Viessmann Vitodens 200 Operating instructions

VITODENS 200
Service instructions
for heating engineers
VitodensĂ200
typeĂWB2, 48.6 to 66.3/44 to 60ĂkW
Wall-mounted gas-fired condensing
boiler wit integral boiler control unit
Natural gas and LPG version
See notes on applicability, pageĂ2.
5692Ă485 GBăăă12/2002 Please keep safe

2
General information
Safety instructions
Please follow these safety instructions closely to prevent accidents and
material losses.
Work on the equipment
Installation, initial start-up,
inspection, maintenance and repairs
must only be carried out by a
competent person ( eating
engineer/installation contractor).
Before working on t e equipment/
eating system, isolate t e mains
electrical supply (e.g. by removing a
separate mains fuse or by means of a
mains electrical isolator) and
safeguard against unaut orised
reconnection.
Close t e main gas s ut-off valve
and safeguard against unaut orised
reopening.
Work on gas equipment
T is must only be carried out by an
approved contractor.
Please observe all commissioning
work specified for gas installations
acc. to TRGI or TRF and all local
regulations.
Repair ork
It is not permitted to carry out repairs
on parts t at fulfil a safety function.
Use only original Viessmann spare
parts, or equivalent parts t at ave
been approved by Viessmann.
Initial start-up
T e initial start-up must be carried
out by t e installer of t e system or a
designated commissioning engineer;
all actual values s ould be recorded
in a commissioning/service report.
Instructing the system user
T e system installer must and t e
operating instructions to t e system
user and instruct im/ er in t e
operation of t e system.
¨ĂSafety instruction
In this instruction manual, this
heading denotes information which
must be observed to prevent
accidents and material losses.
¨This symbol denotes important
information which must be
observed to prevent material
losses.
Applicability
12.2 to 48.6 kW/11 to 44 kW
from serial no.
Natural gas version
7142124 2 00001
7159979 2 00001
LPG version
7159981 2 00001
16.6 to 66.3 kW/15 to 60 kW
from serial no.
Natural gas version
7142125 2 00001
7159980 2 00001
LPG version
7159982 2 00001
5692Ă485 GB

3
Contents
Index
Page
General information
Safety instructionsĂ 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ApplicabilityĂ 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start-up, inspection and maintenance
StepsĂćĂinitial start-up, inspection and maintenanceĂ 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Furt er details regarding t e individual stepsĂ 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Diagnosis using t e control unitĂ 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RepairsĂ 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strapping plug configuration and codingĂ 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control unit for constant temperature mode
Function descriptionĂ 53
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test settingsĂ"TĂ1" and "TĂ2"Ă 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C anging parameters in service settingsĂ"SĂ1" to "SĂ7"Ă 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanning temperaturesĂ 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ControlĂunit for eather-compensated mode ith standard programming unit
Function descriptionĂ 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calling up coding levelĂ1Ă 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating curvesĂ 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting eating curvesĂ 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary coding levelĂ1Ă 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calling up coding levelĂ2Ă 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary coding levelĂ2Ă 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brief scanĂ 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanning temperaturesĂ 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ControlĂunitĂforĂ eather-compensatedĂmodeĂ ithĂComfortrolĂprogrammingĂunit
Function descriptionĂ 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calling up coding addressĂ 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating curvesĂ 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting eating curvesĂ 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary of coding addressesĂ 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brief scanĂ 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanning temperaturesĂ 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection and iring diagrams
HPower supply and pump connectionsĂ 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HComponentsĂ 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts listsĂ 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Commissioning/service reportĂ 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SpecificationĂ 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas restrictorsĂ 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of conformityĂ 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer's certificateĂ 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IndexĂ 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692Ă485 GB

