Viessmann VITOLIGNO 200-S Quick guide

Installation and service instructions
for contractors
VIESMANN
Vitoligno 200-S
Type VL2A
High performance wood gasification boiler
for split logs up to 50 cm long
For applicability, see the last page
VITOLIGNO 200-S
5777 985 GB 3/2017 Please keep safe.

2
Please follow these safety instructions closely to
prevent accidents and material 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 environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for author-
ised contractors.
■Work on electrical equipment must only be carried
out by a qualified electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■All relevant safety regulations as defined by DIN, EN,
DVGW, VDE and locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI and SWKI
Safety instructions for working on the system
Working on the system
■Isolate the system from the power supply (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 reconnection.
Danger
Hot surfaces can cause burns.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the boiler, burner,
flue system or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing 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 func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions
Safety instructions
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Safety instructions for operating the system
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to prevent flue
gases from spreading.
What to do if water escapes from the appliance
Danger
When water escapes from the appliance there is
a risk of electrocution.
Switch off the heating system by means of an
external isolator (for example fuse box, domestic
power distribution).
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of conden-
sate or other causes. Ensure an adequate supply of
combustion air.
Instruct system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be non-
closable.
Extractors
Operating appliances that extract air to the outside
(cooker hoods, extractors, air conditioning units, etc.)
can create negative 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 poisoning due to
reverse flow of the flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5777 985 GB

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1. Information Disposal of packaging ............................................................................ 6
Symbols ................................................................................................. 6
Intended use .......................................................................................... 7
Maintenance and cleaning ..................................................................... 7
2. Preparing for installation ................................................................................................................ 8
3. Installation sequence Fitting the thermal insulation .................................................................. 12
■Fitting the retaining rails ..................................................................... 12
■Fitting the tie-bars ............................................................................... 13
■Inserting the lower thermal insulation mat .......................................... 14
■Aligning the retaining rails and fitting the front panel .......................... 15
■Fitting the display panel and sensors ................................................. 15
■Routing cables from all components to the control unit ...................... 17
■Electric ignition system (if available) ................................................... 17
■Fitting the doors .................................................................................. 18
■Fitting the side panels and back panel ............................................... 19
Electrical connections ............................................................................ 19
■Overview of electrical connections ..................................................... 20
■Inserting cables and applying strain relief .......................................... 20
■Other electrical connections ............................................................... 20
Power supply ......................................................................................... 20
■Guidelines ........................................................................................... 20
Fitting the covers ................................................................................... 21
Connections on the flue gas side ........................................................... 22
Connections on the water side .............................................................. 22
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 24
5. Codes Code 1 ................................................................................................... 46
■Calling up code 1 ................................................................................ 46
Code 2 ................................................................................................... 54
■Calling up code 2 ................................................................................ 54
6. Service checks Service menu ......................................................................................... 58
■Calling up the service menu ............................................................... 58
■Leaving the service menu ................................................................... 58
Calling up operating conditions and sensors ......................................... 58
■Diagnosis ............................................................................................ 58
7. Troubleshooting Fault display ........................................................................................... 61
■Checking and acknowledging faults ................................................... 61
■Calling up acknowledged fault messages .......................................... 61
■Plain text fault display ......................................................................... 61
■Calling up fault codes from the fault memory (fault history) ............... 61
■Deleting the fault codes from the fault memory .................................. 62
■Fault codes ......................................................................................... 62
8. Maintenance Fuse ....................................................................................................... 65
Battery ................................................................................................... 65
High limit safety cut-out ......................................................................... 65
■Triggering the function ........................................................................ 65
■Cancelling the function ....................................................................... 65
Sensors .................................................................................................. 66
■Connection ......................................................................................... 66
■Checking the sensors ......................................................................... 66
Lambda probe ........................................................................................ 67
■Checking the Lambda probe .............................................................. 67
■Connection ......................................................................................... 67
Index
Index
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■Calibrating the Lambda probe ............................................................ 67
■Lambda probe specification ................................................................ 68
Extension kit for heating circuit with mixer ............................................. 69
■Overview of electrical connections ..................................................... 69
■Required settings ................................................................................ 69
■Extension kit specification .................................................................. 70
■Mixer motor ......................................................................................... 71
9. Parts lists Overview of assemblies ......................................................................... 73
Thermal insulation assembly ................................................................. 74
Control unit assembly ............................................................................ 76
Overview of boiler assemblies ............................................................... 79
Doors assembly ..................................................................................... 80
Fireproof material assembly .................................................................. 82
Flue gas inlet/outlet assembly, 20 and 30 kW ....................................... 84
Flue gas inlet/outlet assembly, 40 and 50 kW ....................................... 86
Miscellaneous assembly ........................................................................ 88
10. Function description Display and operating elements ............................................................ 90
■Programming unit ............................................................................... 90
Heating circuit control unit ..................................................................... 90
■Control functions ................................................................................. 90
■DHW temperature control ................................................................... 91
■Screed drying ..................................................................................... 91
11. Connection and wiring dia-
gram
Connection and wiring diagram ............................................................. 93
■Position of the PCB ............................................................................ 93
■Overview of PCB ................................................................................ 94
■230 V connections .............................................................................. 95
■LV connections ................................................................................... 96
Heating circuit extension module (accessories) .................................... 97
■PCB HKK 2.01 .................................................................................... 97
12. Commissioning/service
reports
................................................................................................................ 99
13. Specification ................................................................................................................100
14. Disposal Final decommissioning and disposal ..................................................... 102
15. Certificates Declaration of conformity ....................................................................... 103
16. Keyword index ................................................................................................................104
Index
Index (cont.)
5777 985 GB

