VITODENS 100-W
Installation and Service
Instructions
for use by heating contractor
Vitodens 100-W
WB1A Series
Wall-mounted, natural gas-fired condensing boiler
For natural gas
Heating input 29 to 100 MBH
8.5 to 29.3 kW
Read and save these instructions
for future reference.
IMPORTANT
Vitodens 100-W, WB1A
(with preinstalled coaxial vent pipe
adaptor)
Please file in Service Binder
5581 775 v1.3 08/2009
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Safety, Installation and Warranty Requirements
2
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).
H Licensed professional heating
contractor
The installation, service, and
maintenance of this equipment must
be performed by a licensed
professional heating contractor.
"
Please see section
entitled “Important
Regulatory and
Installation
Requirements” in the
Installation Instructions.
H 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
Installation Requirements”
in the Installation Instructions.
H Advice to owner
Once the installation work is
complete, the heating contractor
must familiarize the system
operator/ultimate owner with all
equipment, as well as safety
precautions/requirements, shut-down
procedure, and the need for
professional service annually before
the heating season begins.
H Carbon monoxide
Improper installation, 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, service and
maintenance of this
equipment to avoid
formation of carbon monoxide, please
see the Installation Instructions of the
Vitodens Venting System.
H Equipment venting
Never operate boiler without an
installed venting system. An improper
venting system can cause carbon
monoxide poisoning.
H Warranty
Information contained in
this and related product
documentation must be
read and followed. Failure
to do so may render
warranty null and void.
5581 775 1.3
Installers must follow local
regulations with respect to
installation of carbon monoxide
detectors. Follow manufacturer’s
maintenance schedule of boiler.
WARNING
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Index
3
Page
Safety
Important Regulatory and Installation Requirements 5
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General Information
About these Installation Instructions 8
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Applicability 9
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Product Information 9
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Mechanical Room 10
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Set-up
Before Set-up 12
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Minimum Clearances 12
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Boiler Connections
Preparing the Connections 13
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Connections overview 13
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Dimensions overview without bottom connections 13
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Dimensions overview with connections 13
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Dimensions overview with connections and alternative drain
connection 13
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Wall Mounting 16
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Wall mounting bracket installation 16
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Mounting Vitodens 100-W boiler 18
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Connections 18
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Flue gas connection 18
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Proper piping practice 19
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Gas connection and piping 19
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Gas piping pressure test 21
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Heating water connections 22
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Condensate connection 23
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Fill siphon with water 23
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Safety Connections and Pressure Testing 24
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Installing safety devices on the boiler 24
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Performing pressure test on the boiler 25
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Installation Examples 26
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Boiler in heating/cooling application 34
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Boiler with low water cut-off (remote mounted, field supplied) 35
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Low-loss header 36
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Venting Connection 37
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Control Connections
Electrical Connections 37
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Removing the control unit and opening
the power pump module 37
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Electrical connections to the power pump module 38
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Closing the power pump module and reinstalling the
control unit 39
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Reinstalling the front cover panel 39
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5581 775 1.3
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4
Initial Start-up,
Inspection and Maintenance
Necessary Tools 40
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Overview of Controls and Indicators 41
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Overview of Components 43
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Procedure (Overview) 44
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Steps 45
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Troubleshooting
Troubleshooting Steps 60
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Overview of Controls and Indicators 60
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Changing Room Temperature 61
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Diagnosis 62
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Sequence of operation and potential faults during each
start-up cycle 62
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Diagnostics table: Faults with fault display on control unit 63
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Correction 65
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Remove front cover panel 65
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Check boiler temperature sensor 65
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Check fixed high limit 66
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Check fuses 67
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Additional Information
Technical Data 68
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Burner Program Sequence of Operation 70
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Wiring Diagram 71
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Parts List 72
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Maintenance Record 74
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Lighting and Operating Instructions 75
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5581 775 1.3
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Safety
5
Important Regulatory and Installation Requirements
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.
Special Requirements for Side-Wall Vented Appliances
In the Commonwealth of Massachusetts
The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of
side-wall vented gas appliances as follows:
(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 gasfitter 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 gasfitter 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.
Continued on following page.
5581 775 1.3
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Safety
6
Important Regulatory and Installation Requirements
(continued)
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.
