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............................................................
5285 961 v1.3

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.
5285 961 v1.3

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.
5285 961 v1.3

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.
5285 961 v1.3
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....................................................................................................................................
5285 961 v1.3

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.
5285 961 v1.3
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

Initial Start-up and Service
11
Steps (continued)
2. Check power supply connection
Initial start-up
A power module is supplied with the
Vitodens 200 boiler, which requires a
120 VAC power supply from a wall
receptacle.
The module contains a 120/230 VAC
step-up transformer to power the
Vitodens 200 with 230 VAC. Refer to
the Installation Instructions shipped
with the module for wiring details
and/or Installation Instructions of the
boiler.
Voltage range
The voltage at connector must be
230 V (see wiring diagram).
Neutral conductor
The electrical power supply must have
a neutral conductor.
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.
Please note:
The outer conductor ”L” and the
neutral conductor ”N” must not be
interchanged.
See wiring diagram in section entitled
”Additional Information” in this
manual.
5285 961 v1.3
IMPORTANT

Initial Start-up and Service
12
Steps (continued)
3. Select language (if required)
Initial start-up
Menu-driven programming unit.
LANGUAGE / LANGUE
>ENGLISH:.................A
>FRANÇAIS:...............B
>BACK / RETOUR: ......D
Open cover:
Menu option Button
→SYSTEM ”D”
→FACTORY SETTING ”A”
→LANGUAGE ”C”
Select language.
4. Heating contractor address input
Initial start-up
Menu-driven programming unit.
This option allows the system user to access name and telephone number of the
heating contractor on the display (see Vitodens 200 Operating Instructions) almost
immediately after a system fault has occurred.
HEATING CONTRACTOR
INPUT NAME/TEL.:
TEL.:
>CHANGE: -/+
>POSITION FORWARD:A
>POSITION BACK: ......B
>INSTALLER SETUP: ...D
Open the cover:
Menu option Button
→SYSTEM ”D”
→INSTALLER SETUP ”C”
→CODE PLEASE: ”B-C-C-B”
→DIAGNOSIS ”A”
→HEATING
CONTRACTOR ”C”
Position cursor as required using
the ”A”and”B” buttons.
Select the required characters (number,
letter, special character) by turning
the ”G” selector knob (turn
clockwise or counterclockwise).
Sequence of available characters:
0123456789ABCDEF
GHIJKLMNOPQRSTUV
WXYZ=<>.:k?,–i/()
Characters already selected can be
deleted with the space character ”k”or
overwritten with another character.
Upon exiting the input menu
(INSTALLER SETUP ”C”), name and
telephone number of the heating
contractor are automatically stored.
5285 961 v1.3

Initial Start-up and ServiceInitial Start-up and Service
13
Steps (continued)
Initial start-up 5. Select appropriate gas type Service
The Vitodens 200 boiler is for use with
gases whose characteristics fall within
the following ranges. Do not use any
other types of gas.
1. Ensure that the fuel type listed on
the boiler rating plate is the correct
type for the installation being
attempted.
2. Record fuel type in Maintenance
Record on page 70.
Natural gas Propane gas
Heating value (gross) Btu/ft3970 to 1100 2466 to 2542
Specific gravity 0.57 to 0.70 1.522 to 1.574
Ultimate carbon dioxide (CO2) % 11.7 to 12.2 13.73 to 13.82
6. Measure static pressure and running pressure
Initial start-up Service
Static pressure
1. To measure static and/or running
pressure remove burner cover panel
as per the removal and reinstallation
instructions on page 7 in these
instructions.
2. Close gas shutoff valve (field
supplied).
3. Loosen screw in test nipple ”PE” A
on the gas combination valve, do not
remove completely. Connect
manometer.
4. Open the gas shutoff valve.
5. Measure static pressure. Values
must be:
H14“w.c.max.forNG
H14“w.c.max.forLP
6. Enter measured value into
Maintenance Record on page 70 in
this manual.
7. Start up boiler, using the on/off
switch on the boiler control.
A CO measurement (see page 16 must
be taken before and after working on
gas appliances to eliminate risks to
health and to guarantee the
satisfactory condition of the system.
The burner is automatically ignited and
starts operation after a safety time has
elapsed.
During initial start-up, the unit may
indicate a fault because of air in the gas
supply pipe (especially for propane gas).
After approx. 5 seconds, press the ”EU”
button to reset the burner. The ignition
procedure is repeated. This boiler
employs a direct spark ignition system.
5285 961 v1.3
PE
A
Measuring static gas supply pressure,
using test nipple “PE”
inlet
outlet
IMPORTANT
IMPORTANT

