Viessmann Vitodens 200-W WB2B Series Operating instructions

VIESMANN
Service instructions
for contractors
Vitodens 200-W
Type WB2B, 80 and 105 kW
Wall mounted gas fired condensing boiler
Natural gas version
For applicability, see the last page
VITODENS 200-W
5692 761 GB 1 /2008 Please keep safe.

Please follow these safety instructions closely to prevent accidents and
material 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
environmental pollution.
Note
Details identified by the word "Note"
contain 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 fit-
ter.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
&The system must be commissioned
by the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental 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.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances 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
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close all doors leading to the
living space.
Safety instructions
2
Safety instructions
5692 761 GB

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
supply 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
unauthorised reconnection.
!Please note
Electronic modules can be
damaged 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
fulfil a safety function can com-
promise 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
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 761 GB

Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance ................................... 5
Further details regarding the individual steps .............................................. 7
Coding
Code 1........................................................................................................ 36
Code 2........................................................................................................ 39
Resetting codes to their delivered condition ................................................ 59
Service scans
Service level overview ............................................................................... 60
Temperatures, boiler coding card and brief scans ....................................... 61
Checking outputs (relay test) ...................................................................... 64
Scanning operating conditions and sensors ................................................ 65
Troubleshooting
Fault display ............................................................................................... 68
Fault codes................................................................................................. 70
Repairs ...................................................................................................... 81
Function description
Constant temperature control unit ............................................................... 88
Weather-compensated control unit.............................................................. 89
Extensions for external connections (accessories) ...................................... 91
Control functions ........................................................................................ 95
Remote control DIP switches ...................................................................... 101
Electronic combustion control unit............................................................... 102
Designs
Connection and wiring diagram –internal connections ................................ 104
Connection and wiring diagram –external connections ............................... 105
Parts lists .................................................................................................. 107
Commissioning/service reports
Specification............................................................................................. 113
Certificates
Declaration of conformity ............................................................................ 114
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 115
Keyword index .......................................................................................... 116
Index
4
Index
5692 761 GB

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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• • 01. Opening the boiler ................................................................ 7
•02. Filling the heating system ................................................. 8
•03. Venting the boiler .................................................................. 9
•04. Venting the heating system............................................... 9
•05. Filling the siphon with water............................................. 10
••• 06. Checking all connections on the heating water
side and DHW side for leaks
•07. Checking the power supply connection
• • 08. Setting the time and date (if required) –only for
weather-compensated control units.............................. 11
•09. Selecting the language (if required) –only for
weather-compensated control units.............................. 11
• • 10. Checking the gas type......................................................... 12
••• 11. Function sequence and possible faults........................ 12
••• 12. Checking the static and supply pressure .................... 14
•13. Setting the maximum output ........................................... 15
•14. Checking the balanced flue system for tightness
(annular gap check) ............................................................. 16
• • 15. Removing the burner and checking the burner
gasket........................................................................................ 17
• • 16. Checking the burner gauze assembly &replacing,
if required................................................................................. 19
• • 17. Checking and adjusting the ignition and ionisation
electrodes ................................................................................ 20
• • 18. Cleaning the combustion chamber/heat exchanger
and installing the burner .................................................... 20
• • 19. Checking the condensate drain and cleaning the
siphon........................................................................................ 22
Steps - commissioning, inspection and maintenance
5
Commissioning, inspection, maintenance
5692 761 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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• • 20. Checking the neutralising system (if installed)
• • 21. Checking the diaphragm expansion vessel and
system pressure.................................................................... 22
••• 22. Checking the function of all safety valves
••• 23. Checking the tightness of electrical connections
••• 24. Checking all gas equipment for tightness at
operating pressure .............................................................. 22
••• 25. Flue gas emissions test...................................................... 23
•26. Matching the control unit to the heating system ...... 24
•27. Adjusting the heating curves (only for weather-
compensated control units).............................................. 29
•28. Connecting the control unit to the LON system
(only for weather-compensated control units) .......... 32
•29. Instructing the system user .............................................. 34
•30. Scanning and resetting the "Service" display ........... 34
Steps - commissioning, inspection and . . . (cont.)
6
Commissioning, inspection, maintenance
5692 761 GB

