Viessmann Vitodens 200-W System Quick guide

Installation and service instructions
for contractors
VIESMANN
Vitodens 200-W
Type B2HA, 45 and 60 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 200-W
5623 715 GB 2/2013 Please keep safe.

2
Please follow these safety instructions closely to
prevent accidents and material losses.
Safety instructions explained
Danger
This symbol warns against the risk of injury.
!Please note
This symbol warns against the risk of material
losses and environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for quali-
fied contractors.
■Work on gas installations must only be carried out by
a registered gas fitter.
■Work on electrical equipment must only be carried
out by a qualified electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
Regulations
Observe the following when working on this system:
■Statutory regulations regarding the prevention of
accidents
■Statutory regulations regarding environmental pro-
tection
■Codes of practice of the 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) Regulations
– the appropriate Building Regulation either the
Building regulations, the Building Regulation (Scot-
land), Building Regulations (Northern Ireland),
– the Water Fittings Regulation or Water Bylaws in
Scotland,
– the current I.E.E. Wiring Regulations.
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Do not smoke. Prevent naked flames and
sparks. Do not switch lights or electrical appli-
ances on or off.
■Close the gas shut-off valve.
■Open windows and doors.
■Evacuate any people from the danger zone.
■Notify your gas or electricity supply utility from
outside the building.
■Shut off the electricity supply to the building
from a safe place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threatening poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close all doors in the living space.
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of conden-
sate or other causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Life-threatening poisoning caused by carbon
monoxide in the flue gas occurs as a result of
leaking or blocked flue systems or an insufficient
supply of combustion air.
Ensure the flue system is in proper working
order. It must not be possible to close apertures
for interconnected combustion air supply.
Extractors
Operating appliances that extract air to the outside
(cooker hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to reverse flow of the
flue gas.
Danger
The simultaneous operation of the boiler and
appliances that extract air to the outside can
result in life threatening poisoning due to
reverse flow of the flue gas.
Fit an interlock circuit or take suitable steps to
ensure a sufficient supply of combustion air.
Safety instructions
Safety instructions
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3
Working on the system
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■Isolate the system from the power supply (e.g. by
removing the separate fuse or by means of a mains
isolator) and check that it is no longer 'live'.
■Safeguard the system against reconnection.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing any work, touch earthed
objects, such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of your
system.
Defective components must be replaced with
genuine Viessmann spare parts.
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5623 715 GB

