Viessmann Vitopend 200-W Operating instructions

VIESMANN
Installation and service
instructions
for contractors
Vitopend 200-W
Type WHKA, 10.5 to 29.3 kW
Gas fired combi boiler
for balanced flue operation
Natural gas and LPG version
For applicability, see the last page
VITOPEND 200-W
5592 817 GB 3/2007 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.
!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
designed for qualified personnel.
&Work on gas equipment must only
be carried out by a qualified gas fit-
ter.
&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
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&the Code of Practice of relevant
trade associations,
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances ON or OFF.
&Close the gas shut-off valve.
&Open windows and doors.
&Remove all people from the
danger zone.
&Notify your gas or electricity
supplier from outside the
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close all doors leading to the
living space.
Safety instructions
2
Safety instructions
5592 817 GB

Working on the system
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a main isolator.
&Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which
fulfil a safety function can com-
promise the safe operation of
your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5592 817 GB

Installation instructions
Preparing for installation
Product information .................................................................................... 6
Preparing for installation ............................................................................. 6
Installation sequence
Installing the boiler and making all connections ........................................... 9
Flue gas connection.................................................................................... 10
Gas connection .......................................................................................... 11
Opening the control unit casing ................................................................... 12
Electrical connections................................................................................. 13
Fitting the programming unit into the control unit.......................................... 16
Fitting the front panel .................................................................................. 17
Service instructions
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance ................................... 18
Further details regarding the individual steps .............................................. 20
Coding
Code 1........................................................................................................ 53
Code 2........................................................................................................ 55
Resetting codes to their delivered condition ................................................ 70
Service scans
Service level overview ................................................................................ 71
Temperatures, boiler coding card and brief scans ........................................ 72
Checking outputs (relay test) ...................................................................... 75
Scanning operating conditions and sensors ................................................ 76
Troubleshooting
Fault display ............................................................................................... 79
Fault codes................................................................................................. 81
Repairs ...................................................................................................... 89
Function description
Constant temperature control unit ............................................................... 98
Weather-compensated control unit.............................................................. 99
Extensions for external connections (accessories) ...................................... 101
Control functions ........................................................................................ 105
Remote control DIP switches ...................................................................... 111
Index
4
Index
5592 817 GB

Designs
Connection and wiring diagram –internal connections ................................ 113
Connection and wiring diagram –external connections ............................... 115
Parts lists .................................................................................................. 117
Commissioning/service reports ............................................................... 123
Specification............................................................................................. 124
Certificates
Declaration of conformity ............................................................................ 126
Keyword index .......................................................................................... 127
Index (cont.)
5
Index
5592 817 GB

Vitopend 200-W, WHKA
Set up for operation with natural gas E.
May be converted with a conversion kit to natural gas LL or LPG.
The Vitopend 200-W should generally only be delivered to those countries spe-
cified on the type plate. For deliveries to alternative countries, an approved con-
tractor, on his own initiative, must arrange an individual approval in accordance
with the law of the land.
Preparing for installation
Preparing the boiler installation
On-site preparation of the gas, water and electrical connections:
Installation aid or mounting frame installation instructions.
Product information
6
Preparing for installation
5592 817 GB

AHeating flow Rp¾"
BHot water Rp½"
CGas connection
DCold water Rp½"
EHeating return Rp¾"
FFill & drain valve
GCable entry
1. Prepare the water connections.
Flush the heating system.
2. Prepare the gas connection
according to TRGI or TRF or all
local regulations.
Preparing for installation (cont.)
7
Preparing for installation
5592 817 GB
Installation

3. Prepare the electrical connections.
&Power supply cable: NYM-
J 3 x 1.5 mm
2
, fuse max. 16 A,
230 V~, 50 Hz.
&Accessory cables: NYM with the
required number of conductors
for the external connections.
&Allow all cables in area "G" to
protrude 1200 mm from the wall.
Preparing for installation (cont.)
8
Preparing for installation
5592 817 GB

