Viessmann Vitosorp 200-F User manual

Installation and service instructions
for contractors
VIESMANN
Vitosorp 200-F
Type D2RA, 1.8 to 16.7 kW
Gas adsorption heating appliance
Natural gas and LPG version
For applicability, see the last page
VITOSORP 200-F
5678 044 GB 09/2016 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 quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■Work on electrical equipment may 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 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
Safety instructions for working on the system
Working on the system
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■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.
■Wear suitable personal protective equipment when
carrying out any work.
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 for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Do not smoke. Prevent naked flames and
sparks. Never 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.
■Have the power supply to the building shut off
from a safe place (outside the building).
Safety instructions
Safety instructions
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What to do 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
If water escapes from the appliance there is a
risk of electrocution.
Switch off the heating system at the external iso-
lator (e.g. fuse box, domestic power distribu-
tion).
Danger
If water escapes from the appliance there is a
risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be harmful to
health.
Never let condensate touch your skin or eyes
and do not swallow it.
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.
Inform 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.)
5678 044 GB

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1. Information Disposal of packaging ............................................................................ 7
Symbols ................................................................................................. 7
Intended use .......................................................................................... 7
Product information ................................................................................ 8
■Condensing module ............................................................................ 8
■Sorption module ................................................................................. 8
■Accessories required (order separately) ............................................. 8
2. Preparing for installation Installation preparations ......................................................................... 10
■Transportation ..................................................................................... 10
■Installation room requirements ........................................................... 10
■Preparations for installing the appliance ............................................. 11
3. Installation sequence Siting the appliance ............................................................................... 15
■Removing the side panels .................................................................. 15
■Fitting the condensing module on the sorption module ...................... 16
Connections on the primary side ........................................................... 19
■Connecting supplied pipe sections to the sorption module ................ 19
Connections on the secondary side ....................................................... 20
Condensate connection ......................................................................... 21
Aligning the appliance ............................................................................ 22
Flue gas connection ............................................................................... 23
Gas connection ...................................................................................... 23
Electrical connections ............................................................................ 24
■Connection to the process control unit ............................................... 24
■Solar thermal system in conjunction with combi cylinder and primary
thermal store ....................................................................................... 25
■Opening the Vitotronic control unit ...................................................... 26
■Routing flexible cables to the wiring chamber of the Vitotronic con-
trol unit ................................................................................................ 27
■Overview of electrical connections in the Vitotronic control unit ......... 28
■Outside temperature sensor ! .......................................................... 29
■External demand via switching contact .............................................. 29
■External demand via 0 – 10 V input .................................................... 29
■External blocking via switching contact .............................................. 30
■Connecting accessories to the mains at plug lH (230 V~) in the
Vitotronic control unit .......................................................................... 31
■Power supply fÖ ................................................................................. 32
■Connecting Vitocom (accessories) to LON ......................................... 32
■Closing the Vitotronic control unit and inserting the programming
unit ...................................................................................................... 33
Fitting the front panels ........................................................................... 34
4. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 35
5. Code 1 Calling up coding level 1 ........................................................................ 63
■Resetting all codes to their delivered condition (reset) ....................... 63
"General" .............................................................................................. 63
"Boiler" ................................................................................................. 65
"Process" ............................................................................................. 65
"DHW" ................................................................................................... 66
"Solar" .................................................................................................. 66
"Heating circuit" .................................................................................. 67
6. Code 2 Calling up coding level 2 ........................................................................ 71
■Resetting all codes to their delivered condition (reset) ....................... 71
"General" .............................................................................................. 71
"Boiler" ................................................................................................. 76
"Process" ............................................................................................. 76
Index
Index
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5
"DHW" ................................................................................................... 78
"Solar" .................................................................................................. 79
"Heating circuit" .................................................................................. 82
7. Diagnosis and service
scans
Calling up the service level .................................................................... 87
Diagnosis ............................................................................................... 87
■Calling up operating data .................................................................... 87
■Brief scan ............................................................................................ 88
Testing outputs (relay test) ..................................................................... 89
