Viessmann VITOTRONIC 200 Quick guide

VIESMANN
Installation and service
instructions
for contractors
Vitotronic 200
Type GW1
Weather-compensated, digital boiler control unit
For applicability, see the last page
VITOTRONIC 200
5592 801 GB 2/2007 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 801 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 801 GB

Installation instructions
Preparing for installation
System version 1 ........................................................................................ 6
System version 2 ........................................................................................ 7
System version 3 ........................................................................................ 8
System version 4 ........................................................................................ 10
System extension ....................................................................................... 11
Installation sequence
Overview of electrical connections .............................................................. 15
Inserting cables and applying strain relief.................................................... 16
Inserting the boiler coding card ................................................................... 18
Changing the high limit safety cut-out setting (if required) ............................ 18
Changing the control thermostat setting (if required).................................... 20
Connecting sensors.................................................................................... 21
Connecting pumps...................................................................................... 22
Connecting servomotors ............................................................................. 25
External connections at plug aBÖ................................................................ 25
External connections at plug aVD................................................................ 28
External connections at plug aVH................................................................ 29
Connecting central fault messaging to plug gÖ ............................................ 30
Connecting an AC burner............................................................................ 30
Connecting a three-phase burner ................................................................ 32
Power supply.............................................................................................. 35
Fitting the control unit front.......................................................................... 37
Opening the control unit .............................................................................. 38
Service instructions
Commissioning
Display and control elements ...................................................................... 39
Changing the language............................................................................... 40
Testing the high limit safety cut-out ............................................................. 40
Matching the coding addresses to the system version ................................. 40
Checking outputs (actuators) and sensors................................................... 42
Adjusting the heating curves ....................................................................... 43
Integrating a control unit into the LON ......................................................... 47
Service scans
Service level summary ............................................................................... 50
Temperatures, boiler coding card and brief scans ........................................ 51
Operating conditions................................................................................... 53
Display "Service" ........................................................................................ 55
Index
4
Index
5592 801 GB

Troubleshooting
Faults that are displayed at the programming unit........................................ 56
Function description
Boiler water temperature control ................................................................. 66
Heating circuit control ................................................................................. 71
Cylinder temperature control....................................................................... 76
Coding
Resetting codes to their delivered condition ................................................ 81
Code 1........................................................................................................ 81
Code 2........................................................................................................ 83
Designs
Connection and wiring diagram ................................................................... 101
Components
Components from the parts list.................................................................... 105
Radio clock receiver, part no. 7450 563....................................................... 111
Flue gas temperature sensor, part no. 7450 630 .......................................... 113
Remote control ........................................................................................... 115
Boiler coding card....................................................................................... 118
Function extension 0 - 10 V, part no. 7174 718 ............................................ 118
Plug-in adaptor for external safety equipment, part no. 7143 526 ................. 119
Secondary air device Vitoair, part no. 7338 725, 7339 703........................... 122
Parts lists .................................................................................................. 124
Specification............................................................................................. 127
Keyword index .......................................................................................... 128
Index (cont.)
5
Index
5592 801 GB

Single boiler system with Therm-Control
Vitoplex 200, type SX2, to 560 kW
Vitoplex 300, type TX3
Vitorond 200, type VD2A, to 270 KW
For function description see page 67.
ABoiler with Vitotronic 200 with
LON communication module
BDHW cylinder
CVitotronic 200-H with
LON communication module
DMixer circuit
Plug
!Outside temperature sensor
§Boiler water temperature sen-
sor
%Cylinder temperature sensor
aJATherm-Control temperature
sensor
sÖ A1 Closing the mixers with exter-
nal heating circuit control units
sA Cylinder primary pump
sK DHW circulation pump
fÖ Power supply, 230 V/50 Hz
fA Burner stage 1
lÖ Burner stage 2/mod.
System version 1
6
Preparing for installation
5592 801 GB

Single boiler system with shunt pump for raising the return
temperature
Vitomax 300-LT
Vitoplex 100, type SX1
Vitoplex 200, type SX2
Vitoplex 300, type TX3
Vitorond 200, type VD2
For function description see page 68.
ABoiler with Vitotronic 200 with
LON communication module
BDHW cylinder
CVitotronic 200-H with
LON communication module
DMixer circuit
Plug
!Outside temperature sensor
§Boiler water temperature sen-
sor
%Cylinder temperature sensor
aJATemperature sensor T1*1
aJBTemperature sensor T2
sÖ A1 Closing the mixers with exter-
nal heating circuit control units
sA Cylinder primary pump
sK DHW circulation pump
System version 2
7
Preparing for installation
5592 801 GB
Installation
*1For Vitoplex boilers, the sensor well included in the standard delivery can be used.
Install the sensor well inside the boiler. Seal the port with a plug.

