Viessmann VITODENS 200-W WB2B 80 User manual

Start-up/Service Instructions
for use by heating contractor
Vitodens 200-W, WB2B Series
Models WB2B 80, 105
Wall-mounted, natural gas-fired condensing boiler
or operation with natural gas and liquid propane gas
Heating input 104 to 370 MBH
30 to 108 kW
VITODENS 200-W 

Read and save these instructions
for future reference.
IMPORTA T
This trademark is registered with the U.S. Patent and Trademark Office.
5443 207 v1.5 11/2012
Please file in Service Binder

Safety, Installation and Warranty Requirements
2
Safety, Installation and Warranty Requirements
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the
instructions listed below and details printed in this manual can cause product/property damage,severe personal injury, and/or loss
of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
HLicensed professional heating
contractor
The installation, service, and
maintenance of this equipment must
be performed by a licensed
professional heating contractor.
"
Please see section
entitled “Important
Regulatory and
Installation
Requirements” in the
Installation Instructions.
HProduct documentation
Read all applicable documentation
before commencing installation. Store
documentation near boiler in a readily
accessible location for reference in
the future by service personnel.
"
For a listing of
applicable literature,
please see section
entitled “Important
Regulatory and
Installation Requirements”
in the Installation Instructions.
HCarbon monoxide
Improper installation, service and/or
maintenance can cause flue products
to flow into living space. lue
products contain poisonous carbon
monoxide gas.
"
For information
pertaining to the proper
installation, service and
maintenance of this
equipment to avoid
formation of carbon monoxide, please
see the Installation Instructions of the
Vitodens 00-W Direct Vent System.
HEquipment venting
Never operate boiler without an
installed venting system. An improper
venting system can cause carbon
monoxide poisoning.
HWarranty
Information contained in
this and related product
documentation must be
read and followed. Failure
to do so renders warranty
null and void.
HAdvice to owner
Once the installation work is
complete, the heating contractor
must familiarize the system
operator/ultimate owner with all
equipment, as well as safety
precautions/requirements, shut-down
procedure, and the need for
professional service annually before
the heating season begins.
Warning
This boiler requires fresh air for safe operation and must be installed with provisions for adequate combustion and
ventilation air (in accordance with local codes and regulations of authorities having jurisdiction).
Do not operate this boiler in areas with contaminated combustion air. High levels of contaminants such as dust, lint or
chemicals can be found at construction sites, home renovations, in garages, workshops, in dry cleaning/laundry facilities,
near swimming pools and in manufacturing facilities.
Contaminated combustion air will damage the boiler and may lead to substantial property damage, severe personal injury
and/or loss of life. Ensure boiler/burner is inspected and serviced by a qualified heating contractor at least once a year in
accordance with the Start-up/Service Instructions of the boiler.
Operating and Service Documentation
It is recommended that all product documentation such as parts lists, operating and service instructions be handed over to
the system user for storage. Documentation is to be stored near boiler in a readily accessible location for reference by
service personnel.
5443 207 v1.5
Installers must follow local
regulations with respect to
installation of carbon monoxide
detectors. Follow manufacturer’s
maintenance schedule of boiler.
WAR I G

Table of Contents
3
Page
General Information
Safety, Installation and Warranty Requirements 2 ...................................
Operating and Service Documentation 2 ......................................................
Important Regulatory and Installation Requirements 4 ...........................
About these Start-up/Service Instructions 6 ................................................
ecessary Tools 6 ...................................................................................................
Applicability 7 ............................................................................................................
Product Information 7 ............................................................................................
Mechanical Room 8 .................................................................................................
Removing Front Enclosure Panel 9 ...................................................................
Initial Start-up
and Service
Steps 10 ........................................................................................................................
Control Technology
Outdoor Reset Programming Unit (Vitotronic 200, HO1) 26 ..................
Coding
Coding Level 1 37 .....................................................................................................
Coding Level 2 40 .....................................................................................................
Service Scans
Service Level Overview 50 .....................................................................................
Temperatures, Boiler Coding Card and Brief Scans 51 .............................
Checking Outputs (Relay Test) 52 ......................................................................
Scanning Operating Conditions and Sensors 53 ...........................................
Troubleshooting
Diagnostics 54 .............................................................................................................
Corrective Action 60 ................................................................................................
Additional Information
Control Functions 64 .................................................................................................
Burner Program Sequence of Operation 67 ....................................................
Wiring Diagrams 68 ..................................................................................................
Parts Lists 70 ...............................................................................................................
Maintenance Record 73 ..........................................................................................
Technical Data 74 ......................................................................................................
Lighting and Operating Instructions 76 .............................................................
5443 207 v1.5

