Viessmann Vitodens 200-W System Operating instructions

VIESMANN
Service instructions
for contractors
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 683 GB 6 /2007 Please keep safe.

Please follow these safety instructions closely to prevent accidents and
material 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
environmental pollution.
Note
Details identified by the word "Note"
contain 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 fit-
ter.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
&The system must be commissioned
by the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental 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.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances 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
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close all doors leading to the
living space.
Safety instructions
2
Safety instructions
5692 683 GB

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
supply 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
unauthorised reconnection.
!Please note
Electronic modules can be
damaged 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
fulfil a safety function can com-
promise 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
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 683 GB

Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance ................................... 5
Further details regarding the individual steps .............................................. 7
Coding
Code 1........................................................................................................ 37
Code 2........................................................................................................ 40
Resetting codes to their delivered condition ................................................ 60
Service scans
Service level overview ............................................................................... 61
Temperatures, boiler coding card and brief scans ....................................... 62
Checking outputs (relay test) ...................................................................... 65
Scanning operating conditions and sensors ................................................ 66
Troubleshooting
Fault display ............................................................................................... 69
Fault codes................................................................................................. 71
Repairs ...................................................................................................... 82
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
Specification............................................................................................. 116
Certificates
Declaration of conformity ............................................................................ 118
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 119
Keyword index .......................................................................................... 120
Index
4
Index
5692 683 GB

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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•01. Filling the heating system ................................................. 7
•02. Venting the boiler .................................................................. 8
•03. Venting the heating system............................................... 8
•04. Filling the siphon with water............................................. 9
••• 05. Checking all connections on the heating water
side and DHW side for leaks
•06. Checking the power supply connection
• • 07. Setting the time and date (if required) –only for
weather-compensated control units.............................. 9
•08. Selecting the language (if required) –only for
weather-compensated control units.............................. 10
• • 09. Checking the gas type......................................................... 10
•10. Gas type conversion (only for operation with LPG).11
••• 11. Function sequence and possible faults........................ 11
••• 12. Checking the static and supply pressure .................... 13
•13. Setting the maximum output ........................................... 15
•14. Checking the balanced flue system for soundness
(annular gap check) ............................................................. 16
• • 15. Removing the burner and checking the burner
gasket (replace gasket every 2 years)........................... 17
• • 16. Checking the burner gauze assembly &replacing,
if required................................................................................. 19
• • 17. Checking and adjusting the ignition and ionisation
electrodes ................................................................................ 20
• • 18. Cleaning the combustion chamber/heat exchanger
and installing the burner .................................................... 20
• • 19. Checking the condensate drain and cleaning the
siphon........................................................................................ 22
Steps - commissioning, inspection and maintenance
5
Commissioning, inspection, maintenance
5692 683 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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• • 20. Checking the neutralising system (if installed)
• • 21. Checking the diaphragm expansion vessel and
system pressure.................................................................... 22
••• 22. Checking the function of all safety valves
••• 23. Checking the tightness of electrical connections
••• 24. Checking all gas equipment for soundness at
operating pressure .............................................................. 22
••• 25. Flue gas emissions test...................................................... 23
••• 26. Checking the external LPG safety valve (if
installed)
•27. Matching the control unit to the heating system ...... 24
•28. Adjusting the heating curves (only for weather-
compensated control units).............................................. 30
•29. Connecting the control unit to the LON system
(only for weather-compensated control units) .......... 33
•30. Instructing the system user .............................................. 35
•31. Scanning and resetting the "Service" display ........... 35
Steps - commissioning, inspection and . . . (cont.)
6
Commissioning, inspection, maintenance
5692 683 GB

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/m
3
&–Vitodens 200-W from 60 kW and multi-boiler systems: 2.0 mol/m
3
&An antifreeze additive suitable for heating systems can be mixed with
the fill water. The antifreeze manufacturer must verify its suitability.
1. Check the inlet pressure of the dia-
phragm expansion vessel.
2. Close the gas shut-off valve.
3. Fill the heating system at the boiler
fill & drain valve A(on the connec-
tion set, accessories or on-site).
(Minimum system pressure
> 1.0 bar).
4. Close boiler fill & drain valve A.
Further details regarding the individual steps
7
Commissioning, inspection, maintenance
5692 683 GB

