Viessmann Vitodens 200-W System Operating instructions

Service instructions
for contractors
VIESMANN
Vitodens 200-W
Type WB2C, 80 and 105 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 200-W
5692 902 GB 3/2011 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 902 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.)
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Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 6
Further details regarding the individual steps....................................................... 8
Code 1
Calling up coding level 1...................................................................................... 39
General/group "1"................................................................................................. 40
Boiler/group "2".................................................................................................... 42
DHW/group "3"..................................................................................................... 43
Solar/group "4"..................................................................................................... 44
Heating circuit 1, heating circuit 2, heating circuit 3/group "5"............................. 46
Code 2
Calling up coding level 2...................................................................................... 53
General/group "1"................................................................................................. 54
Boiler/group "2".................................................................................................... 62
DHW/group "3"..................................................................................................... 64
Solar/group "4"..................................................................................................... 66
Heating circuit 1, heating circuit 2, heating circuit 3/group "5"............................. 73
Diagnosis and service scans
Calling up the service level................................................................................... 81
Diagnosis.............................................................................................................. 82
Checking outputs (relay test)................................................................................ 88
Troubleshooting
Fault display......................................................................................................... 90
Fault codes........................................................................................................... 92
Repair................................................................................................................... 106
Function description
Constant temperature control unit........................................................................ 112
Weather-compensated control unit...................................................................... 113
Internal extensions (accessories)......................................................................... 114
External extensions (accessories)........................................................................ 116
Control functions.................................................................................................. 120
Allocating heating circuits to the remote control................................................... 127
Electronic combustion controller.......................................................................... 127
Designs
Connection and wiring diagram – internal connections ....................................... 129
Connection and wiring diagram – external connections....................................... 130
Index
Index
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Parts list
Heat cell assembly............................................................................................... 132
Burner assembly.................................................................................................. 134
Hydraulic assembly.............................................................................................. 135
Sheet metal parts assembly................................................................................. 136
VBC134-A04.102 control unit assembly............................................................... 137
Miscellaneous....................................................................................................... 138
Commissioning/service reports
............................................................................................................................. 140
Specification....................................................................................................... 141
Certificates
Declaration of conformity...................................................................................... 142
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 142
Keyword index.................................................................................................... 143
Index
Index (cont.)
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Opening the boiler.......................................................... 8
•2. Filling the heating system.............................................. 9
•3. Venting the boiler by flushing....................................... 10
•4. Selecting the language (if required) – only for
weather-compensated control units............................. 10
• • 5. Setting the time and date (if required) – only for
weather-compensated control units............................. 11
•6. Venting the heating system........................................... 11
•7. Filling the siphon with water......................................... 12
••• 8. Checking all connections on the heating water side
and DHW side for leaks
•9. Checking the power supply
•10. Designating heating circuits – only for weather-
compensated control units............................................ 12
• • 11. Checking the gas type.................................................... 13
•12. Gas type conversion (only for operation with LPG).... 13
••• 13. Function sequence and possible faults....................... 14
••• 14. Checking the static and supply pressure..................... 16
•15. Maximum output setting................................................ 18
•16. Checking the balanced flue system for tightness
(annular gap check)........................................................ 18
• • 17. Removing the burner and checking the burner gasket 19
• • 18. Checking the burner gauze assembly & replacing if
required........................................................................... 20
• • 19. Checking and adjusting the ignition and ionisation
electrodes........................................................................ 21
• • 20. Cleaning the combustion chamber/heat exchanger
and installing the burner................................................ 22
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
• • 21. Checking the condensate drain and cleaning the
siphon.............................................................................. 23
• • 22. Checking the neutralising system (if installed)
• • 23. Checking the diaphragm expansion vessel and
system pressure............................................................. 23
••• 24. Checking the function of safety valves
••• 25. Checking electrical connections for firm seating
••• 26. Checking gas equipment for tightness at operating
pressure .......................................................................... 24
••• 27. Flue gas emissions test................................................. 24
••• 28. Checking the external LPG safety valve (if installed)
•29. Matching the control unit to the heating system ........ 26
•30. Adjusting the heating curves (only for weather-
compensated control units)........................................... 33
•31. Connecting the control unit to the LON....................... 35
•32. Scanning and resetting the "Service" display............. 37
•33. Instructing the system user........................................... 38
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
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Opening the boiler
4.
2x
2.
3.
1.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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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 a water hardness in excess of the following values, e.g.
with a small softening system for heating water (see the Viessmann Vitoset
pricelist):
Single boiler systems and multi boiler systems ≤ 200 kW:
11.2 °dH (2.0 mol/m3)
Multi boiler systems > 200 kW: 8.4 °dH (1.5 mol/m3)
■ An antifreeze additive suitable for heating systems can be added to 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 boiler drain
& fill valve A. (Minimum system
pressure > 1.0 bar).
