Viessmann VITODENS 200 Operating instructions

VIESMANN
Service instructions
for contractors
Vitodens 200
Type WB2A, 8.8 to 20.0 kW
Wall mounted gas fired condensing boiler
Natural gas and LPG version
For applicability, see the last page
VITODENS 200
5692 580 GB 4/2006 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 580 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 mains isola-
tor.
&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 580 GB

Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance ................................... 5
Further details regarding the individual steps .............................................. 7
Coding
Code 1........................................................................................................ 35
Code 2........................................................................................................ 38
Resetting codes to their delivered condition ................................................ 57
Service scans
Service level overview ............................................................................... 58
Temperatures, boiler coding card and brief scans ....................................... 59
Checking outputs (relay test) ...................................................................... 62
Scanning operating conditions and sensors ................................................ 63
Troubleshooting
Fault display ............................................................................................... 66
Fault codes................................................................................................. 68
Repairs ...................................................................................................... 78
Function description
Constant temperature control unit ............................................................... 86
Weather-compensated control unit.............................................................. 87
Extensions for external connections (accessories) ...................................... 89
Control functions ........................................................................................ 93
Remote control DIP switches ...................................................................... 99
Designs
Connection and wiring diagrams –internal connections .............................. 101
Connection and wiring diagrams –external connections.............................. 102
Parts lists .................................................................................................. 104
Commissioning/service reports ............................................................... 110
Specification............................................................................................. 111
Certificates
Declaration of conformity ............................................................................ 113
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 114
Keyword index .......................................................................................... 115
Index
4
Index
5692 580 GB

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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•01. Filling the heating system ................................................. 7
•02. Venting the boiler .................................................................. 8
•03. Venting the heating system............................................... 8
•04. Filling the siphon with water............................................. 9
•05. Checking the power supply connection
• • 06. Setting the time and date (if required) - only for
weather-compensated control units.............................. 9
•07. Selecting the language (if required) - only for
weather-compensated control units.............................. 10
• • 08. Checking the gas type......................................................... 10
•09. Gas type conversion............................................................ 11
••• 10. Function sequence and possible faults ....................... 11
••• 11. Checking static and supply pressure ........................... 13
•12. Setting the maximum output ........................................... 14
••• 13. Checking all connections on the heating water
(primary) side and DHW (secondary) side for leaks
••• 14. Checking the burner (recording values on page
110 of the commissioning report)
•15. Checking the balanced flue system for soundness
(annular gap check) ............................................................. 15
• • 16. Burner removal ..................................................................... 16
• • 17. Checking the burner gasket and the burner gauze
assembly .................................................................................. 17
• • 18. Checking and adjusting the ignition and ionisation
electrodes ................................................................................ 18
• • 19. Cleaning the heating surfaces and installing the
burner........................................................................................ 18
Steps - commissioning, inspection and maintenance
5
Commissioning, inspection, maintenance
5692 580 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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• • 20. Checking the condensate drain and cleaning the
siphon........................................................................................ 20
• • 21. Checking the neutralising system (if installed)
• • 22. Checking the diaphragm expansion vessel and
system pressure.................................................................... 20
••• 23. Checking the function of all safety valves
••• 24. Checking the tightness of electrical connections
••• 25. Checking all gas equipment for soundness at
operating pressure .............................................................. 21
••• 26. Flue gas emissions test...................................................... 21
••• 27. Checking the ionisation current ..................................... 23
••• 28. Checking the external LPG safety valve (if
installed)
•29. Matching the control unit to the heating system ...... 24
•30. Adjusting the heating curves (only for weather-
compensated control units).............................................. 28
•31. Connecting the control unit to the LON system
(only for weather-compensated control units) .......... 31
•32. Instructing the system user .............................................. 33
•33. Scanning and resetting the "Maintenance" display 33
Steps - commissioning, inspection and . . . (cont.)
6
Commissioning, inspection, maintenance
5692 580 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 hardness above 3.0 mol/m
3
, e.g. with a small
softening system for heating water (see the Viessmann Vitoset price-
list).
&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 at the boiler
fill & drain valve Ain the heating
return (on the connection set or on
site). (Minimum system pressure
> 0.8 bar).
Note
If the control unit has not been
switched ON prior to filling the sys-
tem, then the servomotor of the
diverter valve will still be in its cen-
tral position, and the system will be
completely filled.
4. If the control unit had already been
switched ON before filling began:
Switch ON the control unit and acti-
vate the filling program via coding
address "2F:2".
5. Close boiler fill & drain valve A.
6. Close the shut-off valves on the
heating water side.
Further details regarding the individual steps
7
Commissioning, inspection, maintenance
5692 580 GB

