Viessmann Vitodens 200-W System Operating instructions

Please file in Service Binder
Service Instructions
5683 710 - 09 06/2015
for use by heating contractors
Vitodens 200-W,
Type B2HA 112 and 150
Wall-mounted, gas-fired condensing boiler
Natural gas and LPG version
For operation with Natural Gas and Liquid Propane Gas
Heating input 113 to 530 MBH
33 to 150 kW
Read and save these instructions
for future reference.
Product may not be exactly as shown
VITODENS
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200-W
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IMPORTANT

Vitodens 200-W B2HA 112, 150 Service
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5683 710 - 09
Safety
Safety, Installation and Warranty Requirements
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with
the instructions listed below and details printed in this manual can cause product/property damage, severe personal
injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information
found in manual subsections).
WARNING
Installers must follow local regulations with respect to
installation of carbon monoxide detectors. Follow the
Viessmann maintenance schedule of the boiler contained
in this manual.
Product documentation
Read all applicable documentation before commencing
installation. Store documentation near boiler in a
readily accessible location for reference in the future
by service personnel.
For a listing of applicable literature,
please see section entitled “Important
Regulatory and Safety Requirements”.
Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.
Licensed professional heating contractor
The installation, adjustment, service and maintenance
of this equipment must be performed by a licensed
professional heating contractor.
Please see section entitled
“Important Regulatory and Installation
Requirements”.
Contaminated air
Air contaminated by chemicals can cause by-products
in the combustion process, which are poisonous to
inhabitants and destructive to
0 equipment.
For a listing of chemicals which
cannot be stored in or near the
boiler room, please see subsection
entitled “Mechanical room” in the
“Installation Instructions”.
Advice to owner
Once the installation work is complete, the heating
contractor must familiarize the system operator/
ultimate owner with all equipment, as well as safety
precautions/requirements, shutdown procedure, and
the need for professional service annually before the
heating season begins.
Carbon monoxide
Improper installation, adjustment, service and/or
maintenance can cause flue products to flow into
living space. Flue products contain poisonous carbon
monoxide gas.
For information pertaining to the
proper installation, adjustment, service
and maintenance of this equipment to
avoid formation of carbon monoxide,
please see subsection entitled
“Mechanical room” and “Venting
requirements” in the “Installation Instructions”.
Fresh air
This equipment requires fresh air for
safe operation and must be installed
ensuring provisions for adequate
combustion and ventilation air exist.
For information pertaining to the
fresh air requirements of this product,
please see subsection entitled
“Mechanical room” in the “Installation
Instructions”.
Equipment venting
Never operate boiler without an installed venting
system. An improper venting system can cause
carbon monoxide poisoning.
For information pertaining to
venting and chimney requirements,
please see section entitled “Venting
Connection”. All products of
combustion must be safely vented
to the outdoors.
Operating and Service Documentation
It is recommended that all product documentation such as
parts lists, operating and service instructions be handed
over to the system user for storage. Documentation is to
be stored near boiler in a readily accessible location for
reference by service personnel.
WARNING
This boiler requires fresh air for safe operation and must
be installed with provisions for adequate combustion
and ventilation air (in accordance with local codes and
regulations of authorities having jurisdiction).
Do not operate this boiler in areas with contaminated
combustion air. High levels of contaminants such as
dust, lint or chemicals can be found at construction
sites, home renovations, in garages, workshops, in dry
cleaning/laundry facilities, near swimming pools and in
manufacturing facilities.
Contaminated combustion air will damage the boiler
and may lead to substantial property damage, severe
personal injury and/or loss of life. Ensure boiler/burner is
inspected and serviced by a qualified heating contractor
at least once a year in accordance with the Service
Instructions of the boiler.