4. Close boiler drain & fill valve A.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Venting the boiler by flushing
E D
C
B
F
A
1. Close shut-off valves A and B.
2. Connect the drain hose to drain valve
C.
Connect the fill hose to boiler drain &
fill valve F (if no longer connec-
ted).
3. Close shut-off valve D.
4. Open valve F.
5. Vent the first indirect coil through
shut-off valve E at mains pressure
until no more air noise is audible.
6. Close shut-off valve E and open
shut-off valve D.
7. Vent the second indirect coil through
shut-off valve D at mains pressure
until no more air noise is audible.
8. Close valves C and F.
9. Open shut-off valve E.
Note
Shut-off valves D and E must be
open to enable the boiler to operate.
Selecting the language (if required) – only for weather-compen-
sated control units
Note
At the commissioning stage, the display
is in German (default setting)
Extended menu:
1. å
2. "Settings"
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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3. "Language"
Sprache
Cesky CZ
Deutsch DE
Dansk
English
DK
GB
Wählen mit
Ø
ç
4. Set the required language with /.
Setting the time and date (if required) – only for weather-com-
pensated control units
During commissioning, or after pro-
longed time out of use, the time and date
need to be reset.
Extended menu:
1. å
2. "Settings"
3. "Time / Date"
4. Set current time and date.
Venting the heating system
1. Close the gas shut-off valve and
switch the control unit ON.
2. Activate venting program (see next
steps).
Note
For function and sequence of the
venting program, see page 122.
3. Check the system pressure.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Activating the venting function
Weather-compensated control unit Constant temperature control unit
Service menu
1. Press OK and å simultaneously for
approx. 4 s.
2. "Service functions"
3. "Venting"
Venting function is enabled.
4. Ending venting function:
Press OK or ä.
Service menu
1. Press OK and å simultaneously for
approx. 4 s.
2. Select "5" and confirm with OK.
"On" flashes.
3. Enable the venting function with OK.
"EL on" is shown constantly.
4. Ending venting function:
Press ä.
Filling the siphon with water
B
C
A
1. Pull off cap A downwards.
2. Undo union nut B and pull off siphon
C downwards.
3. Fill siphon C with water and refit it.
Note
Never twist the supply hose during
assembly. Route the drain hose with-
out any bends and with a constant
fall.
4. Push on cap A from below.
Designating heating circuits – only for weather-compensated
control units
In the delivered condition, the heating
circuits are designated "Heating circuit
1", "Heating circuit 2" and "Heating cir-
cuit 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:
Operating instructions
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the gas type
The boiler is equipped with an electronic combustion controller that adjusts the burner
for optimum combustion in accordance with the prevailing gas quality.
■ Consequently, for natural gas there is no adjustment required across the entire
Wobbe index range.
The boiler can operate in the Wobbe index range 9.5 to 15.2 kWh/m3, (34.2 to
54.7 MJ/m3).
■ Convert the burner for operation with LPG (see "Gas type conversion" on
page 13).
1. Determine the gas type and Wobbe
index by asking your local gas supply
utility or LPG supplier.
2. Convert the burner for operation with
LPG (see page 13).
3. Record the gas type in the report on
page 140.
Gas type conversion (only for operation with LPG)
1
2
A
1. Set adjusting screw A on both gas
trains to "2".
2. Turn ON/OFF switch "8" ON.
3. Select the gas type in coding address
"82":
■ Call up code 2
■ Call up "General" (weather-com-
pensated control)
or
Group "1" (constant temperature
control)
■ In coding address "11", select
value "9"
■ In coding address "82", select
value "1" (LPG operation)
■In code "11" select value ≠ "9".
■ End service functions.
4. Open the gas shut-off valve.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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5. Affix label "G 31" (included with the
technical documentation) in a clearly
visible position, near the gas train on
the cover panel.
Function sequence and possible faults
Display Measures
Control unit
issues a heat
demand
no Increase set value
and ensure heat is
drawn off
yes
Fan starts no After approx. 51 s
fault F9
Check the fan, fan
connecting cables,
power at the fan
and fan control
yes
Ignition no Fault EE Check the ignition
module (control
voltage 230 V
across plugs
"X2.1" and "X2.2")
yes
Gas train opens no Fault EE Check the gas train
(control voltage
230 V); check the
gas supply pres-
sure
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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yes
Ionisation current
builds
Symbol A
no Fault EE Check the ionisa-
tion electrode
adjustment and the
gas line for air-
locks
yes
Burner in opera-
tion
no Stops below the
set boiler water
temperature and
restarts immedi-
ately
Check the flue gas
system for tight-
ness (flue gas
recirculation),
check the gas flow
pressure
yes
Automatic calibra-
tion of the com-
bustion controller
no
Fault E3 Ensure adequate
heat transfer.
