Viessmann FB2A Operating instructions

Installation and service
instructions
for contractors
VIESMANN
Vitodens 242-F
Type FB2A
Compact Energy Tower with a gas condensing boiler
4.8 to 26 kW natural gas and LPG version
G.C. no: 47-819-18 (19 kW)
G.C. no: 47-819-19 (26kW)
For applicability, see the last page
VITODENS 242-F
5418 193 GB 6/2009 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on gas equipment must only be
carried out by a qualified gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental protection,
■ the Code of Practice of relevant trade
associations,
■ all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical appli-
ances ON or OFF.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
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3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the
living space.
Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which ful-
fil a safety function can compro-
mise the safe operation of your
heating system.
Replace faulty components only
with original Viessmann spare
parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
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4
Installation instructions
Preparing for installation
Product information.............................................................................................. 6
Preparing for installation....................................................................................... 6
Installation sequence
Installing the boiler............................................................................................... 10
Opening the control unit casing............................................................................ 15
Electrical connections........................................................................................... 16
Closing the control unit casing............................................................................. 20
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 22
Further details regarding the individual steps....................................................... 24
Code 1
Calling up code 1.................................................................................................. 61
General................................................................................................................. 61
Boiler.................................................................................................................... 63
DHW..................................................................................................................... 66
Solar..................................................................................................................... 66
Heating circuit 1/heating circuit 2......................................................................... 67
Code 2
Calling up coding level 2...................................................................................... 72
General................................................................................................................. 72
Boiler.................................................................................................................... 74
DHW..................................................................................................................... 75
Solar..................................................................................................................... 76
Heating circuit 1/heating circuit 2......................................................................... 78
Diagnosis and service scans
Diagnosis.............................................................................................................. 81
Checking outputs (relay test)................................................................................ 83
Troubleshooting
Fault display......................................................................................................... 85
Fault codes........................................................................................................... 86
Repairs................................................................................................................. 93
Index
Index
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5
Function description
Internal extensions............................................................................................... 108
External extensions (accessories)........................................................................ 110
Control functions.................................................................................................. 112
Remote control DIP switches............................................................................... 118
Electronic combustion controller.......................................................................... 119
Designs
Internal connection diagram................................................................................. 121
External connection diagram................................................................................ 122
Connection diagram solar control module............................................................ 124
Parts lists............................................................................................................ 125
Commissioning/service reports........................................................................ 135
Specification....................................................................................................... 136
Certificates
Declaration of conformity...................................................................................... 137
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 138
Keyword index.................................................................................................... 139
Index
Index (cont.)
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Vitodens 242-F, FB2A
Set up for operation with natural gas H.
For conversion to LPG P (without conversion kit), see page 30.
The Vitodens 242-F should generally only be delivered to those countries specified
on the type plate. For deliveries to alternative countries, an approved contractor, on
his own initiative, must arrange individual approval in accordance with the law of the
land.
Preparing for installation
Transport
If possible, leave the boiler on the pallet
during handling.
If space constraints make it necessary,
the boiler can be split for handling.
Installation instructions provided
!Please note
To prevent equipment damage,
never set the boiler down on
its front or side panels or apply
loads to these areas.
Installation
Required room height: min. 2100 mm and the boiler weight is 161 (19kW) to 165kg
(26kW) (dry).
Preparing the boiler installation
Use a connection set, available as an
accessory, to make the connection on
the gas and water sides. The following
overview shows sample connection sets
for installation on finished walls to the top
or side.
!Please note
To prevent equipment damage,
install all pipework free of load
and torque stresses.
Preparing the connections on site:
Connection set installation
instructions.
Preparing for installation
Product information
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7
65
1996
2008
100
719
46
40
50
1367
1422
1477
1532
1587
1642
1697
1752
1807
1875
1930
1135 1100
140
60
320
370
436
449
440
55
220
330
224
50
595
50
600
C
F
D
A
B
E
G
H
ASolar return R ¾"
BHeating flow R ¾"
CDHW R ½"
DGas connection R ½"
EDHW circulation R ½" (separate
accessory)
FCold water R ½"
GHeating return R ¾"
HSolar flow R ¾"
KCondensate drain to the back into
the wall
LSide condensate drain
MCable entry
NDHW safety valve drain
Preparing for installation
Preparing for installation (cont.)
5418 193 GB
Installation