General Information
4
Important Regulatory and Installation Requirements
Codes
The installation of this unit shall be in
accordance with local codes or, in the
absence of local codes, use
CAN/CSA-B149.1 or .2 Installation
Codes for Gas Burning Appliances for
Canada. or U.S. installations use the
National uel Gas Code ANSI Z223.1.
Always use latest editions of codes.
In Canada all electrical wiring is to be
done in accordance with the latest
edition of CSA C22.1 Part 1 and/or
local codes. In the U.S. use the
National Electrical Code ANSI/N PA
70. The heating contractor must also
comply with both the Standard for
Controls and Safety Devices for
Automatically ired Boilers,
ANSI/ASME CSD-1, and the Installation
Code for Hydronic Heating Systems,
CSA B214-01, where required by the
authority having jurisdiction.
Instructing the system user
The installer of the system is
responsible to ensure the system
operator/ultimate owner is made
familiar with the system functioning,
its activation, and its shut-down.
Initial start-up
Initial start-up must be performed by a
qualified heating contractor. Proper
completion of the Maintenance Record
by the heating contractor is also
required.
Working on the equipment
The installation, adjustment, service,
and maintenance of this boiler must be
done by a licensed professional heating
contractor who is qualified and
experienced in the installation, service,
and maintenance of hot water boilers.
There are no user serviceable parts on
the boiler, burners, or control.
The following topics must be
covered:
Proper system operation sequence.
Explain the equipment.
Demonstrate an emergency
shut-down, what to do and what not.
Explain that there is no substitute for
proper maintenance to help ensure
safe operation.
The Maintenance Record is located
on page 73 of this manual.
Please carefully read this manual prior
to attempting start-up, maintenance
or service. Any warranty is null and
void if these instructions are not
followed.
For information regarding other
Viessmann System Technology
componentry, please reference
documentation of the respective
product.
We offer frequent installation and
service seminars to familiarize our
partners with our products. Please
inquire.
Ensure main power supply to
equipment, the heating system, and all
external controls has been deactivated.
Close main gas supply valve. Take
precautions in all instances to avoid
accidental activation of power during
service work.
The completeness and functionality of
field supplied electrical controls and
components must be verified by the
heating contractor. These include low
water cut-offs, flow switches (if used),
staging controls, pumps, motorized
valves, air vents, thermostats, etc.
Technical literature
Literature for the Vitodens boiler:
- Technical Data Manual
- Installation Instructions
- Start-up/Service Instructions
- Operating Instructions
and User’s Information Manual
- Instructions of other Viessmann
products utilized and installed
- Installation codes mentioned
in this manual
Leave all literature at the installation
site and advise the system
operator/ultimate owner where the
literature can be found. Contact
Viessmann for additional copies.
This product comes with several
safety instruction labels attached.
Do not remove!
Contact Viessmann immediately if
replacement labels are required.
5443 207 v1.5