4
Initial start-up, inspection and maintenance
StepsĂćĂinitial start-up, inspection and maintenance
For further instructions concerning the individual steps see pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
C1. Filling the heating systemĂ 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C2. Checking the electrical mains connection
C3. Changing the language (if necessary)Ă 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 4. Checking the gas typeĂ 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C5. ChangingĂtheĂgasĂtype (seeĂseparateĂinstallationĂinstructions)
C I M 6. Checking the idle and the supply pressureĂ 8. . . . . . . . . . . . . . . . . . . .
C7. Function sequence and possible errors during
initial start-upĂ 10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 8. Checking the CO2 settingsĂ 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C9. Max. outputĂ 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 10. Fully checking the burner
(recordĂvaluesĂon pageĂ108 of commissioning report)
C11. Leak testing the BF system (circular gap check)Ă 16. . . . . . . . . .
I M 12. Removing the burner and checkingĂthe
burner gasket for leaksĂ 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 13. Checking the burner gauze assemblyĂ 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 14. CheckingĂ&ĂadjustingĂignitionĂ& ionisationĂelectrodesĂ 18. . . .
I M 15. Cleaning the combustion chamber/heating surfaces
and installing the burnerĂ 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 16. Checking the condensate drainĂ 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 17. Checking the neutralising system (if installed)Ă20. . . . . . . . . . . . . . . . .
C I M 18. Checking all connections on the primary and on the
secondary side for leaks
C M 19. Checking the diaphragm expansion vessel and
the system pressure
C I M 20. Checking the function of all safety valves
C I M 21. Checking the tightness of electrical connections
5692Ă485 GB

5
Initial start-up, inspection and maintenance
StepsĂćĂinitial start-up, inspection and maintenance (cont.)
Commissioning steps
Inspection steps
Maintenance steps Page
C I M 22. Checking all gas components for leaks at
operating pressure
C M 23. Checking the ionisation currentĂ 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 24. Checking the external LPG safety valve
(if installed)
C25. Matching up the coding addresses
(control unit for eather-compensated mode)Ă 22
. . . . . . . . . . . . .
5692Ă485 GB

6
Initial start-up, inspection and maintenance
Further details regarding the individual steps
Filling the heating system
1. C eck t e inlet pressure of t e
diap ragm expansion vessel.
2. Fill t e system via tapĂA, vent
t e system and c eck t e system
pressure (min. system pressure
>Ă0.8Ăbar).
3. Close t e s ut-off valves on t e
eating water side of t e system.
4. Connect t e drain ose to ball
valveĂB.
5. Open ball valvesĂA and B, and
vent until no furt er air noises are
audible.
6. Close ball valvesĂA and B, and
open t e s ut-off valves on t e
eating water side.
5692Ă485 GB
BA

7
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Changing the language (if necessary)Ăć
only ith Comfortrol menu-assisted programming unit
SPRACHE/LANGUAGE
>DEUTSCH:.........A
>ENGLISH:.........B
>ZURÜCK/BACK:....D
Open cover:
Menu item Key
³SYSTEM "D"
³BASIC SETTINGS "A"
³LANGUAGE "C"
Select t e required language.
Check the gas type
¨ĂSafety instruction
The natural gas version cannot be converted to LPG.
1. Enquire t e gas type and Wobbe
indexĂ(Wo) from your local mains
or LPG gas supplier.
Please note:
In the as delivered condition,
itodensĂ200 is set up for natural
gasĂE or LPGĂP.
Natural gasĂEĂversion:
The boiler can be operated in the
Wobbe index range 12.0 to
16.1ĂkWh/m 3 (43.2 to 58.0ĂMJ/m3).
LPGĂPĂversion:
The boiler can be operated in the
Wobbe index range 21.4 to
22.5ĂkWh/m 3 (76.9 to 81.0ĂMJ/m3).
2. Compare t e gas category (type)
and group wit t e details on t e
burner label.
3. T e burner must be converted acc.
to t e details provided by t e
mains gas or t e LPG supplier to
matc t e fuel provided, if t ese
details do not matc .
See separate conversion kit
installation instructions.
After conversion from
Hnatural gasĂE or LPGĂP to natural
gasĂLL
The boiler can be operated in the
Wobbe index range 10.0 to
13.1ĂkWh/m 3 (36.0 to 47.2ĂMJ/m3).
HLPGĂP to natural gasĂE
The boiler can be operated in the
Wobbe index range 12.0 to
16.1ĂkWh/m 3 (43.2 to 58.0ĂMJ/m3).
4. Record t e gas type in t e service
report on pageĂ108.
5692Ă485 GB

