Viessmann VITODENS 200 User manual

VITODENS 200
Service instructions
for heating engineers
VitodensĂ200
typeĂWB2, 4.5 to 35.0/4 to 32ĂkW
Wall-mounted gas-fired condensing
boiler wit integral boiler control unit
Natural gas and LPG version
See notes on applicability, pageĂ2.
5692Ă486ĂGBăăă12/2002 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
Gas-fired condensing boiler
4.5 to 12/4 to 11 (16*1)ĂkW 6.6 to 26.3/6 to 24ĂkW 8.7 to 35.0/8 to 32ĂkW
from serial no. & ig er from serial no. & ig er from serial no. & ig er
7170313Ă2Ă00001Ăkkk 7170310Ă2Ă00001Ăkkk 7170309Ă2Ă00001Ăkkk
7170315Ă2Ă00001Ăkkk 7170316Ă2Ă00001Ăkkk 7170311Ă2Ă00001Ăkkk
Gas-fired condensing combination boiler
6.6 to 26.3/6 to 24ĂkW
from serial no.
7170312Ă2Ă00001Ăkkk or 7170314Ă2Ă00001Ăkkk
*1Domestic hot water heating 16 kW.
5692Ă486ĂGB

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 28
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RepairsĂ 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strapping plug configuration and codingĂ 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control unit for constant temperature mode
Function descriptionĂ 57
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test settingsĂ"TĂ1" and "TĂ2"Ă 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C anging parameters in service positionsĂ"SĂ1" to "SĂ7"Ă 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanning temperaturesĂ 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control unit for eather-compensated mode ith standard programming unit
Function descriptionĂ 65
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calling up coding levelĂ1Ă 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating curvesĂ 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting eating curvesĂ 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary coding level 1Ă 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calling up coding levelĂ2Ă 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary coding levelĂ2Ă 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brief scanĂ 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanning temperaturesĂ 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control unit for eather-compensated mode ith Comfortrol programming unit
Function descriptionĂ 85
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calling up coding addressĂ 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating curvesĂ 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting eating curvesĂ 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Summary of coding addressesĂ 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brief scanĂ 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanning temperaturesĂ 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection and iring diagrams
HPower supplyĂ 103
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOperating componentsĂ 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts listsĂ 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Commissioning/service reportĂ 118
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SpecificationĂ 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas restrictorsĂ 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of conformityĂ 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer's certificateĂ 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyword indexĂ 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692Ă486ĂGB

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. ChangingĂtheĂgasĂtypeĂ(seeĂseparateĂinstallationĂinstructions)
C I M 6. Checking the static 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 I M 10. Checking all connections on the primary and on the
secondary side for leaks
C M 11. Fully checking the burner
(record the values on p.Ă118 of the commissioning report)
C12. Leak testing the BF system (circular gap check)Ă 16. . . . . . . . .
I M 13. Removing the burner and checking the burner gasket
for leaksĂ 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 14. Checking the burner gauze assemblyĂ 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 15. CheckingĂ&ĂadjustingĂtheĂignitionĂ&ĂionisationĂelectrodesĂ 18
I M 16. Checking the condensate drainĂ 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 17. Checking the neutralising system (if installed)
I M 18. Cleaning the combustion chamber/heating surfaces
and installing the burnerĂ 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M19. Checking the flo limiter and flo s itch filter
(only for gas-fired combination boiler)Ă 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 20. Checking the diaphragm expansion vessel and
the system pressure
5692Ă486ĂGB

5
Initial start-up, inspection and maintenance
StepsĂćĂinitial start-up, inspection and maintenance (cont.)
Commissioning steps
Inspection steps
Maintenance steps Page
C I M 21. Checking the function of all safety valves
C I M 22. Checking the tightness of electrical connections
C I M 23. Checking all gas components for leaks at
operating pressure
C M 24. Checking the ionisation currentĂ 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 25. Checking the external LPG safety valve
(if installed)
C26. Matching up the coding addresses
(control unit for eather-compensated mode)Ă 23
. . . . . . . . . . . .
5692Ă486ĂGB

