Viessmann Vitodens 200-W System Operating instructions

Service instructions
for contractors
VIESMANN
Vitodens 200-W
Type WB2B, 45 and 60 kW
Wall mounted gas fired condensing boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 200-W
5692 760 GB 11/2008 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
5692 760 GB

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.)
5692 760 GB

4
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 6
Further details regarding the individual steps....................................................... 8
Codes
Code 1.................................................................................................................. 38
Code 2.................................................................................................................. 41
Resetting codes to their delivered condition......................................................... 62
Service scans
Service level overview ......................................................................................... 63
Temperatures, boiler coding card and brief scans .............................................. 64
Checking outputs (relay test)................................................................................ 67
Scanning operating conditions and sensors ........................................................ 68
Troubleshooting
Fault display......................................................................................................... 71
Fault codes........................................................................................................... 73
Repairs................................................................................................................. 83
Function description
Constant temperature control unit........................................................................ 91
Weather-compensated control unit...................................................................... 92
Extensions for external connections (accessories).............................................. 94
Control functions.................................................................................................. 98
Remote control DIP switches............................................................................... 104
Electronic combustion control unit........................................................................ 105
Designs
Connection and wiring diagram – internal connections ....................................... 107
Connection and wiring diagram – external connections....................................... 108
Parts lists............................................................................................................ 110
Commissioning/service reports
............................................................................................................................. 115
Specification....................................................................................................... 116
Certificates
Declaration of conformity...................................................................................... 118
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 118
Index
Index
5692 760 GB

5
Keyword index.................................................................................................... 119
Index
Index (cont.)
5692 760 GB

6
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system.............................................. 8
•2. Venting the boiler........................................................... 9
•3. Venting the heating system........................................... 9
•4. Filling the siphon with water......................................... 10
••• 5. Checking all connections on the heating water side
and DHW side for leaks
•6. Checking power supply connection
• • 7. Setting the time and date (if required) – only for
weather-compensated control units............................. 11
•8. Selecting the language (if required) – only for weather-
compensated control units............................................ 12
• • 9. Checking the gas type.................................................... 12
•10. Gas type conversion (only for operation with LPG).... 13
••• 11. Function sequence and possible faults....................... 13
••• 12. Checking the static and supply pressure..................... 15
•13. Setting the maximum output ........................................ 17
•14. Checking the balanced flue system for tightness
(annular gap check)........................................................ 18
• • 15. Removing the burner and checking the burner gasket
(replace gasket every 2 years)...................................... 19
• • 16. Checking the burner gauze assembly & replacing, if
required........................................................................... 21
• • 17. Checking and adjusting the ignition and ionisation
electrodes........................................................................ 22
• • 18. Cleaning the combustion chamber/heat exchanger
and installing the burner................................................ 22
• • 19. Checking the condensate drain and cleaning the
siphon.............................................................................. 24
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5692 760 GB

7
Commissioning steps
Inspection steps
Maintenance steps Page
• • 20. Checking the neutralising system (if installed)
• • 21. Checking the diaphragm expansion vessel and
system pressure............................................................. 24
••• 22. Checking function of safety valves
••• 23. Checking electrical connections for tightness
••• 24. Checking gas equipment for tightness at operating
pressure .......................................................................... 24
••• 25. Flue gas emissions test................................................. 25
••• 26. Checking the external LPG safety valve (if installed)
•27. Matching the control unit to the heating system ........ 26
•28. Adjusting the heating curves (only for weather-
compensated control units)........................................... 31
•29. Connecting the control unit to the LON system (only
for weather-compensated control units)...................... 34
•30. Instructing the system user........................................... 36
•31. Scanning and resetting the "Service" display............. 37
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
5692 760 GB

8
Filling the heating system
!Please note
Unsuitable fill water increases the level of deposits and corrosion and may
lead to boiler damage.
■ Thoroughly flush the entire heating system prior to filling it with water.
■ Only use fill water of potable quality.
■ Soften fill water with a water hardness in excess of the following values, e.g.
with a small softening system for heating water (see the Viessmann Vitoset
pricelist):
– Vitodens 200-W to 45 kW: 3.0 mol/m3
– Vitodens 200-W from 60 kW and multi-boiler systems: 2.0 mol/m3
■ An antifreeze additive suitable for heating systems can be mixed with the
fill water. The antifreeze manufacturer must verify its suitability.
A
1. Check the pre-charge pressure of the
diaphragm expansion vessel.
2. Close the gas shut-off valve.
3. Fill the heating system at the boiler fill
& drain valve A (on the connection
set, accessories or on-site). Minimum
system pressure > 1.0 bar.
4. Close boiler fill & drain valve A.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 760 GB