4
1. Product information Intended use .......................................................................................... 7
Product information ................................................................................ 7
■Vitodens 200-W, type B2HA ............................................................... 7
2. Preparing for installation .................................................................................................................. 8
3. Installation sequence Fitting the boiler and making connections ............................................. 9
■Fitting the wall mounting bracket ........................................................ 9
■Hooking the boiler onto the wall mounting bracket and levelling it ..... 10
Connections on the heating water side .................................................. 11
Flue gas connection ............................................................................... 11
Condensate connection ......................................................................... 12
Gas connection ...................................................................................... 12
Opening the control unit casing ............................................................. 12
Electrical connections ............................................................................ 14
■Circulation pump at plug sÖ ................................................................ 15
■Circulation pump at plug sA ................................................................ 15
■External demand via switching contact .............................................. 15
■External demand via 0 – 10 V input .................................................... 16
■External blocking via switching contact .............................................. 17
■Outside temperature sensor ! .......................................................... 17
■Power supply for accessories at plug lH (230 V~) ............................. 18
■Power supply fÖ ................................................................................. 18
■Routing the connecting cables ........................................................... 19
Closing the control unit casing and inserting the programming unit ...... 20
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 21
5. Code 1 Calling up coding level 1 ........................................................................ 45
■Calling up coding level 1 ..................................................................... 45
General/group "1" .................................................................................. 45
■Coding ................................................................................................ 46
Boiler/group "2" ...................................................................................... 47
■Coding ................................................................................................ 47
DHW/group "3" ...................................................................................... 48
■Coding ................................................................................................ 48
Solar/group "4" ....................................................................................... 48
Heating circuit 1, heating circuit 2, heating circuit 3/group "5" ............... 49
■Coding ................................................................................................ 50
6. Code 2 Calling up coding level 2 ........................................................................ 54
■Calling up coding level 2 ..................................................................... 54
General/group "1" .................................................................................. 54
■Coding ................................................................................................ 55
Boiler/group "2" ...................................................................................... 60
■Coding ................................................................................................ 60
DHW/group "3" ...................................................................................... 61
■Coding ................................................................................................ 61
Solar/group "4" ....................................................................................... 62
■Coding ................................................................................................ 62
Heating circuit 1, heating circuit 2, heating circuit 3/group "5" ............... 64
■Coding ................................................................................................ 65
7. Diagnosis and service
scans
Service level .......................................................................................... 70
Diagnosis ............................................................................................... 70
■Operating data .................................................................................... 70
■Brief scan ............................................................................................ 71
Index
Index
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Checking outputs (relay test) ................................................................. 74
■Weather-compensated control unit ..................................................... 74
■Constant temperature control unit ...................................................... 74
8. Troubleshooting Fault display ........................................................................................... 76
■Weather-compensated control unit ..................................................... 76
■Constant temperature control unit ...................................................... 76
Fault codes ............................................................................................ 77
Repair .................................................................................................... 86
■Checking the outside temperature sensor (weather-compensated
control unit) ......................................................................................... 86
■Checking the boiler water temperature sensors, cylinder tempera-
ture sensor or flow temperature sensor for the low loss header ......... 87
■Checking the flue gas temperature sensor ......................................... 88
■Checking the fuse ............................................................................... 89
■Extension kit, mixer ............................................................................ 89
■Check Vitotronic 200-H (accessory) ................................................... 90
9. Function description Constant temperature control unit ......................................................... 91
■Heating mode ..................................................................................... 91
■DHW heating ...................................................................................... 91
Weather-compensated control unit ........................................................ 91
■Heating mode ..................................................................................... 91
■DHW heating ...................................................................................... 92
■Boosting DHW heating ....................................................................... 92
Internal extensions (accessories) .......................................................... 92
■Internal extension H1 .......................................................................... 92
■Internal extension H2 .......................................................................... 93
External extensions (accessories) ......................................................... 94
■Extension AM1 ................................................................................... 94
■Extension EA1 .................................................................................... 95
Control functions .................................................................................... 96
■External heating program changeover ............................................... 96
■External blocking ................................................................................ 97
■External demand ................................................................................ 97
■Venting program ................................................................................. 98
■Screed drying ..................................................................................... 98
■Raising the reduced room temperature .............................................. 100
■Reducing the heat-up time ................................................................. 100
Assigning heating circuits to the remote control .................................... 101
Electronic combustion control unit ......................................................... 102
10. Designs Connection and wiring diagram – Internal connections ......................... 103
Connection and wiring diagram – External connections ........................ 104
11. Parts lists Ordering parts ........................................................................................105
Overview of the assemblies ...................................................................105
Casing assembly ................................................................................... 106
Heat cell assembly .................................................................................106
Burner assembly ....................................................................................107
Hydraulic assembly ................................................................................108
Control unit assembly ............................................................................ 109
Miscellaneous assembly ........................................................................ 110
12. Commissioning/service
reports
................................................................................................................ 112
13. Specification .................................................................................................................. 113
14. Certificates Declaration of conformity ....................................................................... 114
■Declaration of Conformity for the Vitodens 200-W ............................. 114
Index
Index
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Manufacturer's certificate according to the 1st BImSchV [Germany] .... 114
15. Keyword index .................................................................................................................. 115
Index
Index (cont.)
5623 715 GB

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The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions. It is only designed for the heating of water that is
of potable water quality.
Intended usage presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than heating the building or DHW does not comply with
regulations.
Any usage beyond this must be approved by the man-
ufacturer for the individual case.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and results in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended function (e.g.
if the flue gas and ventilation air paths are sealed).
Product information
Vitodens 200-W, type B2HA
Preset for operation with natural gas E and natural gas
LL.
For conversion to LPG P (without conversion kit), see
the service instructions.
In principle the Vitodens 200-W may only be delivered
to countries listed on the type plate. For deliveries to
alternative countries, an approved contractor must
arrange individual approval on his own initiative and in
accordance with the law of the country in question.
Multi-boiler system
For the installation of a multi boiler system observe the
installation instructions for the multi boiler system
accessories.
Product information
Intended use
5623 715 GB
Service