Initial Start-up and Service
14
Steps (continued)
6. Measure static pressure and running pressure (continued)
Initial start-up Service
Running pressure
8. Measure the running pressure; value
must be:
Use suitable measuring instruments
calibrated with a minimum resolution
of 0.04 “w.c. for measuring the
running pressure.
Running supply pressure with Corrective action
Natural gas Propane gas
Hunder 4 ”w.c. (WB2-44)
Hunder 7 ”w.c. (WB2-60)
under 11 ”w.c. Do not attempt adjustment. Call local
gas utility to increase pressure.
H4 to 14 “w.c. (WB2-44)
H7 to 14 “w.c. (WB2-60)
11 to 14 ”w.c. Start up boiler.
over 14 ”w.c. over 14 ”w.c. Do not attempt adjustment. Call local
gas utility to decrease pressure.
Boiler valve must not be exposed to
pressure over 14 ”w.c.
9. Enter gas type into Maintenance
Record on page 70 in this manual.
10. Switch off the heating system
on/off switch on the boiler control
unit (boiler is shut down), close the
gas shutoff valve, remove the
manometer and re-tighten the
screw in the test nipple ”PE” A.
11. Open gas shutoff valve and check
that the test nipple ”PE” and all gas
connections are gas-tight.
5285 961 v1.3
PE
A
inlet
outlet
Measuring running gas supply pressure,
using test nipple “PE”
Ensure that there is no open flame in
the room.
WARNING
Never purge a gas line into a
combustion chamber. Never use
matches, candles, flame, or other
sources of ignition for purpose of
checking leakage. Use a
soap-and-water solution to check for
leakage. A failure to follow this
warning could result in fire,
explosion, personal injury, or death.
WARNING

Initial Start-up and Service
15
Steps (continued)
7. How the Vitodens 200 boiler operates...
Initial start-up Service
The MatriX burner blower and the combination gas valve are factory calibrated and
pre-adjusted for optimum boiler performance at all firing rates through a
non-mechanical, pneumatic modulating link between combustion air and gas flows.
Blower speed is automatically increased or decreased based on heat demand and
venting system resistances, thereby regulating the amount of combustion air
drawn. The pneumatic modulating link between air and gas introduces the required
amount of gas for correct combustion to meet the current heat demand, based on
a linear relationship between ∆Pairand∆Pgas.
Optimum combustion air flow rate is recognized and monitored by the differential
air pressure sensor (transducer). The output voltage signal of the transducer is
analyzed for logic by the LGM 29.XX burner ignition control unit. The LGM 29.XX
unit contains pre-programmed performance curves and operational safety
parameters unique for every boiler model.
See page 47 for sequence of operation.
Flue gas adaptation function
The Vitodens employs a flue gas adaptation function. This unique function
records, processes, and reacts in real time to fluctuations in pressure drops in the
vent pipe during normal operation caused by partial pipe blockages due to ice
formation at the vent termination, debris and/or sudden high winds. Such increase
in pressure drop, if not promptly corrected, will reduce the combustion air flow
rate, and hence lead to unstable combustion. The differential air pressure sensor
(transducer) records such pressure drops and supplies voltage signals to the LGM
29.XX burner ignition control unit which, in turn (based on stored performance
curves and safety parameters), initiates prompt adjustment of the blower rotational
speed, thus readjusting the combustion air flow rate for optimum combustion. The
same automatic adaptation logic applies if combustion air is reduced (or increased)
due to slower (or faster) blower speed resulting from line voltage drops (or
increases) below (or above) the threshold of 85% (or 110%).
5285 961 v1.3
PE
inlet
outlet
XY
Do not adjust screws X and Y!
FOR FACTORY CALIBRATING
PURPOSES, THE COMBINATION GAS
VALVE IS EQUIPPED WITH
ADJUSTMENT SCREWS X AND Y.
DO NOT ATTEMPT TO ADJUST OR
READJUST THESE SCREWS.
ANY ATTEMPT TO TAMPER WITH
FACTORY PRE-ADJUSTED SETTINGS
WILL LEAD TO UNSTABLE OPERATION
AND WILL AFFECT BOILER
WARRANTY.
WARNING