Opening the boiler
1. Undo screws Aat the bottom and
remove front panel B.
2. Release the side closures and
pivot control unit Cdown.
3. Undo screws and remove cover
panel D.
Further details regarding the individual steps
7
Commissioning, inspection, maintenance
5692 761 GB

Filling the heating system
!Please note
Unsuitable fill water increases the level of deposits and corrosion and
may lead to boiler damage.
&Thoroughly flush the entire heating system prior to filling it with water.
&Only use fill water of potable quality.
&Soften fill water with a water hardness in excess of the following
values, e.g. with a small softening system for heating water (see the
Viessmann Vitoset pricelist):
&Single boiler system and multi-boiler systems ≤200 kW: 11.2 °dH
(2.0 mol/m
3
)
&Multi-boiler systems > 200 kW: 8.4 °dH (1.5 mol/m
3
)
&An antifreeze additive suitable for heating systems can be mixed with
the fill water. The antifreeze manufacturer must verify its suitability.
1. Check the inlet pressure of the dia-
phragm expansion vessel.
2. Close the gas shut-off valve.
3. Fill the heating system via boiler fill
& drain valve A. (minimum system
pressure > 1.0 bar).
4. Close boiler fill & drain valve A.
Further details regarding the individual steps (cont.)
8
Commissioning, inspection, maintenance
5692 761 GB

Venting the boiler
1. Close shut-off valves Aand B.
2. Connect the drain hose to drain
valve C.
Connect the fill hose to boiler fill &
drain valve F(if no longer con-
nected).
3. Close shut-off valve D.
4. Open valve F.
5. Vent the first indirect coil through
shut-off valve Eat mains pressure
until no more air noise is audible.
6. Close shut-off valve Eand open
shut-off valve D.
7. Vent the second indirect coil
through shut-off valve Dat mains
pressure until no more air noise is
audible.
8. Close valves Cand F.
9. Open shut-off valve E.
Note
Shut-off valves Dand Emust be
open to enable the boiler to oper-
ate.
Venting the heating system
1. Close the gas shut-off valve and
switch ON the control unit ON/OFF
switch.
Further details regarding the individual steps (cont.)
9
Commissioning, inspection, maintenance
5692 761 GB

2. Activate the venting program via
coding address "2F:1".
Note
To call up code 1 and for setting the
coding address, see page 36.
For function and sequence of the
venting program, see page 96.
Whilst the venting program runs,
the display shows "EL" (constant
temperature control unit) or
"Entlüftung" (Venting) (weather-
compensated control unit).
3. Check the system pressure.
Filling the siphon with water
1. Pull off cap Adownwards.
2. Undo union nut Band pull off
siphon Cdownwards.
3. Fill siphon Cwith water and refit it.
4. Push on cap Afrom below.
Further details regarding the individual steps (cont.)
10
Commissioning, inspection, maintenance
5692 761 GB

Setting the time and date (if required) –only for weather-
compensated control units
Note
&During commissioning, or after a
prolonged time out of use, it may be
necessary to reset the time and
date, if the time flashes in the dis-
play.
&When the unit is first taken into
operation the display is in German
(default language setting):
Time (see step 1)
Date (see step 2)
Press the following keys:
1. a/bfor the current time.
2. dto confirm; "Datum" is dis-
played.
3. a/bfor the current date.
4. dto confirm.
Selecting the language (if required) –only for weather-com-
pensated control units
Note
When the unit is first taken into opera-
tion the display is in German (default
language setting):
Select heating circuit (see step 1.)
Outside temperature (see step 3.)
Press the following keys:
1. c"Heizkreis wählen" (select
heating circuit) is displayed.
2. dto confirm; wait approx. 4 s.
Further details regarding the individual steps (cont.)
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Commissioning, inspection, maintenance
5692 761 GB