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Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
Viessmann.
AT: Use the ARA statutory disposal system (Altstoff
Recycling Austria AG, licence number 5766).
CH: Packaging waste is disposed of by the HVAC
contractor.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Information
Disposal of packaging
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Information

7
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions. It is only designed for the heating of heating
water that is of potable water quality.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than heating the building or DHW shall be deemed
inappropriate.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Incorrect usage or operation of the appliance (e.g. the
appliance being operated for longer periods when
open) is prohibited and will result in an exclusion of lia-
bility. Incorrect usage also occurs if the components in
the heating system are modified from their intended
use (e.g. if the flue gas and ventilation air paths are
sealed) or if other fuels than those intended for this
appliance are used.
Maintenance and cleaning
!Please note
During maintenance and cleaning work, and
when manipulating the ash box, there is a risk of
fire and burns due to hot parts and ash.
■Wear suitable safety gloves.
■Only dispose of the hot ash in fireproof con-
tainers with covers.
!Please note
Wood dust, ash and soot pose a danger to the
respiratory tract during cleaning work and when
manipulating the ash box.
Wear a dust mask to protect your respiratory
tract.
Note
Observe the country-specific regulations on the dis-
posal of materials, waste and system components.
Note
Before restarting the heating system, all opened cov-
ers and flaps on the boiler must be closed again.
Information
Intended use
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Information

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Clearance dimensions
(480)
520
b
420
(380)
(480)
520
(400)
510
1000 A
a
b420
(380)
(400)
510
1000 A
a
B B
Fig. 1
ARequired clearance for cleaning, heat-up and
recharging
BThe wall clearance can be reduced to 200 mm if
the ignition is not located on this side of the boiler.
Rated heating output kW 20/30 40/50
Dim. a mm 1020 1020
Dim. b mm 640 640
Minimum room height mm 1800 2100
Room height, recommended mm 2300 2600
Dimensions in brackets: Boiler incl. thermal insulation
Note
The specified wall clearances are required for installa-
tion and maintenance work.
Installation room requirements
Installation location requirements:
■The installation room must be dry and free from the
risk of frost.
■Avoid high humidity levels (e.g. from continuous dry-
ing of washing).
■Ambient temperatures between 0 and 35 °C
■Ensure a supply of fresh air.
Danger
Suffocation hazard due to carbon monoxide
produced during incomplete combustion due
to lack of combustion air.
Ensure an adequate supply of fresh air. Never
cover or close vents.
Danger
Easily flammable liquids and materials can
cause deflagration and fires.
Do not store easily flammable substances in the
boiler installation room (e.g. petrol, solvents and
cleaning agents, paints, paper).
Floor condition
The boiler must be positioned on a non-combustible
substrate. Special foundations are not required.
Preparing for installation
Preparing for installation
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Installation