Initial Start-up and Service
16
Steps (continued)
8. Check CO2setting
Initial start-up Service
The Vitodens 200 boiler is factory
preset for operation with natural gas or
propane. It is recommended that a CO2
check be performed at the boiler vent
pipe adaptor as part of the initial
start-up/maintenance procedure.
The MatriX burner of the Vitodens 200
is preset for the entire gas group. No
adjustment or readjustment of the
burner is required.
Depending on the gas type, the CO2
value lies within the range of
H6.6 to 10.0% for natural gas
Happrox. 10.0% for LP
The CO2value measured must be
compared with the above CO2value
ranges of the individual gas type.
If the CO2value measured lies more
than 1% outside the stated range for
NG, or 0.5% outside the stated range
for LP, perform the following steps:
HCheck that correct orifice was used
(see subsection entitled “Check
orifice size” on page 17 and section
“Technical Data” on page 46 of this
manual).
HCheck the venting system for leaks
(see subsection entitled “Check
venting system for leaks” on page 18
of this manual).
1. Connect flue gas analyzer to boiler
vent pipe adaptor (”Flue gas”
measurement opening).
2. Open the gas shutoff valve and start
up the boiler.
3. Trigger a call for heat by adjusting
the setpoint value.
4. Select lower end of rated input
range and check CO2content.
→SYSTEM ”D”
→INSTALLER
SETUP ”C”
→CODE PLEASE ”B-C-C-B”
→DIAGNOSIS ”A”
→RELAY TEST ”A”
Select menu option
CONTINUE ”A” until code
10: MODULATION
10: <PL.90> CLOSED
10: BURNER
10: <PL.41> ON
10: is displayed
5. Select top end of rated input range
and check CO2content
If the value differs by more than one
percentage point, replace burner.
Select menu option
CONTINUE ”A”
until code
11: MODULATION
10: <PL.90> OPEN
10: BURNER
10: <PL.41> ON
10: is displayed
6. Exit the setting mode
HClose cover of programming unit.
HEnter the measured values into
Maintenance Record on page 70 in
this manual.
HClose flue gas measurement
opening .
Do not use the emissions test switch
”S” to trigger a call for heat.
5285 961 v1.3
IMPORTANT
IMPORTANT

Initial Start-up and Service
17
Steps (continued)
9. Clock natural gas meter
Initial start-up Service
Clock natural gas meter to verify input
1. Ensure all other gas equipment
served by the meter is turned off
during timing of gas input to the
Vitodens 200 boiler.
2.Measure the time in seconds it takes
for the boiler to use 10 cu. ft. of
gas. Divide 3600 x 10 by the
number of seconds and you get the
number of cu. ft. of gas used per
hour. Multiply this number by the
heating value of the gas to obtain
Btu per hour input.
For example:
A Vitodens 200, WB2 11-44 boiler
(172 000 Btu/h input) requires 209
seconds to use 10 cu. ft. of natural
gas. After contacting the local utility,
you will find the heating value is
1000 Btu per cu. ft.
Therefore,
3600 x 10/209 x 1000 ≅172 000
Btu/h input.
Therefore, the boiler input is correct.
Burner input formulas
(for low altitude only):
INPUT=(3600÷t) x 1000 where
t=TIME (sec.) for 1 ft.3
INPUT=(3600 x .01 x 1000 x 35.31) ÷T
where
T = TIME (sec.) for .01 m3natural gas
A boiler underfired by 5% is
acceptable. Do not overfire the boiler.
10. Check orifice size
Service
1. Remove burner cover panel (if still
installed) as per the removal and
reinstallation instructions on page 7
in this manual, and reinstall panel
upon completion of service work.
2. Loosen screws Aand take the gas
orifice holder Cout of the fitting.
3. Read orifice size stamped on the
orifice body and cross-reference to
table below. If wrong orifice is
installed, proceed to next step.
4. Push the gas orifice Bsideways out
of the gas orifice holder C.Snap
new and correct gas orifice into gas
orifice holder and push into the gas
train.
See section entitled “Technical Data”
on page 46 of this manual for
information on gas orifices.
Place O-ring Ein groove on new gas
orifice B.
5. Tighten screws A.Tighten to a torque of 1.1 lb.ft./
1.5 Nm.
6. Check all gas connections for leaks
with an approved leak test solution.
Overview of orifices
Boiler model WB2 11-44 WB2 15-60
Natural gas E44 E60
Liquid propane P44 P60
5285 961 v1.3
IMPORTANT
Always contact your gas utility to
obtain the correct heating value before
clocking the meter.
CAUTION
ACB
EIMPORTANT
Stamped identification code

