Viessmann Vitogas 200-F GS2 Operating instructions

Service instructions
for contractors
VIESMANN
Vitogas 200-F
Type GS2
Rated heating output 72 to 144 kW
Gas boilers
Natural gas and LPG version
For applicability, see the last page
VITOGAS 200-F
5692 704 GB 2/2013 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■ Work on gas installations must only be
carried out by a registered gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental protection
■ Codes of practice of the relevant trade
associations
■ All current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW-TR Gas,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI,
SWKI, VKF and EKAS guideline
1942: LPG, part 2
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Do not smoke. Prevent naked
flames and sparks. Do not
switch lights or electrical appli-
ances on or off.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Evacuate any people from the
danger zone.
■ Notify your gas or electricity
supply utility from outside the
building.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5692 704 GB

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If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the installation site.
■ Close all doors in the living
space.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Life-threatening poisoning
caused by carbon monoxide in
the flue gas occurs as a result of
leaking or blocked flue systems
or an insufficient supply of com-
bustion air.
Ensure the flue system is in
proper working order. It must not
be possible to close apertures for
interconnected combustion air
supply.
Extractors
Operating appliances that extract air to
the outside (cooker hoods, extractors, air
conditioning units, etc.) can create neg-
ative pressure. If the boiler is operated at
the same time, this can lead to reverse
flow of the flue gas.
Danger
The simultaneous operation of
the boiler and appliances that
extract air to the outside can
result in life threatening poison-
ing due to reverse flow of the flue
gas.
Fit an interlock circuit or take suit-
able steps to ensure a sufficient
supply of combustion air.
Working on the system
■ Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■ Isolate the system from the power sup-
ply (e.g. by removing the separate fuse
or by means of a mains isolator) and
check that it is no longer 'live'.
■ Safeguard the system against recon-
nection.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Prior to commencing any work,
touch earthed objects, such as
heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Defective components must be
replaced with genuine
Viessmann spare parts.
Safety instructions
Safety instructions (cont.)
5692 704 GB

4
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5692 704 GB

5
Product information
Intended use......................................................................................................... 6
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 7
Further details regarding the individual steps....................................................... 8
Troubleshooting
Diagnosis.............................................................................................................. 25
Ignition system
Time chart and function........................................................................................ 26
Designs
Burner connection diagram.................................................................................. 28
Parts lists............................................................................................................ 30
Commissioning/service reports........................................................................ 35
Specification....................................................................................................... 36
Certificates
Declaration of conformity...................................................................................... 37
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 37
Keyword index.................................................................................................... 39
Index
Index
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The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions. It is only designed
for the heating of water that is of potable
water quality.
Intended usage presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than heating the building or
DHW does not comply with regulations.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect usage also occurs if the components
in the heating system are modified from
their intended function (e.g. if the flue
gas and ventilation air paths are
sealed).
Product information
Intended use
5692 704 GB

