Viessmann Vitodens 200-W System Operating instructions

VIESMANN
Service instructions
for contractors
Vitodens 200-W
Type WB2B, 4.8 to 35.0 kW
Wall mounted gas fired condensing boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 200-W
5692 672 GB 5/2008 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 672 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 672 GB

Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance................................... 5
Further details regarding the individual steps .............................................. 7
Coding
Code 1........................................................................................................ 36
Code 2........................................................................................................ 39
Resetting codes to their delivered condition ................................................ 58
Service scans
Service level overview ............................................................................... 59
Temperatures, boiler coding card and brief scans ....................................... 60
Checking outputs (relay test) ...................................................................... 63
Scanning operating conditions and sensors ................................................ 65
Troubleshooting
Fault display ............................................................................................... 67
Fault codes................................................................................................. 69
Repairs ...................................................................................................... 79
Function description
Constant temperature control unit ............................................................... 90
Weather-compensated control unit.............................................................. 91
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 ............................... 109
Parts lists .................................................................................................. 111
Commissioning/service reports ............................................................... 117
Specification............................................................................................. 118
Certificates
Declaration of conformity ............................................................................ 119
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 120
Keyword index .......................................................................................... 121
Index
4
Index
5692 672 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 the power supply connection
• • 06. Setting the time and date (if required) –only for
weather-compensated control units.............................. 10
•07. Selecting the language (if required) –only for
weather-compensated control units.............................. 10
• • 08. Checking the gas type......................................................... 11
•09. 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) ............................................................. 16
• • 15. Burner removal ..................................................................... 17
• • 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)
Steps - commissioning, inspection and maintenance
5
Commissioning, inspection, maintenance
5692 672 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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•21. Flow limiter (only for gas combi boilers) ..................... 22
• • 22. Checking the diaphragm expansion vessel and
system pressure.................................................................... 23
••• 23. Checking the function of all safety valves
••• 24. Checking the tightness of electrical connections
••• 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) .......... 32
•31. Instructing the system user .............................................. 34
•32. Scanning and resetting the "Service" display ........... 34
Steps - commissioning, inspection and . . . (cont.)
6
Commissioning, inspection, maintenance
5692 672 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 hardness exceeding 3.0 mol/m
3
, 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.
1. Check the inlet pressure of the dia-
phragm expansion vessel.
2. Close the gas shut-off valve.
3. Fill the heating system via the boil-
er fill & drain valve Ain the heat-
ing return (at the connection set or
on site). (Minimum system pres-
sure > 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 cen-
tral position, and the system will be
completely 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.
6. Close the shut-off valves on the
heating water side.
Further details regarding the individual steps
7
Commissioning, inspection, maintenance
5692 672 GB

Venting the boiler
1. Close the shut-off valves on the
heating water side.
2. Connect the drain hose between
top valve Band a drain outlet.
3. Open valves Aand Band vent
using mains pressure until no more
air noise is audible.
If required, move the 3-way valve
into its central position to achieve
complete venting. For this, set
code "2F:2".
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.
Further details regarding the individual steps (cont.)
8
Commissioning, inspection, maintenance
5692 672 GB

2. Activate the venting program via
coding address "2F:1" in code 1.
Note
To call up code 1 and for setting the
coding address, see page 36.
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.
Filling the siphon with water
1. Remove retaining clip Aand
siphon B.
2. Fill siphon Bwith water.
3. Fit siphon Band secure with
retaining clip A.
Further details regarding the individual steps (cont.)
9
Commissioning, inspection, maintenance
5692 672 GB

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.
&When the unit is first taken into
operation the display is in German
(default language setting):
Time (see step 1)
Date (see step 2)
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.
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.
Further details regarding the individual steps (cont.)
10
Commissioning, inspection, maintenance
5692 672 GB