Venting the boiler
1. Close the shut-off valves on the
heating water side.
2. Connect the drain hose between
top valve Band a drain outlet.
3. Open valves Aand B, and vent
at mains pressure until no sound of
escaping air can be heard.
4. Close valves Aand Band open
the heating water shut-off valves.
Venting the heating system
1. Close the gas shut-off valve and
switch ON the control unit.
Further details regarding the individual steps (cont.)
8
Commissioning, inspection, maintenance
5692 580 GB

2. Activate the venting program via
coding address "2F:1" in code 1.
Note
To call up code 1 and for setting the
coding address, see page 35.
For function and sequence of the
venting program, see page 94.
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. Remove the retaining clip and
siphon A.
2. Fill the siphon with water.
3. Fit siphon Aand secure with the
retaining clip.
Setting the time and date (if required) - only for weather-com-
pensated 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 display.
Press the following keys:
1. a/bfor the current time.
2. dto confirm; "Datum" (date)
is displayed.
3. a/bfor the current date.
Further details regarding the individual steps (cont.)
9
Commissioning, inspection, maintenance
5692 580 GB

4. dto confirm.
Selecting the language (if required) - only for weather-com-
pensated control units
Press the following keys:
1. c"Heizkreis wählen" (select
heating circuit) will be dis-
played.
2. dto confirm; wait approx. 4 s.
3. cpress again.
4. bfor the required language.
5. dto confirm.
Checking the gas type
Note
In the delivered condition, the Vitodens 200 is set up for natural gas E.
1. Check the gas category and
Wobbe index (Wo) with your mains
gas or LPG supplier and compare
them with the details on the burner
label.
2. If these details do not match, con-
vert the burner to the available gas
type.
Conversion kit installation
instructions
3. Adjust the gas type via coding
address "1E" at the control unit.
Note
To call up code 1 and for setting the
coding address, see page 35.
4. Record the gas type in the service
report on page 110.
Wobbe index ranges
Gas type Wobbe index range
kWh/m
3
MJ/m
3
Delivered condition
Natural gas E 12.0 to 16.1 43.2 to 58.0
After conversion
Natural gas LL 10.0 to 13.1 36.0 to 47.2
LPG P 20.3 to 21.3 72.9 to 76.8
Further details regarding the individual steps (cont.)
10
Commissioning, inspection, maintenance
5692 580 GB

Gas type conversion
Gas restrictor installation
instructions
Gas restrictor allocation
Gas type Internal 7
gas restric-
tor
&Natural gas
E
mm 6.2
&Natural gas
LL
mm 8.1
&LPG P mm 4.2
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 F5/F9
Check fan cables
and plug-in con-
nectors
Yes
Air pressure
switch enables
start (contact
closed across
terminals "X8.10"
and "X8.11")
No after approx. 51 s
fault E6/F5
Check fan cables
and plug-in con-
nectors, check
fan
Further details regarding the individual steps (cont.)
11
Commissioning, inspection, maintenance
5692 580 GB

Yes
Ignition No Fault F4 Check ignition
module (control
voltage 230 V
across plugs
"X2.1" and
"X2.2")
Yes
Gas combination
valve opens No Fault F4 Check the gas combination valve
(control voltage
230 V); check the
gas supply pres-
sure
Yes
Ionisation cur-
rent builds
(higher than
5 µA)
Symbol A
No Fault F4 Check the ionisa-
tion current,
check the elec-
trode adjustment
and the gas pipe
for airlocks
Yes
Burner in opera-
tion
No Stops below the
set boiler water
temperature and
restarts immedi-
ately
Check flue gas
system for sound-
ness (flue gas re-
circulation),
check gas flow
pressure
For further details regarding faults, see page 68.
Further details regarding the individual steps (cont.)
12
Commissioning, inspection, maintenance
5692 580 GB

Checking 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.
Operation with LPG
Flush the LPG tank twice during commissioning/replacement. Thoroughly vent
the tank and gas supply lines after flushing.
1. Close the gas shut-off valve.
2. Undo the screw inside test connec-
tor "IN"Aon the gas combination
valve, but do not remove, and con-
nect the pressure gauge.
3. Open the gas shut-off valve.
4. Measure the static pressure and
record it in the service report.
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 "E" to reset the
burner.
6. Check the supply (flow) pressure.
Set values:
&Natural gas 20 mbar.
&LPG 50 mbar.
Note
Use suitable test equipment with a
resolution of at least 0.1 mbar, to
measure the supply pressure.
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 port Awith
the screw.
Further details regarding the individual steps (cont.)
13
Commissioning, inspection, maintenance
5692 580 GB

