Viessmann Vitodens 200-W System User manual

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 1/2014 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
■ 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
aÖNORM, EN, ÖVGW-TR Gas,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI,
SWKI, VKF and EKAS guideline
1942: LPG, part 2
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
supplier and your local heating
contractor from outside the
building.
■ 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 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
Leaking or blocked flue systems,
or an insufficient supply of com-
bustion air can cause life threat-
ening poisoning from carbon
monoxide in the flue gas.
Ensure the flue system is in
proper working order. Apertures
for supplying combustion air
must be non-closable.
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.
Danger
Hot surfaces can cause burns.
■ Before maintenance or service
work, switch OFF the appli-
ance 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 electrostatic dis-
charge.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Safety instructions
Safety instructions (cont.)
5585 174 GB

4
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of the sys-
tem.
Faulty components must be
replaced with original Viessmann
spare parts.
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 the
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5585 174 GB

5
Service instructions
Product information
Intended use......................................................................................................... 7
Product information.............................................................................................. 7
Installation instructions
Preparing for installation................................................................................... 8
Installation sequence
Mounting the boiler and making connections....................................................... 10
Connection on the heating water side.................................................................. 12
Flue gas connection............................................................................................. 12
Condensate connection........................................................................................ 13
Gas connection.................................................................................................... 14
Opening the control unit enclosure....................................................................... 14
Electrical connections........................................................................................... 16
Closing the control unit enclosure and inserting the programming unit............... 26
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...................................................................................... 65
General/group "1"................................................................................................. 66
Boiler/group "2".................................................................................................... 69
DHW/group "3"..................................................................................................... 69
Solar/group "4"..................................................................................................... 70
Heating circuit 1, heating circuit 2, heating circuit 3/group "5"............................. 72
Code 2
Calling up coding level 2...................................................................................... 79
General/group "1"................................................................................................. 80
Boiler/group "2".................................................................................................... 89
DHW/group "3"..................................................................................................... 91
Solar/group "4"..................................................................................................... 93
Heating circuit 1, heating circuit 2, heating circuit 3/group "5"............................. 97
Diagnosis and service scans
Service level......................................................................................................... 106
Diagnosis.............................................................................................................. 107
Index
Index
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6
Checking outputs (relay test)................................................................................ 113
Troubleshooting
Fault display......................................................................................................... 115
Fault codes........................................................................................................... 117
Maintenance......................................................................................................... 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....................................... 164
Parts lists
Ordering parts...................................................................................................... 166
Overview of the assemblies................................................................................. 167
Casing assembly.................................................................................................. 168
Heat cell assembly............................................................................................... 170
Burner assembly.................................................................................................. 172
Hydraulic assembly.............................................................................................. 174
Control unit assembly........................................................................................... 176
Miscellaneous assembly...................................................................................... 178
Commissioning/service reports
............................................................................................................................. 179
Specification....................................................................................................... 180
Certificates
Declaration of conformity...................................................................................... 181
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 181
Keyword index.................................................................................................... 182
Index
Index (cont.)
5585 174 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
Preset for operation with natural gas E
and natural gas LL.
For conversion to LPG P (without con-
version kit), see the service instruc-
tions.
In principle the Vitodens 200-W may
only be delivered to countries listed on
the type plate. For deliveries to alterna-
tive 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 sys-
tem observe the installation instructions
for the multi boiler system accessories.
Product information
Intended use
5585 174 GB
Service

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
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)
Preparing for installation
Preparing for installation
5585 174 GB

9
LWithout connection sets (accesso-
ries)
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 installation 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.
1. Prepare the water connections. Thor-
oughly flush the heating system.
2. Prepare the gas connection accord-
ing to TRGI or TRF [or local regula-
tions].
3. Prepare the electrical connections.
■Power cable: NYM-J 3 x 1.5 mm2,
max. fuse rating 16 A, 230 V~.
■ Accessory cables: NYM with the
required number of cores for exter-
nal connections.
■Allow all cables in area "H" to pro-
trude 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 con-
struction materials, use fixing materials
that are suitable for 100 kg loads.
422
480
1975
Ø 10
1.
2.
A
D
C
B
AReference point: boiler top edge
BInstallation template (included with
the boiler)
CTop edge finished floor
DRecommendation
Installation sequence
Mounting the boiler and making connections
5585 174 GB

11
Hooking the boiler onto the wall mounting bracket and levelling
it
1.
2x
2x
4.
3.
2.
5.
Installation sequence
Mounting the boiler and making connections (cont.)
5585 174 GB
Installation

12
Note on step 4
Place the supplied circular level on the
boiler and align boiler vertically using the
adjusting screws.
Connection on the heating water side
A
CB D E F
AExpansion vessel
BSafety valve
CHeating flow
DCylinder flow
ECylinder return
FHeating return
Connect the boiler to the on-site pipe-
work.
Note
Connection layout shown with the con-
nection sets 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 sys-
tem made by Skoberne.
Connect the balanced flue.
Flue system installation instruc-
tions
Installation sequence
Mounting the boiler and making connections (cont.)
5585 174 GB

13
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.
Condensate connection
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 neutral-
ising system.
Installation sequence
Flue gas connection (cont.)
5585 174 GB
Installation

14
A
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 con-
stituents (e.g. nitrides, 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
train.
Maximum test pressure
150 mbar (15 kPa). Where
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 electrostatic dis-
charge.
Prior to commencing any work,
touch earthed objects, such as
heating or water pipes to dis-
charge static loads.
Installation sequence
Gas connection
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15
2x
4x
4.
3.
5.
2.
1.
Installation sequence
Opening the control unit enclosure (cont.)
5585 174 GB
Installation

16
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
ARadio clock receiver
BHeating circuit pump or boiler circuit
pump
CVitotrol 100, type UTDB (only for
constant temperature control units)
When making this connection,
remove jumper between "1" and
"L".
DVitotrol 100, type UTA (only for con-
stant temperature control units)
or
Vitotrol 100 wireless receiver, type
UTDB-RF
When making this connection,
remove jumper between "1" and
"L".
Installation sequence
Electrical connections
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17
Connections on 230 V~ plug
sÖ Boiler circuit pump or heating circuit
pump
■ Variable speed with 0 - 10 V con-
nection
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, type UTDB-RF
Connections to LV plug
!Outside temperature sensor
?Flow temperature sensor for low
loss header (accessory)
%Cylinder temperature sensor (part
of the DHW cylinder connection
set)
aVG KM BUS subscriber (accessory)
■ 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 separate installation
instructions provided with them.
Circulation pump at plug sÖ
High-efficiency circulation pump, speed-
controlled via 0-10 V control voltage
A1~
M
sÖ
LN
?x4
B
ACirculation pump
BPlug in 0 - 10 V connection at X4.
Rated current 2(1) A~
Rated voltage 230 V ~
Note
If a multi-stage circulation pump is con-
nected: Set code 30:0 in group "Boiler/
2".
Installation sequence
Electrical connections (cont.)
5585 174 GB
Installation

18
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
potential-free.
Installation sequence
Electrical connections (cont.)
5585 174 GB

19
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 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 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 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.)
5585 174 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).
!Please note
'Live' contacts lead to short cir-
cuits or phase failure.
The external connection must be
floating.
Installation sequence
Electrical connections (cont.)
5585 174 GB