Vitodens 200-W B2HA 112, 150 Service
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Safety
Safety, Installation and Warranty Requirements
WARNING
Inhaling of fiberglass wool and/or ceramic fiber
materials is a possible cancer hazard. These materials
can also cause respiratory, skin and eye irritation.
Fiberglass wool and ceramic fiber materials
WARNING
Appliance materials of construction, products of
combustion and the fuel contain alumina, silica, heavy
metals, carbon monoxide, nitrogen oxides, aldehydes
and/or other toxic or harmful substances which can
cause serious injury or loss of life and which are
known to the State of California to cause cancer,
birth defects and other reproductive harm. Always
use proper safety clothing, respirators and equipment
when servicing or working nearby the appliance.
The state of California has listed the airborne fibers of
these materials as a possible cancer hazard through
inhalation. When handling these materials, special care
must be applied.
First aid measures
- If eye contact occurs, flush eyes with water to
remove dust. If symptoms persist, seek medical
attention.
- If skin contact occurs, wash affected areas gently
with soap and warm water after handling.
Suppliers of fiberglass wool products recommend the
following precautions be taken when handling these
materials:
- Avoid breathing fiberglass dust and contact with
skin and eyes.
- Use NIOSH approved dust/mist respirator.
- Wear long-sleeved, loose fitting clothing, gloves
and eye protection.
- Wash work clothes separately from other clothing.
Rinse washer thoroughly.
- Operations such as sawing, blowing, tear-out and
spraying may generate airborne fiber concentration
requiring additional protection.
Suppliers of ceramic fiber products recommend the
following first aid measures:
- Respiratory tract (nose and throat) irritation:
If respiratory tract irritation develops, move the
person to a dust free location.
-Eye irritation: If eyes become irritated, flush
immediately with large amounts of lukewarm water
for at least 15 minutes. Eyelids should be held away
from the eyeball to ensure thorough rinsing.
Do not rub eyes.
- Skin irritation: If skin becomes irritated, remove soiled
clothing. Do not rub or scratch exposed skin.
Wash area of contact thoroughly with soap and water.
Using a skin cream or lotion after washing may be
helpful.
- Gastrointestinal irritation: If gastrointestinal tract
irritation develops, move the person to a dust free
environment.

Vitodens 200-W B2HA 112, 150 Service
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Table of Contents
Safety, Installation and Warranty Instructions................2
About these Installation Instructions.............................6
Necessary Tools.........................................................6
Important Regulatory and Installation Requirements........7
Applicability..............................................................9
Product Information....................................................9
Mechanical Room.....................................................10
Accessing the User Interface Programming Unit...........11
Select Language.......................................................11
Set Time and Date....................................................11
Removing Front Enclosure Panel.................................12
Fill Condensate Trap with Water.................................12
Fill Heating System with Water...................................13
Bleed (Vent) Air from Boiler Heat Exchanger................14
Check Power Supply Connection................................15
Designating Heating Circuits......................................15
Select Gas Type.......................................................15
Convert Fuel Type to Liquid Propane Gas.....................16
Setting High Altitude.................................................16
Measure Static Pressure and Running Pressure.............17
Pressure Switches.....................................................18
Sequence of Operation and Potential Faults
During Each Start-up Cycle........................................19
Set Maximum Input...................................................20
Check all Primary and Secondary Circuit
Connections for Leaks...............................................20
Perform Combustion Analysis.....................................20
Check Coaxial Venting System for Leaks.....................21
Remove Burner Assembly..........................................21
Checking the Flue Gas Flapper....................................22
Check Burner Refractory............................................22
Check and Adjust Ignition and Ionization Electrodes......23
Clean Combustion Chamber/Heat Exchanger Surface....23
Check Condensate Drain.........................................24
Check Neutralization Unit (if applicable)......................25
Check Diaphragm Expansion Tank and System Pressure...25
Check Functioning of Safety Valves............................26
Check Electrical Connections......................................26
Check Pipes and Fittings for Leaks..............................26
Clock Natural Gas Meter............................................27
Check CO2Setting....................................................28
Start-up and Shutdown..............................................29
Menu......................................................................29
Functional Description...............................................31
Combustion Management Systems.............................31
Installation Examples.................................................32
Heating Curve Adjustments........................................36
Connecting the Boiler Control to a LON System............38
Safety
General Information
Start-up and Service
Outdoor Reset Programming Unit
Page

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Table of Contents
Coding 1
Coding 2
Diagnosis and Service Scans
Troubleshooting
Function Description
Additional Information
General...................................................................40
Boiler......................................................................42
DHW.......................................................................42
Solar.......................................................................43
Heating Circuit 1, 2 and 3..........................................44
General...................................................................48
Boiler......................................................................55
DHW.......................................................................56
Solar.......................................................................58
Heating Circuit 1, 2 and 3..........................................62
Calling up the Service Level........................................68
Diagnosis.................................................................69
Checking Outputs (Relay Test)...................................71
Fault Display............................................................72
Fault Codes..............................................................72
Corrective Action......................................................80
Checking the outside temperature sensor..................80
Check fuse...........................................................80
Check fuses in the external accessories
connection box......................................................80
Checking the boiler temperature sensor and
fixed high limit, DHW tank temperature sensor or
flow temperature sensor for the low loss header........81
Check the flue gas temperature sensor.....................82
Extension kit for heating circuit with mixing valve......83
Checking the rotational direction of the
mixing valve motor.................................................83
Check the Vitotronic 200-H (accessories)..................83
External Extensions AM1 (accessory)..........................84
Internal Extensions EA1.............................................85
Control Functions......................................................87
Wiring Diagram.........................................................90
Burner Program Sequence of Operation........................92
Parts List.................................................................93
Technical Data.........................................................98
Maintenance Record................................................100
Lighting and Operating Instructions............................101
Page

Vitodens 200-W B2HA 112, 150 Service
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General Information
About these Service Instructions
Take note of all symbols and notations intended to draw attention to potential hazards or important product
information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below.

