Viessmann Vitodens 200-W System Quick guide

Installation and service
instructions
for contractors
VIESMANN
Vitodens 200-W
Type B2HA, 125 and 150 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 200-W
5623 520 GB 6/2012 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
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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3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the
living space.
Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which ful-
fil a safety function can compro-
mise the safe operation of your
heating system.
Replace faulty components only
with original Viessmann spare
parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5623 520 GB

4
Installation instructions
Preparing for installation
Product information.............................................................................................. 6
Preparing for installation....................................................................................... 7
Installation sequence
Fitting the boiler and making connections............................................................ 9
Heating water side connection............................................................................. 13
Flue gas connection............................................................................................. 13
Condensate connection........................................................................................ 14
Gas connection.................................................................................................... 15
Opening the control unit casing............................................................................ 15
Electrical connections........................................................................................... 17
Closing the control unit casing and inserting the programming unit..................... 27
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 28
Further details regarding the individual steps....................................................... 30
Code 1
Calling up coding level 1...................................................................................... 66
General/group "1"................................................................................................. 67
Boiler/group "2".................................................................................................... 70
DHW/group "3"..................................................................................................... 70
Solar/group "4"..................................................................................................... 71
Heating circuit 1, heating circuit 2, heating circuit 3/group "5"............................. 73
Code 2
Calling up coding level 2...................................................................................... 80
General/group "1"................................................................................................. 81
Boiler/group "2".................................................................................................... 90
DHW/group "3"..................................................................................................... 92
Solar/group "4"..................................................................................................... 94
Heating circuit 1, heating circuit 2, heating circuit 3/group "5"............................. 98
Diagnosis and service scans
Calling up the service level................................................................................... 107
Diagnosis.............................................................................................................. 108
Checking outputs (relay test)................................................................................ 114
Index
Index
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5
Troubleshooting
Fault display......................................................................................................... 117
Fault codes........................................................................................................... 119
Repair................................................................................................................... 135
Function description
Constant temperature control unit........................................................................ 143
Weather-compensated control unit...................................................................... 144
Internal extensions (accessories)......................................................................... 145
External extensions (accessories)........................................................................ 148
Control functions.................................................................................................. 152
Assigning heating circuits to the remote control................................................... 160
Electronic combustion control unit........................................................................ 160
Designs
Connection and wiring diagram – internal connections ....................................... 162
Connection and wiring diagram – external connections....................................... 163
Parts lists
Ordering parts...................................................................................................... 165
Overview of the assemblies................................................................................. 166
Casing assembly.................................................................................................. 167
Heat cell assembly............................................................................................... 168
Burner assembly.................................................................................................. 169
Hydraulic assembly.............................................................................................. 169
Control unit assembly........................................................................................... 170
Miscellaneous....................................................................................................... 171
Commissioning/service reports
............................................................................................................................. 173
Specification....................................................................................................... 174
Certificates
Declaration of conformity...................................................................................... 175
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 175
Keyword index.................................................................................................... 176
Index
Index (cont.)
5623 520 GB

6
Vitodens 200-W, B2HA
Preset for operation with natural gas E and LL.
For conversion to LPG P (without conversion kit), see page 37.
Conversion for other countries
The Vitodens 200-W should generally only be delivered to those countries specified
on the type plate. For deliveries to alternative countries, an approved contractor, on
his own initiative, must arrange individual approval in accordance with the law of the
land.
Multi boiler system
In connection with the installation of a multi boiler system observe the installation
instructions of the multi boiler system accessories.
Preparing for installation
Product information
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Dimensions and connections
!Please note
To prevent equipment damage,
install all pipework free of load
and torque stresses.
165.5
165.5
923
1440
95
689
278
905
600
P
40
200
855
1975 1950
E
L
M
O
K
H
N
A
B
C
G
DF
70 70
195
ASafety valve
BExpansion vessel connection G1
CBoiler flow 7 54 mm
DCylinder flow 7 42 mm
EGas connection R 1
FCylinder return 7 42 mm
Preparing for installation
Preparing for installation
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Installation

8
GBoiler return 7 54 mm
HConnection sets (accessories,
shown without the thermal insula-
tion supplied)
KCable entry area at the back
LWithout connection set (accesso-
ries)
MWith connection set (accessories)
NRecommended dimension (single
boiler system without mounting
frame)
ORecommended dimension (multi
boiler system and single boiler sys-
tem with mounting frame)
PCondensate drain
Preparing for the boiler installation
Note
This boiler (protection IP X4 D) is
approved for installation in wet rooms
inside safety zone 1 according to
DIN VDE 0100 [Germany], if hosed
water can be prevented.
Observe DIN VDE 0100 [or local regula-
tions].
1. Prepare the water connections. Thor-
oughly flush the heating system.
2. Prepare gas connection to TRGI [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 "K" to pro-
trude 1400 mm from the wall.
Preparing for installation
Preparing for installation (cont.)
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9
Removing boiler from packaging and levelling
2x
3.
1.
2..
4.
1. Remove packing cushions and keep
them safe.
They are used as a support during
levelling.
2. Undo two screws on the underside.
3. Remove front panel.
4. Push packing cushions onto the
underside of the boiler.
Installation sequence
Fitting the boiler and making connections
5623 520 GB
Installation