8
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the idle and the supply pressure
¨ĂSafety instruction
Measure the CO value before and after any work on gas appliances, to
prevent any health hazards and to ensure the perfect operational condition of
the system.
LPG version:
Flush the LPG tank twice after installation or replacement.
Thoroughly vent the tank and gas lines after flushing.
Idle pressure
1. Close t e gas s ut-off valve.
2. Release t e screw inside test
nippleĂ"PE"ĂA on t e gas
combination valve, but do not
remove, and connect t e pressure
gauge.
3. Open t e gas s ut-off valve.
4. C eck t e idle pressure; it s ould be
Hmax. 25Ămbar for natural gas
and
Hmax. 57.5Ămbar for LPG.
Record t e actual value in t e
service report.
5. Start up t e boiler.
For function sequence and
possible faults during the initial
start-up, see pageĂ10.
On start-up, the boiler can enter a
fault state because of airlocks in
the gas pipe.
After approx. 5Ăseconds, press
keyĂ"EU" to reset the burner.
5692Ă485 GB
PE
A

9
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Gas supply pressure (flo pressure)
6. Test t e supply pressure (flow
pressure); it s ould be
H17.4 to 25Ămbar for natural gas,
H42.5 to 57.5Ămbar for LPG.
Use suitable test equipment with a
resolution of at least 0.1Ămbar to
measure the supply pressure.
Record t e actual value in t e
service report.
Take t e action s own in t e table.
Supply pressure (flo pressure) for Check
natural gas LPG
below 17.4Ămbar below 42.5Ămbar Do not start up. Notify your mains or
LPG gas supplier.
17.4 up to
25Ămbar
42.5 up to
57.5Ămbar
Start up t e boiler.
over 25Ămbar over 57.5Ămbar Install a separate gas pressure governor
upstream of t e system and regulate
t e pressure to 20Ămbar for natural gas
or 50Ămbar for LPG.
Notify your mains gas or LPG supplier.
7. S ut down t e boiler, close t e
gas s ut-off valve, remove t e
pressure gauge and close test
nipple "PE"ĂA wit t e screw.
ă8. C eck t e closing function of t e
gas combination valve:
HConnect t e pressure gauge to
test nipple "PG"ĂB.
HStart up t e boiler.
HSwitc off t e control unit.
HT e nozzle pressure (vacuum)
must rise to 0Ămbar wit in
1Ăsecond. Replace t e gas valve
if t e nozzle pressure rises
more slowly.
ă9. Remove t e pressure gauge, and
close test nippleĂ"PG"ĂB wit
t e screw.
10. ¨ĂSafety instructions
Open the gas shut-off valve and
check for leaks on test nipples
"PE", "PG" and all gas
connections.
5692Ă485 GB
PE
AB
PG

10
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Function sequence and possible errors during the initial start-up
For furt er details see "Troubles ooting".
5692Ă485 GB
Fan starts up
C eck flow switc ,
c eck eating
water circulation
Flow switc as
reacted, plugĂ33
Increase set value
and ensure eat is
drawn off
Control unit issues
a eat demand (set
boiler temp. is 5ĂK
ig er t an actual
boiler temp.)
Differential pressure
sensor enables start
(0.75ĂV across
terminals
"XĂ14.5" & "XĂ14.4")
Yes
Yes
Yes
after approx. 70Ăsec.
Fault
U06ĂĂĂorĂĂĂU:0:6ĂĂĂorĂĂĂ06
C eck cables and
plugs on fan,
c eck fan
C eck air damper
movement. C eck
flue gas system,
C eck differential
pressure sensor
after approx. 70Ăsec.
Fault
U06ĂĂĂorĂĂĂU:0:6ĂĂĂorĂĂĂ06
Continued overleaf
Yes
No
No
No
No
Display screen Check

