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

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 12).
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 12).
3. Record the gas type in the service
report on page 117.
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
Further details regarding the individual steps (cont.)
11
Commissioning, inspection, maintenance
5692 672 GB

Gas type conversion (only for operation with LPG)
1. Set adjusting screw Aat the gas
train to "2".
2. Switch ON system ON/OFF switch
"8".
3. Adjust the gas type (see page 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.
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
Yes
Fan starts No after approx. 51 s
fault F9
Check the fan, fan
connecting
cables, power at
the fan and fan
control
Further details regarding the individual steps (cont.)
12
Commissioning, inspection, maintenance
5692 672 GB

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
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)
Further details regarding the individual steps (cont.)
13
Commissioning, inspection, maintenance
5692 672 GB

For further details regarding faults,
see page 69.
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.
1. Close the gas shut-off valve.
2. Undo the screw inside test connec-
tor "IN" Aon the gas train, but do
not remove, 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.
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.
Further details regarding the individual steps (cont.)
14
Commissioning, inspection, maintenance
5692 672 GB

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 nipple Awith
the screw.
9. Danger
Gas escaping from the test
nipple leads to a risk of
explosions.
Check for tightness.
Open the gas shut-off valve, start
the boiler and check for tightness at
test nipple A.
Supply (flow)
pressure for nat-
ural gas
Supply (flow)
pressure for
LPG
Measures
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.
in excess of
25 mbar
in excess of
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.
Further details regarding the individual steps (cont.)
15
Commissioning, inspection, maintenance
5692 672 GB

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.
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)
ACombustion air port
Further details regarding the individual steps (cont.)
16
Commissioning, inspection, maintenance
5692 672 GB

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 applic-
able.
We recommend that your heating
engineer carries out a simple leak/
tightness test during the commission-
ing of your system. For this, it would
be sufficient to check the CO2or 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 CO2concentration in the
combustion 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.
Burner removal
Further details regarding the individual steps (cont.)
17
Commissioning, inspection, maintenance
5692 672 GB

1. Switch OFF the main power supply
and the ON/OFF switch at the con-
trol unit.
2. Close the gas shut-off valve and
safeguard against reopening.
3. Pull cables from fan motor A, gas
train B, ionisation electrode C,
ignition unit Dand earth tab E.
4. Release gas supply pipe Ffitting.
5. Undo four screws Gand remove
the burner.
!Please note
To prevent damage,
never rest the burner on the
gauze assembly.
Further details regarding the individual steps (cont.)
18
Commissioning, inspection, maintenance
5692 672 GB

Checking the burner gasket and the burner gauze assembly
Check burner gasket Aand burner gauze assembly Efor damage and
replace, if required.
Generally replace the burner gasket every 2 years.
1. Remove electrodes B.
2. Undo three retaining clips Cat
thermal insulation ring Dand
remove thermal insulation ring D.
3. Undo four Torx screws and remove
burner gauze assembly Ewith its
gasket F.
4. Insert and secure a new burner
gauze assembly Ewith a new
gasket F.
Torque: 3.5 Nm.
5. Refit thermal insulation ring D.
6. Refit electrodes B.
Torque: 2.5 Nm.
Further details regarding the individual steps (cont.)
19
Commissioning, inspection, maintenance
5692 672 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.
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 2.5 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.
Further details regarding the individual steps (cont.)
20
Commissioning, inspection, maintenance
5692 672 GB