Viessmann Vitodens 200-W System Operating instructions

Service instructions
for contractors
VIESMANN
Vitodens 200-W
Type WB2B, 4.8 to 35.0 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 200-W
5692 812 GB 10/2009 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
5692 812 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 812 GB

4
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 7
Codes
Code 1.................................................................................................................. 35
Code 2.................................................................................................................. 38
Resetting codes to their delivered condition......................................................... 55
Service scans
Service level overview ......................................................................................... 56
Temperatures, boiler coding card and brief scans .............................................. 57
Checking outputs (relay test)................................................................................ 60
Scanning operating conditions and sensors ........................................................ 61
Troubleshooting
Fault display......................................................................................................... 64
Fault codes........................................................................................................... 66
Repairs................................................................................................................. 76
Function description
Constant temperature control unit........................................................................ 87
Weather-compensated control unit...................................................................... 88
Extensions for external connections (accessories).............................................. 91
Control functions.................................................................................................. 95
Remote control DIP switches............................................................................... 101
Electronic combustion controller.......................................................................... 102
Designs
Connection and wiring diagram – internal connections ....................................... 104
Connection and wiring diagram – external connections....................................... 106
Parts lists............................................................................................................ 108
Commissioning/service reports........................................................................ 114
Specification....................................................................................................... 115
Certificates
Declaration of conformity...................................................................................... 116
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 116
Keyword index.................................................................................................... 117
Index
Index
5692 812 GB

5
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system.............................................. 7
•2. Venting the boiler........................................................... 8
•3. Venting the heating system........................................... 9
•4. Filling the siphon with water......................................... 9
•5. Checking power supply connection
• • 6. Setting the time and date (if required) – only for
weather-compensated control units............................. 10
•7. Selecting the language (if required) – only for
weather-compensated control units............................. 11
• • 8. Checking the gas type.................................................... 11
•9. Gas type conversion (only for operation with LPG).... 12
••• 10. Function sequence and possible faults....................... 12
••• 11. Checking the static and supply pressure .................... 14
•12. Setting the maximum output ........................................ 16
••• 13. Checking all connections on the heating water side
and DHW side for leaks
•14. Checking the balanced flue system for tightness
(annular gap check)........................................................ 17
• • 15. Burner removal .............................................................. 18
• • 16. Checking the burner gasket and the burner gauze
assembly......................................................................... 19
• • 17. Checking and adjusting the ignition and ionisation
electrodes........................................................................ 20
• • 18. Cleaning the heating surfaces and installing the
burner.............................................................................. 20
• • 19. Checking the condensate drain and cleaning the
siphon.............................................................................. 22
• • 20. Checking the neutralising system (if installed)
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5692 812 GB

6
Commissioning steps
Inspection steps
Maintenance steps Page
•21. Flow limiter (only for gas combi boilers)...................... 22
• • 22. Checking the diaphragm expansion vessel and
system pressure............................................................. 23
••• 23. Checking the function of safety valves
••• 24. Checking electrical connections for tightness
••• 25. Checking all gas equipment for tightness at operating
pressure .......................................................................... 23
••• 26. Flue gas emissions test................................................. 23
••• 27. Checking the external LPG safety valve (if installed)
•28. Matching the control unit to the heating system ........ 25
•29. Adjusting the heating curves (only for weather-
compensated control units)........................................... 29
•30. Connecting the control unit to the LON system (only
for weather-compensated control units)...................... 31
•31. Instructing the system user........................................... 33
•32. Scanning and resetting the "Service" display............. 34
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
5692 812 GB

7
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 hardness exceeding 3.0 mol/m3, e.g. using a small
softening system for heating water (see Viessmann Vitoset price list).
■ 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 via the boiler
fill & drain valve A in the heating
return (at the connection set or on
site). (minimum system pressure
> 1.0 bar).
Note
If the control unit has not been
switched ON prior to filling the sys-
tem, then the servomotor of the
diverter valve will still be in its central
position, and the system will be com-
pletely filled.
4. If the control unit had already been
switched ON before filling began:
Switch ON the control unit and acti-
vate the fill program via coding
address "2F:2".
5. Close boiler fill & drain valve A.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 812 GB