IMPORTANT
Warnings draw your attention to the presence of
potential hazards or important product information.
Cautions draw your attention to the presence of
potential hazards or important product information.
Helpful hints for installation, operation or maintenance
which pertain to the product.
This symbol indicates that additional, pertinent
information is to be found.
This symbol indicates that other instructions must
be referenced.
WARNING
Indicates an imminently hazardous situation which,
if not avoided, could result in loss of life, serious injury
or substantial product/property damage.
CAUTION
Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product/
property damage.
Necessary Tools
Testing/analysis equipment (Use only calibrated equipment)
HMultimeter to measure 0 - 120 V, 0 - 12A AC and
0-100 mA DC
HFlue gas analyzer to measure % CO2or O2(i.e.
Bacharach fluid samplers or suitable electronic analyzer)
HManometer to measure gas pressure 0 to 11 "w.c.
(accurately) and up to 28 "w.c. gas pressure (or a non-
electric Magnehelic® manometer may also be utilized)
HStack thermometer 0 to 500°F (0 to 260°C)
HBacharach calculator or suitable tables to calculate
efficiency
HCarbon monoxide measuring equipment 0 to 400 ppm
Cleaning supplies
HPlastic hand brush
HRags
Special items
HApproved leak detection fluid for natural gas and
liquid propane gas
HPipe joint sealant

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General Information
Important Regulatory and Installation Requirements
Codes
The installation of this unit shall be in accordance with
local codes or, in the absence of local codes, use CAN/
CSA-B149.1 or .2 Installation Codes for Gas Burning
Appliances for Canada. For U.S. installations use the
National Fuel Gas Code ANSI Z223.1. Always use latest
editions of codes.
In Canada all electrical wiring is to be done in accordance
with the latest edition of CSA C22.1 Part 1 and/or local
codes. In the U.S. use the National Electrical Code ANSI/
NFPA 70. The heating contractor must also comply with
both the Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1, and
the Installation Code for Hydronic Heating Systems,
CSA B214-01, where required by the authority having
jurisdiction.
Instructing the system user
The installer of the system is responsible to ensure the
system operator/ultimate owner is made familiar with the
system functioning, its activation, and its shut-down.
Initial start-up
Initial start-up must be performed by a qualified heating
contractor. Proper completion of the Maintenance Record
by the heating contractor is also required.
Working on the equipment
The installation, adjustment, service, and maintenance
of this boiler must be done by a licensed professional
heating contractor who is qualified and experienced in
the installation, service, and maintenance of hot water
boilers. There are no user serviceable parts on the boiler,
burners or control.
Ensure main power supply to equipment, the heating
system, and all external controls has been deactivated.
Close main gas supply valve. Take precautions in all
instances to avoid accidental activation of power during
service work.
The completeness and functionality of field supplied
electrical controls and components must be verified by
the heating contractor. These include low water cut-
offs, flow switches (if used), staging controls, pumps,
motorized valves, air vents, thermostats, etc.
The following topics must be covered:
Proper system operation sequence.
Explain the equipment.
Demonstrate an emergency shut-down, what to do and
what not.
Explain that there is no substitute for proper maintenance
to help ensure safe operation.
The Maintenance Record is located in the Service
Instructions
Please carefully read this manual prior to attempting start-
up, maintenance or service. Any warranty is null and void
if these instructions are not followed.
For information regarding other Viessmann System
Technology componentry, please reference documentation
of the respective product.
We offer frequent installation and service seminars to
familiarize our partners with our products. Please inquire.
Technical literature
Literature for the Vitodens boiler:
- Technical Data Manual
- Installation Instructions
- Service Instructions
- Operating Instructions and User’s Information Manual
- Instructions of other Viessmann products utilized and
installed
- Installation codes mentioned in this manual
Leave all literature at the installation site and advise the
system operator/ultimate owner where the literature can
be found. Contact Viessmann for additional copies.
This product comes with several safety instruction labels
attached.
Do not remove!
Contact Viessmann immediately if replacement labels are
required.