3. cpress this button again,
"Außentemperatur" (outside
temperature) is displayed.
4. bfor the required language.
5. dto confirm.
Checking the gas type
The boiler is equipped with an electronic combustion control unit that adjusts
the burner for optimum combustion in accordance with the prevailing gas qual-
ity.
The boiler can be operated with natural gas in the Wobbe index range 10.0 to
16.1 kWh/m
3
(36.0 to 58.0 MJ/m
3
) without conversion.
1. Determine the gas type and Wobbe
index from your gas supply utility.
2. Record the gas type in the service
report on page 112.
Wobbe index ranges
Gas type Wobbe index range
kWh/m
3
MJ/m
3
Delivered condition
Natural gas E
or
12.0 to 16.1 43.2 to 58.0
Natural gas LL 10.0 to 13.1 36.0 to 47.2
Function sequence and possible faults
Display screen Measures
Control unit is-
sues heat de-
mand
No Increase set
value and ensure
heat is drawn off
Yes
Fan starts No after approx. 51 s
fault F9
Check the fan, fan
connecting
cables, power at
the fan and fan
control
Further details regarding the individual steps (cont.)
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Commissioning, inspection, maintenance
5692 761 GB

Yes
Ignition No Fault F4 Check the ignition
module (control
voltage 230 V
across plugs
"X2.1" and
"X2.2")
Yes
Gas train opens No Fault F4 Check the gas
train (control vol-
tage 230 V);
check the gas
supply pressure
Yes
Ionisation cur-
rent builds
Symbol A
No Fault F4 Check the ionisa-
tion electrode ad-
justment and the
gas pipe for air-
locks
Yes
Burner in opera-
tion
No Stops below the
set boiler water
temperature and
restarts immedi-
ately
Check the flue
gas system for
soundness (flue
gas recirculation),
check the gas
flow pressure
Yes
Automatic cali-
bration of the
combustion con-
trol unit
No Fault Eb Check the con-
necting cable and
the ionisation
electrode,
check the flue gas
system (flue gas
recirculation)
Further details regarding the individual steps (cont.)
13
Commissioning, inspection, maintenance
5692 761 GB

For further details regarding faults,
see page 70.
Checking the static and supply pressure
Danger
CO build-up as a result of an incorrect burner setup can have serious
health implications.
Carry out a CO test prior to and after work on gas equipment.
1. Close the gas shut-off valve.
2. Release screw Ainside test nipple
"PE" on one of the two gas trains,
but do not remove it; then connect
the pressure gauge.
3. Open the gas shut-off valve.
4. Measure the static pressure and
record it in the service report on
page 112.
Set value: max. 57.5 mbar.
5. Start the boiler.
Note
During commissioning, the boiler
can enter a fault state because of
airlocks in the gas pipe. After
approx. 5 s press "ERESET" to
reset the burner.
6. Check the supply (flow) pressure.
Set value: 20 mbar.
Note
Use suitable test equipment with a
resolution of at least 0.1 mbar to
measure the supply pressure.
Further details regarding the individual steps (cont.)
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Commissioning, inspection, maintenance
5692 761 GB

7. Record the actual value in the ser-
vice report.
Take the action shown in the follow-
ing table.
8. Shut down the boiler, close the gas
shut-off valve, remove the pressure
gauge and close test nipple Awith
the screw.
9. Danger
Gas escaping from the test
nipple leads to a risk of
explosions.
Check for tightness.
Open the gas shut-off valve, start
the boiler and check for tightness at
test nipple A.
Supply pressure (flow
pressure)
Remedy
below 15 mbar Do not commission, and notify the gas supply utility.
15 to 25 mbar Start the boiler.
above 25 mbar Install a separate gas pressure governor upstream
of the system and set the inlet pressure to 20 mbar
for natural gas. Notify your gas supply utility.
Setting the maximum output
Note
You can limit the maximum output for heating operation. The limit is set via the
modulation range. The max. adjustable heating output is limited upwards by the
boiler coding card.
1. Start the boiler.
Further details regarding the individual steps (cont.)
15
Commissioning, inspection, maintenance
5692 761 GB