11
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
5692Ă485 GB
stops below set boiler
temperature and
restarts again
immediately
Gas combination
valve opens
C eck flue gas
system for possible
leaks (flue gas
recirculation). C eck
gas flow pressure
Ionisation current
builds
( ig er t an 5ĂmA,
green LED lig ts up)
Yes
Fault
U14ĂĂĂorĂĂĂU:1:4ĂĂĂorĂĂĂ14
C eck electrode
settings,
c eck for air bubbles
in gas pipe,
c eck if leads "LĂ1"
and "N" ave been
interc anged,
c eck strapping
plugĂ158
C eck t e gas
combination valve
(drive voltage 20ĂVć),
c eck t e gas
supply pressure
C eck ignition mod-
ule (drive voltage
24ĂVć across plugs
"54+" and "54ć")
Ignition
Yes
Yes
Fault
U14ĂĂĂorĂĂĂU:1:4ĂĂĂorĂĂĂ14
Fault
U14ĂĂĂorĂĂĂU:1:4ĂĂĂorĂĂĂ14
Operational burner
Yes
No
No
No
Display screen Check
Continuation from
previous page

12
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Check the CO2 settings
itodensĂ200 is, depending on version, set up in the factory for natural gasĂE
or LPGĂP.
In case of initial start-up or maintenance, check the CO2 level on the boiler
connection fitting.
Please note:
The MatriX buner for itodensĂ200 is preset for the entire gas group.
Therefore, the burner requires no further setting or adjustment.
Depending on the Wobbe index, the CO2 content reaches levels of
H6.6 to 10.0Ă% for natural gasĂE,
H7.0 to 10.0Ă% for natural gasĂLL and
Happrox. 10.0Ă% for LPGĂP
Compare the measured CO2 value with the above CO2 value ranges of the
individual groups (enquire the gas group from your mains or LPG gas
supplier).
If the actual CO2 value deviates by more than 1Ă% for natural gas or 0.5Ă% for
LPG, proceed as follows:
HCheck whether the correct gas restrictor has been installed (see pageĂ116).
HCarry out a leak test (BF system) (see pageĂ16).
1. Connect a flue gas analyser at flue
outletĂA ("flue gas" port).
2. Start up t e boiler.
3. Create a eat demand (see table
on pageĂ13).
5692Ă485 GB
A

13
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Steps
Control
unit type
4. Select the lo er
rated thermal load
and check the
CO2 content
5. Select the upper
rated thermal
load and check
the CO2 content
If value deviates
by more t an 1Ă%,
see pageĂ12
6. Terminate
the setting
mode
Control unit
for constant
temperature
mode
T1
T2
S1
S2S3S4
S5
S6
S7
+-
50
+-
70
T2
T1
S1
S3S2S4
S6
S5
S7
T2
T1
S1
S3S2S4
S6
S5
S7
HSelect t e
required
eating
program.
HEnter actual
values into
t e service
report.
HClose t e
test port.
Control unit
for eather-
compensated
mode ith
standard
programming
unit
060
5040
32
33+
21
12
-122,6
2,2
1,8
0
1,2
1,0
0,8
0,6
0,2
- +
1-7
1234567
?
-8
6
N
3
6+
8+-7
4
N
5
T
N
+5
-7 +8
-4
N
-4 +5
-7 +8
T
HSelect t e
required
eating
program.
HSet rotary
selector
"s" to t e
required
value.
HEnter actual
values into
t e service
report.
HClose t e
test port.
Control unit
for eather-
compensated
mode ith
ith
menu-guided
Comfortrol
programming
unit
B
A
DC
-+i34567
8
9
10
2
1
34567
8
9
10
2
10
S
³SYSTEM "D"
³INSTALLER
SETUP "C"
³CODE PLS "BĆCĆCĆB"
³DIAGNOSIS "A"
³RELAY TEST "A"
Wit menu item
CONTINUEĂ"A"
up to code
10: MODULATION
10: <ST.90> CLOSED
10: BURNER
10: <ST.41> ON
Wit menu item
CONTINUEĂ"A"
up to code
11: MODULATION
10: <ST.90> OPEN
10: BURNER
10: <ST.41> ON
HClose t e
program-
ming unit.
HEnter actual
values into
t e service
report.
HClose t e
test port.
5692Ă485 GB