Vitodens 200-W B2HA 112, 150 Service
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8
Important Regulatory and Installation Requirements (continued)
General Information
For installations on the Commonwealth of Massachusetts, the following modifications to NFPA-54 chapter 10 apply:
Excerpt from 248 CMR 5-08:
2(a) For all side-wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in
whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side-
wall exhaust vent termination is less than (7) feet above finished grade in the area of the venting, including but not limited
to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side-wall horizontal vented gas
fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an
alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the
installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an
alarm is installed on each additional level of the dwelling, building or structure served by the side-wall horizontal vented
gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed
professional for the installation of hard-wired carbon monoxide detectors.
a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the
hard-wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the
owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during
said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with
the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a
minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented
gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size,
“GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. INSPECTION. The state or local gas inspector of the side-wall horizontally vented gas fueled equipment shall not
approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage
installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition
of NFPA 54 as adopted by the Board; and
2. Product Approved side-wall horizontally vented gas fueled equipment installed in a room or structure separate
from the dwelling, building or structure used in whole or in part for residential purposes.
CSD-1 Field Testing of High Limit Switches for Vitodens boilers – where required by law.
As per ASME Boiler and Pressure Vessel Code, section IV, subsection HG-613 TEMPERATURE CONTROL requirements,
Vitodens 200-W hot water boilers are protected from over-temperature by two temperature-operated controls. These
temperature control devices conform to Standards for Limit Controls, and are accepted by CSA,
a nationally recognized testing agency.
Each boiler is equipped with a manual reset high temperature limit control and a temperature control that will cut off fuel
supply when the system water temperature reaches a preset operating temperature.
VIESSMANN IS NOT RESPONSIBLE FOR ANY DAMAGES THAT THE FOLLOWING TEST PROCEDURE MAY RESULT
IN BY OVERHEATING THE SYSTEM.
The Vitodens 200 boilers are equipped with flow switches or sensors that when activated enable the burner to operate.
The fixed high limit, when tripped, produces a fault that will require manual reset of the boiler control.
Fixed High Limit fault simulation #1:
- Close the boiler valve and jumper across the flow switch.
- Run the boiler at high fire and it will shut down by the coding card (in B2TB models, set coding address 06 to
maximum) but should continue to steady increase the boiler temperature until the fixed high limit is tripped.
- Once the fixed high limit is tripped, slowly open the boiler valve to safely cool the boiler down.
Fixed High Limit fault simulation #2:
- Throttle the boiler valve to a point where the burner will run with as little flow as possible.
- Run the boiler to high fire via relays test.
- When the burner shuts down on the electronic limit, close the ball valve to stop the flow.
- The boiler temperature should continue a steady increase to trip the fixed high limit.
- Once the fixed high limit is tripped, slowly open the boiler valve to safely cool the boiler down.
Fixed High Limit fault simulation #3:
- Remove one of the wires connected to limit switch, this will produce a fault in the boilers control that requires
manual reset.
Flow Switch /Sensor Test:
The Vitodens 200 B2HA models 112 and 150 boilers are equipped with two flow sensing devices. Upon detection of an
inadequate flow rate, the switches will shut down the burner and will prevent restarting until an adequate flow rate is
restored. To test the sensors, throttle down the flow of water to or from the boiler. The boiler will shut down once the
flow has dropped below it’s safe operating set point.

Vitodens 200-W B2HA 112, 150 Service
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Applicability
General Information
Natural gas-fired wall-mounted condensing heating boiler
for weather-responsive operation in closed loop, forced
circulation hot water heating systems for space heating
and domestic hot water (DHW) production.
Models B2HA series boilers are for operation with natural
gas. For a fuel conversion to liquid propane gas (see page
16).
Boiler model must be selected based on an accurate heat
loss calculation of the building. Ensure boiler model is
compatible with connected radiation.
Vitodens 200-W, B2HA series boilers are factory-tested
and calibrated. Further gas valve adjustments are not
typically required during field start-up.
Product Information
CAUTION
The boiler serial number must be provided when
ordering replacement parts. Some replacement parts are
not reverse compatible with previous versions of the
Vitodens 200-W B2HA boiler.
When ordering replacement parts, provide either the
16-digit boiler serial number (on the bar code label) or
the 12-digit ASME/NB serial number, located as shown
underneath boiler front enclosure panel. Refer to page 12
for instructions on how to remove front enclosure panel.
Model No. B2HA 112
Serial No. 7510835 jjjjjjjjj
Model No. B2HA 150
Serial No. 7510836 jjjjjjjjj
IMPORTANT
AInox-Radial heat exchanger made from stainless steel
– for high operational reliability and a long service life.
Large heating output in the smallest of spaces
B Modulating MatriX cylinder burner for extremely
clean combustion and quiet operation
CVariable speed combustion fan for quiet and
economical operation
DGas and water connections
EDigital boiler control unit
Multi boiler system
In connection with the installation of a multi boiler system
observe the installation instructions of the multi boiler
system accessories.
Product may not be exactly as shown
Follow the Vitodens Venting System
Installation Instructions to vent this boiler.

