Viessmann VITOPEND 200 Quick guide

VIESMANN
Installation and service
instructions
for heating engineers
Vitopend 200
Type WHKA
Gas fired combi boiler
forbalancedflueoperation
Natural gas and LPG version
For applicability, see the last page
VITOPEND 200
5862 831 GB 8/2005 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
engineer.
&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,
&theCodeofPracticeofrelevant
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 lead to
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.
&Closealldoorsleadingtothe
living space.
Safety instructions
2
Safety instructions
5862 831 GB

Workingonthesystem
&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 mains isola-
tor.
&Safeguard the system against
unauthorised reconnection.
&When using gas as fuel, also close
the main gas shut‐off valve and
safeguard against unauthorised
reopening.
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 or conversions
can compromise safety and
may invalidate our warranty.
For replacements, use only ori-
ginal spare parts from Viess-
mann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5862 831 GB

Installation instructions
Preparing the installation
Product information .................................................................................... 6
Preparing the installation ............................................................................ 6
Installation steps
Installing the boiler and fitting the connections ............................................ 9
Flue gas connection.................................................................................... 10
Gas connection .......................................................................................... 11
Opening the control unit casing ................................................................... 12
Electrical connections................................................................................. 13
Mounting the programming unit in the control unit........................................ 16
Front panel installation................................................................................ 17
Service instructions
Initial start-up, inspection, maintenance
Steps –initial start-up, inspection and maintenance .................................... 18
Further details regarding the individual steps .............................................. 20
Coding
Code 1........................................................................................................ 50
Code 2........................................................................................................ 52
Resetting codes to the delivered condition .................................................. 69
Service scans
Service level summary................................................................................ 70
Temperatures, boiler coding card and brief scans ........................................ 71
Testing outputs (relay test).......................................................................... 75
Scanning operating conditions and sensors ................................................ 76
Troubleshooting
Fault display ............................................................................................... 78
Calling up fault codes from the fault memory (fault history) .......................... 80
Fault codes................................................................................................. 80
Repairs ...................................................................................................... 88
Function description
Constant temperature control unit ............................................................... 97
Weather–compensated control unit ............................................................. 98
Extension for external connections (accessories)........................................ 100
Control functions ........................................................................................ 104
Remote control DIP switch .......................................................................... 110
Index
4
Index
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Designs
Connection and wiring diagram –internal connections ................................ 111
Connection and wiring diagram –external connections ............................... 113
Parts lists .................................................................................................. 115
Commissioning/service reports............................................................... 121
Specification............................................................................................. 122
Certificates
Declaration of conformity ............................................................................ 124
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 124
Keyword index .......................................................................................... 126
Index (cont.)
5
Index
5862 831 GB

Vitopend 200, WHKA
Set up for operation with natural gas E.
May be converted with a conversion kit to natural gas LL or LPG.
Generally, the Vitopend 200 should only be supplied to the countries stated on
the type plate. For delivery to other countries the acceptance in accordance
with the statutes of that country must be arranged by an authorised contractor.
Preparing the installation
Preparations for boiler installation
On‐site preparation of the gas, water and electrical connections:
Installation instructions Installation template or mounting frame.
Product information
6
Preparing the installation
5862 831 GB

AHeating flow Rp¾"
BHot water Rp½"
CGas connection
DCold water Rp½"
EHeating return Rp¾"
FFill & drain valve
GCable arrangement area
1. Prepare the water connections.
Flush the heating system.
2. Prepare the gas connection
accordingtoTRGIorTRF[orlocal
regulations].
Preparing the installation (cont.)
7
Preparing the installation
5862 831 GB
Installation

3. Prepare the electrical connections.
&Power supply cable: NYM‐
J3x1.5mm
2
, fuse max. 16 A,
230 V~, 50 Hz.
&Cables for accessories: NYM
with the required number of con-
ductors for the external connec-
tions.
&Allow all cables in area "G"to
protrude 1200 mm from the wall.
Preparing the installation (cont.)
8
Preparing the installation
5862 831 GB

Installing the boiler and fitting the connections
9
Installation steps
5862 831 GB
Installation

ATensioning screws on the flue out-
let flange
BParallel boiler adaptor for vertical
and horizontal installation of the
flue gas system (80/80)
CCoaxial boiler adaptor for vertical
installation of the flue gas system
(60/100, 70/110 and 80/125)
DBoiler adaptor bend for horizontal
installation of the flue gas system
(60/100, 70/110 and 80/125)
1. Release the tensioning screws on
the flue outlet flange.
2. Insert the boiler adaptor.
Note
Fit parallel boiler adaptor Cso
that its connector points towards
the left or right.
3. Tighten the tensioning screws.
Flue gas system installation
instructions
Flue gas connection
10
Installation steps
5862 831 GB

AGas shut‐off valve
1. Install a gas shut‐off valve A.
Conversion to other gas
types:
Conversion kit installation
instructions
Notes regarding the operation
with LPG
For the installation of boilers below
ground level, we recommend the
installation of an external safety
solenoid valve in conjunction with
the internal extension H1 (part no.
7179 057).
2. Carry out a gas soundness test.
!Please note
Excessive test pressure
may damage the boiler and
gas valve.
Max. test pressure
150 mbar. If a higher pres-
sure is required for leak
tests, separate the boiler
and the gas train from the
mains gas supply pipe (undo
the compression fitting).
3. Ventilate the gas supply pipe.
Gas connection
11
Installation steps
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Installation

