Viessmann Vitodens 200-W System Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 200-W
Type B2HA, B2KA, 3.2 to 35 kW
Gas council no.
■ System boilers:
41-819-32; 41-819-33; 41-819-34; 41-819-35
■ Combi boilers:
47-819-28; 47-819-29; 47-819-30
For applicability, see the last page
VITODENS 200-W
5772 909 GB 11/2012 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 inten-
ded for qualified 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 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:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental protection
■ 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) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland), Build-
ing Regulations (Northern Ireland),
– 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.
■ 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).
Safety instructions
Safety instructions
5772 909 GB

3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening 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 condensate or other
causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work 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 com-
bustion 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 neg-
ative 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 poison-
ing due to reverse flow of the flue
gas.
Fit an interlock circuit or take suit-
able steps to ensure a sufficient
supply of combustion air.
Working on the system
■ Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■ Isolate the system from the power sup-
ply (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 recon-
nection.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
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 function can compromise
the safe operation of your sys-
tem.
Defective components must be
replaced with genuine
Viessmann spare parts.
Safety instructions
Safety instructions (cont.)
5772 909 GB

4
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5772 909 GB

5
Installation instructions
Preparing for installation
Intended use......................................................................................................... 7
Product information.............................................................................................. 7
Preparing for installation....................................................................................... 8
Installation sequence
Fitting the boiler and making connections............................................................ 11
Flue gas connection............................................................................................. 12
Condensate connection........................................................................................ 13
Gas connection.................................................................................................... 14
Opening the control unit casing............................................................................ 15
Electrical connections........................................................................................... 16
Closing the control unit casing and inserting the programming unit..................... 25
Fitting the front panel............................................................................................ 26
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 27
Further details regarding the individual steps....................................................... 29
Code 1
Calling up coding level 1...................................................................................... 60
"General"/group 1................................................................................................. 61
"Boiler"/group 2.................................................................................................... 64
"DHW"/group 3..................................................................................................... 64
"Solar"/group 4..................................................................................................... 65
"Heating circuit ..."/group 5................................................................................... 67
Code 2
Calling up coding level 2...................................................................................... 73
"General"/group 1................................................................................................. 74
"Boiler"/group 2.................................................................................................... 82
"DHW"/group 3..................................................................................................... 84
"Solar"/group 4..................................................................................................... 86
"Heating circuit ..."/group 5................................................................................... 91
Diagnosis and service scans
Service level......................................................................................................... 100
Diagnosis.............................................................................................................. 101
Checking outputs (actuator test).......................................................................... 107
Index
Index
5772 909 GB

6
Troubleshooting
Fault display......................................................................................................... 110
Fault codes........................................................................................................... 112
Repairs................................................................................................................. 129
Function description
Constant temperature control unit........................................................................ 139
Weather-compensated control unit...................................................................... 140
Internal extensions (accessories)......................................................................... 142
External extensions (accessories)........................................................................ 144
Control functions.................................................................................................. 148
Allocating heating circuits to the remote control................................................... 156
Electronic combustion control unit........................................................................ 156
Designs
Connection and wiring diagram – Internal connections ...................................... 158
Connection and wiring diagram – External connections...................................... 160
Parts lists
Ordering individual parts...................................................................................... 162
Overview of the assemblies................................................................................. 163
Casing.................................................................................................................. 164
Heat cell............................................................................................................... 165
Burner................................................................................................................... 168
Hydraulics type B2HA.......................................................................................... 169
Hydraulics type B2KA........................................................................................... 172
Control unit........................................................................................................... 176
Miscellaneous....................................................................................................... 177
Commissioning/service reports........................................................................ 179
Specification....................................................................................................... 180
Certificates
Declaration of conformity...................................................................................... 182
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 182
Keyword index.................................................................................................... 183
Index
Index (cont.)
5772 909 GB

7
The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions. 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 permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than heating the building or
DHW does not comply with regulations.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect 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, B2KA
Set up for operation with natural gas E.
For conversion to LPG P (without con-
version kit), see "Commissioning,
inspection, maintenance".
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.
Preparing for installation
Intended use
5772 909 GB
Installation

8
!Please note
To prevent equipment damage,
connect all pipework free of load
and torque stress.
360
450
730
1925 H
850
100 215
50
a
A B C D EF K
G
AHeating flow Rp¾
BDHW Rp½ (combi boilers)
Cylinder flow G¾ (system boiler)
CGas connection
DCold water Rp½ (combi boilers)
Cylinder return G¾ (system boiler)
EHeating return Rp¾
FFilling/draining
GWiring area
HMin. clearances below the boiler
KCondensate drain
Preparing for installation
Preparing for installation
5772 909 GB

