Viessmann Vitodens 200-W System Operating instructions

Service instructions
for contractors
VIESMANN
Vitodens 200-W
Type WB2C
Wall mounted gas condensing boiler
4.8 to 35 kW natural gas and LPG version
Gas Council no.:
41-819-14; 41-819-15; 41-819-16; 41-819-17 (system boilers)
47-819-09; 47-819-10; 47-819-11 (combi boilers)
For applicability, see the last page
VITODENS 200-W
5692 857 GB 4/2010 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
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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 menu................................................................................. 83
Diagnosis.............................................................................................................. 83
Checking outputs (relay test)................................................................................ 89
Troubleshooting
Fault display......................................................................................................... 91
Fault codes........................................................................................................... 93
Repairs................................................................................................................. 105
Function description
Constant temperature control unit........................................................................ 115
Weather-compensated control unit...................................................................... 116
Internal extensions (accessories)......................................................................... 118
External extensions (accessories)........................................................................ 120
Control functions.................................................................................................. 124
Allocating heating circuits to the remote control................................................... 132
Electronic combustion controller.......................................................................... 132
Designs
Connection and wiring diagrams – internal connections ..................................... 134
Connection and wiring diagram – external connections....................................... 136
Index
Index
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Parts lists............................................................................................................ 138
Commissioning/service reports........................................................................ 144
Specification....................................................................................................... 145
Certificates
Declaration of conformity...................................................................................... 147
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 148
Keyword index.................................................................................................... 149
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. Filling the heating system.............................................. 8
•2. Checking power supply connection
•3. Selecting the language (if required) - only for weather-
compensated control units............................................ 9
• • 4. Setting the time and date (if required) - only for
weather-compensated control units............................. 9
• • 5. Setting the time and date (if required) - for constant
temperature control units.............................................. 10
•6. Venting the boiler........................................................... 10
•7. Venting the heating system........................................... 11
•8. Filling the siphon with water......................................... 12
••• 9. Checking all connections on the heating water side
and DHW side for leaks
•10. Designating heating circuits – only for weather-
compensated control units............................................ 12
• • 11. Checking the gas type.................................................... 12
•12. Gas type conversion (only for operation with LPG).... 13
••• 13. Function sequence and possible faults....................... 13
••• 14. Checking the static and supply pressure..................... 15
•15. Setting the maximum output......................................... 17
•16. Checking the balanced flue system tightness (annular
gap check)....................................................................... 18
• • 17. Burner removal .............................................................. 19
• • 18. Checking the burner gasket and the burner gauze
assembly......................................................................... 19
• • 19. Checking and adjusting the ignition and ionisation
electrodes........................................................................ 21
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
• • 20. Cleaning the heat exchanger and installing the
burner.............................................................................. 21
• • 21. Checking the condensate drain and cleaning the
siphon.............................................................................. 23
• • 22. Checking the neutralising system (if installed)
•23. Checking the flow limiter (only for gas combi
boilers)............................................................................. 24
• • 24. Checking the diaphragm expansion vessel and
system pressure............................................................. 24
••• 25. Checking the function of safety valves
••• 26. Checking electrical connections for firm seating
••• 27. Checking all gas equipment for tightness at operating
pressure........................................................................... 25
• • 28. Checking the combustion quality................................. 25
••• 29. Checking the external LPG safety valve (if installed)
•30. Matching the control unit to the heating system......... 27
•31. Adjusting the heating curves (only for weather-
compensated control units)........................................... 32
•32. Connecting the control unit to the LON system (only
for weather-compensated control units)...................... 35
•33. Scanning and resetting the Service display................ 37
•34. Instructing the system user........................................... 38
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
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Filling the heating system
!Please note
Unsuitable fill water increases the level of deposits and corrosion and may
lead to boiler damage.
■ Thoroughly flush the entire heating system prior to filling it with water.
■ Only use fill water of potable quality.
■Soften fill water with hardness exceeding 300 ppm (3.0 mol/m3), e.g. using
a small softening system for heating water (see Viessmann Vitoset pricelist).
■ An antifreeze additive suitable for heating systems can be added to the fill
water. The antifreeze manufacturer must verify its suitability.
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 in the heating return (at
the connection set or on site) (mini-
mum system pressure > 1.0 bar).
Note
If the control unit has not been
switched ON prior to filling the sys-
tem, then the servomotor of the
diverter valve will still be in its central
position, and the system will be com-
pletely filled.
Note
If an external filling loop is fitted, it
must meet the requirements of the
Water Fittings Regulations 1999 Sec-
tion G 24.1 and G 24.2.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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4. If the control unit had already been
switched ON before filling began:
Switch control unit ON and activate
filling function (see next chapter).