Initial Start-up and Service
18
Steps (continued)
11. Check all primary and secondary circuit connections for leaks
Initial start-up Service
Check heating system and domestic
hot water connections (if applicable).
Ensure all connections are pressure
tight.
Correct any leaks found on fittings,
pumps, valves, etc.
12. Perform combustion analysis
Initial start-up Service
A CO measurement (see page 16) must
be taken before and after working on gas
appliances to eliminate risks to health
and to guarantee the satisfactory condition
of the system.
Record the measured combustion
values in the sequence stated in the
Maintenance Record on page 70 in this
manual.
13. Check venting system for leaks (circular air gap measurement)
For sealed combustion, coaxial vent only.
Initial start-up
Viessmann strongly recommends that
the heating contractor perform a
simplified leak test during boiler
start-up. For this purpose it is sufficient
to measure the CO2concentration of
the combustion air in the coaxial gap of
the air intake pipe. The vent pipe is
considered sufficiently leak-proof if a
CO2concentration in the combustion
airnohigherthan0.2%oranO
2
concentration no lower than 20.6% is
measured.
If higher CO2values or lower O2values
are measured, check venting system
thoroughly.
Please note!
The vent pipe adaptor comes with two
measurement ports, one for
combustion air intake measurement
and one for flue gas measurement.
Please note!
This test is not applicable for single -
wall venting system (non-sealed
combustion).
Combustion air measuring point
5285 961 v1.3
IMPORTANT

Initial Start-up and Service
19
Steps (continued)
14. Disassemble burner and check burner gasket
Service
1. Remove burner cover panel (if still
installed) as per the removal and
reinstallation instructions on page 7
in this manual, and reinstall panel
upon completion of service work.
2. Switch off the heating system
switch on the control unit and the
power supply.
3. Close gas shutoff valve and secure.
4. Disconnect electrical cables from fan
motor , differential air pressure
sensor , combination gas valve
, ionization electrode , ignition
transformer and grounding .
5. Remove two screws to
disconnect gas line from gas valve.
6. Loosen six hexagon socket head cap
screws and remove burner.
7. Check burner gaskets for damage
and replace if required (see Parts
List).
15. Visually check exterior of burner mesh assembly
Service
To check the exterior of the burner
mesh assembly for physical damages,
such as dents, corrosion and/or
abnormally large holes:
1. Remove burner cover panel, if still
installed (see page 7). Reinstall
panel upon completion of service
work.
Do not replace gasket when visually
inspecting the exterior of the mesh
assembly.
16. Replace burner mesh assembly (if wire mesh is damaged)
Service
1. Remove electrodes .
3. Turn thermal insulation ring
clockwise and remove.
2. Unsrew the eight Torx screws
and remove burner mesh assembly
and assembly gasket .
3. Remove existing burner mesh
assembly gasket .
4. Fit new burner mesh assembly with
the new gasket and tighten with the
eight Torx screws.
Tighten to a torque of 3.3 lb.ft. /
4.5 Nm
5285 961 v1.3
Do not lay burner on burner mesh
assembly (wire mesh)!
CAUTION
IMPORTANT

Initial Start-up and Service
20
Steps (continued)
17. Check and adjust ignition and ionization electrode
Service
1. Remove burner cover panel (if still
installed) as per the removal and
reinstallation instructions on page 7
in this manual, and reinstall panel
upon completion of service work.
2. Check electrodes for wear and
contamination.
3. Clean electrodes with small brush or
emery paper.
4. Check clearances. If clearances are
not satisfactory or the electrodes are
damaged, replace electrodes and
gasket Aand align.
Tighten fastening screws for the
electrodes to a torque of 1.5 lb.ft. /
2Nm.
18. Check condensate drain
Service
Ensure condensate drains freely (e.g. at
siphon trap ).
If necessary, clean siphon trap.
Discharge tubing
Flexible discharge tubing
Siphon trap
If the condensate does not drain freely,
condensate will accumulate in bottom
part of boiler resulting in a burner
shut-down (fault message).
Installation Instructions
Neutralization Unit
(if applicable)
5285 961 v1.3
Do not damage wire mesh when
cleaning.
CAUTION
8+4
5+3
3+0.5
+0
7-1
-0
-0
-0
IMPORTANT