8
Note
The adjustable feet give all height meas-
urements a tolerance of +15 mm.
1. Prepare the heating water connec-
tions.
Flush the heating system thor-
oughly.
Note
Should an additional diaphragm
expansion vessel be required on site,
connect that vessel into the heating
return.
2. Prepare the DHW connections. Install
the safety assembly (accessory or on-
site provision) in accordance with
The Water Fittings Regulations 1999 in
the cold water line (see page 9).
Recommendation:
Install the safety valve above the DHW
cylinder to protect it against contami-
nation, scaling and high tempera-
tures.
Connect the drain hose to the conden-
sate collector. Remove plug from con-
densate collector.
3. Route condensate hose O to the
back (drain in wall K) or to the side
aperture L (see page 6).
Route condensate hose with a U-
bend and connect to on-site drain line
or siphon. Discharge pipes from
expansion valves (safety valve)
should not be connected directly to a
drain and should pass through a visi-
ble tundish, with a AUK3 air gap, and
be located adjacent to the device.
Preparing for installation
Preparing for installation (cont.)
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4. Prepare the gas connection accord-
ing to TRGI or TRF or all local regu-
lations.
5. Prepare the electrical connections.
■ Power supply cable: NYM-
J 3 x 1.5 mm2, fuse max. 16 A,
230 V/50 Hz.
■ Accessory cables: NYM with the
required number of conductors for
the external connections.
■Allow all cables in area "M" (see
page 7) to protrude 2000 mm from
the wall.
Safety assembly to Water Fittings regulations 1999
ASafety assembly to
Water Fittings regulations 1999 (acces-
sory to connection sets for unfinished
walls)
BSafety valve
CVisible blow-off line outlet
DShut-off valve
EFlow regulating valve (installation rec-
ommended)
FPressure gauge connection
GNon-return valve
HDrain
KCold water
LDrinking water filter
MPressure reducer to Water Fittings reg-
ulations 1999
NNon-return valve/pipe separator
OCold water connection at connection
set (accessory)
Preparing for installation
Preparing for installation (cont.)
5418 193 GB
Installation

10
Assembling the boiler
9.
8.
7.
6.
5.
1.
3.
2x
4.
2.
Installation sequence
Installing the boiler
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Connections on the heating water and the DHW side
Shown with connection sets for finished walls (accessories)
AHeating flow R ¾"
BDHW R ½"
CDHW circulation R ½" (separate
accessory)
DCold water R ½"
EHeating return R ¾"
Fitting the drain outlet and drain line to the T&P valve
Separate installation instructions
Installation sequence
Installing the boiler (cont.)
5418 193 GB
Installation

12
DHW circulation connection
DHW circulation connection with
DHW circulation pump connection
set (accessory)
Separate installation instructions
Connections on the solar side
Shown with connection sets for finished walls (accessories)
ASolar return R ¾" BSolar flow R ¾"
Note
The solar circuit pump is integrated into
the boiler.
Install the expansion vessel, available as
an accessory, in the solar return on
site.
Installation sequence
Installing the boiler (cont.)
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Separate installation instructions
Set the safety valve on the solar side and
the pressure gauge for the solar circuit
on site.
Note
Route the blow-off pipe for the safety
valve on the solar side into a suitable and
adequately sized drip container.
Gas connection
AGas connection R ½"
Notes regarding operation with LPG.
We recommend the installation of an
external safety solenoid valve when
installing the boiler in rooms below
ground level.
1. Fix gas shut-off valve to gas connec-
tion A.
2. Carry out a tightness test.
Installation sequence
Installing the boiler (cont.)
5418 193 GB
Installation

14
Note
For the tightness test, use only suita-
ble and approved leak detecting
agents (EN 14291) and devices.
Leak detecting agents with unsuita-
ble contents (e.g. nitrides, sulphides)
can lead to material damage.
Remove residues of the leak detect-
ing agent after testing.
!Please note
Excessive test pressure may
damage the boiler and the gas
valve.
Max. test pressure 150 mbar.
Where higher pressure is
required for tightness tests,
separate the boiler and the
gas valves from the gas sup-
ply pipe (undo the fitting).
3. Vent the gas line.
For conversion to a different gas type
see page 30
Flue gas connection
Connect the balanced flue. The flue ter-
minals have to be installed as described
in accordance with the Building Regula-
tions Part J and BS 5440.
Flue gas system installation
instructions.
Installation sequence
Installing the boiler (cont.)
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1.
3.
2. 2x
5.
4. 7x
Installation sequence
Opening the control unit casing
5418 193 GB
Installation