Opening the control unit casing
12
Installation steps
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Notes regarding the connection of accessories
For details of accessories, also observe the separate installation instruc-
tions provided.
ARadio clock connection BVitotrol 100 UTD (only for con-
stant temperature control units)
CVitotrol 100 UTA (only for constant
temperature control units)
Electrical connections
13
Installation steps
5862 831 GB
Installation

Plug 230 V~
fÖ Power supply
Danger
Incorrect core terminations
can cause severe injuries
and damage to the equip-
ment.
Take care not to inter-
change wires "L1" and "N":
L1: brown
N1: blue
PE: green/yellow
&An isolator must be installed in
the power supply line which
simultaneously separates all
non‐earthed conductors from
the mains with at least 3 mm
contact separation.
For larger cross‐sections (up to
14 mm), remove existing cable
grommets. Secure the cable
with the integral cable seal
(black) found in the lower part of
the casing.
&Fuse max. 16 A.
lH &Power supply accessories
(230 V~ 50 Hz). Where the boi-
ler is installed in a bathroom or
shower room, the connection of
accessories to the power supply
mustnotbecarriedoutatthe
control unit. The power supply
connection can be made imme-
diately at the control unit, if the
boiler is installed outside damp
areas. This connection is con-
trolled 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 opera-
tion)
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, up to 35 m with a
cross‐section of 1.5 mm
2
?Flow temperature sensor for low
loss header (accessories)
%Cylinder temperature sensor (part
of the DHW cylinder connection
set)
aVG KM BUS user (accessories)
&Vitotrol 200 or 300 remote con-
trol unit
&Vitocom 100
&Extension kit for a heating cir-
cuit with mixer
&External extension H1 or H2
Electrical connections (cont.)
14
Installation steps
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Routing connecting cables
!Please note
Connecting cables will be damaged if they are laid onto hot components.
When routing and securing connecting cables on site, ensure that the
maximum permissible temperatures of the cables are not exceeded.
ALow voltage connections
B230 V connections
CInternal extension
DMain PCB
ECommunication module
Electrical connections (cont.)
15
Installation steps
5862 831 GB
Installation

Mounting the programming unit in the control unit
16
Installation steps
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Front panel installation
17
Installation steps
5862 831 GB
Installation

For further information regarding individual steps, see the pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
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••• 1. Filling the heating system ................................................. 20
••• 2. Venting the heating system............................................... 21
••• 3. Checking all connections on the primary and
secondary side for leaks
•4. Checking the power supply connection
•• 5. Setting the time and date (if required) –only for
weather‐compensated control units.............................. 21
•6. Language selection (if required) –only for
weather‐compensated control units.............................. 21
••7. Checking the gas type......................................................... 22
•8. Changing the gas type (see separate installation
instructions)
••• 9. Function sequence and possible faults ....................... 23
••• 10. Checking the static and supply pressure .................... 24
••• 11. Checking the nozzle pressure.......................................... 26
•12. Setting the maximum output ............................................ 28
•13. Testing the balanced flue system (annular gap
test) for soundness .............................................................. 29
•• 14. Draining the heating system............................................. 29
•• 15. Checking and cleaning the burner ................................. 31
•• 16. Checking and cleaning the flue gas heat
exchanger ................................................................................ 33
•• 17. Checking the ignition and ionisation electrodes ...... 34
•18. Flow limiter.............................................................................. 35
••• 19. Checking the diaphragm expansion vessel and
system pressure.................................................................... 36
••• 20. Checking the function of all safety valves
Steps –initial start-up, inspection and maintenance
18
Initial start-up, inspection, maintenance
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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............................................................... 36
••• 23. Flue gas emissions test...................................................... 37
••• 24. Checking the ionisation current...................................... 38
••• 25. Checking the external LPG safety valve (if
required)
•26. Matching the control unit to the heating system....... 39
•27. Adjusting the heating curves (only for weather‐
compensated control units).............................................. 43
•28. Connecting the control unit to the LON system
(only for weather‐compensated control units) .......... 46
•29. Implementing a user check (in conjunction with
the LON system with a weather‐compensated
control unit)............................................................................. 48
•30. Instructing the system user .............................................. 48
•31. Scanning and resetting the "maintenance" display 49
Steps –initial start-up, inspection and . . . (cont.)
19
Initial start-up, inspection, maintenance
5862 831 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 with water.
&Only use fill water of potable quality.
&Fill water with a water hardness in excess of 3.58 mmol/l must be sof-
tened, e.g. with the small softening system for heating water (see the
Vitoset pricelist).
&An anti‐freeze additive suitable for heating systems can be mixed into
the fill water.
AClose the boiler fill & drain valve
1. Check the inlet pressure of the dia-
phragm expansion vessel.
2. Close the gas shut‐off valve.
3. Fill the heating system at the fill
valve in 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 servo drive of the
diverter valve will still be in its cen-
tre position, and the system will be
completely filled.
4. If the control unit had already been
switched ON before filling began:
Start the control unit and activate
thefillprogramviacodingaddress
"2F:2".
Note
To call up coding level 1 and for
setting the coding address, see
page 50.
For function and details of the fill
program, see page 105.
Whilst the fill program runs, the dis-
play shows "bF" (Vitotronic 100) or
"Filling" (Vitotronic 200).
Further details regarding the individual steps
20
Initial start-up, inspection, maintenance
5862 831 GB