General Information
5
Important Regulatory and Installation Requirements (continued)
or installations on the Commonwealth of Massachusetts, the following modifications to N PA-54 chapter 10 apply:
Excerpt from 248 CMR 5-08:
2(a) or all side-wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in
whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the
side-wall exhaust vent termination is less than (7) feet above finished grade in the area of the venting, including but
not limited to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION O CARBON MONOXIDE DETECTORS. At the time of installation of the side-wall horizontal
vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide
detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be
installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon
monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served
by the side-wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to
secure the services of qualified licensed professional for the installation of hard-wired carbon monoxide detectors.
a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or an attic,
the hard-wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent
floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the
owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that
during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with
the above provisions shall comply with N PA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a
minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally
vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch
in size, ”GAS VENT DIRECTLY BELOW. KEEP CLEAR O ALL OBSTRUCTIONS”.
4. INSPECTION. The state or local gas inspector of the side-wall horizontally vented gas fueled equipment shall not
approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage
installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled ”Equipment Not Required To Be Vented” in the most current edition of
N PA 54 as adopted by the Board; and
2. Product Approved side-wall horizontally vented gas fueled equipment installed in a room or structure separate
from the dwelling, building or structure used in whole or in part for residential purposes.
CSD-1 ield Testing of High Limit Switches for Vitodens boilers - where required by law.
VIESSMANN IS NOT RESPONSIBLE OR ANY DAMAGES THAT THE OLLOWING TEST PROCEDURE MAY RESULT IN BY
OVERHEATING THE SYSTEM.
The Vitodens 100/200 boilers are equipped with flow switches that when activated disable or enable the burner to operate.
The fixed high limit, when tripped, produces a fault that will require manual reset of the boiler control.
ixed High Limit fault simulation method #1:
- Close the boiler valve and jump the flow switch.
- Run the boiler at high fire and it will shut down by the coding card (in WB2B models, set coding address 06 to max.) but
should continue to stack the boiler temp until the fixed high limit is tripped.
- Once the fixed high limit is tripped, slowly open the boiler valve to safely cool the boiler down.
ixed High Limit fault simulation method #2:
- Throttle the boiler valve to a point where the burner will run with as little flow as possible.
- Run the boiler to high fire via relays test.
- When the burner shuts down on the electronic limit, close the ball valve to stop the flow.
- The boiler temp should continue to stack to trip the fixed high limit.
- Once the fixed high limit is tripped, slowly open the boiler valve to safely cool the boiler down.
ixed High Limit fault simulation method #3:
- Remove one of the wires connected to limit switch, this will produce a fault in the boilers control that requires manual
reset.
5443 207 v1.5

General Information
6
About these Start-up/Service Instructions
Take note of all symbols and notations intended to draw attention to potential hazards or important product information.
These include ”WAR I G”, ”CAUTIO ”, and ”IMPORTA T”. See below.
Warnings draw your attention to the
presence of potential hazards or
important product information.
Cautions draw your attention to the
presence of potential hazards or
important product information.
Helpful hints for installation,
operation or maintenance which
pertain to the product.
This symbol indicates that additional,
pertinent information is to be found in
column three.
This symbol indicates that other
instructions must be referenced.
ecessary Tools
Special items
HApproved leak detection fluid for
natural gas and liquid propane gas
HPipe joint sealant
Testing/analysis equipment
HMultimeter to measure 0 - 230V,
0 - 12A AC and 0 - 100 A DC
Hlue gas analyzer to measure % CO
2
or O
2
(i.e. Bacharach fluid samplers
or suitable electronic analyzer)
HManometer to measure gas pressure
0 to 11 ”w.c. (accurately) and up to
28 ”w.c. gas pressure (or a
non-electric Magnehelic® manometer
may also be utilized)
HStack thermometer 0 to 500° /
0 to 260°C
HBacharach calculator or suitable
tables to calculate efficiency
HCarbon monoxide measuring
equipment 0 to 400 ppm
Use only calibrated equipment.
Cleaning supplies
HPlastic hand brush
HRags
5443 207 v1.55443 207 v1.5
Indicates an imminently hazardous
situation which, if not avoided, could
result in death, serious injury or
substantial product/property damage.
WAR I G
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or
product/property damage.
CAUTIO
IMPORTA T
5443 207 v1.5