8
!Please note
To prevent equipment damage,
connect all pipework free of load and torque
stress.
40
100160 160
752
1975 1690
850
380
480
875
1166
160
E
A
L
M
O
CB D F
H
P
K
N
200
G
Fig. 1
AExpansion vessel G1
BSafety valve
CHeating flow G1½
DCylinder flow G1½
EGas connection R ¾
FCylinder return G1½
GHeating return G1½
HCable entry area at the back
KAccessories (connection sets)
LWithout connection sets (accessories)
MWith connection sets (accessories)
NRecommended dimension (single boiler system)
ORecommended dimension (multi boiler system)
PCondensate drain
Note
This boiler (IP rating IP X4 D) is approved for installa-
tion in wet rooms inside safety zone 1 in accordance
with DIN VDE 0100, providing the occurrence of hosed
water can be ruled out.
Observe the requirements of DIN VDE 0100 [or local
regulations].
1. Prepare the water connections. Thoroughly flush
the heating system.
2. Prepare the gas connection according to TRGI or
TRF [or local regulations].
3. Prepare the electrical connections.
■Power cable: NYM-J 3 x 1.5 mm2, max.
fuse 16 A, 230 V~.
■Accessory cables: NYM with the required number
of conductors for the external connections.
■Allow all cables in area "H" to protrude 1200 mm
from the wall.
Preparing for installation
Preparing for installation
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Installation

9
Fitting the wall mounting bracket
Note
The enclosed screws and rawl plugs are only suitable
for concrete. For other construction materials, use fix-
ing materials that are suitable for 100 kg loads.
422
480
1975
Ø 10
1.
2.
A
D
C
B
Fig. 2
AReference point: boiler top edge
BInstallation template (included with the boiler)
CTop edge finished floor
DRecommendation
Installation sequence
Fitting the boiler and making connections
5623 715 GB
Installation

10
Hooking the boiler onto the wall mounting bracket and levelling it
1.
2x
4.
3.
2.
5.
2x
Fig. 3
Note on step 4
Place the supplied circular level on the boiler and align
boiler vertically using the adjusting screws.
Installation sequence
Fitting the boiler and making connections (cont.)
5623 715 GB
Installation

11
A
CB D E F
Fig. 4
AExpansion vessel
BSafety valve
CHeating flow
DCylinder flow
ECylinder return
FHeating return
Connect the boiler to the on-site pipework.
Note
Connection layout shown with the connection sets
available as accessories.
Provide the required connections when using on-site
fittings.
Flue gas connection
Note
The labels "System certificate" and "Skoberne GmbH
flue system" enclosed with the technical documenta-
tion may only be used in conjunction with the
Viessmann flue system made by Skoberne.
Connect the balanced flue.
Flue system installation instructions
Do not carry out commissioning until the following
conditions are met:
■Free passage through the flue gas pipes.
■Flue system with positive pressure is gas-tight.
■Apertures for ensuring sufficient combustion air sup-
ply are open and cannot be closed off.
■Applicable regulations on installing and commission-
ing flue systems have been followed.
Danger
Leaking or blocked flue systems or an insuffi-
cient supply of combustion air cause life threat-
ening poisoning due to carbon monoxide in the
flue gas.
Ensure the flue system functions correctly. Aper-
tures for combustion air supply must not be able
to be closed off.
Installation sequence
Connections on the heating water side
5623 715 GB
Installation

12
Fig. 5
1. Pull the condensate hose far enough out of the
boiler that no unnecessary bends are created inside
the boiler. Check the tightness of the siphon con-
nection.
2. Connect the condensate hose with a constant fall
and a pipe vent to the public sewage system or to a
neutralising system.
Gas connection
A
Fig. 6
Notes regarding operation with LPG
We recommend the installation of an external safety
solenoid valve when installing the boiler in rooms
below ground level.
1. Seal gas shut-off valve A into the gas supply pipe.
2. Carry out a tightness test.
Note
Only use suitable and approved leak detection
agents (EN 14291) and devices for the tightness
test. Leak detection agents with unsuitable constitu-
ents (e.g. nitrites, sulphides) can cause material
damage.
Remove residues of the leak detection agent after
testing.
!Please note
Excessive test pressure may damage the
boiler and the gas valve.
Max. test pressure 150 mbar (15 kPa).
Where higher pressure is required for tight-
ness tests, disconnect the boiler and the gas
valves from the gas supply pipe (undo the fit-
ting).
3. Vent the gas line.
Conversion to other gas types:
Service instructions
Opening the control unit casing
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Before beginning work, touch earthed objects,
such as heating or water pipes, to discharge
static loads.
Installation sequence
Condensate connection
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Installation