16
Information regarding the connection of accessories
For the connection, observe the separate installation instructions provided
with the accessory components.
!Please note
Electronic modules can be damaged by electrostatic discharges.
Before beginning work, touch earthed objects, such as heating or water pipes,
to discharge static loads.
X4
C
D
B
L
M
1~
L N
230V~ 230V~
3217654
X3 40962035100
LN
L1N
2153
%
aVG
?
!
A
N L ?? ? ?
ASolar control module KM BUS con-
nection (connected in the delivered
condition)
BSolar control module power supply
CExternal safety solenoid valve
(LPG)
DCyl. primary pump
Plug 230 V~
sA Cylinder primary pump E (fitted
and connected)
fÖ Power supply
Installation sequence
Electrical connections
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Danger
Incorrect core termination
can cause severe injuries
and damage to the equip-
ment.
Take care not to interchange
cores "L1" and "N".
■ Remove any existing individual
cores.
■ Install an isolator in the power
supply line that simultaneously
isolates all non-earthed conduc-
tors from the mains with at least
3 mm contact separation.
Remove the existing cable grom-
met when using larger cross-sec-
tions (up to 714 mm). Secure the
cable with cable grommet F (see
page 19) integrated into the cas-
ing base.
■ Max. fuse rating 16 A.
gD External safety solenoid valve
(LPG) D
Do not remove jumper between "1"
and "L" when making this connec-
tion.
lH Accessories and solar control mod-
ule power supply
Where the boiler is installed in a wet
area, the connection of accessories
to the power supply must not be car-
ried out at the control unit. The
power supply connection for acces-
sories can be made immediately at
the control unit, if the boiler is instal-
led outside wet areas. This connec-
tion is controlled directly with the
system ON/OFF switch (max. 3 A)
Low voltage plug X3
!Outside temperature sensor (only
for weather-compensated control
units)
Installation:
■ North or north-western wall, 2 to
2.5 m above ground level; in multi-
storey buildings, in the upper half
of the second floor
■ Not above windows, doors or ven-
tilation outlets
■ Not immediately below balconies
or gutters
■ Never render over
■ Cable length max. 35 m with a
cross-section of 1.5 mm2
?Flow temperature sensor for low
loss header (accessories)
%Cylinder temperature sensor (fitted
and connected)
aVG KM BUS subscriber (accessory)
■ Vitotrol 200 or 300 remote con-
trol (only for weather-compensa-
ted control units)
■ Extension kit for one heating cir-
cuit with mixer (only for weather-
compensated control units)
■ External extension H1 or H2
■ Open Therm extension
Installation sequence
Electrical connections (cont.)
5418 193 GB
Installation

18
Connecting the collector temperature sensor
Note
Solar control module A is attached to
the l.h. side of the air box.
B
% &aVG A
%Cylinder temperature sensor (fitted
and connected)
Connect collector temperature sensor
& to terminal box B of the prewired
lead connected to solar control module
A.
On-site extension cable: 2-core, cross-
section 1.5 mm2.
Installation sequence
Electrical connections (cont.)
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Routing the connecting cables
!Please note
Connecting cables will be damaged if they touch hot parts.
When routing and securing power cables on site, ensure that the maximum
permissible temperatures for these cables are not exceeded.
ALow voltage connections
B230 V connections
CInternal extension
DMain PCB
ECommunication module (accesso-
ries)
FCable grommet for power supply
cable
Installation sequence
Electrical connections (cont.)
5418 193 GB
Installation

20
1.
4.
2.
5.
3. 2x
6.
Close control unit casing and insert pro-
gramming unit, packed separately.
Note
The programming unit can also be used
in a wall mounting base (accessory) near
the boiler.
Installation sequence
Closing the control unit casing
5418 193 GB