Viessmann Vitodens 200-W System User manual

Installation instructions
for contractors
VIESMANN
Vitodens 200-W
Type WB2C, 45 and 60 kW
Wall mounted gas condensing boiler
Natural gas and LPG version
VITODENS 200-W
5457 570 GB 1/2010 Dispose after installation.

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 appliances must only be
carried out by a qualified gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
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.
Working on the system
■ 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 mains isolator.
■ Safeguard the system against unau-
thorised reconnection.
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
Safety instructions
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Preparing for installation
Product information.............................................................................................. 4
Preparing for installation....................................................................................... 5
■ Preparing the boiler installation......................................................................... 5
Installation sequence
Installing the boiler and making all connections................................................... 7
■Wall mounting bracket installation.................................................................... 7
■Hanging the boiler into the wall mounting bracket............................................ 8
Heating water side connection............................................................................. 9
Flue gas connection............................................................................................. 9
Condensate connection........................................................................................ 10
Gas connection.................................................................................................... 10
Opening the control unit casing............................................................................ 11
Electrical connections........................................................................................... 13
■ Routing the connecting cables.......................................................................... 15
■ Replacing the boiler coding card for installation in a multi-boiler system.......... 16
Closing the control unit casing and inserting the programming unit..................... 17
Fitting the front panel............................................................................................ 19
Commissioning and adjustment........................................................................... 20
Index
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Vitodens 200-W, WB2C
Set up for operation with natural gas E and LL.
For conversion to LPG P (without conversion kit), see the service instructions.
Conversion for other target 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.
For installations in a multi-boiler system, generally the boiler coding card needs to be
replaced (see page 16).
Product information
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Preparing the boiler installation
!Please note
To prevent equipment damage,
install all pipework free of load
and torque stresses.
40
100160 160
200
752
1975 1690
850
380
480
875
1166
160
E
A
L
M
O
CB D F G
H
P
K
N
AExpansion vessel G 1
BSafety valve
CHeating flow G 1½
DCylinder flow G 1½
EGas connection R ¾
FCylinder return G 1½
Preparing for installation
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GHeating return G 1½
HCable entry area at the back
KAccessories (connection sets)
LWithout connection sets (accesso-
ries)
MWith connection sets (accessories)
NRecommended dimension (single
boiler system)
ORecommended dimension (multi-
boiler system)
PCondensate drain
Note
This boiler (protection IP X4 D) is
approved for installation in wet rooms
inside protection area 1 according to
DIN VDE 0100 [Germany], if hosed
water can be prevented.
Observe the requirements of
DIN VDE 0100 [or local regulations].
1. Prepare the water connections. Flush
the heating system thoroughly.
2. Prepare the gas connection accord-
ing to TRGI or TRF [or local regula-
tions].
3. Prepare the electrical connections.
■ Power supply cable: NYM-
J 3 x 1.5 mm2, fuse max. 16 A,
230 V~.
■ Accessory cables: NYM with the
required number of conductors for
the external connections.
■Allow all cables in area "H" to pro-
trude 1200 mm from the wall.
Preparing for installation (cont.)
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Wall mounting bracket installation
Note
The enclosed screws and rawl plugs are
only suitable for concrete. For other con-
struction materials, use fixings 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
Installing the boiler and making all connections
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Hanging the boiler into the wall mounting bracket
2x
1.
3.
2.
Installing the boiler and making all connections (cont.)
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CB D E F
A
AExpansion vessel
BSafety valve
CHeating flow
DCylinder flow
ECylinder return
FHeating return
Connect the boiler to the on-site pipe-
work.
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
Connect the balanced flue. Flue gas system installation
instructions.
Heating water side connection
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Connect the condensate drain with a
constant slope and a pipe vent to the
public sewer.
Gas connection
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 in gas shut-off valve A at the
gas connection.
Condensate connection
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2. Carry out a tightness test.
Note
For the tightness test, use only suita-
ble and approved leak detecting
agents (EN 14291) and devices.
Leak detecting agents with unsuita-
ble constituents (e.g. nitrites, sul-
phides) can lead to material dam-
age.
Remove residues of the leak detect-
ing 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,
separate 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 modules can be dam-
aged by electrostatic dis-
charges.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Gas connection (cont.)
