Viessmann FB2B Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 242-F
Type FB2B, 4.8 to 26 kW
Gas condensing/solar storage combi boiler
Natural gas and LPG version
Gas Council no.:
47-819-18 (19 kW)
47-819-19 (26 kW)
For applicability, see the last page
VITODENS 242-F
5412 755 GB 5/2010 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............................................................................................... 11
Opening the control unit casing............................................................................ 15
Electrical connections........................................................................................... 16
Closing the control unit casing............................................................................. 22
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 24
Further details regarding the individual steps....................................................... 26
Code 1
Calling up coding level 1...................................................................................... 66
General................................................................................................................. 67
Select boiler ......................................................................................................... 69
DHW..................................................................................................................... 70
Solar..................................................................................................................... 70
Heating circuit 1, heating circuit 2, heating circuit 3............................................. 71
Code 2
Calling up coding level 2...................................................................................... 76
General................................................................................................................. 76
Select boiler.......................................................................................................... 84
DHW..................................................................................................................... 86
Solar..................................................................................................................... 88
Heating circuit 1, heating circuit 2, heating circuit 3............................................. 91
Diagnosis and service scans
Calling up the service menu................................................................................. 98
Diagnosis.............................................................................................................. 98
Checking outputs (actuator test).......................................................................... 101
Troubleshooting
Fault display......................................................................................................... 103
Fault codes........................................................................................................... 104
Repairs................................................................................................................. 114
Index
Index
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5
Function description
Control unit........................................................................................................... 127
Internal extensions............................................................................................... 129
External extensions (accessories)........................................................................ 131
Control functions.................................................................................................. 135
Allocating heating circuits to the remote control................................................... 143
Electronic combustion controller.......................................................................... 143
Designs
Internal connection diagram................................................................................. 145
External connection diagram................................................................................ 146
Connection diagram, solar control module........................................................... 148
Parts lists............................................................................................................ 149
Commissioning/service reports........................................................................ 159
Specification....................................................................................................... 160
Certificates
Declaration of conformity...................................................................................... 161
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 162
Keyword index.................................................................................................... 163
Index
Index (cont.)
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6
Vitodens 242-F, FB2B
Set up for operation with natural gas H.
For conversion to LPG P (without conversion kit), see page 32.
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
Handling
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 at least 2100 mm.
The boiler weight is 161 kg (19 kW) to 165 kg (26 kW) (dry).
Preparing the boiler for 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
1930
2008
100
719
46
40
50
1367
1422
1477
1532
1587
1642
1697
1752
1807
1875
1900
1135 1100
140
60
320
370
436
449
A
H
AH
B
D
F
E
G
C
G
E
C
B
F
D
M
K
K
L
440
55
220
330
a
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 area
NDHW safety valve drain
Preparing for installation
Preparing for installation (cont.)
5412 755 GB
Installation

8
Minimum clearances
Area around the Vitodens for maintenance: min. 700 mm.
Maintenance clearances to the l.h. or r.h. side of the Vitodens are not required.
Rated output range 4.8 to 19 kW 6.5 to 26 kW
a (mm) 200 224
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.
Preparing for installation
Preparing for installation (cont.)
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9
2. Prepare the connections on the DHW
side. Install the safety assembly
(accessory or on-site provision) in
accordance with
the Water Fittings Regulations 1999 in
the cold water line (see page 10).
Recommendation:
Install the safety valve above the
DHW cylinder to protect it against
contamination, scaling and high tem-
peratures.
Connect the drain hose to the con-
densate collector. Remove plug from
condensate collector.
3. Prepare the solar connections.
4. 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.
5. Prepare the gas connection accord-
ing to TRGI or TRF or all local regu-
lations.
6. Prepare the electrical connections.
■Power 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.
Preparing for installation
Preparing for installation (cont.)
5412 755 GB
Installation

10
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 connector
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.)
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11
Assembling the boiler
9.
8.
7.
6.
5.
1.
3.
2x
4.
2.
Installation sequence
Installing the boiler
5412 755 GB
Installation