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10
Mechanical Room
General Information
During the early stages of designing a new home, we recommend that proper consideration be given to constructing a
separate mechanical room dedicated to the gas- or oil-fired heating equipment and domestic hot water storage tank(s).
The boiler must be located in a heated indoor area, near a floor drain, and as close as possible to a wall. Whenever
possible, install the boiler near an outside wall so that it is easy to duct the venting system to the boiler.
Locate the boiler on a wall capable of supporting the weight of the boiler filled with water (see section entitled
“Technical Data” on page 98 for information required for total boiler weight calculation). Ensure that the boiler location
does not interfere with the proper circulation of combustion and ventilation air of other fuel burning equipment within
the mechanical room (if applicable).
The maximum room temperature of the mechanical room where the boiler is located must not exceed 104ºF (40ºC).
HEnsure ambient temperatures are higher than 32°F
(0°C) and lower than 104°F (40°C).
HPrevent the air from becoming contaminated by
halogenated hydrocarbons (e.g. as contained in paint
solvents or cleaning fluids) and excessive dust (e.g.
through grinding or polishing work). Combustion air
for the heating process, and ventilation of the boiler
room must be free of corrosive contaminants. To that
end, any boiler must be installed in an area that has no
chemical exposure. The list to the right indicates the
main, currently known sources.
HAvoid continuously high levels of humidity (e.g. through
frequent drying of laundry).
HNever close existing ventilation openings.
Sources of combustion and ventilation air contaminants
Areas likely to contain contaminants:
HNew building construction
HSwimming pools
HRemodelling areas, hobby rooms
HGarages with workshops
HFurniture refinishing areas
HDry cleaning/laundry areas and establishments
HAuto body shops
HRefrigeration repair shops
HMetal fabrication plants
HPlastic manufacturing plants
HPhoto processing plants
HBeauty salons
Products containing contaminants:
HChlorine-type bleaches, detergents and cleaning
solvents found in household laundry rooms
HPaint and varnish removers
HHydrochloric acid, muriatic acid
HChlorine-based swimming pool chemicals
HSpray cans containing chlorofluorocarbons
HChlorinated waxes and cleaners
HCements and glues
HRefrigerant leaks
HCalcium chloride used for thawing
HSodium chloride used for water softening salt
HPermanent wave solutions
HAdhesives used to fasten building products and other
similar items
HAntistatic fabric softeners used in clothes dryers
Boiler operation in marine environments (damp, salty
coastal areas)
WARNING
If you notice fire coming from the appliance, call the fire
department immediately! Do not attempt to extinguish
the fire unless qualified to do so.
WARNING
Fire causes a risk of burns and explosion!
HShut down the boiler
HClose fuel shut-off valves
HUse a tested fire extinguisher, class ABC.
IMPORTANT
The service life of the boiler’s exposed metallic surfaces,
such as the casing and fan housing, is directly influenced
by proximity to damp and salty marine environments. In
such areas, higher concentration levels of chlorides from
sea spray, coupled with relative humidity, can lead to
degradation of the exposed metallic surfaces mentioned
above. Therefore, it is imperative that boilers installed
in such environments not be installed using direct vent
systems which draw outdoor air for combustion. Such
boilers must be installed using room air dependent vent
systems; i.e. using room air for combustion. The indoor
air will have a much lower relative humidity and, hence,
potential corrosion will be minimized.
Installation area conditions
WARNING
Incorrect ambient conditions can lead to damage to the
heating system and put safe operation at risk.

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Start-up and Service
Set Time and Date
Accessing the User Interface Programming Unit
Setting the time and date (if required)
During commissioning, or after prolonged time out of use,
the time and date need to be reset.
Extended menu:
1.
2. “Settings”
3. “Time / Date”
4. Set current time and date.
Select Language
1. Turn up both locks to unlock the user interface
programming unit covers.
2. Slide open the user interface programming unit
covers.
At the commissioning stage, the display is in German.
1. “Sprache” (Language) Deutsch DE (German)
2. Select the required language with
3. Accept by pressing OK.
To change the language
Extended menu:
1.
2. “Settings”
3. “Language”
4. Select the required language with
5. Accept by pressing OK.