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. Remove protective capĂA from
t e c angeover valve, and replace
t e opposite way around (central
position of t e valve for improved
ventilation).
3. Fill t e system via tapĂB, vent t e
system and c eck t e system
pressure (min. system pressure
>Ă0.8Ăbar).
4. Reposition protective capĂA.
5. Close t e s ut-off valves on t e
eating water side of t e system.
6. Connect t e drain ose to upper
ball valveĂC.
7. Open ball valvesĂB and C, and
vent at mains pressure until no
furt er air noises are audible.
8. Close ball valvesĂB and C, and
open t e s ut-off valves on t e
eating water side.
5692Ă486ĂGB

7
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Language selection (if necessary)Ăć
only ith Comfortrol menu-assisted programming unit
SPRACHE/LANGUAGE
>DEUTSCH:.........A
>ENGLISH:.........B
>ZURÜCK/BACK:....D
Open flap:
Menu item Key
³SYSTEM "D"
³BASIC SETTINGS "A"
³LANGUAGE "C"
Select t e required language.
Checking 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",
Vitodens 200 is set up for natural
gas E or LPG P.
Natural gasĂEĂversion:
The boiler can be operated in the
Wobbe index range 12.0 to
16.1 kWh/m3 (43.2 to 58.0 MJ/m3).
LPGĂPĂversion:
The boiler can be operated in the
Wobbe index range 21.4 to
22.5 kWh/m3 (76.9 to 81.0 MJ/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
13.1 kWh/m3 (36.0 to 47.2 MJ/m3).
HLPGĂP to natural gasĂE
The boiler can be operated in the
Wobbe index range 12.0 to
16.1 kWh/m3 (43.2 to 58.0 MJ/m3).
4. Record t e gas type in t e service
report on pageĂ118.
5692Ă486ĂGB

8
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the static 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.
Static pressure
1. Close t e gas s ut-off valve.
2. Release t e screw in 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 static 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 page 10.
On start-up, the boiler can enter a
fault state because of airlocks in
the gas pipe.
After approx. 5 seconds, press
key "EU" to reset the burner.
5692Ă486ĂGB
PE
A

9
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Gas supply pressure (flo pressure)
6. C eck t e supply (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 0.1 mbar 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 t e system. 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.
8. ¨ĂSafety instructions
Open the gas shut-off valve and
check for leaks on test nipple "PE",
and all gas connections.
5692Ă486ĂGB

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".
5692Ă486ĂGB
Fan starts up
C eck water
pressure (switc ing
point of flow switc
0.8Ăbar)
Flow switc
switc ed t roug ,
plugĂ33
Increase set value
and ensure eat is
drawn off
Heat demand from
control unit (set
boiler temp. is 5ĂK
ig er t an actual
boiler temp.)
Differential pressure
sensor enables
start-up (0.75ĂV
across terminals
"XĂ14.5" & "XĂ14.4")
Yes
Yes
Yes
after approx. 70Ăsec.
Fault
U06ĂĂĂorĂĂĂU:0:6ĂĂĂorĂĂĂ06
C eck fan cables
and plugs,
c eck fan
C eck air damper
function; 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.)
5692Ă486ĂGB
stops below set boiler
temperature and
restarts again
immediately
Gas combination
valve opens
C eck flue gas sys-
tem for 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 gas pipe for
airlocks,
c eck if cores "LĂ1"
and "N"
ave been inter-
c anged, c eck
strapping plugĂ158
C eck gas
combination valve
(drive voltage 20ĂVć),
c eck 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.)
Checking the CO2 settings
Vitodens 200 is, depending on version, set up in the factory for natural gas E
or LPG P.
In case of initial start-up or maintenance, check the CO2 level on the boiler
connection fitting.
Please note:
The MatriX burner for Vitodens 200 is preset for the entire gas group.
Therefore, the burner requires no further setting or adjustment.
Depending on the Wobbe index, the CO2content reaches levels of
H6.6 to 10.0% for natural gas E,
H7.0 to 10.0% for natural gas LL and
H8.5 to 10.5% for LPG P.
Compare the measured CO2 value with the above CO2 value ranges of the
individual gas groups (check the gas group with your mains or LPG gas
supplier).
If the actual CO2 value deviates by more than 1% for natural gas or 0.5% for
LPG, proceed as follows:
HCheck whether the correct gas restrictor has been installed (see page 126).
HCarry out a leak test (BF system) (see page 16).
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).
5692Ă486ĂGB
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 output and
check the CO2
content
5. Select upper rated
output and check
CO2 content
If value deviates
by more t an 1Ă%,
replace burner
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
operation
ith standard
programming
unit
060
50
40
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
required
eating
program.
HSet rotary
selectorĂ"s"
to required
value.
HEnter actual
values into
service
report.
HClose test
port.
Control unit
for eather-
compensated
mode 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 pro-
gramming
unit.
HEnter actual
values into
service
report.
HClose test
port.
5692Ă486ĂGB

