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
5585 174 GB 1/2015 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 author-
ised 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 to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for the protection of the envi-
ronment
■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
aÖNORM, EN, ÖVGW-TR Gas, ÖVGW-TRF and
ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
Safety instructions for working on the system
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.
Danger
Hot surfaces can cause burns.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the boiler, burner,
flue system or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing 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.
Replace faulty components only 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 for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Never smoke. Prevent naked flames and
sparks. Never switch lights or electrical 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.
■Have the power supply to the building shut off
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 threatening poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to prevent flue
gases from spreading.
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 an adequate supply of
combustion air.
Instruct system users that subsequent modifications to
the structural conditions are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Apertures for supplying combustion air must be
non-closable.
Extractors
Operating appliances that route exhaust air outdoors
(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 route exhaust air outdoors can
result in life threatening poisoning due to
reverse flow of the flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5585 174 GB

4
1. Information Symbols ................................................................................................. 6
Intended use .......................................................................................... 6
Product information ................................................................................ 7
■Vitodens 200-W, type B2HA ............................................................... 7
2. Preparing for installation .................................................................................................................. 8
3. Installation sequence Mounting the boiler and making the connections .................................. 10
■Fitting the wall mounting bracket ........................................................ 10
■Hooking the boiler onto the wall mounting bracket and levelling it ..... 11
Connection on the heating water side ................................................... 12
Flue gas connection ............................................................................... 12
Condensate connection ......................................................................... 13
Gas connection ...................................................................................... 13
Opening the control unit enclosure ........................................................ 13
Electrical connections ............................................................................ 15
■Circulation pump at plug sÖ ................................................................ 16
■Circulation pump at plug sA ................................................................ 18
■External demand via switching contact .............................................. 18
■External demand via 0 – 10 V input .................................................... 19
■External blocking via switching contact .............................................. 19
■Outside temperature sensor ! .......................................................... 20
■Power supply for accessories at plug lH (230 V~) ............................. 20
■Power supply fÖ ................................................................................. 21
■Routing the connecting cables ........................................................... 23
Closing the control unit enclosure and inserting the programming unit . 24
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 25
5. Code 1 Calling up coding level 1 ........................................................................ 49
General/group "1" .................................................................................. 49
Boiler/group "2" ...................................................................................... 51
DHW/group "3" ...................................................................................... 52
Solar/group "4" ....................................................................................... 52
Heating circuit 1, heating circuit 2, heating circuit 3/group "5" ............... 53
6. Code 2 Calling up coding level 2 ........................................................................ 58
General/group "1" .................................................................................. 58
Boiler/group "2" ...................................................................................... 63
DHW/group "3" ...................................................................................... 65
Solar/group "4" ....................................................................................... 66
Heating circuit 1, heating circuit 2, heating circuit 3/group "5" ............... 69
7. Diagnosis and service
scans
Service level .......................................................................................... 74
Diagnosis ............................................................................................... 75
■Operating data .................................................................................... 75
■Brief scan ............................................................................................ 75
Checking outputs (relay test) ................................................................. 78
■Weather-compensated control unit ..................................................... 78
■Constant temperature control unit ...................................................... 78
8. Troubleshooting Fault display ........................................................................................... 80
■Weather-compensated control unit ..................................................... 80
■Constant temperature control unit ...................................................... 80
Fault codes ............................................................................................ 81
Index
Index
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Maintenance .......................................................................................... 90
■Checking the outside temperature sensor (weather-compensated
control unit) ......................................................................................... 90
■Checking the boiler water temperature sensors, cylinder tempera-
ture sensor or flow temperature sensor for the low loss header ......... 91
■Checking the flue gas temperature sensor ......................................... 91
■Checking the fuse ............................................................................... 92
■Extension kit, mixer ............................................................................ 92
■Check Vitotronic 200-H (accessory) ................................................... 93
9. Parts lists Overview of assemblies ......................................................................... 95
Casing assembly ................................................................................... 96
Heat cell assembly ................................................................................. 98
Burner assembly ....................................................................................100
Hydraulic assembly ................................................................................102
Control unit assembly ............................................................................ 104
Miscellaneous ........................................................................................ 106
10. Function description Constant temperature control unit ......................................................... 108
■Heating mode ..................................................................................... 108
■DHW heating ...................................................................................... 108
Weather-compensated control unit ........................................................108
■Heating mode ..................................................................................... 109
■DHW heating ...................................................................................... 109
■Boosting DHW heating ....................................................................... 109
Internal extensions (accessories) .......................................................... 110
■Internal extension H1 .......................................................................... 110
■Internal extension H2 .......................................................................... 111
External extensions (accessories) ......................................................... 112
■Extension AM1 ................................................................................... 112
■EA1 extension .................................................................................... 113
Control functions .................................................................................... 114
■External heating program changeover ............................................... 114
■External blocking ................................................................................ 115
■External demand ................................................................................ 115
■Venting program ................................................................................. 116
■Screed drying ..................................................................................... 116
■Raising the reduced room temperature .............................................. 118
■Reducing the heat-up time ................................................................. 118
Assigning heating circuits to the remote control .................................... 119
Electronic combustion control unit ......................................................... 120
11. Connection and wiring dia-
gram
Internal connections ...............................................................................121
External connections ............................................................................. 122
12. Commissioning/service
reports
................................................................................................................123
13. Specification ..................................................................................................................124
14. Certificates Declaration of conformity ....................................................................... 125
■Declaration of Conformity for the Vitodens 200-W ............................. 125
Manufacturer's certificate according to the 1st BImSchV [Germany] .... 125
15. Keyword index ..................................................................................................................126
Index
Index (cont.)
5585 174 GB