(c) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM PROVIDED. When the manufacturer of
Product Approved side-wall horizontally vented gas equipment provides a venting system design or venting system
components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the
venting system shall include:
1. Detailed instructions for the installation of venting system design or the venting system components; and
2. A complete parts list for the venting system design or venting system.
(d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a
Product Approved side-wall horizontally vented gas fueled equipment does not provide the parts for venting the flue
gases, but identifies ”special venting systems”, the following requirements shall be satisfied by the manufacturer:
1. The referenced ”special venting system” instructions shall be included with the appliance or equipment installation
instructions; and
2. The ”special venting systems” shall be Product Approved by the Board, and the instructions for that system shall
include a parts list and detailed installation instructions.
(e) A copy of all installation instructions for all Product Approved side-wall horizontally vented gas fueled equipment, all
venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the
appliance or equipment at the completion of the installation.
5581 775 1.3
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Safety
7
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.
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.
The completeness and functionality of
field supplied electrical controls and
components must be verified by the
heating contractor. This includes low
water cut-offs, flow switches (if used),
staging controls, pumps, motorized
valves, air vents, thermostats, etc.
Technical literature
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
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.
5581 775 1.3
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General Information
8
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.
Warnings draw your attention to the
presence of potential hazards or
important product information.
Cautions draw your attention to the
presence of potential hazards or
important product information.
Helpful hints for installation,
operation or maintenance which
pertain to the product.
This symbol indicates that additional,
pertinent information is to be found in
column three.
This symbol indicates that other
instructions must be referenced.
5581 775 1.3
Indicates an imminently hazardous
situation which, if not avoided, could
result in death, serious injury or
substantial product/property damage.
WARNING
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or
product/property damage.
CAUTION
IMPORTANT
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General Information
9
Applicability
Boiler serial number must be provided
when ordering replacement parts.
Both the 16-digit serial number bar
code paper label and the 12-digit
ASME/NB serial number correlate to
each other. Providing either serial
number is sufficient.
Vitodens 100-W, WB1A 8-24, 8-30
Model No. Serial No.
WB1A 8-24 7246174
and
WB1A 8-30 7246175
Product Information
Natural gas-fired wall-mounted hot water heating boiler for space heating.
For operation with constant (set point) boiler water temperatures in closed loop,
forced circulation hot water heating circuits. An external controller is required for
outdoor responsive control and DHW production.
The Vitodens 100-W comes factory set for operation with natural gas, with no
option of conversion to liquid propane.
Boiler model must be selected based on an accurate heat loss calculation of the
building. Ensure boiler model is compatible with connected radiation.
Vitodens 100 boilers are 100% factory tested and calibrated. No further
adjustments are required during field start-up.
To vent this boiler, follow the Vitodens Venting System Installation Instructions.
5581 775 1.3
IMPORTANT
Serial No. location (16-digit
barcode white paper label
located on the left or right
side of the boiler)
ASME/NB stamp serial
number location (12-digit
metallic plate riveted on the
heat exchanger)
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General Information
10
Mechanical Room
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 68 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.
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.
5581 775 1.3
IMPORTANT
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General Information
11
Mechanical Room
(continued)
Installation area conditions
H Ensure ambient temperatures are
higher than 32°F / 0°C and lower
than
104°F / 40°C.
H Prevent the air from becoming
contaminated by halogenated
hydrocarbons (e.g. as contained in
paints 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.
H Avoid continuously high levels of
humidity (e.g. through frequent
drying of laundry).
H Never close existing ventilation
openings.
Sources of combustion and ventilation
air contaminants
Areas likely to contain contaminants:
H New building construction
H Swimming pools
H Remodelling areas, hobby rooms
H Garages with workshops
H Furniture refinishing areas
H Dry cleaning/laundry areas and
establishments
H Auto body shops
H Refrigeration repair shops
H Metal fabrication plants
H Plastic manufacturing plants
H Photo processing plants
H Beauty salons
Products containing contaminants:
H Chlorine-type bleaches, detergents
and cleaning solvents found in
household laundry rooms
H Paint and varnish removers
H Hydrochloric acid, muriatic acid
H Chlorine-based swimming pool
chemicals
H Spray cans containing
chlorofluorocarbons
H Chlorinated waxes and cleaners
H Cements and glues
H Refrigerant leaks
H Calcium chloride used for thawing
H Sodium chloride used for water
softening salt
H Permanent wave solutions
H Adhesives used to fasten building
products and other similar items
H Antistatic fabric softeners used in
clothes dryers
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!
HHHH Shut down the boiler
HHHH Close fuel shut-off valves
HHHH 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.
WARNING
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General Information/Set-up
12
Before Set-up
Before placing boiler in its installation
location, ensure all necessary
accessories are installed.
Minimum Clearances
Recommended minimum service clearances
Refer to the illustrations on the left hand side.
