Viessmann VITODENS 200 Operating instructions

Start-up/Service Instructions
for use by heating contractor
Vitodens 200
WB2 Series
Wall-mounted, gas-fired condensing boiler
For natural gas and liquid propane
Heating input NG 55 to 230 MBH
16 to 67 kW
Heating input LP 55 to 214 MBH
16 to 63 kW
VITODENS 200
Vitodens 200, WB2-44/60
(with preinstalled vent pipe adaptor)
Read and save these instructions
for future reference.
IMPORTANT
Vitodens 200, WB2-44/60
(with preinstalled vent pipe adaptor)
5285 961 v1.3 09/2008
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/orloss
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.
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.
HCarbon monoxide
Improper installation, service and/or
maintenance can cause flue products
to flow into living space. Flue
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 200 Venting 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.
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.
5285 961 v1.3
Installers must follow local
regulations with respect to
installation of carbon monoxide
detectors. Follow manufacturer’s
maintenance schedule of boiler.
WARNING

Index
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 5................................................
Necessary Tools 6...................................................................................................
Removing and Reinstalling Front Enclosure Panel and Cover Panel 7
Initial Start-up
and Service
Procedure (Overview) 8........................................................................................
Steps 9........................................................................................................................
Troubleshooting Troubleshooting Steps 27......................................................................................
Diagnosis 27................................................................................................................
Correction 39...............................................................................................................
Additional Information Overview 45................................................................................................................
Technical Data 46.....................................................................................................
Burner Control Unit LGM 29 47..........................................................................
Control Unit for Weather-Responsive Operation
Hwith programming unit 48.................................................................................
Hjumper assignment and codings 59...............................................................
Replacement of Circuit Board VR20 61............................................................
Replacement of Burner Control Unit LGM 29 62..........................................
Wiring Diagram 65....................................................................................................
Parts Lists
HVitodens 200, WB2 66
......................................................................................
HInstallation fittings (models WB2 11-44 and 15-60) 68........................
Alphabetical Index 69..............................................................................................
Maintenance Record 70..........................................................................................
Lighting and Operating Instructions 71............................................................
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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. For U.S. installations use the
National Fuel 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/NFPA
70. The heating contractor must also
comply with both the Standard for
Controls and Safety Devices for
Automatically Fired 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 70 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
- System Design Guidelines
- 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.
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5
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 ”WARNING”, ”CAUTION”, and ”IMPORTANT”. 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.
5285 961 v1.35285 961 v1.3
Indicates an imminently hazardous
situation which, if not avoided, could
result in death, serious injury or
substantial product/property damage.
WARNING
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or
product/property damage.
CAUTION
IMPORTANT

General Information
6
Necessary Tools
Special items
HApproved leak detection fluid for
natural gas and propane gas
HPipe joint sealant
Testing/analysis equipment
HMultimeter to measure 0 - 230 V,
0 - 12 A AC and 0 - 100 μADC
HFlue gas analyzer to measure % CO2
or O2(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 °F /
0 to 260 °C
HBacharach calculator or suitable
tables to calculate efficiency
HCarbon monoxide measuring
equipment 0 to 400 ppm
Cleaning supplies
HPlastic hand brush
HRags
Use only calibrated equipment.
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General Information
7
Removing and Reinstalling Front Enclosure Panel and Cover Panel
Some of the following start-up/service
steps require the removal of the front
enclosure panel and the cover panel.
To avoid personal injury and/or product
damage of any kind please follow the
instructions below carefully when
removing or reinstalling the front
enclosure panel and cover panel.
To remove front enclosure panel and
cover panel proceed as follows:
1. Close main gas supply valve.
2. Open flip-down cover of front
enclosure panel (by exerting slight
pressure with fingertip). 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.
5. Unlock enclosure panel by giving
cover lock a quarter turn.
6. Remove burner cover panel by
unlocking the two pull-down latches
located on the bottom of the panel,
and slide out panel.
7. Attach front enclosure panel.
8. Secure in place by rotating slotted
screw.
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5.
4.
2.
1.
3.

