1.0 230 (110)
2.5-2.8 9.4-10.5
1" 2e (60) 4 (100)
49 42 0-5,000 (0-1,500)

*5 Measured flue gas temperature with a combustion air temperature of 68°F (20°C). *6 Based on typical boiler cycles, including partial load conditions. *7 Requires 1"(25 mm) tubing. See Vitodens 100-W Installation Instructions for details. *8 For detailed information refer to the Vitodens Venting System Installation Instructions. *9 For 5,000 to 10,000 ft. (1,500 to 3,048 m) operation, a coding address change is required. Refer to the Installation
and Service Instructions for details. For information regarding other Viessmann System Technology componentry, please reference documentation of
respective product.

5600 332 - 13

Additional Information
Technical Data (continued)

Vitodens 100-W, WB1B CombiPlus Installation & Service

Integrated with the Boiler DHW supply temperature Continuous draw rate 1 with DCW temp. of 56ºF (13ºC) Continuous draw rate 2 at t= 63ºF (35K) Maximum allowable working pressure (potable water) Test pressure Connections, DHW and DCW Connections to boiler supply/return and to heating supply/return Dimensions Overall depth
Overall width
Overall height
Height with pipe connector
Integrated pump flow rate DHW production @ 23 ft. (9.8 m) Head pressure
Heating system operation with system side additional drop in pressure of max. 6 ft. of water (1.8 m) Weight

Model No. ºF (ºC) USG/h L/h USG/h L/h
psi psi NPTM (male) " NPTM (male) "
inches mm
inches mm
inches mm
inches mm
USG/min. L/h
USG/min. L/h lbs kg

WB1B 26 140 (60)
99 374 156 589
150 300
b c
9.8 250
17 432 8.7 223
13 331
5.63 1278
6.2 1408
25 11

CombiPLUS Kit
WB1B 35 140 (60)
147 556 216 800
150 300
b c
9.8 250
17 432 8.7 223
13 331
5.63 1278
6.2 1408
25 11

1 Based on boiler max. output and boiler supply temperature of 176ºF (80ºC). 2 DCW and DHW temperature rise would be proportional. Maximum DHW supply temperature is 140ºF (60ºC).

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Burner Program Sequence of Operation

Additional Information

7: Forced low fire
8: coBnu9tr:rnolelreirnaoctpievreation: ctSlvteoPOaasC:slton1oevsrd0te-:mtbbppeiryusnrotagotfieoosnfpegeasd

6: tiFlmaeme stabilization

tiImginnitgion / safety

time

Pre-ignition 5:

O: Stand-by
1: tRe3PSs:Mtt2aMa:(xnisvdae-mfrsiuetftiilmlycasbctltihoaoetnwcueksr) Pre-purge

Call for heat

Fan control
Fan required signal Ignition
Combination gas valve
FSlatmaerts-iugnpaland Maintenance

>1500 rpm

Sequence time

max. 70 s *1 max. 20 s

0.9 s

Transition

0.3 s

>1500 rpm

min. 4.2 s max. 4.8 s

5 s

0.12 s

Modulation range

1.4 s *2

*1 50 seconds for no flame present check and 20 seconds for blower stand-stil check (total 70 seconds). *2 20 second fan operation if flame failure is detected.

Phase Explanation

Stand by

Stand-still status test (safety check)

Maximum blower RPM verification

Pre-purge

S4tart-up anPdreM-iganinittieonnanticmee

Ignition / safety timing

Flame stabilization time

Forced low-fire

Burner in operation: controller active

Post-purge

Combination gas valve proof of closure test

Boiler shutdown / stand-by

End of sequence Continue to next phase Safety shutdown Continue to next phase Continue to next phase Retrial for ignition or safety shutdown Continue to next phase Continue to next phase Continue to next phase Continue, or if FHL tripped, 15 minute forced fan operation Continue to next phase Continue to next phase Waiting for next call for heat

5600 332 - 13

Additional Information

Vitodens 100-W, WB1B CombiPlus Installation & Service

Burner Program Sequence of Operation (continued)

Phase 0: Stand by Complete shutdown until the next call for heat. In this phase both the combination gas valve and the blower are not energized.

Phase 7: Forced low-fire The controller will go into low-fire until required modulation signal (high-low) is processed (e.g. boiler actual water temperature).

Phase 1: Stand-still status test (blower) A call for heat initiates internal blower sensory communications to confirm that the blower is truly in stand-still position. Blower speed measured must be < 300 rpm within a 70 second period.

Phase 8: Burner operation At the end of the flame stabilization period (5 sec.), a release for modulation occurs and the burner temperature controller will take over from the flame safeguard. Forced shutdown after 24 hours continuous operation.

