Viessmann VITODENS 200 User manual

VIESMANN
Service instructions
for heating engineers
Vitodens 200
Type WB2A, 8.8 to 26.0 kW
Gas fired wall mounted condensing boiler
natural gas and LPG version
See applicability on the last page
VITODENS 200
5692 573 GB 6/2004 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.
!Important information
This symbol warns against the
risk of material losses and
environmental pollution.
Note
Details identified by the words "Note"
contain additional information.
Warranty
All warranty rights are void if these
service instructions are not observed.
Target group
These service instructions are exclu-
sively designed for qualified person-
nel.
Work on gas equipment must only be
carried out by a registered gas fitter.
Only approved contractors may mod-
ify this equipment for countries other
than those designated on the type
plate. That contractor will then
arrange for the relevant approval in
that country.
Electrical work must only be carried
out by a qualified electrician.
The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following during service
work:
&all legal instructions regarding the
prevention of accidents,
&the TRGI, TRF and special regula-
tions, e.g. those of the BDH,
aÖVGW-TR Gas, ÖVGW-TRF,
cSVGW,
&all legal instructions regarding
environmental protection,
&the Code of Practice by relevant
trade associations and all local reg-
ulations.
If you notice a smell of gas
Danger
Escaping gas can cause explo-
sionswhichmayleadtoser-
ious injury.
&Do not smoke. Prevent
naked flames and sparks.
Never switch electrical lights
or equipment.
&Open windows and doors.
&Close the gas shut-off valve.
&Remove all personnel from
the danger zone.
&Observe the safety regula-
tions of your local gas sup-
plier which can be found on
the gas meter.
&Notify your heating contrac-
tor from outside the building.
Safety instructions
2
Safety instructions
5692 573 GB

If you smell flue gas
Danger
Flue gas may lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close all doors leading to liv-
ing areas.
Repair work
It is not permitted to carry out repairs
on parts that fulfil a safety function.
Use only original Viessmann spare
parts, or equivalent parts that have
been approved by Viessmann.
Service work on the heating system
&Isolate the system from mains sup-
ply and check that it is no longer
"live", e.g. by removing a separate
fuse or by means of a mains electri-
cal isolator.
&Safeguard the system against
unauthorised reconnection.
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
Ancillary components, spare and
wearing parts
!Important information
Components which are not
tested with the heating system,
the installation of non-
approved spare parts and
unauthorised conversion may
lead to damage to the heating
system, which may affect their
function and limit our warranty.
For conversions or replace-
ments, use only original parts
from Viessmann or those spare
parts which are approved by
Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 573 GB

Initial start-up, inspection, maintenance
Steps - initial start-up, inspection and maintenance ..................................... 5
Further details regarding the individual steps .............................................. 7
Coding
Code 1........................................................................................................ 39
Code 2........................................................................................................ 42
Resetting the coding to the as delivered condition ....................................... 62
Service scans
Service level summary................................................................................ 63
Temperatures, boiler coding card and brief scans ........................................ 64
Checking outputs (relay test) ...................................................................... 68
Scanning operating conditions and sensors ................................................ 69
Troubleshooting
Downloading fault codes history.................................................................. 72
Call up current fault codes .......................................................................... 72
Checking and acknowledging faults ............................................................ 74
Repairs ...................................................................................................... 84
Function description
Constant temperature control unit ............................................................... 96
Weather-compensated control unit.............................................................. 98
Extensions for external connections (accessory)......................................... 100
Control functions ........................................................................................ 104
Designs
Connection and wiring diagrams –internal connections............................... 109
Connection and wiring diagrams –external connections.............................. 111
Parts lists .................................................................................................. 113
Commissioning/service reports............................................................... 120
Specification............................................................................................. 126
Certificates
Declaration of conformity ............................................................................ 127
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 128
Keyword index .......................................................................................... 129
Index
4
Index
5692 573 GB