9
Venting the boiler
B
A
1. Close the shut-off valves on the heat-
ing water side.
2. Connect the drain hose at the boiler
fill & drain valve B (on the connec-
tion set, accessories or on-site).
3. Open valves A and B and vent
using mains pressure until no more
air noise is audible.
4. Close valves A and B and open
the heating water shut-off valves.
Venting the heating system
1. Close the gas shut-off valve and
switch ON the control unit ON/OFF
switch.
2. Activate the venting program via cod-
ing address "2F:1".
Note
To call up code 1 and for setting the
coding address, see page 38.
For function and sequence of the
venting program, see page 99.
Whilst the venting program runs, the
display shows "EL" (constant tem-
perature control unit) or "Entlüf-
tung" (Venting) (weather-compen-
sated control unit).
3. Check the system pressure.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 760 GB

10
Filling the siphon with water
ACB
1. Remove retaining clip A and pull out
insert B.
2. Fill siphon C with water and reas-
semble.
Note
Install the supply hose the correct
way round.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 760 GB

11
Setting the time and date (if required) – only for weather-com-
pensated control units
Note
■ During commissioning, or after a pro-
longed time out of use, it may be nec-
essary to reset the time and date, if the
time flashes in the display.
■ When the unit is first taken into opera-
tion the display is in German (default
language setting):
Time (see step 1)
Uhrzeit
Date (see step 2)
Datum
Sa
Press the following keys:
1. a/bfor the current time.
2. dto confirm; "Datum" is dis-
played.
3. a/bfor the current date.
4. dto confirm.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 760 GB

12
Selecting the language (if required) – only for weather-compen-
sated control units
Note
When the unit is first taken into operation
the display is in German (default lan-
guage setting):
Select heating circuit (see step 1.)
Heizkreis wählen
1
z
Outside temperature (see step 3.)
Außentemperatur
i°C
13
Press the following keys:
1. c"Heizkreis wählen" (select
heating circuit) is displayed.
2. dto confirm; wait approx. 4 s.
3. cpress this button again,
"Außentemperatur" (outside
temperature) is displayed.
4. bfor the required language.
5. dto confirm.
Checking the gas type
The boiler is equipped with an electronic combustion control unit that adjusts the
burner for optimum combustion in accordance with the prevailing gas quality.
■ The boiler can be operated with natural gas in the Wobbe index range 10.0 to
16.1 kWh/m3 (36.0 to 58.0 MJ/m3) without conversion.
■ Convert the burner for operation with LPG (see "Gas type conversion" on
page 13).
1. Determine the gas type and Wobbe
index by asking your local gas supply
utility or LPG supplier.
2. Convert the burner for operation with
LPG (see page 13).
3. Record the gas type in the service
report on page 115.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 760 GB

13
Wobbe index ranges
Gas type Wobbe index range
kWh/m3MJ/m3
Delivered condition
Natural gas E
or
12.0 to 16.1 43.2 to 58.0
Natural gas LL 10.0 to 13.1 36.0 to 47.2
After conversion
LPG P 20.3 to 21.3 72.9 to 76.8
Gas type conversion (only for operation with LPG)
1
2
A
1. Set adjusting screw A at the gas
train to "2".
2. Switch ON/OFF switch "8" ON.
3. Select the gas type in coding address
"82"
■ Call up code 2
■ In coding address "11", select
value "9"
■ In coding address "82", select
value "1" (operation with LPG)
■In code "11" select value ≠ "9"
■ Terminate code 2.
4. Open the gas shut-off valve.
5. Affix label "G 31" (included with the
technical documentation) in a clearly
visible position, near the gas train on
the cap panel.
Function sequence and possible faults
Display screen Measures
Control unit
issues heat
demand
No Increase set value
and ensure heat is
drawn off
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 760 GB

14
Yes
Fan starts No after approx. 51 s
fault F9
Check the fan, fan
connecting cables,
power at the fan
and fan control
Yes
Ignition No Fault F4 Check the ignition
module (control
voltage 230 V
across plugs
"X2.1" and "X2.2")
Yes
Gas train opens No Fault F4 Check the gas train
(control voltage
230 V); check the
gas supply pres-
sure
Yes
Ionisation current
builds
Symbol A
No Fault F4 Check the ionisa-
tion electrode
adjustment and the
gas pipe for air-
locks
Yes
Burner in opera-
tion
No Stops below the
set boiler water
temperature and
restarts immedi-
ately
Check the flue gas
system for sound-
ness (flue gas
recirculation),
check the gas flow
pressure
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 760 GB