9. Danger
Gas escaping from the test
port leads to a risk of explo-
sion.
Check for soundness.
Open the gas shut-off valve, start
the boiler and check the soundness
of test port A.
Supply (flow)
pressure for nat-
ural gas
Supply (flow)
pressure for
LPG
Measures
below 17.4 mbar below 42.5 mbar Do not start the boiler. Notify your
mains gas or LPG supplier.
17.4 to 25 mbar 42.5 to 57.5 mbar Start the boiler.
in excess of
25 mbar
in excess of
57.5 mbar
Install a separate gas pressure gover-
nor upstream of the system and regu-
late the inlet pressure to 20 mbar for
natural gas or 50 mbar for LPG. Notify
your mains gas or LPG supplier.
Setting the maximum output
Note
The maximum output can be limited for heating operation. You can limit the
output via the modulation range.
1. Start the boiler.
2. Press both Kand Fsimulta-
neously until "85" flashes on the
display, (equals 100% of rated out-
put) and "A" is displayed. 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.
Further details regarding the individual steps (cont.)
14
Commissioning, inspection, maintenance
5692 580 GB

Checking the balanced flue system for soundness (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.
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.
Further details regarding the individual steps (cont.)
15
Commissioning, inspection, maintenance
5692 580 GB

Burner removal
1. Switch OFF the control unit ON/
OFF switch and the power supply.
2. Close the gas shut-off valve and
safeguard against reopening.
3. Pull electrical cables from fan
motor A, pressure switch B, gas
valve C, ionisation electrode D
and ignition unit E.
4. Release the gas supply pipe Ffit-
ting.
5. Release four nuts Gand remove
the burner.
!Please note
To prevent damage,
never rest the burner on the
gauze assembly.
Further details regarding the individual steps (cont.)
16
Commissioning, inspection, maintenance
5692 580 GB

Checking the burner gasket and the burner gauze assembly
Check burner gasket Afor damage.
Generally replace the burner gasket every 2 years.
Replace the burner gauze assembly if it is damaged.
1. Remove electrodes B.
2. Undo the three Torx screws and
remove thermal insulating ring C.
3. Undo the four Torx screws and
remove burner gauze assembly D
with its gasket E.
4. Insert and secure a new burner
gauze assembly Dwith a new
gasket E.
Torque: 3.5 Nm.
5. Refit thermal insulation ring C.
6. Refit electrodes B.
Torque: 2.5 Nm.
Further details regarding the individual steps (cont.)
17
Commissioning, inspection, maintenance
5692 580 GB

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.
3. Check clearances. If the gaps are
not as specified or the electrodes
are damaged, replace and align the
electrodes together with new gas-
kets. Tighten the electrode fixing
screws with 2.5 Nm.
Cleaning the heating surfaces and installing the burner
!Please note
Scratches on parts which are in contact with flue gases can lead to corro-
sion.
Only use plastic brushes and NOT wire brushes.
Further details regarding the individual steps (cont.)
18
Commissioning, inspection, maintenance
5692 580 GB

1. If required, clean heating surfaces
Awith a brush or flush with water.
Apply a solvent-/potassium-free
cleaning agent if residues remain:
&Remove soot deposits with alka-
line cleaning agents with addi-
tional surfactants (e.g.
Fauch 600).
&Remove coatings and surface
discolouration (yellow-brown)
with slightly acidic, chloride-free
cleaning agents based on phos-
phoric acid (e.g. Antox 75 E).
&Thoroughly flush with water.
Note
Fauch 600 and Antox 75 E are sup-
plied by
Hebro Chemie GmbH
Rostocker Straße 40
D 41199 Mönchengladbach
2. Install the burner and torque the
screws diagonally with 4 Nm.
3. Secure the gas supply pipe with a
new gasket.
4. Check the gas connections for
soundness.
Danger
Escaping gas leads to a risk
of explosions.
Check all fittings for sound-
ness.
5. Connect the electrical cables/leads
to each corresponding component.
Further details regarding the individual steps (cont.)
19
Commissioning, inspection, maintenance
5692 580 GB

Checking the condensate drain and cleaning the siphon
1. Check that the condensate can
drain freely at the siphon.
2. Remove the retaining clip and the
siphon.
3. Clean the siphon.
4. Fill the siphon with water, fit it to the
boiler and secure with the retaining
clip.
Checking the diaphragm expansion vessel and system pres-
sure
Note
Carry out this test on a cold system.
1. Drain the system, or close the cap
valve on the diaphragm expansion
vessel and reduce the pressure,
until the pressure gauge indicates
"0".
2. If the inlet pressure of the dia-
phragm expansion vessel is lower
than the static system pressure,
top up with nitrogen until the inlet
pressure is raised by 0.1 to 0.2 bar.
3. Top up your heating system with
water and vent until the filling pres-
sure of a cooled system is 0.1 to
0.2 bar higher than the inlet pres-
sure of the diaphragm expansion
vessel.
Permiss. operating pressure: 3 bar
Further details regarding the individual steps (cont.)
20
Commissioning, inspection, maintenance
5692 580 GB