10
A
5.
A7 9 mm drilled holes for attaching
lifting gear
5. !Please note
To prevent damage,
do not level boiler without
packing cushions.
Level boiler with pallet.
Installation sequence
Fitting the boiler and making connections (cont.)
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11
Fitting the wall mounting bracket
Note
The enclosed screws and rawl plugs are
only suitable for concrete. For other con-
struction materials, use fixings that are
suitable for 145 kg loads.
1975
Ø 12
BC
D
A
2.
1.
AReference point: boiler top edge
BInstallation template (included with
the boiler)
CTop edge finished floor
DRecommendation
Installation sequence
Fitting the boiler and making connections (cont.)
5623 520 GB
Installation

12
Hooking the boiler into the wall mounting bracket and levelling
it
1.
3.
2x
3.
2.
Installation sequence
Fitting the boiler and making connections (cont.)
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13
A
BCDE
AExpansion vessel connection
BBoiler flow
CCylinder flow
DCylinder return
EBoiler return
Note
Residual water may escape when undo-
ing the locking caps.
Flue gas connection
Note
The labels "System certificate" and "Sko-
berne GmbH flue system" enclosed with
the technical documentation may only be
used in conjunction with the Viessmann
flue system made by Skoberne.
Installation sequence
Heating water side connection
5623 520 GB
Installation

14
A
1. Only for open flue operation:
Remove outer gasket A (ventilation
air).
2. Connect flue pipe or flue ventilation
air pipe.
Flue system installation instruc-
tions.
Condensate connection
Connect the condensate hose with a
constant fall and a pipe vent to the public
sewage system or to a neutralising sys-
tem.
Installation sequence
Flue gas connection (cont.)
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A
Information on operation with LPG
We recommend the installation of an
external safety solenoid valve when
installing the boiler in rooms below
ground level.
1. Seal in gas shut-off valve A into the
gas supply pipe.
2. Carry out a tightness test.
Note
Only use suitable and approved leak
detecting 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
Opening the control unit casing
!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.
Installation sequence
Gas connection
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Installation

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3. 2. 2x
1.
4. 4x
5.
Installation sequence
Opening the control unit casing (cont.)
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L N
230V~ 230V~
5
96 40
40962035100
1LN
X4 2 1
2
1
32 15 4
X3
LN
21
M
1~
X19
X14
A
B
21
20
L 1
C
D
145
145
LN
M
1~
ARadio clock receiver
BHeating circuit pump or boiler circuit
pump
CVitotrol 100 UTDB (only for constant
temperature control)
When making this connection,
remove jumper between "1" and
"L".
DVitotrol 100 UTA (only for constant
temperature control)
or
Vitotrol 100 UTDB-RF radio clock
receiver
When making this connection,
remove jumper between "1" and
"L".
Installation sequence
Electrical connections
5623 520 GB
Installation

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Connections at plug 230 V~
sÖ Boiler circuit pump or heating circuit
pump, variable speed with 0 - 10 V
connection
sA Circulation pump, optional connec-
tion:
■ 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 (accessory)
■ Vitotrol 200A or 300A remote
control
■ Vitocom 100
■ Extension kit for one heating cir-
cuit with mixer
■ Solar control module, type SM1
■ Vitosolic
■ Extension AM1
■ Extension EA1
■ Wireless base station
Information on connecting
accessories
When connecting accessories
observe the separate installation
instructions provided with them.
Circulation pump at plug sÖ:
A1~
M
sÖ
LN
?x4
B
ACirculation pump
BOnly with variable speed heating cir-
cuit pump:
Plug in 0 - 10 V connection at X4.
Rated current 2(1) A~
Rated voltage 230 V~
Installation sequence
Electrical connections (cont.)
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Circulation pump at plug sA:
A
1~
M
sA
LN
?
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 condi-
tion)
39:2
External demand via switching contact
Connection options:
■ Extension EA1 (accessory, see sepa-
rate installation instructions).
■Plug lH.
Connection
!Please note
'Live' contacts lead to short cir-
cuits or phase failure.
The external connection must be
floating.
Installation sequence
Electrical connections (cont.)
5623 520 GB
Installation

20
Plug lH Extension EA1
A
lH
N
?
1L
AFloating contact
When making this connec-
tion, remove jumper be-
tween 1 and L.
B
[{S
DE [{D DE
[{A
DE
A
AFloating contact
BExtension EA1
Burner operation is load-dependent if the contact is closed. The boiler water is heat-
ed 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 Extension EA1
"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 circuit"/"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 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.)
5623 520 GB