For further instructions on individual steps, see pages indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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•1. Filling the heating system ................................................. 7
•2. Venting the boiler.................................................................. 9
•3. Venting the heating system............................................... 9
•4. Filling the siphon with water............................................. 10
•5. Checking the electrical mains connection
•6. Language selection (if required) - only for weather-
compensated control units ............................................... 10
•• 7. Setting the time and date (if required) - only for
weather-compensated control units.............................. 11
••8. Checking the gas type......................................................... 11
•9. Gas type conversion............................................................ 12
••• 10. Function sequence and possible faults ....................... 12
••• 11. Checking static and supply pressure ........................... 14
••• 12. Checking the CO2settings ................................................ 16
•13. Setting the max. output ...................................................... 18
••• 14. Check all connections on the primary and DHW
side for leaks
••• 15. Checking the burner (recording values on
page 120 of the commissioning report)
•16. Checking the balanced flue system for soundness
(annular gap check) ............................................................. 19
•• 17. Removing the burner and checking the burner
gasket (replace gasket every two years)...................... 20
•• 18. Checking the burner gauze assembly........................... 21
•• 19. Checking and adjusting the ignition and ionisation
electrodes ................................................................................ 22
•• 20. Cleaning the combustion chamber/cleaning the
heating surfaces and installing the burner ................. 23
Steps - initial start-up, inspection and maintenance
5
Initial start-up, inspection, maintenance
5692 573 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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•• 21. Checking the condensate drain and cleaning the
siphon........................................................................................ 24
•• 22. Checking the neutralising system (if installed)
•23. Flow limiter (only for gas combination boilers)......... 25
••• 24. Checking the diaphragm expansion vessel and
system pressure
••• 25. Checking the function of all safety valves
••• 26. Checking tightness of electrical connections
••• 27. Checking all gas equipment for soundness at
operating pressure............................................................... 25
••• 28. Checking the ionisation current...................................... 26
••• 29. Checking the external LPG safety valve (if
installed)
•30. Matching the control unit to the heating system....... 27
•31. Connecting the control unit to the LON system
(only for weather-compensated control units) .......... 32
•32. Implementing a user check (in conjunction with
the LON system) .................................................................... 33
•33. Adjusting heating curves (only for weather-
compensated control units).............................................. 34
•34. Instructing the system user .............................................. 37
•35. Scanning and resetting the "Maintenance" display 37
Steps - initial start-up, inspection and maintenanc . . . (cont.)
6
Initial start-up, inspection, maintenance
5692 573 GB

Filling the heating system
1. Check the charge pressure of the
diaphragm expansion vessel.
2. Close the gas shut-off valve.
3. !Important information
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 with water.
&Only use fill water of pota-
ble quality.
&Soften fill water harder
than 20 °dH (3.58 mmol/l).
For suitable means of
water softening, see the
Vitotec price list.
&An anti-freeze additive
suitable for heating sys-
temscanbemixedwith
the fill water.
Fill the heating system via the boi-
ler fill & drain valve A.(minimum
system pressure > 0.8 bar).
Note
The diverter valve actuator will be
in the central position, and the sys-
tem will be completely filled, if the
control unit has not been switched
ON before the system was filled.
Further details regarding the individual steps
7
Initial start-up, inspection, maintenance
5692 573 GB

4. If the control unit had already been
switched ON before filling began:
Start the control unit and in code 1,
set coding address 2F:2.
The diverter valve will then be in its
central position.
Note
To call up code 1 and for setting the
coding address, see page 39.
Whilst filling is in progress, the dis-
play shows bF (constant tempera-
ture control unit) or "Filling"
(weather-compensated control
unit).
Continue filling the system.
5. Close the boiler fill & drain valve
A.
6. Set coding address 2F:0.
Further details regarding the individual steps (cont.)
8
Initial start-up, inspection, maintenance
5692 573 GB

Venting the boiler
1. Close the shut-off valves on the
heating water side.
2. Connect the drain hose on upper
valve Bwith a drain outlet.
3. Open valves Aand B,andvent
at mains pressure, until no sound of
escaping air can be heard.
4. Close valves Aand B, and open
the primary shut-off valves.
Venting the heating system
1. Close the gas shut-off valve and
start the control unit.
Further details regarding the individual steps (cont.)
9
Initial start-up, inspection, maintenance
5692 573 GB

2. Activate the venting program via
coding address 2F:1.
Note
To call up code 1 and for setting the
coding address, see page 39.
For function and sequence of the
venting program, see page 105.
Whilst venting is in progress, the
display shows EL (constant tem-
perature control unit) or "Venting"
(weather-compensated control
unit).
3. Check the system pressure.
Filling the siphon with water
1. Remove the retaining clip and
siphon A.
2. Fillthesiphonwithwater.
3. Fit siphon Aandsecurewiththe
retaining clip.
Language selection (if required) - only for weather-compen-
sated control units
1. Press c.
The display shows "Select heating
circuit".
2. Press d.
3. After approx. 4 seconds press c.
4. Select the required language with
b.
5. Confirm with d.
Further details regarding the individual steps (cont.)
10
Initial start-up, inspection, maintenance
5692 573 GB