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 4.9.2005 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.
Clearances to combustibles
Top Front Rear Left Right Vent pipe
*1
0 0 AL, CL 0 0 0 0
AL = Alcove
CL = Closet
*1
Refer to the Installation Instructions of the Vitodens
Venting System for details.
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.
CAUTION
Top clearance -
12”.
See Vitodens
Venting System
Installation
Instructions.
12”/300 mm
*
4”/100 mm
28”/
700 mm
¼”/5 mm ¼”/5 mm¼”/5 mm
Front
12”/305 mm
Top
*
12”/305 mm
0”/mm
28”/700 mm
Side
0”/mm
Back
Sid
e
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Boiler Connections
13
Preparing the Connections
Use an approved pipe sealant or teflon tape when
connecting the following installation fittings.
Connections overview
This section constitutes an overview only! Refer to subsequent sections for
detailed information on individual piping connections.
Piping connections for Vitodens
100-W, WB1A 8-24 and 8-30 (factory
supplied)
Legend
BWR Boiler water return, ¾”
BWS Boiler water supply, ¾”
BD Boiler drain
BF Boiler fill
GC Gas connection, ¾” NPTM
(male thread)
PRV Pressure relief valve
NPT National Pipe Thread
PG Pressure gage
VC Vent connection
5581 775 1.3
BWS
BWR
NPT
GC
PRV
BD
PG
BF
VC
NPT
NPT
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Boiler Connections
14
Preparing the Connections
(continued)
Dimensions overview without bottom connections
Connections Vitodens 100-W,
WB1A 8-24, 8-30
Legend
Boiler water supply, NPT ¾” (male
thread)
Condensate drain, plastic hose
Ø 0.87” / 22mm
Gas connection, NPT ¾” (male
thread)
Boiler water return, NPT ¾” (male
thread)
a 7” / 180 mm
b 15¾” / 400 mm
c 2¼” or 27/16” / 58 mm or 62 mm
d 27½” / 700 mm
e 47/8” / 123 mm
f 7¼” / 183 mm
g 133/8” / 340 mm
h 5” / 125 mm
Vitodens 100-W, WB1A
side view
When preparing gas, water
and electrical connections in
the field, see section entitled
“Wall Mounting” on page 16
of this manual for information
regarding the installation of
the wall mounting bracket.
The maximum ambient temperature
must not exceed 104 ºF/40 ºC.
H Heating water connections and gas
connection to be made in the field.
See illustration to the left and
connection-specific section for
details.
H See subsection entitled “Power
supply connection” for details
regarding power supply to the
Vitodens 100-W boiler.
5581 775 1.3
d
c
h
e
g
a f
b
e
IMPORTANT
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Boiler Connections
15
Preparing the Connections
(continued)
Dimensions overview with connections
This section constitutes an overview only! Refer to subsequent sections for
detailed information on individual piping connections.
Piping connections for Vitodens
100-W, WB1A 8-24 and 8-30 (factory
supplied)
Legend
BWR Boiler water return, ¾”
BWS Boiler water supply, ¾”
BD Boiler drain
BF Boiler fill
GC Gas connection, ¾” NPTM
(male thread)
PRV Pressure relief valve
PG Pressure gage
VC Venting connection
5581 775 1.3
14” /
355mm
15¾” /
400mm
27/8” / 73mm
5
3
/
8
” / 137mm
27½” / 700mm
33” / 838mm
12” / 300mm
2¼”
or
27/16”
/
58mm
or
62 mm
6” /
152mm
47/8” /
123mm
47/8” /
123mm
VC
PRV
BD
GC
PG
BF
BWS
BWR
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Boiler Connections
16
Wall Mounting
Wall mounting bracket installation
Legend
Mounting template
Finished floor level
Dimensions
a 12” / 300mm
b min. 45” / 1143mm
The Vitodens 100-W can be
wall-mounted on
H a brick/concrete wall
H wood studs
H metal studs
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 (Ø3/8”/10 mm), using
mounting template supplied with the
boiler.
2. Align wall mounting bracket and
attach to wall with the screws and
plastic anchors supplied.
5581 775 1.3
Ø3/8” /
10mm
2x
1.
2.
a
b
Whichever mounting method is used,
ensure that the bracket is tightly and
securely fastened to wall. Failure to
secure boiler properly could cause
boiler to loosen, posing a severe
safety hazard.