14
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Max. output
The max. output can be limited for the eating operation.
You set this limit via the modulation range.
The control pressure acts as standard value for setting the required output.
1. Start up t e boiler.
2. Select t e upper rated eating
output:
See table on pageĂ13.
3. Remove t e caps from test
nipplesĂA of t e gas combination
valve.
4. Connect t e gauge to bot test
nipplesĂA.
Please note:
Control pressureĂ=Ădifferential
pressure.
This lies between 0.25 and 4Ămbar.
Use a suitable pressure gauge
with a range from 0 to 10Ămbar.
acuum pressure is applied to
both test nipples. The vacuum
pressure on the test nipple with
the "+" symbol is lower, and that
on the test nipple with the "ć" is
higher.
Connect the pressure gauge
accordingly.
5692Ă485 GB
PE
PG
A A

15
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
ă5. Release t e bottom part of
control unitĂB and pivot down.
ă6. Unscrew protective coverĂC and
rear casing lidĂD.
ă7. Turn potentiometerĂE wit a
screwdriver anticlockwise, until
t e control pressure corresponds
to t e required output in
accordance wit t e table below.
Please note:
Whilst checking the pressure,
wait approx. 5Ăminutes, until the
pressure has stabilised.
ă8. Remove t e pressure gauge
fittings from test nipplesĂA and
seal t e nipples wit t e caps.
ă9. Assemble control unitĂB, flip it
up and secure wit screws.
10. Record t e settings for max. output
on t e type plate included wit t e
"Tec nical documentation". Affix
t e type plate on t e inside of t e
front cover of t e front panel.
Rated
output*1
kW 11 15 20 25 30 35 40 44 45 50 55 60
Control
pressure
at rated
output
11ĂĆĂ44ĂkW
15ĂĆĂ60ĂkW
mbar
mbar
0.25
ćć
0.46
0.25
0.83
0.44
1.29
0.69
1.86
1.00
2.53
1.36
3.31
1.78
4.00
2.15
ćć
2.25
ćć
2.78
ćć
3.36
ćć
4.00
*1Rated output relative to T /TR 75/60 ºC, gasĂGĂ20/GĂ25 and 8.5Ă% CO2 content.
5692Ă485 GB
+–

16
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Leak testing the BF system (checking the circular gap)
For balanced flue systems tested together with the gas-fired wall-mounted
boilers, some Federal States (e.g. NordrheinĆWestfalia) waive the leak test
(overpressure test) during commissioning by the district chimney sweep.
We recommend that your heating engineer carries out a simple leak test
during the initial start-up of your system. It would be sufficient to check the
CO2 concentration in the combustion air at the annular gap in the BF line.
The flue pipe is deemed to be sufficiently tight, if the CO2 concentration in the
combustion air is a maximum of 0.2Ă% and the O2 concentration is a minimum
of 20.6Ă%.
If actual CO2 values are higher or O2 values are lower, then you must test the
flue pipe for leaks at a static overpressure of 200ĂPa.
ACombustion air test nipple
(ventilation air)
5692Ă485 GB
A