9
Rated heating output
kW
Dim. a
mm
3.2 - 19.0 136
6.5 - 26.0 158
8.8 - 35.0 158
Note
This boiler (IP rating: IP X4D) is
approved for installation in wet rooms
inside safety zone 1 in accordance with
IEEE Wiring Regulations, providing the
occurrence of hosed water can be ruled
out.
Observe the IEEE Wiring Regulations.
1. Fit the supplied pre-plumbing jig or
mounting frame at the installation
location.
Pre-plumbing jig or mounting
frame installation instruc-
tions.
2. Prepare the connections on the water
side to the valves on the pre-plumb-
ing jig or mounting frame.
Thoroughly flush the heating sys-
tem.
3. Prepare the gas connection accord-
ing to TRGI or TRF [or local regula-
tions].
4. Prepare the electrical connections.
■Power cable: NYM-J 3 x 1.5 mm2,
fuse max. 16 A, 230 V, 50 Hz.
■ Accessory cables: NYM with the
required number of conductors for
the external connections.
■ All cables should protrude
1200 mm from the wall near "G".
Cold water installation
ACold water connection, boiler
BDrain
CVisible discharge pipe outlet point
DSafety valve
ENon-return valve
FShut-off valve
GCold water
HSafety assembly
Safety assembly H must be installed as
per the Water Regulation Guide if the
mains water supply pressure exceeds
10 bar, and no DHW pressure reducing
valve is installed.
Only use a non-return valve or a com-
bined shut-off and non-return valve in
conjunction with a safety valve.
If the safety valve is used, the cold water
shut-off valve on the boiler must not be
shut off.
Preparing for installation
Preparing for installation (cont.)
5772 909 GB
Installation

10
Remove the toggle on the cold water
shut-off valve (if installed) to prevent
anyone shutting it off manually.
Shock arrestor
If draw-off points that could cause pres-
sure peaks (water hammer/shock) are
connected to the same pipework as the
boiler (such as pressure washers, wash-
ing machines or dishwashers), we would
recommend the installation of a shock
arrestor near the source of such pres-
sure shocks.
g: Fit a small domestic expansion ves-
sel if water hammer occurs.
Preparing for installation
Preparing for installation (cont.)
5772 909 GB

11
2x
6.
7.
5.
3.
2x
2.
1.
4.
Installation sequence
Fitting the boiler and making connections
5772 909 GB
Installation

12
Fitting the connections
A B C D E F
AHeating flow
BDHW (combi boilers)
Cylinder flow (system boiler)
CGas connection
DCold water (combi boilers)
Cylinder return (system boiler)
EHeating return
FFilling/draining
Flue gas connection
Note
■ The labels "System certificate" and
"Skoberne GmbH flue system"
enclosed with the technical documen-
tation may only be used in conjunction
with the Viessmann flue system made
by Skoberne.
■ During installation and positioning of
the flue system, observe Part J and
BS 5440 building regulations.
Connecting the balanced flue
Flue system installation instruc-
tions.
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 com-
bustion air supply are open and cannot
be closed off.
■ Applicable regulations on installing
and commissioning flue systems have
been followed.
Danger
Leaking or blocked flue systems
or an insufficient supply of com-
bustion air cause life threatening
poisoning due to carbon monox-
ide in the flue gas.
Ensure the flue system functions
correctly. Apertures for combus-
tion air supply must not be able to
be closed off.
Installation sequence
Fitting the boiler and making connections (cont.)
5772 909 GB

13
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
connection.
2. ■ The condensate pipe is connected
with the discharge pipe of the
safety valve. The condensate hose
supplied meets the temperature
requirements that are part of the
CE certification.
■ We recommend the internal con-
nection of the condensate pipe to
the domestic drain, either directly
or via a tundish.
■ If the condensate pipe is routed
outside the building, use a pipe with
7 30 mm at least, and protect this
pipe from frost. Avoid long external
pipelines.
!Please note
Frozen condensate pipes
can result in faults and dam-
age to the boiler.
Always insulate conden-
sate pipes against frost.
■ Observe local building regulations.
Connect condensate pipe A to the
public sewage system with a con-
stant fall and a pipe vent.
Observe the local waste water regu-
lations.
Note
Fill the siphon with water before com-
missioning.
Installation sequence
Condensate connection
5772 909 GB
Installation