Setting the time and date (if required) - only for weather-com-
pensated control units
Note
During commissioning, or after prolonged time out of use, it may be necessary
to set the time and date.
1. Press D.
2. Set the time with a/b.
3. Confirm with d;"Date" will be dis-
played.
4. Set the current date with a/b.
5. Confirm with d.
Checking the gas type
1. Enquire about the gas type and
Wobbe index (Wo) from your local
mains gas or LPG supplier.
Note
In the as delivered condition, Vito-
dens 200 is set up for natural
gas E.
The boiler can be operated in the
Wobbe index range 12.0 to
16.1 kWh/m
3
(43.2to58.0MJ/m
3
).
2. Compare the gas category (gas
type) and gas group with the details
on the burner label.
3. If these details do not match the
fuel provided, the burner must be
convertedaccordingtothedetails
provided by the mains gas or the
LPG supplier.
Seeseparateconversionkit
installation instructions.
After conversion to
&Natural gas LL
The boiler can be operated in the
Wobbe index range 10.0 to
13.1 kWh/m
3
(36.0to47.2MJ/
m
3
).
&LPG P
The boiler can be operated in the
Wobbe index range 21.4 to
22.5 kWh/m
3
(76.9to81.0MJ/
m
3
).
Further details regarding the individual steps (cont.)
11
Initial start-up, inspection, maintenance
5692 573 GB

4. Set 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 39.
5. Record the gas type in the service
report on page 120.
Gas type conversion
Gas restrictor installation
instructions.
Gas restrictor allocation
Gas type Int. 7gas
restrictor
&Natural
gas E
mm 6.2
&Natural
gas LL
mm 8.1
&LPG P mm 4.2
Function sequence and possible faults
For further details regarding faults, see page 72.
Display screen Remedy
Control unit
issues a heat
demand
No Increase set
value and ensure
heat is drawn off
Yes
Fan starts
No
After approx.
51 seconds
Check fan cables
and plugs
fault
F9
Further details regarding the individual steps (cont.)
12
Initial start-up, inspection, maintenance
5692 573 GB

Yes
Air pressure lim-
iter enables start
(contact closed
between term-
inals X8.10 and
X8.11)
No
After approx.
51 seconds
Check fan cables
and fan plug-in
connections,
check fan
fault
E6
Yes
Ignition No Fault Check the ignition
module (control
voltage 230 V
across plugs X2.1
and X2.2)
F4
Yes
Gas combination
valve opens No Fault Check the gas combination valve
(control voltage
230 V), check the
gassupplypres-
sure
F4
Yes
Ionisation cur-
rent builds
(higher than
5µA) No
Fault Check the ionisa-
tion current,
check the elec-
trode adjustment
and the gas pipe
for airlocks
symbol AF4
Further details regarding the individual steps (cont.)
13
Initial start-up, inspection, maintenance
5692 573 GB

Yes
Operational bur-
ner
Stops below set
boiler tempera-
ture and immedi-
ately restarts
again
Check flue gas
system for sound-
ness (flue gas
recirculation),
check gas flow
pressure
Checking static and supply pressure
Danger
Higher CO emissions can lead to poisoning.
Measure the CO value before and after any work on gas equipment to
prevent any health hazards and to ensure the perfect operational condi-
tion of the system.
Operation with LPG
Flush the LPG tank twice during commissioning/replacement. Thoroughly vent
the tank and gas lines after flushing.
1. Close the gas shut-off valve.
2. Release the screw inside test nip-
ple IN Aon the gas combination
valve, but do not remove, and con-
nect the pressure gauge.
3. Open the gas shut-off valve.
4. Check the static pressure; it should
be a max. of 57.5 mbar. Record the
actual value in the service report.
Further details regarding the individual steps (cont.)
14
Initial start-up, inspection, maintenance
5692 573 GB

5. Start up boiler.
Note
During commissioning, the boiler
can enter a fault state because of
airlocks in the gas pipe. After
approx. 5 seconds, press Eto
reset the burner.
6. Check the supply (flow) pressure; it
should be
&20 mbar for natural gas,
&and 50 mbar for LPG.
Note
Use suitable test equipment with a
resolution of at least 0.1 mbar to
measure the supply pressure.
Record the actual value in the ser-
vice report.
Taketheactionshowninthetable.
Supply (flow)
pressure for nat-
ural gas
Supply (flow)
pressure for
LPG
Remedy
Below 17.4 mbar Below 42.5 mbar Do not start up. Notify your mains gas or
LPG supplier.
17.4 to 57.5 mbar 42.5 to
57.5 mbar
Start up boiler.
In excess of
57.5 mbar
In excess of
57.5 mbar
Install a separate gas governor down-
stream of the system and regulate the
pressure to 20 mbar for natural gas or
50 mbar for LPG. Notify your mains gas
or LPG supplier.
7. Shut down the boiler, close the gas
shut-off valve, remove the pressure
gauge, and close test nipple A
with the screw.
Further details regarding the individual steps (cont.)
15
Initial start-up, inspection, maintenance
5692 573 GB