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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Preparing for commissioning and filling the heating
system............................................................................. 8
••• 2. Checking the gas type.................................................... 9
••• 3. Changing the gas type (if required).............................. 10
••• 4. Checking the static and supply pressure..................... 10
••• 5. Checking the nozzle pressure....................................... 13
••• 6. Determining the flue gas values.................................... 16
••• 7. Checking the ionisation current.................................... 17
••• 8. Checking the draught..................................................... 18
• • 9. Removing the burner...................................................... 19
• • 10. Checking the burner tubes............................................ 19
• • 11. Checking the pilot burner.............................................. 20
•12. Cleaning the heating surfaces (if required).................. 21
• • 13. Fitting the burner............................................................ 22
••• 14. Checking connections on the water side for tightness
••• 15. Checking the safety equipment
••• 16. Checking firm seating of electrical connections
••• 17. Checking all gas equipment for tightness at operating
pressure........................................................................... 22
••• 18. Checking the external LPG safety valve (if installed)
••• 19. Commissioning the system
••• 20. Checking the closing function of the valves in the gas
train
••• 21. Checking the flue gas monitoring device..................... 23
•22. Instructing the system user........................................... 24
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Preparing for commissioning and filling the heating system
Fill water
!Please note
Unsuitable fill water increases
the level of deposits and corro-
sion and may lead to boiler dam-
age.
■ Flush the heating system thor-
oughly before filling.
■ Only use fill water of potable
quality.
■ An antifreeze additive suitable
for heating systems can be
added to the fill water. The anti-
freeze manufacturer must ver-
ify its suitability.
■ Fill and top-up water with a
water hardness in excess of
the following values must be
softened, e.g. with a small soft-
ening system for heating water.
Total permissible hardness of the fill and top-up water
Total heating
output
Specific system volume (Conversion rate 1 mol/m3 = 100
ppm)
kW < 20 l/kW ≥ 20 l/kW to
< 50 l/kW
≥ 50 l/kW
≤ 50 ≤ 3.0 mol/m3 ≤ 2.0 mol/m3 < 0.02 mol/m3
> 50 to ≤ 200 ≤ 2.0 mol/m3 ≤ 1.5 mol/m3 < 0.02 mol/m3
> 200 to ≤ 600 ≤ 1.5 mol/m3 ≤ 0.02 mol/m3 < 0.02 mol/m3
> 600 < 0.02 mol/m3 < 0.02 mol/m3 < 0.02 mol/m3
Only for commissioning with
Vitotronic 300, type GW2
Check that the high limit safety cut-out of
the control unit is not set higher than
110 °C; adjust to max. 110 °C if
required.
Safety equipment block for 72 to 96 kW
Commissioning, inspection, maintenance
Further details regarding the individual steps
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Safety equipment block for 108 to
144 kW
APressure gauge
1. Check that the installation room vent
is open.
2. Check the pre-charge pressure of the
expansion vessel.
If the pre-charge pressure of the
expansion vessel is lower than the
static system pressure, top up with
sufficient nitrogen to make the pre-
charge pressure higher than the
static system pressure (0.1 to
0.2 bar/10 to 20 kPa).
3. Open any installed check valves.
4. Fill the heating system with water and
vent it until the charge pressure at the
pressure gauge is higher than the
pre-charge pressure of the expan-
sion vessel (0.1 to 0.2 bar/10 to
20 kPa).
Minimum system pressure 0.8 bar
(8 kPa), permiss. operating pressure
3 bar (0.3 MPa).
5. Return the check valves to their oper-
ating position.
Checking the gas type
The boiler is factory set for
natural gas E.
Note
The boiler can be operated in the Wobbe
index range 12.0 to 16.1 kWh/m3 (43.2
to 58.0 MJ/m3).
1. Check the gas type and Wobbe index
with your gas supply utility or your
LPG supplier and compare them with
the details on the burner label.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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2. If the details do not match, convert
the burner to the available gas type,
in accordance with the information
provided by the gas supply utility or
the LPG supplier.
Conversion kit installation
instructions
3. Record the gas type in the report on
page 35.
Wobbe index range Natural gas E Natural gas
LL
LPG P
G20 G25 G31
kWh/m312.0 to 16.1 10.0 to 13.1 21.4 to 22.5
MJ/m343.2 to 58.0 36.0 to 47.2 76.9 to 81.0
Changing the gas type (if required)
Conversion kit installation
instructions
Checking the static and supply pressure
Danger
CO build-up as a result of incor-
rect burner adjustment can have
serious health implications.
Carry out a CO test before and
after work on gas appliances.
Operation with LPG
Flush the LPG tank twice during com-
missioning or replacement. Vent the tank
and gas connection line thoroughly after
flushing.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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A
ATop test nipple: "P.IN" (input), static
and supply pressure
01. Close the gas shut-off valve.
02. Remove the screw inside top test
nipple A at the gas train and con-
nect the pressure gauge.
03. Open the gas shut-off valve.
04. Check the static pressure:
■ Natural gas: max. 25 mbar
(2.5 kPa)
■ LPG: max. 57.5 mbar (5.75 kPa)
Record the actual value in the serv-
ice report.
05. Start the boiler.
Note
During commissioning, the boiler
can enter a fault state (several
times) because of airlocks in the gas
line. To reset, switch the control unit
ON/OFF switch OFF and ON again.
The ignition process will then be
repeated.
06. Check the supply pressure (flow
pressure):
■ Natural gas: 17.4 to 25 mbar (1.74
to 2.5 kPa)
■ LPG: 42.5 to 57.5 mbar (4.25 to
5.75 kPa) (at 50 mbar/5 kPa pre-
charge pressure)
Record the actual value in the serv-
ice report.
Note
Use a suitable measuring device
with a resolution of at least
0.1 mbar (10 Pa) to check the supply
pressure.
07. Take action as shown in the follow-
ing table.
08. Switch OFF the control unit ON/OFF
switch (the boiler shuts down).
09. Close the gas shut-off valve.
10. Remove the pressure gauge and
seal top test nipple A with screw.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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11. Open the gas shut-off valve and
check top test nipple A for gas
tightness.
Danger
Gas escaping from the test
nipple leads to a risk of
explosion.
Check the test nipple for gas
tightness.
Supply (flow) pres-
sure for natural
gas
Supply (flow)
pressure for LPG
(at 50 mbar,
5 kPa pre-charge
pressure)
Action
Below 17.4 mbar
(1.74 kPa)
Below 42.5 mbar
(4.25 kPa)
Do not start the boiler. Notify your gas
supply utility or LPG supplier.
17.4 to 25 mbar
(1.74 to 2.5 kPa)
42.5 to 57.5 mbar
(4.25 to 5.75 kPa)
Start the boiler.
Above 25 mbar
(2.5 kPa)
Above 57.5 mbar
(5.75 kPa)
Position a separate gas pressure gover-
nor upstream of the system and regulate
the pre-charge pressure to 20 mbar
(2 kPa) for natural gas or 50 mbar
(5 kPa) for LPG.
Notify your gas supply utility or LPG sup-
plier.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the nozzle pressure
ATop test nipple: "P.IN" (input), static
and supply pressure
BPlug with connecting cable
CHexagon screw (full load adjust-
ment)
DPhillips screw (partial load adjust-
ment)
E2 plugs a:Ö (modulation coil)
FBottom test nipple: "P.OUT" (out-
put)
GNozzle cap
HGas nozzle
KGas manifold
Disabling the l.h. gas train (BV1)
1. Close the gas shut-off valve.
2. Seal at least the r.h. half of the gas
nozzles H with nozzle caps G sup-
plied.
3. Open the screw at bottom test nipple
F of the l.h. gas train (BV1) by one
full turn.
4. Connect the pressure gauge at bot-
tom test nipple F of the l.h. gas train
(BV1) to check the nozzle pressure.
5. Disconnect plug B from the r.h. gas
train (BV2).
6. Open the gas shut-off valve.
Start the boiler.
7. Enable the emissions test function
"S" (full load):
Operating instructions
8. Counterhold Phillips screw D.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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9. Reduce the nozzle pressure at the
l.h. gas train (BV1) with hexagon
screw C to 0 (no end-stop).
Note
Turning anti-clockwise: Nozzle pres-
sure decreases.
Note
The flame of the main burner extin-
guishes and the flame of the pilot burner
stays lit.
Adjusting the r.h. gas train (BV2)
01. Remove the pressure gauge from
bottom test nipple F of the l.h. gas
train (BV1) and seal aperture with
screw.
02. Open the screw at bottom test nip-
ple F of the r.h. gas train (BV2) by
one full turn.
03. Connect the pressure gauge at bot-
tom test nipple F of the r.h. gas
train (BV2) to check the nozzle pres-
sure.
04. Connect plug B to the r.h. gas train
(BV2).
05. Counterhold Phillips screw D.
06. Adjust the nozzle pressure at the
r.h. gas train (BV2) with hexagon
screw C in accordance with the
value in the table on page 16.
07. Check the setting values and record
them in the report.
08. Pull one of the two plugs a:Ö E
from the modulation coil on the gas
train.
Note
The flame of the main burner extin-
guishes.
09. Test the nozzle pressure at partial
load.
In case of deviation from the value
in the table on page 16:
■Counterhold hexagon screw C.
■ Adjust the nozzle pressure at Phil-
lips screw D.
10. Check the setting values and record
them in the report.
11. Reconnect the plug a:Ö E previ-
ously pulled from the modulation
coil on the gas train.
Adjusting the l.h. gas train (BV1)
01. Disconnect plug B from the r.h.
gas train (BV2).
02. Remove the pressure gauge from
bottom test nipple F of the r.h. gas
train (BV2) and seal aperture with
screw.
03. Connect the pressure gauge at bot-
tom test nipple F of the l.h. gas
train (BV1) to check the nozzle pres-
sure.
04. Counterhold Phillips screw D.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 704 GB