12
Connections on the heating water and the DHW side
A
B
D
E
E
D
B
A
A B D E
C
C
C
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
DHW circulation connection
DHW circulation connection with
DHW circulation pump connection
set (accessory)
Separate installation instructions
Installation sequence
Installing the boiler (cont.)
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13
Connections on the solar side
B
A
AB
A
B
Shown with connection sets for finished walls (accessories)
ASolar return R ¾ or Ø22 mm smooth
tube
BSolar flow R ¾ or Ø22 mm smooth
tube
Note
The solar circuit pump is integrated into
the boiler.
The expansion vessel, available as an
accessory, is installed in the solar
return.
Separate installation instructions
The solar safety valve can be fitted in the
boiler. Set 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. A drip
container (2.5 litres) to be fitted in the
boiler is available as an accessory.
Installation sequence
Installing the boiler (cont.)
5412 755 GB
Installation

14
Gas connection
Shown with connection sets for finished walls (accessories)
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.
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.
Installation sequence
Installing the boiler (cont.)
5412 755 GB

15
!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 32
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.
Opening the control unit casing
1.
3.
2. 2x
Installation sequence
Installing the boiler (cont.)
5412 755 GB
Installation

16
5.
4. 7x
Electrical connections
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.
Installation sequence
Opening the control unit casing (cont.)
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17
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)
BPower supply, solar control module
(connected in the delivered condi-
tion)
CExternal safety solenoid valve
(LPG)
DCylinder primary pump
Plug 230 V~
sA Cylinder primary pump D (fitted
and connected)
fÖ Power supply
■ Remove any existing individual
cores.
Danger
Incorrect core termination
can cause severe injuries
and damage to the equip-
ment.
Installation sequence
Electrical connections (cont.)
5412 755 GB
Installation

18
Never interchange cores
"L1" and "N".
■ 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.
We additionally recommend
installing an AC/DC-sensitive
RCD (RCD class B ) for
DC (fault) currents that can occur
with energy efficient equipment.
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 21) integrated into the cas-
ing base.
■ Max. fuse rating 16 A.
gD External safety solenoid valve
(LPG) C
Do not remove jumper between "1"
and "L" when making this connec-
tion.
lH Power supply of accessories
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. If the
boiler is installed outside wet areas,
the power supply for accessories
can be connected directly to the
control unit (230 V/50 Hz). The con-
nection is switched by the system
ON/OFF switch.
Note
If the total system current exceeds
6 A, connect one or more extensions
via a mains isolator directly to the
mains supply; see page 19.
Low voltage plug X3
!Outside temperature sensor
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 200A or 300A remote
control
■ Vitocom 100
■ Extension kit for one heating cir-
cuit with mixer
■ Extension AM1 or EA1
■ Open Therm extension
Installation sequence
Electrical connections (cont.)
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19
Connection of accessories
145 145 40A 40 145 145 40A 40
B C
145 40 96
A
145 145 40A 40
D
E
ABoiler control unit
BExtension kit for a heating circuit
with mixer M2
CExtension kit for heating circuit with
mixer M3
DExtension AM1, EA1 and/or solar
control module SM1
EON/OFF switch
If a current flows to the actuators con-
nected (e.g. circulation pumps) that is
higher than the safety level of the acces-
sory, only use the output concerned to
control an on-site relay.
Accessories Internal fuse protection
Extension kit for one heating circuit with mixer 2 A
Extension AM1 4 A
Extension EA1 2 A
Solar control module SM1 2 A
Connecting the collector temperature sensor
Note
Solar control module A is attached to
the l.h. side of the air box.
Installation sequence
Electrical connections (cont.)
5412 755 GB
Installation

20
B
% &aVG A
Connect collector temperature sensor
& to terminal box B of solar control
module A.
On-site extension cable: 2-core, cross-
section 1.5 mm2.
Note
The cylinder temperature sensor for
solar heating % is delivered fitted and
connected.
Installation sequence
Electrical connections (cont.)
5412 755 GB