14
A
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 con-
stituents (e.g. nitrites, sulphides) can
cause material damage.
Remove residues of the leak detec-
tion agent after testing.
!Please note
Excessive test pressure may
damage the boiler and the gas
valve.
Max. test pressure 150 mbar.
Where higher pressure is
required for tightness tests,
disconnect the boiler and the
gas valves from the gas sup-
ply pipe (undo the fitting).
3. Vent the gas line.
Conversion to other gas types:
Service instructions (details for
converting to LPG are on page
35)
Installation sequence
Gas connection
5772 909 GB

15
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
2x
4x
4.
3.
5.
2.
1.
Installation sequence
Opening the control unit casing
5772 909 GB
Installation

16
L N
230V~ 230V~
596 40
40962035100
1LN
2 1
145
21
32 15 4 28
145
A
AJumper
Installation sequence
Electrical connections
5772 909 GB

17
Connections at plug 230 V~
fÖ Power supply
lH ■ Power supply for accessories
■ External demand/blocking
■ Room temperature control unit
(remove jumper A when con-
necting):
– Vitotrol 100, UTA
– Vitotrol 100, UTDB
– Vitotrol 100, UTDB-RF
Connections at LV plug
X3 Plug X3 can be removed to facili-
tate installation.
!Outside temperature sensor
?Flow temperature sensor for
low loss header (accessories)
X4 KM BUS connection, heating cir-
cuit pump
%Type B2HA:
Cylinder temperature sensor (part
of the DHW cylinder connection
set)
Type B2KA:
Comfort sensor (connected at the
factory)
aVG KM BUS subscriber (accessories)
To connect several accessories,
see page 22.
■ Vitotrol 200A or 300A remote
control
■ Vitocom 100, type GSM
■ Extension kit for one heating cir-
cuit with mixer
■ Solar control module, type SM1
■ Vitosolic
■ Extension AM1
■ Extension EA1
■ Wireless base station
■ KM BUS distributor
Information on connecting
accessories
When connecting accessories
observe the separate installation
instructions provided with them.
Installation sequence
Electrical connections (cont.)
5772 909 GB
Installation

18
Outside temperature sensor !
For fitting the wireless outside tempera-
ture sensor (wireless accessory):
Wireless base station installation
and service instructions
Fitting location for outside tempera-
ture sensor
■ North or north-western wall, 2 to
2.5 m above ground level; in multi
storey buildings, in the upper half of
the second floor
■ Not above windows, doors or vents
■ Not immediately below balconies or
gutters
■ Never render over
Outside temperature sensor connec-
tion
2-core lead, length max. 35 m with a
cross-section of 1.5 mm2
External demand via switching contact
Connection options:
■ Extension EA1 (accessory, see sepa-
rate installation instructions).
■Plug lH.
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).
!Please note
'Live' contacts lead to short cir-
cuits or phase failure.
The external connection must be
potential-free and comply with
the requirements of safety cate-
gory II.
Installation sequence
Electrical connections (cont.)
5772 909 GB

19
Plug lH Extension EA1
A
lH
N
?
1L
AFloating contact (when connecting,
remove jumper across L and 1)
B
[{S
DE [{D DE
[{A
DE
A
AFloating contact
BExtension EA1
Codes
■ "4b:1" in group "General"/1.
■ Effect of the function on the relevant
heating circuit pump:
Coding address "d7" in group "Heating
circuit" (only with weather-compensa-
ted control units).
■ Effect of the function on the circulation
pump for cylinder heating (if installed):
Coding address "5F" in group "DHW"/
3.
Codes
■ Set "3A" (DE1), "3b" (DE2) or "3C"
(DE3) in group "General"/1 to 2.
■ Effect of the function on the relevant
heating circuit pump:
Coding address "d7" in group "Heating
circuit" (only with weather-compensa-
ted control units).
■ Effect of the function on the circulation
pump for cylinder heating (if installed):
Coding address "5F" in group "DHW"/
3.
External demand via 0 – 10 V input
Connection at 0 – 10 V input to exten-
sion EA1.
Ensure DC separation between the earth
conductor and the negative pole of the
on-site voltage source.
Installation sequence
Electrical connections (cont.)
5772 909 GB
Installation

20
L?NL
?
N
fÖ
SP
aBJ
230 V~
Ö
[{{]
0-10V f-]
A
U0-10 V

+
+-
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 sepa-
rate installation instructions).
The burner is switched off if this contact
is closed. The heating circuit pump and
(if installed) the circulation pump for cyl-
inder heating are switched according to
the set code (see following table
"Codes").
!Please note
'Live' contacts lead to short cir-
cuits or phase failure.
The external connection must be
potential-free and comply with
the requirements of safety cate-
gory II.
Installation sequence
Electrical connections (cont.)
5772 909 GB