Vitodens 200-W B2HA 112, 150 Service
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Start-up and Service
Fill Condensate Trap with Water
Filling the siphon with water
1. Undo union nut Fand pull off condensate trap C
downwards.
2. Fill condensate trap Cwith water.
3. Reinstall condensate trap C and reconnect union
nut F.
Removing Front Enclosure Panel
Some of the following service steps require the removal
of the front enclosure panel. To avoid personal injury
and/or product damage of any kind please follow the
instructions below carefully when removing the front
enclosure panel.
IMPORTANT
Close the main gas supply valve.
1. Remove the external accessories connection box
cover.
2. Loosen the screws at the bottom of the boiler as
shown (do not remove completely).
3. Slide out and remove front enclosure panel.
Legend
AOpen or vented field supplied drainage system
BFlexible discharge tubing
CCondensate trap
DRubber cap
EThreaded cap
FUnion nut

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Start-up and Service
Fill Heating System with Water
Maximum operating pressure...80 psig
Minimum operating pressure...14 to 23 psig
Pressure relief valve...............80 psig
CAUTION
Unsuitable fill water increases the level of deposits and
corrosion, and may lead to damage to the equipment.
HThoroughly flush the entire heating system prior to
filling with water.
HOnly use water of potable quality.
HThe water will have to be softened if it is harder than
8.77 grains / 150 ppm total dissolved solids.
HInhibitors or antifreeze additives suitable for heating
systems may be added manually.
3. To remove debris and/or sludge ensure that the
system piping is flushed out. Failure to do so could
cause settlement in the boiler causing overheating
and damage not covered by warranty.
Note: System fill pressure must be approximately
3 psig higher than the static head when the
system is cold.
4. Fill the heating system with water at the boiler fill (BF)
and drain air completely from the boiler drain (BD).
Note: Water treatment should be considered in areas
where it is known that boiler feed water
contains a high mineral content and hardness.
In areas where freezing might occur, an
antifreeze may be added to the system water
to protect the system. Please adhere to the
specifications given by the antifreeze
manufacturer. Do not use automotive silicate-
based antifreeze. Please observe that an
antifreeze/water mixture may require a
backflow preventer within the automatic
water feed and influence components such
as diaphragm expansion tanks, radiation, etc.
A 40% antifreeze content will provide freeze-up
protection to -10°F (-23°C). Do not use
antifreeze other than specifically made for hot
water heating systems. System also may
contain components which might be negatively
affected by antifreeze. Check total system
frequently when filled with antifreeze.
5. Bleeding the heating system
1. Close the gas shut-off valve and switch the
control unit ON.
2. Activate venting program (see next steps).
Note: During the venting program, the circulation
pump will be alternately switched ON and
OFF for 30 seconds respectively over a
period of 20 minutes. The burner is
switched OFF during the venting program.
3. Check the system pressure.
Activating filling (bleeding) program:
1. Press OK and simultaneously for approximately
4 seconds.
2. “Service functions”
3. “Filling”
4. Ending filling function: Press OK
or .
1. Open system isolation valves at Cand D(if
installed).
Note: Before filling the heating system with water,
check that all necessary flow check valves are
installed.
2. Check inlet pressure of the diaphragm expansion tank.
Note: If the nitrogen pressure of the precharged
expansion tank is less than the static pressure
of the system, inflate membrane pressure to
slightly exceed pressure of system.
The static pressure required at the tank is
based upon the static height of the system.
The system fill pressure value must be equal
to the expansion tank pressure value at
approximately 60ºF (15.6ºC).
Legend
BD Boiler Drain
BF Boiler Fill
BR Boiler Return
BS Boiler Supply
GC Gas Connection
PRV Pressure Relief Valve

Vitodens 200-W B2HA 112, 150 Service
5683 710 - 09
14
Bleed (Vent) Air from Boiler Heat Exchanger
Start-up and Service
Legend
BD Boiler Drain
BF Boiler Fill
BR Boiler Return
BS Boiler Supply
GC Gas Connection
PRV Pressure Relief Valve
1. Connect hose to boiler filling tap and other end to
a fresh water supply (or heating medium).
2. Open fresh water supply valve and then the boiler
filling tap slowly (isolation valves must be closed
during fill/bleed process).
3. Flush boiler heat exchanger via boiler supply and
return (for at least 10 minutes.) until all air is
removed from the boiler.
4. When the drain valve begins to bleed water, close
boiler drain valve, then boiler fill valve and open
system isolation valves.
5. a. Close the gas shut-off valve and switch the
control unit ON.
b. Activate venting program (see next steps).
Note: For function and sequence of the venting
program, see page 85.
c. Check the system pressure.
6. Activating the venting program:
Service menu
- Press OK and simultaneously for approximately
4 seconds.
- “Service functions”
- “Venting”
Venting function is enabled.
Ending venting function:
- Press OK or .
7. Check system pressure.
8. Ensure adequate fuel supply exists and open gas
shutoff valve.