5. Close boiler drain & fill valve A.
Activating filling function with
weather-compensated control units:
1. Press OK and å simultaneously
for approx. 4 s.
2. "Service functions"
3. "Filling"
4. Ending filling function:
Press OK or ä.
Activating filling function with con-
stant temperature control units:
1. Press OK and å simultaneously
for approx. 4 s.
2. Select "4" with Ú and confirm with
OK.
When the filling function is active, "bF
on" will be displayed.
3. Ending filling function:
Press ä.
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"
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Setting the time and date (if required) - for constant temperature
control units
The time and date need to be reset dur-
ing commissioning or after prolonged
time out of use. After starting the system,
the display flashes the time ( ).
Press the following keys:
1. / for the required time.
2. OK to confirm; the new time unit is
saved, appears.
3. / for the required date.
4. OK to confirm; the new date is
saved.
Venting the boiler
B
A
1. Close the shut-off valves on the heat-
ing water side.
2. Connect the drain hose between top
valve B and a drain outlet.
3. Open valves A and B, and vent at
mains pressure until no sound of
escaping air can be heard.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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4. Close valves A and B, remove the
filling equipment and open the shut-
off valves on the heating water side.
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 126.
3. Check the system pressure.
Activating the venting program with
weather-compensated control units:
1. Press OK and å simultaneously
for approx. 4 s.
2. "Service functions"
3. "Venting"
4. Terminating venting program:
Press OK or ä.
Activating venting program with con-
stant temperature control units:
1. Press OK and å simultaneously
for approx. 4 s.
2. Select "5" with Ú and confirm with
OK.
When the venting function is active,
"EL on" will be displayed.
3. Terminating venting program:
Press ä.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Filling the siphon with water
AB
1. Remove retaining clip A and siphon
B.
2. Fill siphon B with water.
3. Fit siphon B and secure with retain-
ing clip A.
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
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 be operated 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).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 857 GB

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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 service
report on page 144.
Gas type conversion (only for operation with LPG)
1
2
A
1. Set adjusting screw A at the gas
train to "2".
2. Turn ON/OFF switch 8 ON.
3. Select the gas type in coding address
"82":
■ Call up code 2
■"General" (control unit for
weather-compensated mode)
or
Group "1" (constant temperature
control units) - call up
■ 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.
5. Affix label "G31" (supplied with the
technical documentation) adjacent to
the type plate on the top.
Function sequence and possible faults
Display Measures
Control unit
issues a heat
demand
no Increase set value
and ensure heat is
drawn off
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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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
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
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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yes
Automatic calibra-
tion of the com-
bustion controller
no Fault Eb Initiate a heat
draw-off. Switch
the boiler OFF and
ON again.
Press reset button
R.
For further fault details, see page 91.
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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A
1. Close the gas shut-off valve.
2. Undo screw A inside test nipple
"IN" on the gas train but do not
remove it, and connect the pressure
gauge.
3. Open the gas shut-off valve.
4. Measure the static pressure and
record it in the service report on
page 144.
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
reset button R to reset the burner.
6. Check the supply (flow) pressure.
Set value:
■ Natural gas: 20 mbar
■ LPG: 37 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 service
report on page 144.
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. Open the gas shut-off valve and start
the boiler.
Danger
Gas escaping from the test
nipple leads to a risk of explo-
sions.
Check test nipple A for tight-
ness.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Supply pressure (flow pressure) Measures
for natural gas for LPG
below 17.4 mbar below 25 mbar Do not start the boiler. Notify your gas
supply utility or LPG supplier.
17.4 to 25 mbar 25 to 47 mbar Start the boiler.
above 25 mbar above 47 mbar Install a separate gas pressure governor
upstream of the system and regulate the
supply pressure to 20 mbar for natural
gas or 37 mbar for LPG. Notify your gas
supply utility or LPG supplier.
Setting the maximum output
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the balanced flue system 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 %.
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Burner removal
G
D
E
4x
C
B
A
F
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. Pull cables from fan motor A, gas
train B, ionisation electrode C,
ignition unit D and earth tab E.
4. Release gas supply pipe fitting F.
5. Undo four screws G and remove the
burner.
!Please note
To prevent damage,
never rest the burner on the
gauze assembly.
Checking the burner gasket and the burner gauze assembly
Check burner gasket A and burner gauze assembly E for damage and replace if
required.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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B F 3xE D A C
1. Remove electrodes B.
2. Undo three retaining clips C at ther-
mal insulation ring D and remove
thermal insulation ring D.
3. Undo four Torx screws and remove
burner gauze assembly E with its
gasket F.
4. Insert and secure a new burner
gauze assembly E with a new gas-
ket F.
Torque: 3.5 Nm.
5. Refit thermal insulation ring D.
6. Refit electrodes B.
Torque: 4.5 Nm.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 857 GB