Press reset button
R.
Fault Eb Check gap
between ionisation
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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For further details regarding faults, see
page 90.
Checking the static and supply pressure
Danger
CO build-up as a result of incorrect burner adjustment can have serious health
implications.
Carry out a CO test before and after work on gas appliances.
Operation with LPG
Flush the LPG tank twice during commissioning or replacement. Vent the tank and
gas supply line thoroughly after flushing.
A
1. Close the gas shut-off valve.
2. Release screw A inside test nipple
"PE" on one of the two gas trains, but
do not remove it; then connect the
pressure gauge.
3. Open the gas shut-off valve.
4. Check the static pressure and record
it in the report on page 140.
Set value: max. 57.5 mbar.
5. Start the boiler.
Note
During commissioning, the boiler can
enter a fault state because of airlocks
in the gas line. After approx. 5 s,
press R to reset the burner.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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6. Check the supply (flow) pressure. Set
values:
■ Natural gas 20 mbar
■ LPG 50 mbar
Note
Use a suitable measuring device with
a resolution of at least 0.1 mbar to
check the supply pressure.
7. Record the actual value in the
report.
Take the action shown in the follow-
ing table.
8. Shut down the boiler, close the gas
shut-off valve, remove the pressure
gauge and close test nipple A with
the screw.
9. Danger
Gas escaping from the test
nipple leads to a risk of explo-
sion.
Check for gas tightness.
Open the gas shut-off valve, start the
boiler and check for tightness at test
nipple A.
Supply (flow) pres-
sure for natural
gas
Supply (flow)
pressure for LPG
Measures
below 15 mbar below 42.5 mbar Do not start the boiler. Notify your gas
supply utility or LPG supplier.
15 to 25 mbar 42.5 to 57.5 mbar Start the boiler.
above 25 mbar above 57.5 mbar Install a separate gas pressure governor
upstream of the system and regulate the
pre-charge pressure to 20 mbar for natu-
ral gas or 50 mbar for LPG. Notify your
gas supply utility or LPG supplier.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Maximum output setting
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.
Weather-compensated control unit:
1. Press OK and å simultaneously
for approx. 4 s.
2. "Service functions"
3. "Max. output"
4. "Change?" Select "Yes".
A value flashes on the display (e.g.
"85"). In the delivered condition, this
value represents 100 % of rated out-
put.
5. Select required value.
Constant temperature control unit:
1. Press OK and å simultaneously
for approx. 4 s.
2. Select Ú "3" and confirm with OK.
A value flashes on the display (e.g.
"85") and "A" appears. In the deliv-
ered condition, this value represents
100 % of rated output.
3. Select required value and confirm
with OK.
Checking the balanced flue system for tightness (annular gap
check)
A
ACombustion air aperture
For balanced flue systems tested
together with the wall mounted gas fired
boiler, the requirement for a tightness
test during commissioning by the flue
gas inspector is not applicable.
We recommend that your heating engi-
neer carries out a simple leak/tightness
test during the commissioning of your
system. For this, it would be sufficient to
check the CO2 or O2 concentration in the
combustion air at the annular gap of the
balanced flue pipe.
The flue pipe is deemed to be gas-tight
if the CO2 concentration in the combus-
tion air is no higher than 0.2 % or the
O2 concentration is at least 20.6 %.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 902 GB

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If actual CO2 values are higher or O2 val-
ues are lower, then pressure test the flue
pipe with a static pressure of 200 Pa.
Removing the burner and checking the burner gasket
K
F
D
H
E
C
A
L
G
B
1. Switch OFF the main power supply
and the ON/OFF switch at the control
unit.
2. Close the gas shut-off valve and safe-
guard against reopening.
3. Unlock control unit A and pivot for-
wards.
4. Remove cover panel B.
5. Pull cables from fan motor C, gas
train D, ignition unit E, earthing
point F and ionisation electrode
G.
6. Release gas supply pipe fittings H.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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7. Undo six screws K and remove the
burner.
!Please note
To prevent any damage,
never touch the mesh of the
burner gauze assembly.
8. Check burner gasket L for damage.
Replace gasket if required.
Checking the burner gauze assembly & replacing if required
A
CB3x EF D4x
1. Remove electrodes A.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 902 GB