Vitodens 200-W B2HA 112, 150 Service
15
5683 710 - 09
Start-up and Service
Check Power Supply Connection
Note: The outer conductor “L “ and the neutral conductor
“N” must not be interchanged.
See wiring diagram on page 88 in section entitled
“Additional Information”.
IMPORTANT
In Canada all electrical wiring is to be done in accordance
with the latest edition of CSA C22.1 Part 1 and/or local
codes. In the U.S. use the National Electrical Code ANSI/
NFPA 70. The heating contractor must also comply with
both the Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI, ASME CSD-1.
Select Gas Type
Note: the Vitodens 200-W, B2HA boiler is factory set to
operate with natural gas . See following subsection
for conversion instructions to liquid propane gas.
1. Ensure that the fuel type listed on the boiler rating
plate is the correct type for the installation being
attempted.
2. Record fuel type in Maintenance Record on page 96.
The Vitodens 200-W boiler is for use with gases whose
characteristics fall within the following ranges.
Do not use any other types of gas.
Natural gas Liquid propane gas
Heating value (gross) Btu/ft3970 to 1100 2466 to 2542
Specific gravity 0.57 to 0.70 1.522 to 1.574
Ultimate carbon dioxide (CO2) % 11.7 to 12.2 13.73 to 13.82
An external accessories connection box is attached to
the Vitodens 200-W, B2HA boiler, which requires a
120VAC power supply from a wall receptacle (15A fuse
protected).
Refer to the Installation Instructions shipped with the
boiler.
Voltage range
The voltage at connector 40 of the boiler control must be
120V (see wiring diagram).
Neutral conductor
The electrical power supply must have a neutral
conductor.
Designating Heating Circuits
In the delivered condition, the heating circuits are
designated "Heating circuit 1", "Heating circuit 2" and
"Heating circuit 3" (if installed).
If the system user prefers, the heating circuits can be
designated differently to suit the specific system.
To enter names for heating circuits:
Refer to the Operating Instructions

Vitodens 200-W B2HA 112, 150 Service
5683 710 - 09
16
Convert Fuel Type to Liquid Propane Gas
1. Set adjusting screw Aat the gas valve to “2” (using
a hex key, 2.5 mm).
Note: The Vitodens 200-W, B2HA boiler comes
factory adjusted for operation with natural gas.
Coding address “82” is set to “0” (operation
with natural gas) in the factory default setting.
2. Switch ON/OFF switch “8” to ON.
Note: Slide the black control cover outwards to
access the ON/OFF switch.
3. Call up coding level 2 (see page 45).
4. Call up “General”.
5. In coding address “11” select value “9”.
6. In coding address “82” select value “1” (operation
with liquid propane gas).
7. Go back to coding address “11” and select any value
(except “9”).
8. Terminate coding level 2 and open gas shut-off valve.
9. Apply supplied fuel conversion labels.
Start-up and Service
Setting High Altitude
In the factory default setting, the boiler is equipped to
operate in altitudes of up to 5,000 ft. (1,500 m).
Altitude can be set using coding address 93:
(in coding level 2 General).
- Coding 11:9 must be set in order to unlock coding 93:.
- 93:0 is reserved for altitudes up to 5000 ft. (1500 m).
- 93:6 must be set for altitudes from 5000 ft. (1500 m).
to 10000 ft. (3000 m)
- Setting back to 93:0 turns off the high altitude
function.
IMPORTANT
Do not set or use coding addresses 93:1 to 93:5.
- After setting coding address 93:, set coding address 11:0
- The program is automatically disabled after 20 minutes.