Installing the boiler and making all connections
9
Installation sequence
5592 817 GB
Installation

ATensioning screws on the boiler
connection flange
BParallel boiler flue connection for
the vertical and horizontal instal-
lation of the flue gas systems 80/
80
CCoaxial boiler flue connection for
the vertical installation of the flue
gas systems 60/100 or 80/125
DBoiler connection bend for the
horizontal installation of the flue
gas system 60/100
1. Release the tensioning screws on
the boiler outlet flange.
2. Insert the boiler flue connection.
Note
Fit the parallel connectors of boiler
flue connection Bso they point
towards the left or right.
3. Tighten the tensioning screws.
Flue gas system installation
instructions
Flue gas connection
10
Installation sequence
5592 817 GB

1. Install a gas shut-off valve A.
Conversion to other gas
types:
Conversion kit installation
instructions
Notes regarding operation with
LPG
For the installation of boilers below
ground level, we recommend the
installation of an external safety
solenoid valve in conjunction with
internal extension H1.
2. Carry out a leak/soundness test.
!Please note
Excessive test pressure
may damage the boiler and
the gas valve.
Max. test pressure
150 mbar. Where higher
pressure is required for
soundness tests, separate
the boiler and the gas valves
from the gas supply pipe
(undo the fitting).
3. Vent the gas supply pipe.
Gas connection
11
Installation sequence
5592 817 GB
Installation

Opening the control unit casing
12
Installation sequence
5592 817 GB

Information regarding the connection of accessories
For details of accessories, also observe their separate installation
instructions provided.
!Please note
Electronic modules can be damaged by electrostatic discharges.
Touch earthed objects, such as heating or water pipes, to discharge sta-
tic loads to earth.
ARadio clock connection
Electrical connections
13
Installation sequence
5592 817 GB
Installation

BVitotrol 100 UTD (only for con-
stant temperature control units)
CVitotrol 100 UTA (only for constant
temperature control units)
Plug 230 V~
fÖ Power supply
Danger
Incorrect core terminations
can cause severe injuries
and damage to the equip-
ment.
Never interchange cores
"L1" and "N".
&Install an isolator in the power
supply line that simultaneously
separates all non-earthed con-
ductors from the mains with at
least 3 mm contact separation.
&Remove the existing cable
grommet when using larger
cross-sections (up to 714 mm).
Secure the cable with cable
grommet F(see page 14) inte-
grated into the casing base.
&Max. fuse rating 16 A.
lH Power supply of accessories
Where the boiler is installed in wet
areas, the connection to the
power supply of accessories out-
side the wet area must not be car-
ried out at the control unit. The
power supply connection for
accessories can be made immedi-
ately at the control unit, if the boil-
er is installed outside wet areas.
This connection is controlled
directly with the system ON/OFF
switch (max. 3 A)
&Vitotrol 100 UTA
&Vitotrol 100 UTD
Low voltage plugs
!Outside temperature sensor (only
for weather-compensated control
units)
Installation:
&North or north-western wall, 2 to
2.5 m above ground level; in
multi-storey buildings, in the
upper half of the second floor
&Not above windows, doors or
ventilation outlets
&Not immediately below balco-
nies or gutters
&Never render over
&Cable length max. 35 m with a
cross-section of 1.5 mm
2
?Flow temperature sensor for low
loss header (accessories)
aVG KM BUS subscriber (acces-
sories)
&Vitotrol 200 or 300 remote con-
trol (only for weather-compen-
sated control units)
&Vitocom 100
&Extension kit for one heating
circuit with mixer (only for
weather-compensated control
units)
&External extension H1 or H2
Electrical connections (cont.)
14
Installation sequence
5592 817 GB