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Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The work sequences for commissioning, inspection
and maintenance are summarised in the chapter
"Commissioning, inspection and maintenance "and are
marked as follows:
Symbol Meaning
Work sequences required during commis-
sioning
Not required during commissioning
Symbol Meaning
Work sequences required during inspec-
tion
Not required during inspection
Work sequences required during mainte-
nance
Not required during maintenance
Intended use
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 use 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 shall be deemed
inappropriate.
Information
Symbols
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Information

7
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended use (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, approved contractors must
arrange individual approval on their 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.
Information
Intended use (cont.)
5585 174 GB
Information

8
!Please note
To prevent appliance 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, to
DIN VDE 0100, providing hosed water is prevented.
Observe the requirements of DIN VDE 0100.
1. Prepare the water connections. Thoroughly flush
the heating system.
2. Prepare the gas connection according to TRGI or
TRF [or local regulations].
Preparing for installation
Preparing for installation
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Installation

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3. Prepare the electrical connections.
■Power cable: NYM-J 3 x 1.5 mm2, max. fuse rat-
ing 16 A, 230 V~.
■Accessory cables: NYM with the required number
of cores for external connections.
■Allow all cables in area "H" to protrude 1200 mm
from the wall.
Preparing for installation
Preparing for installation (cont.)
5585 174 GB
Installation

10
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
Mounting the boiler and making the connections
5585 174 GB
Installation

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Hooking the boiler onto the wall mounting bracket and levelling it
1.
2x
2x
4.
3.
2.
5.
Fig.3
Note on step 4
Place the supplied circular level on the boiler and align
boiler vertically using the adjusting screws.
Installation sequence
Mounting the boiler and making the connections (cont.)
5585 174 GB
Installation

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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 situation shown with the connection sets
that are available as accessories.
Provide the required connections when using on-site
fittings.
Flue gas connection
Note
Only use the "System certificate" and "Skoberne
GmbH flue system" labels in conjunction with the
Viessmann flue system made by Skoberne.
Connect the balanced flue pipe.
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
Connection on the heating water side
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Installation

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Fig.5
1. Pull the condensate hose far enough out so that no
unnecessary bends are created inside the boiler.
Check the tightness of the siphon connection.
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. Check the gas connection for leaks.
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. nitrides, sulphides) can cause material
damage.
Remove leak detection agent residues after testing.
!Please note
Excessive test pressure will damage the
boiler and the gas train.
Maximum test pressure 150 mbar (15 kPa). If
a higher pressure is required for tightness
tests, disconnect the boiler and the gas train
from the main supply pipe (undo the fitting).
3. Purge the gas line.
Conversion to alternative gas types:
Service instructions
Opening the control unit enclosure
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes, to dis-
charge static loads.
Installation sequence
Condensate connection
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Installation

14
2x
4x
4.
3.
5.
2.
1.
Fig.7
Installation sequence
Opening the control unit enclosure (cont.)
5585 174 GB
Installation