Phase 2: Pre-purge speed test Controller sends and receives signal to / from fan speed controller to verify maximum rpm of the blower.
Phase 3: Pre-purge Pre-purge cycle starts within the pre-programmed timing. Pre-purge timing is in addition to previous phase (2). The fan speed must be greater than 1500 rpm.
Phase 4: Pre-ignition The ignition spark is initiated and controlled.
Phase 5: Ignition / safety timing The gas valve opens during the safety timing period (4.8 secs.). If a flame is detected, this phase ends immediately in < 4.8 secs. If the flame is not established after 3 trials, the burner will lock out and will require a manual reset.

Phase 9: Post-purge speed test Both gas valves are closed during this phase. End call for heat. Post-purge occurs during the programmed period. If the fixed high limit trips during normal operation, the blower will purge for 15 minutes to cool the heat exchanger.
Phase 10: Combination gas valve proof of closure test If during the normal operation of the burner a controlled (or uncontrolled) shut-down occurs, a complete mechanical and electrical gas valve proof of closure test will be performed by the flame safeguard. After a successful mechanical and electrical proof of closure test, the flame safeguard will expect that the flame is not present. If, however, the flame existed for a period of >30 seconds, the flame safeguard will go into permanent lock-out.

Phase 6: Flame stabilization Controller required time for flame stabilization.

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Wiring Diagram - Natural gas / Propane

Additional Information

5600 332 - 13

Additional Information
Service Function Overview

Vitodens 100-W, WB1B CombiPlus Installation & Service

Service / Function
Filling
Relay Test
Red. Max. Heat
Capacity Eco
Comfort
Boiler with or without Combi Plus

Addition / Condition
-
Activated Relay Test -

Selector Position /

Dial

Selection

Selector

Dial Left

Selector

Dial Right

Selector

Dial Right

Selector

Dial Left

Selector

Dial Right

r + w

Mid-

Position

Activation Sequence

Selector Position / Selector Dial Selection Dial

Control

Range

Control

Range

Control

Range

3.
Position / Selection
-
Position 1 And Below Minimum
Load
Between 1 And 6 Selected Inputs
Position 6 And Above Full Input
-

SERV Static SERV
Static SERV
Static SERV Static SERV + A Static

Display
r + w Static A
Static A
Static A
Static <<<
Flashing

Control

Range

SERV

ECO

momentary Static

Control

Range

SERV COMFORT

momentary Static

Left Control SERV

Right

Control

Range Without

Static

Range

Combi Plus

w Static

Right Control Range With Combi Plus

SERV Static

w Static

-
<
Flashing <<<
Flashing <<<<<
Flashing
-.-.-
Flash 0
Flashing
1
Flashing

Left Control SERV

Gas

r + w

Mid-

Left

Position

Control

Range Natural Gas

Static

Static Flashing

Range

Right Control SERV

Range Propane Gas

Static

Static Flashing

Left Control SERV

High Altitude

r + w

Mid-

Right

Range

Static

Static Flashing

Position

Control

0 - 5000 ft.

Adjustment

Range

Right Control SERV

Range 5000 - 10000 ft.

Static

Static Flashing

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Parts List

Model No. WB1B 26 WB1B 35

Serial No. 7374861 7374862

WB1B 26c WB1B 35c

7457960 7457961

Ordering Replacement Parts:
Please provide Model and Serial Number from rating plate A when ordering replacement parts. Order replacement
components from your Viessmann distributor.

Parts 007 022 050 051 052 053 054 055 056 057 058 059 060 061 062
087

Gas connection pipe Front panel Burner gasket, d=187 x 5.5 mm Combustion chamber door refractory Burner tube Gasket for burner tube Ignition+ionization electrode block Gasket for electrode block Radial fan NRG118-CVI,120/1/60 Gas valve/Venturi assembly, 120/1/60 Burner mounting flange assembly Venturi extension Gasket for radial fan Gasket set for gas connection pipe Gasket set for gas valve / Venturi assembly Flip-down cover

Other Parts (not illustrated) 090 Hinges for control housing (set of 10) 107 Touch-up spray paint "Vitowhite" 108 Touch-up paint stick "Vitowhite" 109 Conversion kit, NG > LPG 110 Conversion kit, LPG > NG 400 Installation fittings (see separate Parts List) 420 Installation / Service Instructions 421 Operating Instructions 422 Installation Instructions, Venting System 423 Warranty Sheet Condensing 424 Parts List

A CSA rating plate

Additional Information

5600 332 - 13

Additional Information
Parts List (continued)
Parts 001 Heat exchanger assembly, ASME 002 Heat exchanger connection pipe (supply) 003 Heat exchanger connection pipe (return) 004 Spring clips (set) 006 Fastener set (return pipe) 009 Vent pipe adaptor 010 P-Trap 011 Gasket for flue gases 012 Air intake cover 013 Air intake cap 014 Test port cap (set of 2) 015 Wall-mount bracket 016 Combustion chamber refractory 0S1t7art-uCpoannddenMsaatinetepnipaence 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 set for heat exchanger 030 Heating supply connection pipe 031 Heating return connection pipe 070 Heating return connection elbow
including air vent (027) 0S8t2art-uFpixaenddhMigahinlitmenita,n2c1e0ºF (99ºC) 083 Boiler sensor 084 Flue gas sensor 088 Flow switch VK315M
B ASME Rating plate