8. Danger
Gas escaping from the test
nipple leads to a risk of
explosion.
Check for gas leaks.
Open the gas shut-off valve, start
up the boiler and check soundness
of test nipple A.
Checking the CO2settings
Vitodens 200 is set up in the factory for natural gas E, and can be converted to
natural gas LL or LPG P using a conversion kit.
During commissioning or maintenance, check the CO2level at the boiler adap-
tor.
Subject to the Wobbe index, the CO2content fluctuates between
&7.4 to 10.5 % for natural gas E
&7.8 to 10.5 % for natural gas LL and
&8.5to11.0%forLPGP.
Compare the actual CO2value with the above CO2value ranges for the indivi-
dual gas groups (check the gas group with your mains gas or LPG supplier).
If the actual CO2value deviates by more than 1 % for natural gas or 0.5 % for
LPG, proceed as follows:
&Check whether the correct gas restrictor has been installed.
&Check the balanced flue system for soundness, see page 19.
Further details regarding the individual steps (cont.)
16
Initial start-up, inspection, maintenance
5692 573 GB

1. Connect a flue gas analyser at flue
gas connector Aontheflueoutlet.
2. Open the gas shut-off valve, com-
mission the boiler and create a heat
demand.
3. Select the lower rated output.
Constant temperature control unit:
&Press both keys 9and dsimul-
taneously until the display shows
1.
Weather-compensated control unit:
&Press both keys 9and dsimul-
taneously until the display shows
"Relay test".
&With a/bin the display, select
"Basic load".
4. Check the CO2content. Should the
actual value deviate by more than
1 % from the above range, imple-
ment steps from page 16 (possibly
replace the burner).
5. Enter actual values into the service
report.
6. Set the upper rated output.
Constant temperature control unit:
&With a/bin the display, select
2.
Weather-compensated control unit:
&With a/bin the display, select
"Full load".
Further details regarding the individual steps (cont.)
17
Initial start-up, inspection, maintenance
5692 573 GB

7. Check the CO2content. Should the
actual value deviate by more than
1 % from the above range, imple-
ment steps from page 16 (possibly
replace the burner).
8. After testing, press d.
9. Enter actual values into the service
report.
Setting the max. output
Note
The max. output can be limited for heating operation. You can limit the output
via the modulation range.
1. Start up the boiler.
2. Press Kand Fsimultaneously
until 85 flashes on the display (=
rated output) and Aappears. On
weather-compensated control units
the display additionally shows
"Max. output".
3. With a/bselect the required
value in % of rated output as max.
output.
4. Confirm the set value with d.
5. Record the settings for max. 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
Theoutputcanalsobelimitedfor
DHW loading. For this, change coding
address 6F in code 2.
Further details regarding the individual steps (cont.)
18
Initial start-up, inspection, maintenance
5692 573 GB

Checking the balanced flue system for soundness (annular
gap check)
ACombustion air aperture
For balanced flue systems tested
together with gas fired wall mounted
boilers, some Federal States (e.g.
Northrhein-Westphalia) waive the
requirement for a soundness test
(overpressure test) during commis-
sioning by the flue gas inspector.
For such cases we recommend that
your heating contractor carries out a
simple soundness test during the
initial start-up of your system. For
this, it would be sufficient to check the
CO2concentration in the combustion
air at the annular gap in the balanced
flue pipe.
Thefluepipeisdeemedtobesound,
if the CO2concentration of the com-
bustion 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, carry out a pressure
testonthefluepipeatastaticpres-
sure of 200 Pa.
Further details regarding the individual steps (cont.)
19
Initial start-up, inspection, maintenance
5692 573 GB

Removing the burner and checking the burner gasket
(replace gasket every two years)
1. Switch OFF the control unit ON/
OFF switch and the mains electri-
cal 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 gas connection pipe F.
5. Release four nuts G,andremove
the burner.
!Important information
To prevent damage,
never rest the burner on the
gauze assembly.
Further details regarding the individual steps (cont.)
20
Initial start-up, inspection, maintenance
5692 573 GB