2. Press Kand Fsimultaneously
until a value flashes (e.g. "85") and
"A" appears. In the delivered con-
dition, this value represents 100 %
of rated output.
On weather-compensated control
units, the display additionally
shows "Max. output".
3. With a/bselect the required
value in % of rated output as maxi-
mum output.
4. Confirm the set value with d.
5. Record the settings for maximum
output on the additional type plate
included with the "technical docu-
mentation". Affix the type plate next
to the original type plate on top of
the boiler.
Note
The output can also be limited for
DHW heating. For this, change coding
address "6F" in code 2.
Checking the balanced flue system for tightness (annular
gap check)
ACombustion air port
For balanced flue systems tested
together with the wall mounted gas
fired boiler, some authorities waive
the requirement for a soundness test
(overpressure test) during commis-
sioning by the flue gas inspector.
We recommend that your heating
engineer carries out a simple sound-
ness test during the commissioning of
your system. For this, it would be suf-
ficient to check the CO2or O2concen-
tration in the combustion air at the
annular gap of the balanced flue pipe.
Further details regarding the individual steps (cont.)
16
Commissioning, inspection, maintenance
5692 761 GB

The flue pipe is deemed to be sound if
the CO2concentration in the combus-
tion air is no higher than 0.2 % or the
O2concentration is at least 20.6 %.
If actual CO2values are higher or O2
values are lower, then pressure test
the flue pipe with a static pressure of
200 Pa.
Removing the burner and checking the burner gasket
Further details regarding the individual steps (cont.)
17
Commissioning, inspection, maintenance
5692 761 GB

1. Switch OFF the main power supply
and the ON/OFF switch at the con-
trol unit.
2. Close the gas shut-off valve and
safeguard against reopening.
3. Unlock control unit Aand pivot
forwards.
4. Remove cover panel B.
5. Pull cables from fan motor C, gas
train D, ignition unit E, earth tab
Fand ionisation electrode G.
6. Release gas supply pipe fittings
H.
7. Undo six screws Kand remove
the burner.
8. Check burner gasket Lfor
damage. Replace gasket, if
required.
Further details regarding the individual steps (cont.)
18
Commissioning, inspection, maintenance
5692 761 GB

Checking the burner gauze assembly &replacing, if required
1. Remove electrodes A.
2. Undo three retaining clips Bat
thermal insulation ring Cand
remove thermal insulation ring C.
3. Release four Torx screws Dand
remove burner gauze assembly
E.
4. Remove old burner gauze assem-
bly gasket F.
5. Insert a new burner gauze assem-
bly with a new gasket and secure
with four Torx screws.
Note
Torque: 4.5 Nm
Further details regarding the individual steps (cont.)
19
Commissioning, inspection, maintenance
5692 761 GB

6. Refit the thermal insulation ring C
and electrodes A.
Checking and adjusting the ignition and ionisation electro-
des
AIgnition electrodes BIonisation electrode
1. Check the electrodes for wear and
contamination.
2. Clean the electrodes with a small
brush (not with a wire brush) or
emery paper.
!Please note
Do not damage
the wire gauze.
3. Check the electrode gaps. If the
gaps are not as specified or the
electrodes are damaged, replace
and align the electrodes together
with new gaskets. Tighten the elec-
trode fixing screws with 2 Nm.
Cleaning the combustion chamber/heat exchanger and
installing the burner
!Please note
Scratches on parts that are in contact with flue gases can lead to corro-
sion.
Never use brushes to clean the heating surfaces.
Further details regarding the individual steps (cont.)
20
Commissioning, inspection, maintenance
5692 761 GB