8. Troubleshooting Fault display ........................................................................................... 91
■Acknowledging a fault message ......................................................... 91
■Calling up acknowledged fault messages .......................................... 91
■Calling up fault codes from the fault memory (fault history) ............... 91
Fault codes ............................................................................................ 91
9. Maintenance Regeneration process ............................................................................102
Bringing the Vitotronic and process control units into maintenance
position .................................................................................................. 102
Overview of internal components .......................................................... 103
Draining the heating water side of the heating system .......................... 104
■Draining the secondary circuit ............................................................ 104
■Draining the process circuit ................................................................ 105
Setting the control valve motor position .................................................106
Checking the temperature sensors ........................................................107
■Temperature sensor overview ............................................................ 107
■Curves for Viessmann NTC 10 kΩ ......................................................108
Fault "A3" on first heat demand after commissioning ........................... 108
Checking the pressure sensor ............................................................... 108
Checking the secondary circuit temperature limiter ...............................109
Checking the high limit safety cut-out .................................................... 110
Checking the fuses ................................................................................ 110
Checking the plate heat exchanger ....................................................... 111
Mixer extension kit ................................................................................. 111
■Checking the setting of rotary selector S1 .......................................... 111
■Checking the rotational direction of the mixer motor .......................... 111
■Changing the rotational direction of the mixer motor (if required) ...... 112
Checking the Vitotronic 200-H (accessories) .........................................112
10. Parts lists Assembly overview ................................................................................ 114
Heat cell casing ..................................................................................... 116
Heat cell ................................................................................................. 118
Burner .................................................................................................... 120
Heat cell hydraulics ................................................................................122
Control unit ............................................................................................ 124
Sorption module .....................................................................................126
Sorption module casing ......................................................................... 128
Sorption module hydraulics ................................................................... 130
■Process circuit .................................................................................... 130
■Primary and secondary circuit ............................................................ 134
Miscellaneous ........................................................................................ 136
11. Function description Control unit ............................................................................................ 138
■Functional principle in sorption mode ................................................. 138
■Operating modes ................................................................................ 138
■Heating mode ..................................................................................... 139
■DHW heating ...................................................................................... 139
■Boosting DHW heating ....................................................................... 139
Cooling the process circuit .....................................................................139
Index
Index
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Internal extensions (accessories) .......................................................... 140
■Internal H1 extension ..........................................................................140
■Internal H2 extension ..........................................................................140
External extensions (accessories) ......................................................... 141
■AM1 extension ....................................................................................141
■EA1 extension .................................................................................... 142
Control functions ....................................................................................143
■External operating program changeover ............................................ 143
■External blocking ................................................................................ 144
■External demand ................................................................................ 144
■Process circuit filling and venting program ......................................... 144
■Filling program for the secondary circuit .............................................144
■Venting program for the secondary circuit .......................................... 145
■Screed drying ..................................................................................... 145
■Raising the reduced room temperature .............................................. 147
■Reducing the heat-up time ................................................................. 147
Assigning heating circuits to the remote control .................................... 148
Entering Vitocom 100 PIN code via Vitotronic ....................................... 148
Hydronic balancing ................................................................................ 149
Electronic combustion control unit ......................................................... 149
12. Schemes Process control unit/Vitotronic control unit .............................................150
Process control unit connection scheme ............................................... 151
Vitotronic control unit connection scheme ............................................. 153
13. Commissioning/service
reports
................................................................................................................155
14. Specification ................................................................................................................156
15. Appendix Final decommissioning and disposal ..................................................... 159
16. Certificates Declaration of conformity ....................................................................... 160
Manufacturer's certificate according to the 1st BImSchV [Germany] .... 160
17. Keyword index ................................................................................................................161
Index
Index (cont.)
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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
Intended use
The appliance is intended solely for installation and
operation 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 heating up 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.
Information
Disposal of packaging
5678 044 GB
Information