17
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Removing the burner and checking the burner gasket for leaks
1. Switc off t e system on t e
control unit and t e mains
electrical supply.
2. Close t e gas s ut-off valve and
safeguard against re-opening.
3. Pull t e electrical cables off fan
motorĂA, differential pressure
sensorĂB, gas valveĂC, ionisation
electrodeĂD, ignition unitĂE and
eart ĂF.
4. Loosen gas connection pipeĂG.
5. Slacken six nutsĂH and remove
t e burner.
¨Do not rest the burner on the
gauze assembly (wire mesh).
6. C eck t e burner gasket for
damage (U-s aped gasket, see
parts list) and replace if necessary.
¨Generally, replace the burner
gasket every two years.
5692Ă485 GB
HHH
E
H
H
G
D
B
C
H
A F

18
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the burner gauze assembly
Replace t e burner gauze assembly
if t e wire mes is damaged.
1. Remove electrodes A.
2. Turn t ermal insulation ringĂB
clockwise and remove.
3. Slacken eig t Torx screwsĂC, and
remove burner gauze assemblyĂD
and assembly gasketĂE.
4. Insert a new burner gauze
assemblyĂD wit new assembly
gasketĂE, and secure wit eig t
Torx screws.
Torque: 4.5ĂNm
5. Refit t ermal insulation ringĂB.
Checking and adjusting the ignition and ionisation electrodes
1. C eck t e electrodes for wear and
contamination.
2. Clean t e electrodes wit a small
brus or emery paper.
¨Ensure that wire mesh is not
damaged.
3. C eck all clearances. If t e gaps
are not as specified or t e
electrodes are damaged, replace
and align t e electrodes toget er
wit new gaskets.
Tig ten t e fixing screws wit
2ĂNm.
5692Ă485 GB
AB C
ED
A
70
-1
3+0.5
0

19
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Cleaning the combustion chamber/heating surfaces and
installing the burner
1. Clean combustion c amberĂA
and eating surfacesĂB, if
required, wit a brus , or flus
wit water.
¨Avoid scratching parts that are
in contact with flue gases.
Only use plastic brushes and
NOT wire brushes.
Apply a solvent-/potassium-free
cleaning agent w ere residues
remain:
HRemove soot deposits wit
alkaline cleaning agents wit
additional surfactants
(e.g. Fauc Ă600).
HRemove coatings and surface
discolouration (yellowĆbrown)
wit slig tly acidic, c loride-free
cleaning agents based on
p osp oric acid
(e.Ăg. AntoxĂ75ĂE).
HFlus t orougly wit water.
Please note:
FauchĂ600 and AntoxĂ75ĂE are
supplied by
Hebro Chemie GmbH
Rostocker StraßeĂ40
DĆ41199ĂMönchengladbach
c:
Intec BassersdorfĂAG
GrindelstrasseĂ12
Postfach
CHĆ8303ĂBassersdorf
2. Install t e burner and torque
diagonally to 4.5ĂNm.
3. Secure t e gas connection pipe
wit a new gasket.
¨ĂSafety instruction
Carry out a leak test.
4. Connect t e electrical leads to t e
corresponding components.
5692Ă485 GB
A
B

20
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the condensate drain
C eck t at t e condensate can freely
drain (at sip onĂA), and clean t e
sip on if necessary.
Checking the neutralizing system (accessory)
1. C eck t e pH value of t e
condensate wit a pH test strip.
Replace t e granulate if t e p
value reac esĂ<Ă6.5.
Please note:
Part no. for pH test strips:
9517Ă678.
2. In case of contamination:
Flus t e neutralisation system
wit tap water.
Observe the manufacturer's
instructions regarding the
neutralisation system.
3. Top up to t e marking.
The granulate is used up as it
neutralises the condensate. The
red marker strip indicates the
minimum fill height.
5692Ă485 GB
A