13
2x
4x
4.
3.
5.
2.
1.
Fig. 7
Installation sequence
Opening the control unit casing (cont.)
5623 715 GB
Installation

14
L N
230 V~ 230 V~
5
96 40
40962035100
1
LN
X4 2 1
2
1
32 15 4
X3
LN
21
M
1~
X19
X14
A
B
21
20
L1
C
D
145
145
LN
Fig. 8
ARadio clock receiver
BHeating circuit pump or boiler circuit pump
CVitotrol 100 UTDB (only for constant temperature
control units)
When making this connection, remove jumper
between "1" and "L".
DVitotrol 100 UTA (only for constant temperature
control units)
or
Vitotrol 100 UTDB-RF wireless receiver
When making this connection, remove jumper
between "1" and "L".
Connections at plug 230 V~
sÖ Boiler circuit pump or heating circuit pump
■Variable speed with 0 - 10 V connection
sA Circulation pump, optional connection:
■DHW circulation pump
■External heating circuit pump
■Circulation pump for cylinder heating
fÖ Power supply
lH ■Power supply for accessories
■External demand/blocking
■Vitotrol 100 UTA
■Vitotrol 100 UTDB
■Vitotrol 100 UTDB-RF
Connections at LV plug
!Outside temperature sensor
?Flow temperature sensor for low loss header
(accessories)
%Cylinder temperature sensor (part of the DHW
cylinder connection set)
aVG KM BUS subscriber (accessories)
■Vitotrol 200A or 300A remote control
■Vitocom 100 GSM
■Extension kit for one heating circuit with mixer
■Solar control module, type SM1
■Vitosolic
■Extension AM1
■EA1 extension
■Wireless base station
Installation sequence
Electrical connections
5623 715 GB
Installation

15
Information on connecting accessories
When connecting accessories observe the sep-
arate installation instructions provided with
them.
Circulation pump at plug sÖ
A1~
M
sÖ
LN
?x4
B
Fig. 9
ACirculation pump
BPlug in 0 - 10 V connection at X4
Rated current 2(1) A~
Rated voltage 230 V~
Circulation pump at plug sA
A
1~
M
sA
LN
?
Fig. 10
ACirculation pump
Rated current 2(1) A~
Rated voltage 230 V~
Set function of connected component in coding
address "39"
Function Code
DHW circulation pump 39:0
Heating circuit pump for heating circuit
without mixer A1
39:1
Circulation pump for cylinder heating
(delivered condition)
39:2
External demand via switching contact
Connection options:
■Extension EA1 (accessory, see separate installation
instructions).
■Plug lH.
Connection
!Please note
'Live' contacts lead to short circuits or phase fail-
ure.
The external connection must be potential-
free.
Installation sequence
Electrical connections (cont.)
5623 715 GB
Installation

16
Plug lH EA1 extension
A
lH
N
?
1L
AFloating contact
When making this connection, remove jumper
between 1 and L.
B
[{S
DE [{D DE
[{A
DE
A
AFloating contact
BEA1 extension
Burner operation is load-dependent if the contact is closed. The boiler water is heated to the value set in coding
address "9b" in group "General"/"1". The boiler water temperature is limited by this set value and the electronic
maximum limit (coding address "06" in group "Boiler"/"2").
Codes
Plug lH EA1 extension
"4b:1" in group "General"/"1" Set "3A" (DE1), "3b" (DE2) or "3C" (DE3) in group "General"/"1" to 2.
■Select effect of the function on the relevant heating circuit pump in coding address "d7" in group "Heating cir-
cuit"/"5".
■Select effect of the function on the circulation pump for cylinder heating in coding address "5F" in group
"DHW"/"3".
External demand via 0 – 10 V input
Connection at 0 – 10 V input to extension EA1.
Ensure DC separation between the earth conductor
and the negative pole of the on-site voltage source.
L?NL
?
N
fÖ
SP
aBJ
230 V~
Ö
[{{]
0-10V f-]
A
U0-10 V
+
+-
Fig. 11
0 – 1 V ≙ No default set boiler water temperature
1 V ≙ Set value 10 °C
10 V ≙ Set value 100 °C
Installation sequence
Electrical connections (cont.)
5623 715 GB
Installation