sL Shunt pump
(with the Vitorond always run-
ning when the burner is
started)
fÖ Power supply, 230 V/50 Hz
fA Burner stage 1
lÖ Burner stage 2/mod.
System version 3
Single boiler system with shunt pump and three-way mixer
for raising the return temperature
Vitomax 300-LT
Vitoplex 100, type SX1
Vitoplex 200, type SX2
Vitoplex 300, type TX3
Vitorond 200, type VD2
For function description see page 68.
ABoiler with Vitotronic 200 with
LON communication module
BDHW cylinder
CVitotronic 200-H with
LON communication module
DMixer circuit
System version 2 (cont.)
8
Preparing for installation
5592 801 GB

Plug
!Outside temperature sensor
§Boiler water temperature sen-
sor
%Cylinder temperature sensor
aJATemperature sensor T1*1
aJBTemperature sensor T2
sA Cylinder primary pump
sK DHW circulation pump
sL Shunt pump
fÖ Power supply, 230 V/50 Hz
fA Burner stage 1
gS A1 Mixer motor, return tempera-
ture raising facility
lÖ Burner stage 2/mod.
Required coding
0C:1 Constant return temperature control
System version 3 (cont.)
9
Preparing for installation
5592 801 GB
Installation
*1For Vitoplex boilers, the sensor well included in the standard delivery can be used.
Install the sensor well inside the boiler. Seal the port with a plug.

Single boiler system with Vitocrossal 300, optionally with
one low temperature heating circuit
Note
The heating circuits with the higher return temperature are connected to the
upper return connector and those with lower return temperatures to the lower
return connector.
For systems without low temperature heating circuit, always connect to the
lower return connector.
Connect at least 15 % of the rated output to the lower return connector.
ABoiler with Vitotronic 200 with
LON communication module
BDHW cylinder
CVitotronic 200-H with
LON communication module
DMixer circuit
ELow temperature heating circuit
or
FUnderfloor heating circuit
GTemperature limiter (maximum
limit)
System version 4
10
Preparing for installation
5592 801 GB

HSecondary pump (for wiring, see
page 24)
KPrimary pump (for wiring, see
page 24)
Plug
!Outside temperature sensor
§Boiler water temperature sen-
sor
%Cylinder temperature sensor
sÖ A1 Heating circuit without mixer
sA Cylinder primary pump
sK DHW circulation pump
fÖ Power supply, 230 V/50 Hz
fA Burner stage 1
lÖ Burner stage 2/mod.
Required coding
0d:0 Without Therm-Control
System extension
DHW heating with cylinder primary system
In systems with temporarily high DHW demand and large cylinder capacity with
offset heating and draw-off times.
System version 4 (cont.)
11
Preparing for installation
5592 801 GB
Installation

ABoiler with Vitotronic 200 BVitocell 100-L
CVitotrans 222
Plug
%Terminals 1 and 2:
Cylinder temperature sensor 1
(top)
Terminals 2 and 3:
Cylinder temperature sensor 2
(bottom)
aJBTemperature sensor Vitotrans
222
sÖ A1 Primary pump
sA Secondary pump
sK DHW circulation pump
gS A1 Three-way mixing valve motor
Required coding
4C:1 Primary pump connection at plug sÖ A1
4E:1 Motor connection for three-way mixing valve at plug gS A1
55:3 Cylinder thermostat, cylinder primary system
System extension (cont.)
12
Preparing for installation
5592 801 GB

In conjunction with system version 2
EJunction box (on-site)
FShunt pump
GControl thermostat, part
no. Z001 886
The sensor input aJBis used to con-
trol the Vitotrans 222. Therefore, the
shunt pump must be controlled by a
separate thermostat.
Required coding: "4d:2".
In conjunction with system version 3
A separate Vitotronic 200-H must be
used for regulating the Vitotrans 222.
The boiler control unit affects the con-
stant return temperature control
(see coding address "4E").
System extension (cont.)
13
Preparing for installation
5592 801 GB
Installation

System with flue gas/water heat exchanger
ABoiler with Vitotronic 200 BVitotrans 300
CCirculation pump for Vitotrans 300
Circulation pump for Vitotrans 300
CCirculation pump
DContactor relay, part no. 7814 681
(only for power consumption
higher than 2 A)
The circulation pump is started paral-
lel to the burner.
Required coding:
"4C:3" for connecting the circulation
pump to plug sÖ A1.
Note
Create system versions on site, where
output sÖ A1 must be used as switch-
ing contact or heating circuit pump
connection.
System extension (cont.)
14
Preparing for installation
5592 801 GB