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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, type UTDB (only for constant temper-
ature control units)
When making this connection, remove jumper
between "1" and "L".
DVitotrol 100, type UTA (only for constant tempera-
ture control units)
or
Vitotrol 100 wireless receiver, type UTDB-RF
When making this connection, remove jumper
between "1" and "L".
Connections on 230 V~ plug
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, type UTDB-RF
Connections to LV plug
!Outside temperature sensor
?Flow temperature sensor for low loss header
(accessory)
Installation sequence
Electrical connections
5585 174 GB
Installation

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%Cylinder temperature sensor (part of the DHW
cylinder connection set)
aVG KM BUS subscriber (accessories)
■Vitotrol 200A or 300A remote control
■Vitocom 100 GSM
■Mixer extension kit
■Solar control module, type SM1
■Vitosolic
■AM1 extension
■EA1 extension
■Wireless base station
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
?
aVF
Fig.9
AHigh-efficiency circulation pump, speed-controlled
via 0 - 10 V control voltage
Insert plug aVF (0 - 10 V connection) at X4.
Rated current 2(1) A~
Rated voltage 230 V ~
Adjust function of circulation pump
Hydraulic connection/ connection require-
ments
Control unit setting
Coding address/group
Circulation pump setting
Single boiler system with:
■Heating circuit without mixer
■Connection without low loss header and with-
out heating water buffer cylinder
■Max pump speed:
E6: ... /heating circuit
■Min. pump speed:
E7: ... /heating circuit
For further details, see the fol-
lowing diagram and the "Heating
circuit..." chapter under code 2.
Ext. In
Ext. In
2
6
1212
2
6
Single boiler system with heating circuits con-
nected to low loss header or heating water buf-
fer cylinder
30:0/Boiler/2
Ext. In
2
6
1212
2
6
Recommended for Δt = 15 K
■45 kW: = 4 ≙ 2.58 m3/h
■60 kW: = 7 ≙ 3.44 m3/h
Installation sequence
Electrical connections (cont.)
5585 174 GB
Installation

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Hydraulic connection/ connection require-
ments
Control unit setting
Coding address/group
Circulation pump setting
Multi boiler system 30:0/Boiler/2
Ext. In
2
6
1212
2
6
Recommended for Δt = 15 K
■45 kW: = 4 ≙ 2.58 m3/h
■60 kW: = 7 ≙ 3.44 m3/h
Multi-stage circulation pump (on site) 30:0/Boiler/2
Circulation pump VI Para 25/1-11
Rated voltage V~ 230
Power consump-
tion
W max. 140
min. 8
Residual head of circulation pump (coding address
E6 and E7)
When connecting a heating circuit without mixer and
without low loss header or heating water buffer cylin-
der, the circulation pump is controlled as a function of
outside temperature. The min. and max. speeds of the
circulation pump are limited by the settings for coding
addresses E6 and E7.
100
00 1000
Flow rate in l/h
200
600
800
1000
300
400
500
700
900
2000 3000 4000
10
0
20
60
80
100
30
40
50
70
90
kPa
1100 110
1200 120
A
B
C
D
E
F
G
Residual head
mbar
Fig.10
Setting for coding addresses E6, E7
Curve Coding address
value
Pump rate, circula-
tion pump
A40 40 %
B50 50 %
C60 60 %
D70 70 %
E80 80 %
F90 90 %
G100 100 %
Installation sequence
Electrical connections (cont.)
5585 174 GB
Installation

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Circulation pump at plug sA
A
1~
M
sA
LN
?
Fig.11
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.
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".
Installation sequence
Electrical connections (cont.)
5585 174 GB
Installation

19
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.12
0 – 1 V ≙ No default set boiler water temperature
1 V ≙ Set value 10 °C
10 V ≙ Set value 100 °C
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
between 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.
Installation sequence
Electrical connections (cont.)
5585 174 GB
Installation

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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
Power supply for accessories at plug lH (230 V~)
■Installation of boiler outside wet rooms:
Connect the power supply of accessories to the
boiler control unit. This connection is switched
directly with the ON/OFF switch of the control unit.
■Installation of boiler in a wet room:
Do not connect the power supply of accessories out-
side the wet area to the boiler control unit.
If the total system current exceeds 6 A, connect one or
more extensions via an ON/OFF switch directly to the
mains supply (see next chapter).
Installation sequence
Electrical connections (cont.)
5585 174 GB
Installation