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External blocking via switching contact
Connection options:
■Plug lH.
■Extension EA1 (accessory, see separate installation
instructions).
!Please note
'Live' contacts lead to short circuits or phase fail-
ure.
The external connection must be floating.
Plug lH Extension EA1
A
lH
N
?
1L
AFloating contact
When making this connection, remove jumper be-
tween 1 and L.
B
[{S
DE [{D DE
[{A
DE
A
AFloating contact
BExtension EA1
The burner is switched off if this contact is closed. The heating circuit pump and circulation pump for cylinder
heating are switched according to the set code (see the following table "Codes").
!Please note
When blocked, there is no frost protection for
the
heating system.
Codes
Plug lH Extension EA1
"4b:2" in group "General"/"1" Set "3A" (DE1), "3b" (DE2) or "3C" (DE3) in group "General"/"1" to 3 or 4.
■Select effect of the function on the heating circuit pump in coding address "d6" in group "Heating circuit"/"5".
■Select effect of the function on the circulation pump for cylinder heating in coding address "5E" in group
"DHW"/"3".
Outside temperature sensor !
Fitting outside temperature sensor RF (wireless acces-
sory):
Wireless base station
Fitting location for outside temperature sensor
■North or north-westerly wall, 2 to 2.5 m above
ground level; in multi storey buildings, in the top half
of the second floor
■Not above windows, doors or vents
■Not immediately below balconies or gutters
■Never render over
Outside temperature sensor connection
2-core lead, length up to 35 m with a cross-section of
1.5 mm2
Installation sequence
Electrical connections (cont.)
5623 715 GB
Installation

18
Power supply for accessories at plug lH (230 V~)
Where the boiler is installed in a wet area, the power
supply connection for accessories outside the wet area
must not be made at the control unit. If the boiler is
installed outside wet areas, then the power supply con-
nection for accessories can be made directly at the
control unit. This connection is switched directly with
the ON/OFF switch of the control unit.
If the total system current exceeds 6 A, connect one or
more extensions directly to the mains supply via an
ON/OFF switch (see next chapter).
Connection of accessories
Power supply and KM BUS
Power supply to all accessories via heat source control unit
145 145 40 A 40 145 145 40 A 40
B C
145 40 96
A
145 145 40 A 40
D
E
Fig. 12
Some accessories with direct power supply
145 145 40 A 40 145 145 40 A 40
B C
145 40 96
A
145 145 40 A 40
D
E
Fig. 13
AHeat source control unit
BExtension kit for heating circuit with mixer M2
CExtension kit for heating circuit with mixer M3
DExtension AM1, EA1 and/or solar control module,
type SM1
EON/OFF switch
A buffer relay must be fitted if the current flowing to the
connected working parts (e.g. circulation pumps) is
higher than the safety level of the relevant accessory.
Accessories Internal fuse protec-
tion
Extension kit for heating circuit
with mixer
2 A
Extension AM1 4 A
Extension EA1 2 A
Solar control module, type
SM1
2 A
Power supply fÖ
Danger
Incorrect core allocation can result in serious
injury and damage to the appliance.
Take care not to interchange wires "L1" and "N".
■Install an isolator in the power cable which simulta-
neously separates all non-earthed conductors from
the mains with contact separation of at least 3 mm.
Furthermore, we recommend installing an AC/DC-
sensitive RCD (RCD class B ) for DC (fault)
currents that can occur with energy efficient equip-
ment.
■Max. fuse rating 16 A.
Installation sequence
Electrical connections (cont.)
5623 715 GB
Installation

19
Routing the connecting cables
!Please note
If connecting cables touch hot components they
will be damaged.
When routing and securing connecting cables
on site, ensure that the maximum permissible
temperatures for these cables are not exceeded.
5
Fig. 14
ALV connections
B230 V connections
CInternal extension
DMain PCB
ECommunication module
FCable grommet for power cable
%Plugs for connecting the cylinder temperature sen-
sor to the cable harness
Remove the existing cable grommet when using larger
cross-sections (up to 7 14 mm). Secure the cable with
cable grommet F integrated into the casing base
(black).
Installation sequence
Electrical connections (cont.)
5623 715 GB
Installation

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1.
3. 2x
2.
4.
4.
6.
Fig. 15
Insert programming unit (packed separately) into the
control unit support.
Note
The programming unit can also be inserted into a wall
mounting base (accessories) near the boiler.
Wall mounting base installation instructions
Installation sequence
Closing the control unit casing and inserting the programming unit
5623 715 GB
Installation