Vitodens 200-W B2HA 112, 150 Service
17
5683 710 - 09
1. To measure static and/or running pressure remove
boiler enclosure panel as indicated page 12 in these
instructions.
2. Close gas shutoff valve (field supplied).
3. Loosen screw at inlet gas pressure port Aon the
gas combination valve, do not remove completely.
Connect manometer.
4. Open the gas shutoff valve.
5. Measure static pressure. Values must be:
14 “w.c. maximum for NG
14 “w.c. maximum for LPG
6. Enter measured value into Maintenance Record on
page 96 in this manual.
7. Start up boiler, using the ON/OFF switch “8” on the
boiler control.
Note: Slide the black control cover outwards to
access the ON/OFF switch.
8. Measure the running pressure; value must be:
Note: Use suitable measuring instruments calibrated
with a minimum resolution of 0.04 “w.c. for
measuring the running pressure.
9. Enter gas type into Maintenance Record on page 96
in this manual.
10. Switch off the ON/OFF switch “8” on the boiler
control, close the gas shut-off valve, remove the
manometer and re-tighten the screw at inlet gas
pressure port A.
Start-up and Service
Measure Static Pressure and Running Pressure
A CO measurement (see page 25) must be taken before
and after working on gas appliances to eliminate risks to
health and to guarantee the satisfactory condition of the
system.
The burner is automatically ignited and starts operation
after a safety time has elapsed. During initial start-up,
the unit may indicate a fault because of air in the gas
supply pipe (especially for liquid propane gas). After
approx. 5 seconds, press the ”R” button to reset the
burner. The ignition procedure is repeated. This boiler
employs a direct spark ignition system.
WARNING
Ensure that there is no open flame in the room.
WARNING
Never purge a gas line into a combustion chamber.
Never use matches, candles, flame, or other sources of
ignition for purpose of checking leakage. Use a soap and
water solution to check for leakage. A failure to follow
this warning could result in fire, explosion, personal
injury or death.
IMPORTANT
IMPORTANT
Running supply pressure with Corrective action
NG LPG
under 4 ”w.c. under 4 ”w.c. Do not start the boiler.
Notify your gas supply
utility or LPG supplier.
4 to 14 “w.c. 10 to 14 “w.c. Start up boiler.
over 14 “w.c. over 14 “w.c. Do not attempt
adjustment. Call local
gas utility to decrease
pressure or install up
stream gas pressure
regulator. Boiler valve
must not be exposed to
pressure over 14 ”w.c.

Vitodens 200-W B2HA 112, 150 Service
5683 710 - 09
18
Pressure Switches
Start-up and Service
Rear View
GDW1 low pressure gas switch (n.c.)
When the gas pressure rises above 4” w.c. the switch
will open and the burner will operate. When the gas
pressure drops below 4” w.c. the switch will close and
the boiler control will shut off the burner.
GDW2 high pressure gas switch (n.o.)
When the gas pressure rises above 3.5” w.c. the switch
will close and the boiler control will shut off the burner.
If either switch is activated (closed position) the burner
will shut down, but no fault will be displayed on the
control.
Check address 38 in coding 2, if the value is 2 then one
of the switches has been activated (closed).

Vitodens 200-W B2HA 112, 150 Service
19
5683 710 - 09
Start-up and Service
Sequence of Operation and Potential Faults During Each Start-up Cycle
Measures
Call for heat by control
Fan starts up
Display message
Increase set value and ensure
heat is drawn off
yes
no After approx.
51 s fault F9
Check the fan, fan connecting cables,
power at the fan and fan control
yes
yes
yes
yes
no
no
no
no
Ignition
Gas combination valve opens
Ionization current builds
Symbol A
Burner in operation Stops below
the set boiler
water
temperature
and restarts
immediately
Fault EE
Fault EE
Fault EE Check the ignition module
(control voltage 120 V across
plugs “X2.1” and “X2.2”)
Fault EE Check the gas train
(control voltage 120 V); check
the gas supply pressure
Check the ionization electrode
adjustment and the gas line for airlocks
Check the flue gas system for tightness
(flue gas recirculation), check the gas
flow pressure
Automatic calibration of
the combustion controller
Fault E3
Fault EB
Ensure adequate heat transfer.
Press reset button R.
Check gap between ionization electrode
and burner gauze assembly. Check
allocation of gas type (coding address
82, gas train setting). Check flue system;
remedy flue gas recirculation if required.
Press reset button R.
yes
no
no
For further details regarding faults, see page 72.

Vitodens 200-W B2HA 112, 150 Service
5683 710 - 09
20
Start-up and Service
Set Maximum Input
The maximum input (or output) for heating operation can
be limited. The limit is set via the modulation range. The
maximum adjustable heating input (or output) is limited
upwards by the boiler coding card.
Note: The input for DHW production can be limited as
well. To do so, change coding address “6F” in
coding level 2.
1. Press OK and simultaneously for approximately
4 seconds.
2. “Service functions”
3. “Maximum output”
4. “Change?” Select “Yes”.
A value flashes on the display (e.g.“85”). In the
factory setting, this value represents 100%
of rated input (or output).
5. Select required value.
Check All Primary and Secondary Circuit Connections for Leaks
Perform Combustion Analysis
Check heating system and domestic hot water
connections (if applicable). Ensure all connections
are pressure tight. Correct any leaks found on fittings,
pumps, valves, etc.
A CO measurement (see page 28) must be taken before
and after working on gas appliances to eliminate risks to
health and to guarantee the satisfactory condition of the
system.
Record the measured combustion values in the sequence
stated in the Maintenance Record on page 100 in this
manual.
IMPORTANT