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
nipplesĂAof t e gas combination
valve.
4. Connect t e gauge to bot test
nipplesĂA.
Please note:
Control pressure = differential
pressure.
This lies between 0.25 and 4 mbar.
Use a suitable pressure gauge
with a range from 0 to 10 mbar.
Vacuum 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.
5692Ă486ĂGB
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. 5 minutes, 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 kW 4 6 8 11 15 18 20 24 28 32
Rated
thermal
load
kW 4.20 6.30 8.33 11.50 15.60 18.80 20.80 25.00 29.20 33.30
Control pressure
at rated
output
HĂ4ĂĆĂ11 (16)ĂkW
HĂ6ĂĆĂ24ĂkW
HĂ8ĂĆĂ32ĂkW
mbar
mbar
mbar
0.25
ćć
ćć
0.57
0.25
ćć
1.00
0.45
0.25
1.90
0.85
0.48
ćć
1.57
0.88
ćć
2.25
1.27
ćć
2.78
1.57
ćć
4.00
2.25
ćć
ćć
3.07
ćć
ćć
4.00
Rated output or rated thermal load relative to gas G 20/G 25 and 8.5% CO2 content.
5692Ă486ĂGB
+–

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
CO2concentration 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 0.2% and the O2 concentration is a minimum
of 20.6%.
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 200 Pa.
ACombustion air test nipple
(ventilation air)
5692Ă486ĂGB
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. PullĂelectricalĂcablesĂoffĂfanĂmotorĂA,
differential pressure sensorĂB, gas
valveĂC, ionisation electrodeĂD,
ignition unitĂE and eart ĂF.
4. Remove gas supply pipeĂG from
t e gas combination valve.
5. Slacken four Allen screwsĂH and
remove t e burner.
¨Do not rest the burner on the
gauze assembly (wire mesh).
6. C eck t e burner gasket (U-s aped
gasket, see parts list) for damage
and replace, if necessary.
¨Replace the burner gasket
every 2 years as standard.
Checking the burner gauze assembly
Replace t e burner gauze assembly
if t e wire mes is damaged.
1. Remove electrodes A.
2. Slacken six Torx screwsĂB and
remove burner gauze assemblyĂC.
3. Remove old gauze assembly
gasketĂD.
4. Insert a new burner gauze assembly
wit new assembly gasket, and
secure wit six Torx screws.
Torque: 3.5 Nm
5692Ă486ĂGB
HAHB
GCHDFHE
CBD
AA

18
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
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 A.
Tig ten t e electrode fixing
screws wit 2ĂNm.
5692Ă486ĂGB
8+0.4 5+0.3
3+0.5 7+0
–1

19
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.
5692Ă486ĂGB
A

20
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 which
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:
Fauch 600 and Antox 75 E are
supplied by
Hebro Chemie GmbH
Rostocker Straße 40
DĆ41199 Mönchengladbach
c:
Intec Bassersdorf AG
Grindelstrasse 12
Postfach
CHĆ8303 Bassersdorf
2. Install t e burner and torque
diagonally to 4ĂNm.
3. Install t e gas supply pipe.
¨ĂSafety instruction
Carry out a leak test.
4. Connect t e electrical leads to
eac relevant component.
5692Ă486ĂGB
A
B