Vitodens 100-W, WB1B CombiPlus Installation & Service

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Parts List (continued)
Parts 008 Pressure gage (PSI) 080 Control console 081 Control console cover 085 Fuse, 2.5A/250V (pkg of 10)
(for control console 080) 086 Power/Pump control module
Other Parts (not illustrated) 089 Fuse, 6.3A/250V (pkg of 10)
(for 086 Power/pump control module) 063 Control bracket 101 Wiring harness, X20 102 Connecting cable No. 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

Additional Information

Installation fittings Parts 0414 Pressure relief valve 0402 Nipple, c" x 2" 0403 Sediment fauset 0404 Tee, c" 0405 Nipple, c" x 3b" 0406 Gas ball valve, c" 0407 Extension, c" x 3"
Other Parts (not illustrated) 0410 Accessory pack (metal stud mount kit) 0413 Outdoor temperature sensor 0416 Temperature gauge 2" 30-250ºF *1 0425 Parts list, Installation fittings
*1 Install anywhere in supply piping near boiler A Vitodens boiler see separate parts list and
for CombiPLUS Kit see separate parts list
95

5600 332 - 13

Additional Information
Parts List (continued)

CombiPLUS Kit Part No. 7459 305

Model No. WB1B 26c WB1B 35c

Serial No. 7457960 7457961

Ordering Replacement Parts: Please provide Model and Serial Number *1 when ordering replacement parts. Order replacement components from your Viessmann distributor.

Parts
010 Cover panel 020 Bottom panel 101 Nipple, c in. HEX 102 Flex pipe, c in. x 7 in. 103 Flex pipe, c in. x 12 in. 104 Connectors (set of 2)
with clips and O-rings 105 Sealing grommet 106 Accessory pack, anchors
(set of 4) 107 Pressure relief valve, c in. 150 psig 108 Tee, c in. brass 109 Gaskets, assortment of b in., c in. 110 Adaptor,
G c" F x NPT c" M 111 Adaptor,
G b in. F x NPT b in. M 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 set)
400 Installation / Service Instructions 401 Quick Start-up Guide 402 Parts List 403 Installation Template 404 Touch-up spray paint "Vitowhite" 405 Touch-up paint stick "Vitowhite"

*1 Serial no. is located on bottom of unit. See separate parts list for boiler.

Vitodens 100-W, WB1B CombiPlus Installation & Service

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Parts List (continued)
Parts 323 Accessory pack, plugs, clips
(340 and 344), and O-rings 330 Replacement powerhead,
UPS15-78, 115/1/60 331 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) 3S4t4art-upCalinpdSMIVaisnpteencaianlc(eset 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) 392 Diverter valve assembly
Start-up and Maintenance

Additional Information

5600 332 - 13

Additional Information
Maintenance Record

Measurements Static pressure

Service date:
by: "w.c.

Running pressure (supply pressure)

Natural gas Liquid Propane gas

"w.c. "w.c.

Carbon dioxide content CO2

at lower end of rated input range vol.-% (low-fire)

at upper end of rated input range vol.-% (high-fire)

Oxygen content O2
at lower end of rated input range vol.-% (low-fire)
at upper end of rated input range vol.-% (high-fire)

Carbon monoxide content CO at lower end of rated input range
at upper end of rated input range

ppm ppm

Service date:
by:

Setpoint value max. 14 "w.c. 4-14 "w.c. 10-14 "w.c.
Never exceed 50 ppm air-free Never exceed 200 ppm air-free

Vitodens 100-W, WB1B CombiPlus Installation & Service

5600 332 - 13

Vitodens 100-W, WB1B CombiPlus Installation & Service
Lighting and Operating Instructions

Additional Information

FOR YOUR SAFETY READ BEFORE OPERATING

W A R N I N G: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.
B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS · Do not try to light any appliance. · Do not touch any electric switch; do not use any phone in your building. · Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. · If you cannot reach your gas supplier, call the fire department.

C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and 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.

5. Close main gas shut-off valve.
6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to the next step.

4. This appliance is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand.

7. Open main gas shut-off valve. 8. Turn on all electric power to the appliance.

Manual gas shutoff

9. Set thermostat or other operating control to desired setting.

Closed

10. If the appliance will not operate, follow the instructions "To Turn Off Gas To Appliance" and call your service technician or gas supplier.

Open
TO TURN OFF GAS TO APPLIANCE
1. Set thermostat or other operating control to lowest setting. 2. Turn off all electric power to the appliance if service is to be performed. 3. Close main gas shut-off valve.

5600 332 - 13

Technical information subject to change without notice.

Printed on environmentally friendly (recycled and recyclable) paper.

Vitodens 100-W, WB1B Operating & User's Information

References

Acrobat Distiller 10.0.0 (Windows)