General InformationGeneral Information
7
Applicability
When ordering replacement parts,
provide either the 16-digit boiler serial
number (on the bar code label) or the
12-digit ASME/ B serial number,
located as shown underneath boiler
front enclosure panel. Refer to page 9
for instructions on how to remove front
enclosure panel.
G and LPG
Model o. WB2B 80
Serial No. 7424193 jjjjjjjjj
Model o. WB2B 105
Serial No. 7424194 jjjjjjjjj
G Only
Model o. WB2B 80
Serial No. 7374868 jjjjjjjjj
Model o. WB2B 105
Serial No. 7374869 jjjjjjjjj
Product Information
Natural gas-fired wall-mounted condensing heating boiler for weather-responsive
operation in closed loop, forced circulation hot water heating systems for space
heating and domestic hot water (DHW) production.
The Vitodens 200-W, WB2B series boiler comes factory set for operation with
natural gas. or fuel conversion to liquid propane gas no conversion kit is
required (see page 14).
Boiler model must be selected based on an accurate heat loss calculation of the
building. Ensure boiler model is compatible with connected radiation.
Vitodens 200-W, WB2B series boilers are factory-tested and calibrated. urther
gas valve adjustments are not typically required during field start-up.
Follow the Vitodens Venting System Installation Instructions to vent
this boiler.
5443 207 v1.5
The boiler serial number must be
provided when ordering replacement
parts. Some replacement parts are
not reverse compatible with previous
versions of the Vitodens 200-W
WB2B boiler.
CAUTIO
IMPORTA T
Fig. 1 Locating boiler serial numbers for ordering replacement parts
1 -digit ASME/NB serial number
(located on metallic plate riveted
to the heat exchanger)
16-digit boiler serial number
on white bar code label
labelled “Boiler Serial Number”
is also located on the bottom
of the boiler.
Stainless steel Inox-Radial
heat exchanger
5443 207 v1.5

General Information
8
Mechanical Room
During the early stages of designing a new home, we recommend that proper consideration be given to constructing a
separate mechanical room dedicated to the gas- or oil-fired heating equipment and domestic hot water storage tank(s).
The boiler must be located in a heated indoor area, near a floor drain, and as close as possible to a wall. Whenever possible,
install the boiler near an outside wall so that it is easy to duct the venting system to the boiler.
Locate the boiler on a wall capable of supporting the weight of the boiler filled with water (see section entitled “Technical
Data” on page 74 for information required for total boiler weight calculation). Ensure that the boiler location does not
interfere with the proper circulation of combustion and ventilation air of other fuel burning equipment within the mechanical
room (if applicable).
The maximum room temperature of the mechanical room where the boiler is located must not exceed 104º / 40ºC.
Installation area conditions
HEnsure ambient temperatures are
higher than 32° / 0°C and lower
than 104° / 40°C.
HPrevent the air from becoming
contaminated by halogenated
hydrocarbons (e.g. as contained in
paint solvents or cleaning fluids) and
excessive dust (e.g. through grinding
or polishing work). Combustion air for
the heating process, and ventilation
of the boiler room must be free of
corrosive contaminants. To that end,
any boiler must be installed in an area
that has no chemical exposure. The
list to the right indicates the main,
currently known sources.
HAvoid continuously high levels of
humidity (e.g. through frequent
drying of laundry).
HNever close existing ventilation
openings.
Sources of combustion and ventilation
air contaminants
Areas likely to contain contaminants:
HNew building construction
HSwimming pools
HRemodelling areas, hobby rooms
HGarages with workshops
Hurniture refinishing areas
HDry cleaning/laundry areas and
establishments
HAuto body shops
HRefrigeration repair shops
HMetal fabrication plants
HPlastic manufacturing plants
HPhoto processing plants
HBeauty salons
Products containing contaminants:
HChlorine-type bleaches, detergents
and cleaning solvents found in
household laundry rooms
HPaint and varnish removers
HHydrochloric acid, muriatic acid
HChlorine-based swimming pool
chemicals
HSpray cans containing
chlorofluorocarbons
HChlorinated waxes and cleaners
HCements and glues
HRefrigerant leaks
HCalcium chloride used for thawing
HSodium chloride used for water
softening salt
HPermanent wave solutions
HAdhesives used to fasten building
products and other similar items
HAntistatic fabric softeners used in
clothes dryers
Boiler operation in marine environments
(damp, salty coastal areas)
The service life of the boiler’s exposed
metallic surfaces, such as the casing
and fan housing, is directly influenced
by proximity to damp and salty marine
environments. In such areas, higher
concentration levels of chlorides from
sea spray, coupled with relative
humidity, can lead to degradation of
the exposed metallic surfaces
mentioned above. Therefore, it is
imperative that boilers installed in such
environments not be installed using
direct vent systems which draw
outdoor air for combustion. Such
boilers must be installed using room air
dependent vent systems; i.e. using
room air for combustion. The indoor air
will have a much lower relative
humidity and, hence, potential
corrosion will be minimized.
5443 207 v1.5
Incorrect ambient conditions can lead
to damage to the heating system and
put safe operation at risk.
WARNING
If you notice fire coming from the
appliance, call the fire department
immediately! Do not attempt to
extinguish the fire unless qualified to
do so.
WARNING
Fire causes a risk of burns and
explosion!
H
HH
HShut down the boiler
H
HH
HClose fuel shut-off valves
H
HH
HUse a tested fire extinguisher,
class ABC.
WARNING
IMPORTA T