15
Yes
Automatic calibra-
tion of the com-
bustion control
unit
No Fault Eb Check the con-
necting cable and
the ionisation elec-
trode,
check the flue gas
system (flue gas
recirculation)
For further details regarding faults, see
page 73.
Checking the static and supply pressure
Danger
CO build-up as a result of an incorrect burner setup can have serious health
implications.
Carry out a CO test prior to and after work on gas equipment.
Operation with LPG
Flush the LPG tank twice during commissioning/replacement. Thoroughly vent the
tank and gas supply lines after flushing.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 760 GB

16
A
1. Close the gas shut-off valve.
2. Release screw A inside test con-
nector "PE" on the gas train, but do
not remove it; then connect the pres-
sure gauge.
3. Open the gas shut-off valve.
4. Measure the static pressure and
record it in the service report on
page 115.
Set value: max. 57.5 mbar.
5. Start the boiler.
Note
During commissioning, the boiler can
enter a fault state because of airlocks
in the gas pipe. After approx. 5 s
press "
E
RESET" to reset the
burner.
6. Check the supply (flow) pressure. Set
values:
■ Natural gas 20 mbar
■ LPG 50 mbar
Note
Use suitable test equipment with a
resolution of at least 0.1 mbar to
measure the supply pressure.
7. Record the actual value in the service
report.
Take the action shown in the follow-
ing table.
8. Shut down the boiler, close the gas
shut-off valve, remove the pressure
gauge and close test nipple A with
the screw.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 760 GB

17
9. Danger
Gas escaping from the test
nipple leads to a risk of explo-
sions.
Check for tightness.
Open the gas shut-off valve, start the
boiler and check for tightness at test
nipple A.
Supply (flow) pres-
sure for natural
gas
Supply (flow)
pressure for LPG
Measures
below 15 mbar below 42.5 mbar Do not start the boiler. Notify your mains
gas or LPG supplier.
15 to 25 mbar 42.5 to 57.5 mbar Start the boiler.
above 25 mbar above 57.5 mbar Install a separate gas pressure governor
upstream of the system and regulate the
pre-charge pressure to 20 mbar for natu-
ral gas or 50 mbar for LPG. Notify your
mains gas or LPG supplier.
Setting the maximum output
Note
You can limit the maximum output for heating operation. The limit is set via the
modulation range. The max. adjustable heating output is limited upwards by the boiler
coding card.
1. Start the boiler.
2. Press K and F simultaneously
until a value flashes (e.g. "85") and
"A" appears. In the delivered condi-
tion, this value represents 100 % of
rated output.
On weather-compensated control
units, the display additionally shows
"Max. output".
3. With a/b select the required value
in % of rated output as maximum out-
put.
4. Confirm the set value with d.
5. Record the settings for maximum out-
put on the additional type plate inclu-
ded with the "technical documenta-
tion". Affix the type plate next to the
original type plate on top of the
boiler.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 760 GB

18
Note
The output can also be limited for DHW
heating. For this, change coding address
"6F" in code 2.
Checking the balanced flue system for tightness (annular gap
check)
A
ACombustion air port
For balanced flue systems tested
together with the wall mounted gas fired
boiler, the requirement for a tightness
test during commissioning by the flue
gas inspector is not applicable.
We recommend that your heating engi-
neer carries out a simple leak/tightness
test during the commissioning of your
system. For this, it would be sufficient to
check the CO2 or O2 concentration in the
combustion air at the annular gap of the
balanced flue pipe.
The flue pipe is deemed to be gas-tight
if the CO2 concentration in the combus-
tion air is no higher than 0.2 % or the
O2 concentration is at least 20.6 %.
If actual CO2 values are higher or O2 val-
ues are lower, then pressure test the flue
pipe with a static pressure of 200 Pa.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 760 GB

19
Removing the burner and checking the burner gasket (replace
gasket every 2 years)
G
L
K
H
C
B A
F
E
D
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 760 GB

20
1. Switch OFF the main power supply
and the ON/OFF switch at the control
unit.
2. Close the gas shut-off valve and safe-
guard against reopening.
3. Pivot control unit A forward.
4. Remove cover panel B.
5. Pull cables from fan motor C, gas
train D, ignition unit E, earth tab
F and ionisation electrode G.
6. Release gas supply pipe H fitting.
7. Undo six screws K and remove the
burner.
8. Check burner gasket L for damage.
Generally replace the burner gasket
every 2 years.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 760 GB