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3.
2. 2x
1.
4. 8x
5.
Opening the control unit casing (cont.)
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5
2
1
32 17 6 5 4
X3
40962035100
L 1
L N
230V~
LN
230V~
96 40
1
AC
D
LN
20
B
X4
145145
ARadio clock receiver
BHeating circuit pump or boiler circuit
pump
Only with variable speed heating cir-
cuit pump:
Insert plug aVG into X4.
CVitotrol 100 UTDB (only for constant
temperature control units).
When making this connection,
remove jumper between "1" and
"L".
DVitotrol 100 UTA (only for constant
temperature control units)
or
Vitotrol 100 UTDB-RF wireless
receiver.
When making this connection,
remove jumper between "1" and
"L".
Electrical connections
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Information regarding the con-
nection of accessories
For the connection, observe the
separate installation instructions
provided with the accessory com-
ponents.
230 V~ plugs
sÖ Circulation pump
fÖ Power supply [terminals]
Danger
Incorrect core termination
can cause severe injuries
and damage to the equip-
ment.
Take care not to interchange
wires "L1" and "N".
■ Install an isolator in the power
supply line that simultaneously
isolates all non-earthed conduc-
tors from the mains with at least
3 mm contact separation.
We additionally recommend
installing an AC/DC-sensitive
RCD (RCD class B ) for
DC (fault) currents that can occur
with energy-efficient equipment.
■ Max. fuse rating 16 A.
lH ■ Power supply accessories (230 V/
50 Hz). Where the boiler is instal-
led in a wet area, the connection
of accessories to the power sup-
ply must not be carried out at the
control unit. The power supply
connection for accessories can be
made immediately at the control
unit, if the boiler is installed out-
side wet areas. This connection is
directly controlled with the system
ON/OFF switch (max. 3 A).
■ Vitotrol 100 UTA
■ Vitotrol 100 UTDB
■ Vitotrol 100 UTDB-RF
Low voltage plugs
!Outside temperature sensor (only
for weather-compensated control
units).
Installation:
■ 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
ventilation outlets
■ Not immediately below balco-
nies or gutters
■ Never render over
■ 2-core lead, max. 35 m length
with a cross-section of 1.5 mm2
?Flow temperature sensor for low
loss header (accessories)
Electrical connections (cont.)
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%Cylinder temperature sensor (part
of the DHW cylinder connection
set).
Connection to cables with plugs
outside of the control unit.
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
Routing the connecting cables
!Please note
If connecting cables touch hot components they will be damaged.
When routing and securing connecting cables on site, ensure that the maxi-
mum permissible temperatures for these cables are not exceeded.
5
ALow voltage connections
B230 V connections
CInternal extension
DMain PCB
ECommunication module
FCable grommet for power cable
Electrical connections (cont.)
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%Plugs for connecting the cylinder
temperature sensor to the cable har-
ness
Remove the existing cable grommet
when using larger cross-sections (up to
714 mm). Secure the cable with cable
grommet F (black) integrated into the
casing base.
Replacing the boiler coding card for installation in a multi-boiler
system
If this boiler is installed in a multi-boiler
system, always replace the fitted boiler
coding card with the equivalent card for
multi-boiler systems.
The boiler coding card for multi-boiler
systems is secured at the cover panel
behind the control unit.
Corresponding installation
instructions are supplied with the
boiler coding card.
Electrical connections (cont.)
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2.
1.
3. 2x
6.
5.
4.
Closing the control unit casing and inserting the programming unit
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Insert programming unit (packed sepa-
rately) into the control unit support.
Note
The programming unit can also be used
in a wall mounting base (accessory) near
the boiler.
Wall mounting base installation
instructions
Closing the control unit casing and inserting… (cont.)
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2.
2x
2.
1.
Note
Ensure the locking screws are screwed
in before operating.
Fitting the front panel
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For commissioning and adjust-
ment, see service instructions.
Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Viessmann Werke GmbH&Co KG
D-35107 Allendorf
Telephone: [phone]
Fax: [phone]
www.viessmann.com
5457 570 GB Subject to technical modifications.
Printed on environmentally friendly,
chlorine-free bleached paper
Commissioning and adjustment