Venting the boiler
1. Close the shut-off valves on the
heating 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 Aand Band vent
using mains pressure until no more
air noise is audible.
4. Close valves Aand Band 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
coding address "2F:1".
Note
To call up code 1 and for setting the
coding address, see page 37.
For function and sequence of the
venting program, see page 99.
Whilst the venting program runs,
the display shows "EL" (constant
temperature control unit) or
"Entlüftung" (venting) (weather-
compensated control unit).
3. Check the system pressure.
Further details regarding the individual steps (cont.)
8
Commissioning, inspection, maintenance
5692 683 GB

Filling the siphon with water
1. Remove retaining clip Aand pull
out insert B.
2. Fill siphon Cwith water and reas-
semble.
Note
Install the supply hose the correct
way round.
Setting the time and date (if required) –only for weather-
compensated control units
Note
&During commissioning, or after a
prolonged time out of use, it may be
necessary to reset the time and
date, if the time flashes in the dis-
play.
&During commissioning these terms
appear in German (delivered condi-
tion):
Time (see step 1)
Date (see step 2)
Press the following keys:
1. a/bfor the current time.
2. dto confirm; "Datum" (date)
is displayed.
3. a/bfor the current date.
4. dto confirm.
Further details regarding the individual steps (cont.)
9
Commissioning, inspection, maintenance
5692 683 GB

Selecting the language (if required) –only for weather-com-
pensated control units
Note
When the unit is first taken into opera-
tion the display is in German (default
language setting):
Select heating circuit (see step 1.)
Outside temperature (see step 3.)
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 qual-
ity.
&The boiler can be operated with natural gas in the Wobbe index range 10.0 to
16.1 kWh/m
3
(36.0 to 58.0 MJ/m
3
) without conversion.
&Convert the burner for operation with LPG (see "Gas type conversion" on
page 11).
1. Determine the gas type and Wobbe
index by asking your local gas sup-
ply utility or LPG supplier.
2. Convert the burner for operation
with LPG (see page 11).
3. Record the gas type in the service
report on page 115.
Further details regarding the individual steps (cont.)
10
Commissioning, inspection, maintenance
5692 683 GB

Wobbe index ranges
Gas type Wobbe index range
kWh/m
3
MJ/m
3
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. Set adjusting screw Aat the gas
train to "2".
2. Switch ON/OFF switch "8" ON.
3. Adjust the gas type in coding
address "82" (for a detailed
description of the individual steps,
see page 88):
&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.
Function sequence and possible faults
Display screen Measures
Control unit is-
sues heat de-
mand
No Increase set
value and ensure
heat is drawn off
Further details regarding the individual steps (cont.)
11
Commissioning, inspection, maintenance
5692 683 GB

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 vol-
tage 230 V);
check the gas
supply pressure
Yes
Ionisation cur-
rent builds
Symbol A
No Fault F4 Check the ionisa-
tion electrode ad-
justment 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
soundness (flue
gas recirculation),
check the gas
flow pressure
Further details regarding the individual steps (cont.)
12
Commissioning, inspection, maintenance
5692 683 GB

Yes
Automatic cali-
bration of the
combustion con-
trol unit
No Fault Eb Check the con-
necting cable and
the ionisation
electrode,
check the flue gas
system (flue gas
recirculation)
For further details regarding faults,
see page 71.
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.
Further details regarding the individual steps (cont.)
13
Commissioning, inspection, maintenance
5692 683 GB

1. Close the gas shut-off valve.
2. Release screw Ainside test con-
nector "PE" on the gas train, but do
not remove it; then connect the
pressure 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 "ERESET" 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 ser-
vice 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 port Awith
the screw.
Further details regarding the individual steps (cont.)
14
Commissioning, inspection, maintenance
5692 683 GB