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Handling and siting
Observe the shipping information on the packag-
ing.
!Please note
Severe jolts can damage the combustion cham-
ber and the hopper components.
Do not subject the boiler to any severe jolts dur-
ing handling and positioning.
Transport:
■Transport the boiler to the installation location in an
upright position and, if possible, on the pallet.
■The boiler can be secured for transportation:
–With an eye bolt screwed into the centre bracket
on the boiler.
–With a transport belt fitted around the boiler
between the hopper door and ignition door.
■Remove the lower door (inspection door or ash door)
from the boiler for transportation with a pallet truck.
Aligning the boiler
!Please note
Do not damage or lose the foot caps on the
adjustable feet.
Pay attention to the foot caps when lifting the
boiler and removing the pallet.
10
20
Fig. 2
Align the boiler on the adjustable feet with an inclina-
tion towards the front. This allows air bubbles trapped
in the boiler water to escape.
Checking the position of the doors
Note
To ensure the doors are leakproof and the door han-
dles operate easily, the position of the doors must be
checked before installation work begins.
Preparing for installation
Preparing for installation (cont.)
5777 985 GB
Installation

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B
A
Fig. 3
ANuts on hinge and lock plate
BOnly for the lock plate: Nut on the eye screw
1. Test the hopper door, ignition door and ash door
with a paper strip (approx. 20 mm wide).
You should not be able to pull out the jammed
paper strip from any of the 4 sealing faces.
Alternatively: Carry out a chalk test
In order to accurately test the door tightness, apply
chalk to the sealing contour of the boiler body.
Close the doors, open them again and examine the
packing cord.
Leaks are evident where the chalk has left no mark
on the packing cord.
2. If necessary, adjust the door in question.
Note
If required, either the hinges or the lock plates or
both can be adjusted.
Observe the following sequence:
■Undo nuts A.
■Shift the hinge or lock plate. To do this with the
lock plate, adjust the nuts B on the eye screw.
■Retighten nuts A.
Preparing for installation
Preparing for installation (cont.)
5777 985 GB
Installation

11
Removing the doors
2.
1.
3x
M8 x 25
A
3x
4.
3.
5.
B
6.
Fig. 4
1. Remove headless screws.
2. Unhook the doors.
Keep washers A safe.
3. Remove the display panel with outside tempera-
ture sensor and boiler water temperature sensor
from the boiler.
4. Remove transport brackets from inner doors and
the combustion chamber.
Note
Fully insert the thermal insulation plates of the
combustion chamber.
5. Undo screw and remove air damper guard.
6. Remove all spring hooks B from the thermal insu-
lation mats so that the retaining rails can be fitted.
Preparing for installation
Preparing for installation (cont.)
5777 985 GB
Installation

12
Fitting the retaining rails
4,8 x 9,5
Fig. 5
Loosely fit the retaining rails; do not tighten the screws.
Note
The screws are not tightened until the tie-bars have
been fitted and the base protection plate is installed
(see page 15).
■When fitting the front left rail, pay attention to the
cables of the door contact switch.
■If any edges of the thermal insulation jacket protrude
at the sides, push them behind the retaining rails.
Installation sequence
Fitting the thermal insulation
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Installation

13
Fitting the tie-bars
4,8 x 9,5
Fig. 6
Installation sequence
Fitting the thermal insulation (cont.)
5777 985 GB
Installation

14
Inserting the lower thermal insulation mat
2.
90°
1.
2x
90°
5.
3.
4.
Fig. 7
1. Bend the tabs on both sides of the base protection
plate downwards.
2. Insert the thermal insulation mat with the black side
facing down.
3. Turn the tabs on the plinth trim inwards.
4. Insert the base protection plate.
5. Slide the base protection plate with the recess onto
the tab bolt.
Installation sequence
Fitting the thermal insulation (cont.)
5777 985 GB
Installation

15
Aligning the retaining rails and fitting the front panel
8x
1.
0
4.
3.
A
2.
Fig. 8
ACleaning gate
1. If necessary, align the retaining rails on the r.h. and
l.h. side of the boiler and tighten the screws.
2. Secure the location studs to the front retaining
rails.
3. Insert the thermal insulation mat into the front
panel.
4. Position the front panel on the location studs and
press together firmly, first at the bottom, then at the
top.
Note
For easier handling, first place the front panel on
cleaning gate A.
Fitting the display panel and sensors
!Please note
Damaged capillary tubes will result in faulty sen-
sor function.
Never kink the capillary tubes.
Note
The ribbon cable of the programming unit must not be
kinked.
Installation sequence
Fitting the thermal insulation (cont.)
5777 985 GB
Installation