8
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 opened by the system user) is prohibi-
ted and will result in an exclusion of liability. 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).
Product information
The Vitosorp 200-F, type D2RA is a hybrid appliance
consisting of a condensing module and a sorption
module.
A plate heat exchanger and safety valve provide inte-
gral system separation for the heating circuit and proc-
ess circuit.
Condensing module
Wall mounted gas condensing boiler with Inox-Radial
heat exchanger and the following integral components:
■Modulating, fan-assisted MatriX cylinder burner with
Lambda Pro Control for natural gas and LPG to
DVGW Code of Practice G260 [Germany]
■High efficiency circulation pump for the heating cir-
cuit
■Vitotronic 200 control unit for gas condensing boiler
with sorption function and weather-compensated
mode, with outside temperature sensor and LON
communication module
Preset for operation with natural gas E and natural
gas LL.
For conversion to LPG P (without conversion kit), see
page 46.
The Vitosorp 200-F, type D2RA may only be supplied
to those countries specified on the type plate. For
deliveries to other countries, approved contractors
must arrange individual approval on their own initiative
and in accordance with the law of the country in ques-
tion.
Sorption module
Integral components:
■Vacuum tight sorber with zeolite-coated stainless
steel heat exchangers
■High performance film evaporator
■Evaporator pump and demineralised water
■High efficiency circulation pump for the primary cir-
cuit
■Control valve
■Process control unit
■Process circuit expansion vessel
An alternating adsorption and desorption process
(sorption cycle) moisturises and subsequently dries the
zeolite heat exchanger inside the vacuum-tight sorp-
tion module.
Both geothermal energy and solar thermal can be
used as the natural heat source (primary source).
Geothermal energy as natural heat source
By means of a connected geothermal probe, the sorp-
tion module can use this process to provide energy
from the ground at a higher temperature level suitable
for heating.
Solar thermal as natural heat source
The sorption module draws the energy for the adsorp-
tion process from a combi cylinder or primary thermal
store heated by solar collectors.
Accessories required (order separately)
Installation on finished walls
■Connection set for installation on finished walls, for
upward connection
or
■Connection set with pre-mounting bracket for instal-
lation on finished walls, for upward connection
or
■Connection set for installation on finished walls, for
connection to the left or right
or
■Connection set with pre-mounting bracket for instal-
lation on finished walls, for connection to the left or
right
Information
Intended use (cont.)
5678 044 GB
Information

9
For solar thermal systems:
■Solar pack with collectors and combi cylinder
or
■Solar thermal cylinder pack for retrofitting to an exist-
ing solar thermal system
For geothermal heat:
■Accessories for primary circuit (e.g. brine circuit
pressure switch, brine manifold for geothermal col-
lector, etc.)
Information
Product information (cont.)
5678 044 GB
Information

10
Transportation
!Please note
Tilting at a steep angle will damage the sorption
module of the gas adsorption heating appliance.
It is essential that the maximum tilting angle is
not exceeded during transportation. See the fol-
lowing table.
Never use a sack truck to transport the appli-
ance into a building.
We recommend using the transport handles with
loops or the transport aid (accessories).
!Please note
Impact, compression and tensile loads can
cause damage to the outside panels of the
appliance.
Never apply loads/weight to the top, front or
side panels of the appliance.
Note
The front and side panels can be removed for easier
handling (see Fig. 3, page 15).
Transportation Tilt indicators Action
Delivery
(tilt indicators on
the packaging)
40°
(not triggered)
We recommend commissioning the appliance within 48 h.
60° to 70° Do not commission; inform sales consultant.
Handling
(tilt indicators inside
the appliance)
40° We recommend commissioning the appliance within 48 h.
60° Commission the appliance within 48 h.
70°
(triggered)
Do not commission; inform sales consultant.
60° 60°
60° 60°
40°- 60°
70°
40° 60° 70°
40°60°70°
40° 60° 70°
40°60°70°
Fig. 1 Handling
Installation room requirements
!Please note
Unfavourable ambient conditions can lead to
malfunctions and appliance damage.
■The installation location must be dry and free
from the risk of frost.
■Ensure ambient temperatures between 0 and
35 °C.
Danger
Dust, gases and vapours can be damaging to
health and trigger explosions.
Avoid dust, gases and vapours in the installation
room.
Preparing for installation
Installation preparations
5678 044 GB
Installation