General Information
9
Removing Front Enclosure Panel
Some of the following start-up/service
steps require the removal of the front
enclosure panel. To avoid personal
injury and/or product damage of any
kind please follow the instructions
below carefully when removing the
front enclosure panel.
1. Close main gas supply valve.
2. Access the control unit by lifting and
pivoting the control cover and
switch off system on/off switch.
3. Turn off power supply to boiler and
ensure that power supply cannot be
activated during the duration of the
start-up/service work.
4. Loosen the screws Aat the bottom
of the boiler as shown (do not
remove completely).
5. Slide out and remove front enclosure
panel B.
6. Release locking tabs located on both
sides of the control unit C, and fold
control down.
7. Undo screws and remove cover D.
5443 207 v1.5
Fig. Accessing the control to switch off the boiler
2.
2x
B D
A
C
4.
5.
Fig. 3 Removing front enclosure panel
6.
7.

Initial Start-up and Service
10
Steps
1. Bleed air from boiler heat exchanger
I nitial start-up
1. Close isolation valves (not shown)
connected to Aand B.
2. Connect drain hose to drain valve
C, and connect fill hose to boiler
fill valve F.
3. Close isolation valve D(located
inside the boiler).
4. Open fill valve F.
5. Bleed air from boiler heat exchanger
via isolation valve Eand out
through drain valve Cuntil no
more air noise is audible.
6. Close isolation valve Eand open
isolation valve D.
7. Bleed air from boiler heat exchanger
via isolation valve Dand out
through drain valve Cuntil no
more air noise is audible.
8. Close fill and drain valves Cand
F. Open isolation valve E.
9. If the control unit has not been
switched ON prior to filling the
system, switch the control to ON,
and activate the air bleed program
by setting coding address “2 ” to
“1” (boiler pump sÖ will be switch
ON and O for 30 sec. at a time
over a period of 20 minutes. The
program is automatically disabled
after 20 minutes, and coding
address “2 ” is set back to “0”).
10.Check system pressure.
11.Ensure adequate fuel supply exists
and open gas shutoff valve.
Isolation valves Dand Emust be
open for the boiler to operate
properly (each flow pipe through
valves Dand Eis equipped with
a flow switch).
To access coding level 1 and setting
the coding address see page 37. For
function and sequence of the air
bleed program, see page 65. While
the air bleed program is running, the
display will show ”Entlüftung”
(bleeding air).
Max. operating pressure...60 psig
Min. operating pressure...14 to 3 psig
Pressure relief valve......30 psig
2. Fill siphon with water
I nitial start-up
1. Pull off cap Adownwards.
2. Undo union nut Band pull off
siphon Cdownwards.
3. ill siphon Cwith water, and
reassemble.
4. Push on cap Afrom below.
5443 207 v1.5
Fig. 4
E D
C FA B
B
C
A