16
2.
7.
C5.
3.
3.9 x 9.5
1.
4.
aBÖ
A
B
B
6.
8.
9.
Fig. 9
AFlow temperature sensor
BSensor for high limit safety cut-out
CSensor for thermally activated safety valve (not
part of the standard delivery)
aBÖ High limit safety cut-out
1. Open the control unit cover panel.
2. Fit the display panel. When doing this, fold the rib-
bon cable upwards in front of the control unit
enclosure.
Note
Do not kink the ribbon cable inside the control unit
enclosure.
3. Pull the thermal insulation forwards by hand and
hold it tight.
4. Seal in and install the sensor well for the thermally
activated safety valve.
5. Insert the thermally activated safety valve sensor
(not included in standard delivery) as far as it will
go.
6. Push the supplied corrugated hose completely
over the high limit safety cut-out sensor capillaries.
Note
The corrugated hose protects the capillaries from
damage and kinking.
7. Pull the thermal insulation forwards by hand.
Thread the sensors through the holes in the ther-
mal insulation mat.
8. Push the flow temperature sensor and sensor for
high limit safety cut-out into the sensor well as far
as they will go.
!Please note
Damaged capillary tubes will result in faulty
sensor function
■Never kink the capillary tubes.
■When routing, ensure a minimum radius of
5 mm.
9. Secure the sensors with clips.
Installation sequence
Fitting the thermal insulation (cont.)
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Installation

17
Routing cables from all components to the control unit
Fig. 10
1. Route cables (e.g. external electrical cables) to the
control unit. When doing this, take account of the
system components in accordance with the system
version.
System examples
2. Bundle the cables together and secure them to the
wiring rail and retaining rail.
!Please note
Contact with hot components causes damage to
cables.
After installation, cables must not come into con-
tact with hot components.
Electric ignition system (if available)
If an electric ignition system (accessories) has been
ordered, install this now.
"Electric ignition system" installation instructions
Installation sequence
Fitting the thermal insulation (cont.)
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Installation

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Fitting the doors
3x
A
2.
3.
1.
Fig. 11
AWasher (1 per door)
Installation sequence
Fitting the thermal insulation (cont.)
5777 985 GB
Installation

19
Fitting the side panels and back panel
Route external cables through the opening in the back
panel.
A
3,9 x 9,5
4. 3.
1.
5.
2.
Fig. 12
AType plate
Secure the side panels with the screws supplied.
Electrical connections
When connecting external switching contacts and
components to the safety low voltage of the control
unit, the relevant safety requirements of protection
class II must be observed. This means 8.0 mm air and
creep paths or 2.0 mm insulation thickness against live
components.
Ensure the safe electrical separation of all on-site com-
ponents (incl. PCs/laptops) in accordance with
EN 60 335 and IEC 65.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing any work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Installation sequence
Fitting the thermal insulation (cont.)
5777 985 GB
Installation

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Overview of electrical connections
Overview of PCB and connection/wiring diagram
from page 94.
Inserting cables and applying strain relief
Line entry
2.
1.
Fig. 13
■Secure all cables to the control unit additionally with
cable ties.
■Seal unnecessary apertures in the control unit base
with cable grommets (not cut out).
Other electrical connections
System examples For the power supply, see the following chapter.
Power supply
Guidelines
Regulations
Connect the power supply and implement all safety
measures (e.g. RCD circuit) in accordance with
IEC 60364-4-41, the connection requirements of your
local power supply utility, and VDE or national regula-
tions. Protect the power cable to the control unit with a
fuse with a max. rating of 13 A.
Note
Make earthing cable PE longer than the other connect-
ing cables to ensure it will not be pulled off under ten-
sion.
Mains isolator requirements (if necessary)
For combustion equipment to DIN VDE 0116, the
mains isolator installed on site must comply with the
requirements of DIN VDE 0116 "section 6" [or local
regulations]. Fit the mains isolator outside the installa-
tion room; it must be able to isolate all non-earthed
conductors simultaneously with at least 3 mm contact
separation.
Recommended power cable
3-core cable selected from the following options:
■H05VV-F3G 1.5 mm2
■H05RN-F3G 1.5 mm2
1. Check that the power cable to the control unit is fit-
ted with a fuse with a max. rating of 13 A.
2. Connect the power cable in the junction box and
the control unit (on site).
Danger
Incorrect core assignment can result in serious
injury and damage to the appliance.
Take care not to interchange wires "L1" and "N":
L1 Brown
N1 Blue
PE Green/yellow
Colour coding to DIN IEC 60757:
BN Brown
BU Blue
GNYE Green/yellow
Installation sequence
Electrical connections (cont.)
5777 985 GB
Installation