Initial Start-up and Service
8
Procedure (Overview)
Initial start-up steps
Service steps
I1. Fill heating system with water Page 9................................................................................................................
I2. Check power supply connection Page 11..............................................................................................................
I3. Select language (if required) Page 12.....................................................................................................................
I4. Heating contractor address input Page 12...........................................................................................................
I S 5. Select appropriate gas type Page 13......................................................................................................................
I S 6. Measure static pressure and running pressure Page 13.................................................................................
I S 7. How the Vitodens 200 boiler operates... Page 15............................................................................................
I S 8. Check CO2setting Page 16........................................................................................................................................
I S 9. Clock natural gas meter Page 17..............................................................................................................................
S10. Check orifice size Page 17..........................................................................................................................................
I S 11. Check all primary and secondary circuit connections for leaks Page 18................................................
I S 12. Perform combustion analysis Page 18...................................................................................................................
I13. Check venting system for leaks (circular air gap measurement) Page 18..............................................
S14. Disassemble burner and check burner gasket Page 19..................................................................................
S15. Visually check exterior of burner mesh assembly Page 19...........................................................................
S16. Replace burner mesh assembly (if wire mesh is damaged) Page 19........................................................
S17. Check and adjust ignition and ionization electrode Page 20........................................................................
S18. Check condensate drain Page 20.............................................................................................................................
S19. Check neutralization unit (if applicable) Page 21................................................................................................
S20. Clean combustion chamber/heat exchanger surfaces, and mount burner Page 21...........................
I S 21. Check diaphragm expansion tank and system pressure Page 22...............................................................
I S 22. Check functioning of safety valves Page 22.......................................................................................................
I S 23. Check electrical connections Page 23....................................................................................................................
I S 24. Check gas pipes and fittings for leaks Page 23.................................................................................................
S25. Measure ionization current Page 24........................................................................................................................
I26. Verify programming unit system coding addresses Page 24.......................................................................
I27. Check extension kit for heating circuit with mixing valve Page 25..........................................................
I28. Check Dekamatik-HK Page 26....................................................................................................................................
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Initial Start-up and Service
9
Steps
1. Fill heating system with water
Initial start-up
1. Open system isolation valves (if
installed).
Please note:
Before filling the heating system with
water, check that all necessary flow
check valves are installed.
2. Check inlet pressure of the
diaphragm expansion tank.
If the nitrogen pressure of the
precharged expansion tank is less
than the static pressure of the
system, inflate membrane pressure to
slightly exceed pressure of system.
The static pressure required at the
tank is based upon the static height
of the system. The system fill
pressure value must be equal to the
expansion tank pressure value at
approx. 60 ºF/15.6 ºC.
3. To remove debris and/or sludge
ensure that the system piping is
flushed out. Failure to do so could
cause settlement in the boiler
causing overheating and damage
not covered by warranty.
4. Optional:
Fill the heating system with water
at the boiler filling and drain tap
and drain air completely from the
system at ball valve barb fitting .
Max. boiler
operating pressure ......45 psig
Min. boiler
operating pressure ......12 psig
Pressure relief valve ......30 psig
System fill pressure must be
approximately 3 psig higher than the
static head when the system is cold.
Water treatment should be
considered in areas where it is known
that boiler feed water contains a high
mineral content and hardness.
In areas where freezing might occur,
an antifreeze may be added to the
system water to protect the system.
Please adhere to the specifications
given by the antifreeze manufacturer.
Do not use automotive silicate-based
antifreeze. Please observe that an
antifreeze/water mixture may require
a backflow preventer within the
automatic water feed and influence
components such as diaphragm
expansion tanks, radiation, etc. A
40% antifreeze content will provide
freeze-up protection to -10°F/-23°C.
Do not use antifreeze other than
specifically made for hot water
heating systems. System also may
contain components which might be
negatively affected by antifreeze.
Check total system frequently when
filled with antifreeze.
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Air vent

Initial Start-up and Service
10
Steps (continued)
1. Fill heating system with water (continued)
Initial start-up
5. Check system pressure and open
ball valve
6. Shut off the boiler from the heating
system on heating water side (close
shutoff valve ).
7. Connect drain hose to drain valve
or .
8. Open drain valve or and vent
the boiler with system pressure
until noise due to the presence of
air is eliminated.
9. Close drain valve or and
open ball valve .
10. Check system pressure.
11. Ensure proper/adequate fuel supply
exists. Open gas shutoff valve.
5285 961 v1.3
Water flow
Air vent