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05. Adjust the nozzle pressure at the
l.h. gas train (BV1) with hexagon
screw C in accordance with the
value in the table on page 16.
Note
Turning clockwise: Nozzle pressure
rises.
06. Pull one of the two plugs a:Ö E
from the modulation coil on the gas
train.
07. Test the nozzle pressure at partial
load.
In case of deviation from the value
in the table on page 16:
■Counterhold hexagon screw C.
■ Adjust the nozzle pressure at Phil-
lips screw D.
Note
Turning clockwise: Nozzle pressure
rises.
08. Check the setting values and record
them in the report.
09. Shut down the boiler and close the
gas shut-off valve.
10. Remove the pressure gauge from
bottom test nipple F of the l.h. gas
train (BV1) and seal aperture with
screw.
11. Connect plug B to the r.h. gas train
(BV2).
12. Remove all nozzle caps from the
r.h. half of the pilot gas nozzles.
13. Danger
Gas escaping from the test
nipple leads to a risk of
explosion.
Check the test nipple for gas
tightness.
Open the gas shut-off valve and
start the appliance.
Rated heating
output
kW 72 84 96 108 120 132 144
Natural gas E / G20
Pilot gas nozzle 26-2
Nozzle pressure at
full load
mbar
kPa
14.7
1.47
14.7
1.47
14.3
1.43
14.5
1.45
13.9
1.39
14.0
1.40
14.1
1.41
Nozzle pressure at
partial load
mbar
kPa
6.6
0.66
6.4
0.64
6.2
0.62
6.3
0.63
6.0
0.60
6.0
0.60
6.2
0.62
Nozzle designation 2.90 2.90 2.95 2.95 3.00 3.00 3.00
Air restrictor 7 mm — — — — — — —
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Rated heating
output
kW 72 84 96 108 120 132 144
Natural gas LL / G25
Pilot gas nozzle 29-2
Nozzle pressure at
full load
mbar
kPa
13.3
1.33
13.3
1.33
12.1
1.21
12.5
1.25
12.5
1.25
12.9
1.29
12.9
1.29
Nozzle pressure at
partial load
mbar
kPa
5.8
0.58
5.7
0.57
5.2
0.52
5.5
0.55
5.6
0.56
5.6
0.56
5.7
0.57
Nozzle designation 3.30 3.30 3.40 3.40 3.40 3.40 3.40
Air restrictor 7 mm 50 50 50 50 50 50 50
LPG P / G31
Pilot gas nozzle 26-1
Nozzle pressure at
full load
mbar
kPa
32.1
3.21
32.1
3.21
32.8
3.28
31.7
3.17
31.9
3.19
30.9
3.09
32.7
3.27
Nozzle pressure at
partial load
mbar
kPa
13.4
1.34
13.4
1.34
13.4
1.34
13.7
1.37
13.2
1.32
13.1
1.31
13.6
1.36
Nozzle designation 1.90 1.90 1.90 1.90 1.90 1.90 1.90
Air restrictor 7 mm — — — — — — —
Number of burner tubes 6 7 8 9 10 11 12
Gas nozzles
Total number 6 7 8 9 10 11 12
Number covered up 3 4 4 5 5 6 6
Note
The values in the nozzle pressure table
apply to the following ambient condi-
tions:
■ Air pressure: 1013 mbar (101.3 kPa)
■ Temperature: 15 °C
Wobbe index see page 10.
Determining the flue gas values
Danger
CO build-up as a result of incor-
rect burner adjustment can have
serious health implications.
Carry out a CO test before and
after work on gas appliances.
Determine the flue gas values and
record them in the report.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 704 GB