CAUTION
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Boiler Connections
Installation of mounting bracket
a
a = 16”/407 mm
Installation of mounting bracket on wood studs
16”/407 mm
3/16”
2x
Installation of mounting bracket on metal studs
5/8”
2x
16”/407 mm
17
Wall Mounting
(continued)
Mounting bracket installation (continued)
Installation of mounting bracket on
wood and metal studs
To mount the Vitodens 100-W boiler
on wood or metal studs, install
mounting bracket on wall as shown on
previous page.
Refer to drawings on the left and
below for more detailed installation
information.
Install mounting bracket on wood studs
as per illustration.
Drill3/16” pilot holes to insert mounting
bolts.
Ensure that holes are located in the
center of each wood stud.
Install mounting bracket on metal studs
as per illustration.
Drill5/8” pilot holes to insert mounting
bolts.
Ensure that holes are located in the
center of each metal stud.
Secure mounting bracket with bolts to
metal studs as shown.
5581 775 1.3
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Boiler Connections
Boiler Connections
18
Wall Mounting
(continued)
Mounting Vitodens 100-W boiler
1. Remove the screw at the top of
boiler.
2. Press down on springs at bottom of
boiler and remove the front
enclosure panel.
3. Remove front enclosure panel.
4. Mount boiler onto the mounting
bracket.
For installation of the
mounting bracket, see
subsection entitled “Wall
mounting bracket
installation” on page 16 of
this manual.
Connections
Flue gas connection
Combustion air
Flue gases
The Vitodens 100-W boiler comes with
a preinstalled vent pipe adaptor (as
shown).
Run venting system, single-pipe,
double-pipe or coaxial, through the side
wall or the roof, taking the shortest
possible route and at a rising angle
(min. 3º).
Read and follow the
Installation Instructions
Vitodens Venting System for
details.
5581 775 1.35581 775 1.3
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Boiler Connections
19
Connections
(continued)
Proper piping practice
Support piping by proper suspension
method. Piping must not rest on or be
supported by boiler.
Gas connection and piping
Legend
Water supply connection
Condensate drain connection
Gas connection
Water return connection
1. Make gas connection in accordance
with codes CAN/CSA B149.1 or
National Fuel Gas Code ANSI
Z223.1/NFPA 54, as well as local
codes where applicable.
2. Close gas shutoff valve on boiler.
3. Perform leak test.
4. Bleed air from gas supply pipe.
See following page for details on gas
connection and piping.
5581 775 1.3
Usemoderateamountofdope
Leave 2 end threads bare
hread pipe right length
2imperfectthreads
¨
zz
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Boiler Connections
20
Connections
(continued)
Gas connection and piping (continued)
Legend
Gas connection
Accessible manual gas shutoff
(factory supplied)
Drip leg
Max. gas supply pressure: 14 “w.c.
1. Refer to current CAN/CSA B149.1 or
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.
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.
5581 775 1.35581 775 1.3
IMPORTANT
The gas supply piping must be leak
tested before placing the boiler in
operation.
WARNING
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.
CAUTION
IMPORTANT
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Boiler Connections
21
Connections
(continued)
Gas piping pressure test
When performing the gas piping pressure test, ensure the following requirements are
met.
½ psig = 14 ”w.c.
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.
5581 775 1.3
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.
WARNING
IMPORTANT
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Boiler Connections
22
Connections
(continued)
Heating water connections
Legend
BWR Boiler water return, ¾”
BWS Boiler water supply, ¾”
BD Boiler drain
BF Boiler fill
GC Gas connection, ¾” NPTM
PRV Pressure relief valve
NPT National Pipe Thread
PG Pressure gage
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
. . . .. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . .. . . .
Damage resulting from pressure
exceeding those values stated is not
covered by Viessmann warranty.
H Use a two-hand wrench method
when tightening fittings or piping
onto the boiler connectors. Use one
wrench to prevent the boiler pipes
from 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.
H All plumbing must meet or exceed all
local state and national plumbing
codes.
SUPPORT ALL PIPING USING
HANGERS. DO NOT support piping by
the unit or its components.
H Use isolation valves to isolate system
components.
5581 775 1.35581 775 1.3
BWS
BWR
NPT
GC
PRV
BD
PG
BF
IMPORTANT
IMPORTANT
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Boiler Connections
23
Connections
(continued)
Condensate connection
Flexible discharge tubing
Discharge tubing
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)
Pipe ventilation must take place
between the siphon trap and the
neutralization unit (if applicable).
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.
5581 775 1.3
IMPORTANT
IMPORTANT
At initial start-up, flue gases may be
emitted from the condensate drain.
Fill the siphon with water before
start-up.
WARNING
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