Routing the connecting cables
!Please note
If connecting cables touch hot components they will be damaged.
When routing and securing connecting cables on site, ensure that the
maximum permissible temperatures for these cables are not exceeded.
ALow voltage connections
B230 V connections
CInternal extension
DMain PCB
ECommunications module
FCable grommet for power supply
cable
Electrical connections (cont.)
15
Installation sequence
5592 817 GB
Installation

Fitting the programming unit into the control unit
16
Installation sequence
5592 817 GB

Fitting the front panel
17
Installation sequence
5592 817 GB
Installation

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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••• 01. Filling the heating system ................................................. 20
••• 02. Venting the heating system............................................... 21
••• 03. Checking all connections on the heating water
side and DHW side for leaks
•04. Checking the power supply connection
• • 05. Setting the time and date (if required) –only for
weather-compensated control units.............................. 21
•06. Changing the language (if required) –only for
weather-compensated control units.............................. 22
• • 07. Checking the gas type......................................................... 22
•08. Changing the gas type (see separate installation
instructions)
••• 09. Function sequence and possible faults ....................... 23
••• 10. Checking the static and supply pressure .................... 25
••• 11. Checking the nozzle pressure .......................................... 27
•12. Setting the maximum output ............................................ 29
•13. Checking the balanced flue system for soundness
(annular gap check) ............................................................. 30
• • 14. Draining the heating system............................................. 30
• • 15. Checking and cleaning the burner ................................. 32
• • 16. Checking and cleaning the flue gas heat
exchanger ................................................................................ 34
• • 17. Checking the ignition and ionisation electrodes ...... 35
•18. Flow limiter.............................................................................. 36
••• 19. Checking the diaphragm expansion vessel and
system pressure.................................................................... 37
••• 20. Checking the function of all safety valves
Steps - commissioning, inspection and maintenance
18
Commissioning, inspection, maintenance
5592 817 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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••• 21. Checking the tightness of electrical connections
••• 22. Checking all gas equipment for soundness at
operating pressure............................................................... 37
••• 23. Flue gas emissions test...................................................... 38
••• 24. Checking the ionisation current...................................... 40
••• 25. Checking the external LPG safety valve (if
installed)
•26. Matching the control unit to the heating system....... 41
•27. Adjusting the heating curves (only for weather-
compensated control units).............................................. 45
•28. Connecting the control unit to the LON system
(only for weather-compensated control units) .......... 49
•29. Instructing the system user .............................................. 51
•30. Scanning and resetting the "Service" display ........... 51
Steps - commissioning, inspection and . . . (cont.)
19
Commissioning, inspection, maintenance
5592 817 GB
Service

Filling the heating system
!Please note
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 it with water.
&Only use fill water of potable quality.
&Soften fill water with hardness exceeding 3.0 mol/m
3
, e.g. using a
small softening system for heating water (see Viessmann Vitoset price
list).
&An antifreeze additive suitable for heating systems can be mixed with
the fill water. The antifreeze manufacturer must verify its suitability.
1. Check the inlet pressure of the dia-
phragm expansion vessel.
2. Close the gas shut-off valve.
3. Fill the heating system at boiler fill
& drain valve Ain the heating
return (on the connection set or on
site). (Minimum system pressure
> 0.8 bar).
Note
If the control unit has not been
switched ON prior to filling the sys-
tem, then the servomotor of the
diverter valve will still be in its cen-
tral position, and the system will be
completely filled.
4. If the control unit was already
switched ON before filling began:
Switch ON the control unit and acti-
vate the filling program via code
"2F:2".
5. Close boiler fill & drain valve A.
6. Close the shut-off valves on the
heating water side.
Note
To call up coding level 1 and for set-
ting the coding address, see page 53.
For function and details of the fill pro-
gram, see page 106.
Whilst the fill program is running, the
display shows "bF" (Vitotronic 100) or
"Befüllung" (filling) (Vitotronic 200).
Further details regarding the individual steps
20
Commissioning, inspection, maintenance
5592 817 GB