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Checking the ionisation current
8888
DBurner control unit
1. Pull ionisation cable C from ionisa-
tion electrode E.
2. Connect the measuring device A as
shown in the diagram:
■Push plug-in adaptor (7 6/4) B
into ionisation cable C.
■Push adaptor cable (7 4/6) F
onto ionisation electrode E.
■Push measuring device plug A
into plug-in adaptor B and adap-
tor cable F.
3. Start the boiler.
4. Check the ionisation current.
■ When the pilot burner is lit:
Min. 1.0 µA
■ When the main burner is lit:
Min. 3.0 µA
5. Record the actual values in the
report.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 704 GB

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Checking the draught
2 x D
D
ATest port 7 10 mm
Check the draught in Pa
(100 Pa = 1 mbar, test port behind the
draught hood) and record it in the report
on page 35.
Note
Required boiler draught: 3 Pa
(0.03 mbar).
The chimney draught must not exceed
10 Pa (0.1 mbar). It may be necessary to
fit a draught stabiliser into the chimney.
(Seek the agreement of your local flue
gas inspector [where appropriate].)
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Removing the burner
1. Pull the plug from burner control unit
C.
2. Undo the fitting on gas supply pipe
B.
3. Undo the nuts and screws and care-
fully pull burner A forward and out.
Checking the burner tubes
1. Check the gas outlets for damage. 2. Clean the burner tubes with com-
pressed air.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the pilot burner
3
7
1. Check ionisation electrode A, pilot
burner B and ignition electrode C
for damage.
2. Check the electrode gaps.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 704 GB