8
Venting the boiler
A
B
1. Close the shut-off valves on the heat-
ing water side.
2. Connect the drain hose between top
valve B and a drain outlet.
3. Open valves A and B and vent
using mains pressure until no more
air noise is audible.
If required, move the 3-way valve into
its central position to achieve com-
plete venting. For this, set code "2F:
2".
4. Close valves A and B and open
the heating water shut-off valves.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 812 GB

9
Venting the heating system
1. Close the gas shut-off valve and
switch ON the control unit.
2. Activate the venting program via cod-
ing address "2F:1" in code 1.
Note
To call up code 1 and for setting the
coding address, see page 35.
For function and sequence of the
venting program, see page 96.
Whilst the venting program runs, the
display shows "EL" (constant temper-
ature control unit) or "Venting"
(weather-compensated control unit).
3. Check the system pressure.
Filling the siphon with water
AB
1. Remove retaining clip A and siphon
B.
2. Fill siphon B with water.
3. Fit siphon B and secure with retain-
ing clip A.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 812 GB

10
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 812 GB

11
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 12).
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 12).
3. Record the gas type in the service
report on page 114.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 812 GB

12
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 system ON/OFF switch
"8".
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).
■Set code "11" ≠ "9".
■ Terminate code 2.
4. Open the gas shut-off valve.
5. Affix label "G31" (included with the
technical documentation) adjacent to
the type plate on the cover panel.
Function sequence and possible faults
Display Measures
Control unit
issues a heat
demand
no Increase set value
and ensure heat is
drawn off
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 812 GB

13
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 EE Check the ignition
module (control
voltage 230 V
across plugs
"X2.1" and "X2.2")
yes
Gas train opens no Fault EE Check the gas train
(control voltage
230 V); check the
gas supply pres-
sure
yes
Ionisation current
builds
Symbol A
no Fault EE Check the ionisa-
tion electrode
adjustment and the
gas line 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 tight-
ness (flue gas
recirculation),
check the gas flow
pressure
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 812 GB

14
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 66.
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 812 GB

15
A
1. Close the gas shut-off valve.
2. Undo the screw inside test connector
"IN" A on the gas train, but do not
remove, then connect the pressure
gauge.
3. Open the gas shut-off valve.
4. Measure the static pressure and
record it in the service report.
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 line. 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 812 GB

16
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 pressure (flow pressure) Measures
for natural gas for LPG
below 17.4 mbar below 42.5 mbar Do not start the boiler. Notify your mains
gas or LPG supplier.
17.4 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.
Note
The output can also be limited for DHW
heating. For this, change coding address
"6F" in code 2.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 812 GB

17
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 812 GB

18
Burner removal
G
4x
E
D
C
B
F
G
4x
E
D
C
B
A
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. Pull cables from fan motor A, gas
train B, ionisation electrode C,
ignition unit D and earth tab E.
4. Release gas supply pipe F fitting.
5. Undo four screws G and remove the
burner.
!Please note
To prevent damage,
never rest the burner on the
gauze assembly.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 812 GB

19
Checking the burner gasket and the burner gauze assembly
Check burner gasket A and burner gauze assembly E for damage and replace, if
required.
Generally replace the burner gasket every 2 years.
CADE 3xFB
1. Remove electrodes B.
2. Undo three retaining clips C at ther-
mal insulation ring D and remove
thermal insulation ring D.
3. Undo four Torx screws and remove
burner gauze assembly E with its
gasket F.
4. Insert and secure a new burner
gauze assembly E with a new gas-
ket F.
Torque: 3.5 Nm.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 812 GB

20
5. Refit thermal insulation ring D.6. Refit electrodes B.
Torque: 2.5 Nm.
Checking and adjusting the ignition and ionisation electrodes
6+2
0
4+0,5
0
10±1
A
A B
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 sand
paper.
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 gas-
kets. Tighten the electrode fixing
screws with 2.5 Nm.
Cleaning the heating surfaces and installing the burner
!Please note
Scratches on parts that are in contact with flue gas can lead to corrosion.
Never use brushes to clean the heat exchanger.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 812 GB