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

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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

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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

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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

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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