Note
When connecting plugs aVD,aVH,sA and sK, bundle the individual cores of the
cables closely to the terminals.
This ensures that, in case of failure, for example when detaching a wire, the
wires cannot drift into the adjacent voltage area.
Main PCB low voltage
!Outside temperature sensor
§Boiler water temperature sen-
sor
%Cylinder temperature sensor/
cylinder temperature sensor 2
for cylinder primary system
(accessories)
aG Flue gas temperature sensor
(accessories)
aJATherm-Control temperature
sensor
or
Return temperature sensor T1
(accessories)
Overview of electrical connections
15
Installation sequence
5592 801 GB
Installation

aJBReturn temperature sensor T2
(accessories)
or
Temperature sensor cylinder
primary system (accessories)
aVD External hook-up
aVG KM BUS subscriber (acces-
sories)
aVH External hook-up
Main PCB 230 V~
sÖ A1 Heating circuit pump
or
Primary pump cylinder primary
system
or
Circulation pump –flue gas/
water heat exchanger
or
Switching output
sA Cylinder primary pump (acces-
sories)
sK DHW circulation pump (on
site)
sL Shunt pump or boiler circuit
pump (on site)
fÖ Power supply
fA Burner stage 1
gÖ Central fault message
gS A1 Mixer motor, return tempera-
ture raising facility
or
Motor for three-way mixing
valve, cylinder primary system
lÖ Burner stage 2/mod.
aBÖ External connections, e.g.
supplementary safety equip-
ment
aBA Safety chain, zero volt
aBH Power supply connection of
accessories
&When connecting external switching
contacts or components to the low
voltage circuit of the control unit,
please observe the safety require-
ments of protection class II, i.e.
8.0 mm air gap/creep path or
2.0 mm insulation thickness towards
'live' components.
&Ensure the safe electrical separa-
tion for all on-site components (incl.
PC/laptops), i.e. conforming to
EN 60 335 or IEC 65.
Inserting cables and applying strain relief
Installing the control unit on the boiler
&Route cables from below through
the front panel of the boiler into the
wiring chamber of the control unit.
Control unit fitted to the boiler side
&Route cables from below out of the
cable trunking into the control unit.
Overview of electrical connections (cont.)
16
Installation sequence
5592 801 GB

ACables with moulded strain relief
BOn-site cables; strip up to 100 mm
insulation
CPlug connection diagram
DDome for plug connection array
Inserting cables and applying strain relief (cont.)
17
Installation sequence
5592 801 GB
Installation

Only use the boiler coding card sup-
plied with the boiler (see table).
Boiler Boiler coding card Part no.
Vitocrossal 200, type CM2 1041 7820 145
Vitocrossal 300, type CM3 1042 7820 146
Vitocrossal 300, type CR3 1041 7820 145
Vitocrossal 300, type CT3 1040 7820 144
Vitomax 300-LT 1070 7820 383
Vitoplex 100, type SX1 1001 7820 140
Vitoplex 200, type SX2 1001 7820 140
Vitoplex 300, type TX3 1010 7820 141
Vitorond 200, type VD2 1020 7820 142
Vitorond 200, type VD2A 1020 7820 142
Insert the boiler coding card through
the cut-out in the cover into slot "X7".
Changing the high limit safety cut-out setting (if required)
The high limit safety cut-out is supplied with a factory setting of 110 °C.
Inserting the boiler coding card
18
Installation sequence
5592 801 GB

Setting values
Low temperature
boiler
Vitocrossal 300
High limit safety cut-out 110 °C 100 °C 110 °C 100 °C
Control thermostat (see page 20) 100 °C 87 °C 100 °C 87 °C
Electronic maximum temperature
limit of the boiler water temperature,
coding address "06" (see page 85)
95 °C 85 °C 95 °C 85 °C
Conversion to 100 °C
Changing the high limit safety cut-out setting (if . . . (cont.)
19
Installation sequence
5592 801 GB
Installation

The control thermostat is supplied with a factory setting of 95 °C.
Conversion to 100 °C
!Please note
Excessive DHW temperatures
can damage the DHW cylinder.
If the system is operated in
conjunction with a DHW cylin-
der, ensure that the maximum
permissible DHW temperature
is not exceeded. If necessary,
install suitable safety equip-
ment for this purpose.
A75 to 100 °C
1. Remove rotary selector "R".
Changing the control thermostat setting (if required)
20
Installation sequence
5592 801 GB