9. Danger
Gas escaping from the test
nipple leads to a risk of
explosions.
Check for soundness.
Open the gas shut-off valve, start
the boiler and check for soundness
at test connector A.
Supply (flow)
pressure for nat-
ural 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 gover-
nor upstream of the system and regu-
late the inlet pressure to 20 mbar for
natural 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 Kand Fsimultaneously
until a value flashes (e.g. "85") and
"A" appears. In the delivered con-
dition, this value represents 100 %
of rated output.
On weather-compensated control
units, the display additionally
shows "Max. output".
3. With a/bselect the required
value in % of rated output as maxi-
mum output.
4. Confirm the set value with d.
5. Record the settings for maximum
output on the additional type plate
included with the "technical docu-
mentation". Affix the type plate next
to the original type plate on top of
the boiler.
Further details regarding the individual steps (cont.)
15
Commissioning, inspection, maintenance
5692 683 GB

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 soundness (annular
gap check)
ACombustion air port
For balanced flue systems tested
together with the wall mounted gas
fired boiler, some authorities waive
the requirement for a soundness test
(overpressure test) during commis-
sioning by the flue gas inspector.
We recommend that your heating
engineer carries out a simple sound-
ness test during the commissioning of
your system. For this, it would be suf-
ficient to check the CO2or O2concen-
tration in the combustion air at the
annular gap of the balanced flue pipe.
The flue pipe is deemed to be sound if
the CO2concentration in the combus-
tion air is no higher than 0.2 % or the
O2concentration is at least 20.6 %.
If actual CO2values are higher or O2
values are lower, then pressure test
the flue pipe with a static pressure of
200 Pa.
Further details regarding the individual steps (cont.)
16
Commissioning, inspection, maintenance
5692 683 GB

Removing the burner and checking the burner gasket
(replace gasket every 2 years)
Further details regarding the individual steps (cont.)
17
Commissioning, inspection, maintenance
5692 683 GB

1. Switch OFF the main power supply
at the control unit and the ON/OFF
switch.
2. Close the gas shut-off valve and
safeguard against reopening.
3. Pivot control unit Aforward.
4. Remove cover panel B.
5. Pull cables from fan motor C, gas
train D, ignition unit E, earth tab
Fand ionisation electrode G.
6. Release gas supply pipe Hfitting.
7. Undo six screws Kand remove
the burner.
8. Check burner gasket Lfor
damage.
Generally replace the burner gas-
ket every 2 years.
Further details regarding the individual steps (cont.)
18
Commissioning, inspection, maintenance
5692 683 GB

Checking the burner gauze assembly &replacing, if required
1. Remove electrodes A.
2. Undo three retaining clips Bat
thermal insulation ring Cand
remove thermal insulation ring C.
3. Release four Torx screws Dand
remove burner gauze assembly
E.
4. Remove old burner gauze assem-
bly gasket F.
5. Insert a new burner gauze assem-
bly with a new gasket and secure
with four Torx screws.
Note
Torque: 4.5 Nm
6. Refit the thermal insulation ring C
and electrodes A.
Further details regarding the individual steps (cont.)
19
Commissioning, inspection, maintenance
5692 683 GB

Checking and adjusting the ignition and ionisation electro-
des
AIgnition electrodes BIonisation electrode
1. Check the electrodes for wear and
contamination.
2. Clean the electrodes with a small
brush (not with a wire brush) or
emery paper.
!Please note
Do not damage
the wire gauze.
3. Check the electrode gaps. If the
gaps are not as specified or the
electrodes are damaged, replace
and align the electrodes together
with new gaskets. Tighten the elec-
trode fixing screws with 2 Nm.
Cleaning the combustion chamber/heat exchanger and
installing the burner
!Please note
Scratches on parts that are in contact with flue gases can lead to corro-
sion.
Only use plastic brushes and NOT wire brushes.
Further details regarding the individual steps (cont.)
20
Commissioning, inspection, maintenance
5692 683 GB