Viessmann VITODENS 200 Start-Up/Service Instructions
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Viessmann VITODENS 200 Start-Up/Service Instructions

Viessmann VITODENS 200 Start-Up/Service Instructions

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Start-up/Service Instructions
for use by heating contractor
Vitodens 200, WB2 Series
Wall-mounted, gas-fired condensing boiler
For natural gas and liquid propane
Heating input NG 55 to 230 MBH
16 to 67 kW
Heating input LP 55 to 214 MBH
16 to 63 kW
VITODENS
5285 961 - 01
07/2020
200
r
Product may not be exactly as shown
IMPORTANT
Read and save these instructions
for future reference.
Please file in Service Binder

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Summary of Contents for Viessmann VITODENS 200

  • Page 1 Start-up/Service Instructions for use by heating contractor Vitodens 200, WB2 Series Wall-mounted, gas-fired condensing boiler For natural gas and liquid propane Heating input NG 55 to 230 MBH 16 to 67 kW Heating input LP 55 to 214 MBH 16 to 63 kW...

  • Page 2: Safety, Installation And Warranty Requirements

    Instructions of the boiler. Installers must follow local regulations with respect to installation of carbon monoxide detectors. Follow the Viessmann maintenance schedule of the boiler contained in this manual. Operating and Service Documentation It is recommended that all product documentation such as parts lists, operating and service instructions be handed over to the system user for storage.

  • Page 3: Table Of Contents

    Heating Contractor Address Input ......9 Select Appropriate Gas Type ........10 Measure Static Pressure and Running Pressure ..10 How the Vitodens 200 Boiler Operates ..... 12 Check CO 2 Setting ..........13 Clock Natural Gas Meter ...........14 Check Orifice Size ............14 Check all Primary and Secondary Circuit Connections for Leaks ..............15...

  • Page 4: Important Regulatory And Installation Requirements

    - Start-up/Service Instructions contractor. Proper completion of the Maintenance Record - Operating Instructions and User’s Information Manual by the heating contractor is also required. - Instructions of other Viessmann products utilized and The Maintenance Record is located in the Service installed Instructions.

  • Page 5: About These Service Instructions

    General Information Vitodens 200 WB2 Service About these Service Instructions Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below. Warnings draw your attention to the presence of WARNING potential hazards or important product information.

  • Page 6: Cover Panel

    General Information Vitodens 200 WB2 Service Removing and Reinstalling Front Enclosure Panel and Cover Panel Some of the following start-up/service steps require the removal of the front enclosure panel and the cover panel. To avoid personal injury and/or product damage of any...

  • Page 7: Fill Heating System With Water

    Fill the heating system with water at the boiler filling and drain tap A and drain air completely from the system at manual air bleed valve B (use supplied key) as per the Vitodens 200 Installation Instructions. Max. boiler operating pressure ..45 psig Min. boiler operating pressure ..12 psig Pressure relief valve ....30 psig...
  • Page 8 The module contains a 120/230 VAC step-up transformer with the latest edition of CSA C22.1 Part 1 and/or local to power the Vitodens 200 with 230 VAC. Refer to the codes. In the U.S. use the National Electrical Code ANSI/ Installation Instructions shipped with the module for NFPA 70.

  • Page 9: Select Language

    Comfortrol Menu-driven programming unit. This option allows the system user to access name and telephone number of the heating contractor on the display (see Vitodens 200 Operating Instructions) almost immediately after a system fault has occurred. Open the cover: Menu option...

  • Page 10: Select Appropriate Gas Type

    2. Record fuel type in Maintenance Record on page 73. The Vitodens 200 boiler is for use with gases whose characteristics fall within the following ranges. Do not use any other types of gas.
  • Page 11 Start-up and Service Vitodens 200 WB2 Service Measure Static Pressure and Running Pressure (continued) Running pressure 8. Measure the running pressure; value must be: Use suitable measuring instruments calibrated with a minimum resolution of 0.04 “w.c. for measuring the running pressure.

  • Page 12: How The Vitodens 200 Boiler Operates

    Start-up and Service Vitodens 200 WB2 Service How the Vitodens 200 Boiler Operates... The MatriX burner blower and the combination gas valve are factory calibrated and pre-adjusted for optimum boiler performance at all firing rates through a non-mechanical, pneumatic modulating link between combustion air and gas flows.

  • Page 13: Check Co 2 Setting

    “Technical Data” on page 40 of this manual). Check the venting system for leaks (see subsection The MatriX burner of the Vitodens 200 is preset for the entitled “Check venting system for leaks” on page 15 entire gas group. No adjustment or readjustment of the of this manual).

  • Page 14: Clock Natural Gas Meter

    For example: 1. Ensure all other gas equipment served by the meter A Vitodens 200-W 11-44 boiler (172 000 Btu/h input) is turned off during timing of gas input to the requires 209 seconds to use 10 cu. ft. of natural gas.

  • Page 15: For Leaks

    Check Venting System for Leaks (circular air gap measurement) For sealed combustion, coaxial vent only. Viessmann strongly recommends that the heating contractor perform a simplified leak test during boiler start-up. For this purpose it is sufficient to measure the CO concentration of the combustion air in the coaxial gap of the air intake pipe.

  • Page 16: Disassemble Burner And Check Burner Gasket

    Start-up and Service Vitodens 200 WB2 Service Disassemble Burner and Check Burner Gasket 1. Remove burner cover panel (if still installed) as per the removal and reinstallation instructions on page 6 in this manual, and reinstall panel upon completion of service work.

  • Page 17: Check And Adjust Ignition And Ionization Electrode

    Start-up and Service Vitodens 200 WB2 Service Check and Adjust Ignition and Ionization Electrode 1. Remove burner cover panel (if still installed) as per the removal and reinstallation instructions on page 6 in this manual, and reinstall panel upon completion of service work.

  • Page 18: Check Neutralization Unit

    Start-up and Service Vitodens 200 WB2 Service Check Neutralization Unit (if applicable) 1. Check the pH value of the condensate with pH measuring strip. If the pH value is less than 6.5, replace granulate. IMPORTANT pH measuring strip must be field supplied.

  • Page 19: Check Diaphragm Expansion Tank And System Pressure

    Start-up and Service Vitodens 200 WB2 Service Check Diaphragm Expansion Tank and System Pressure Perform check with the system cold. 1. Drain boiler/system and reduce pressure until the manometer reading is ”0”. 2. If the nitrogen pressure of the precharged expansion...

  • Page 20: Check Gas Pipes And Fittings For Leaks

    Start-up and Service Vitodens 200 WB2 Service Check Gas Pipes and Fittings for Leaks WARNING CAUTION The gas supply piping must be leak tested before placing Ensure all joints of gas line are pressure tight and that the boiler in operation.

  • Page 21: Check Extension Kit For Heating Circuit With Mixing Valve

    Start-up and Service Vitodens 200 WB2 Service Check Extension Kit for Heating Circuit with Mixing Valve Checking the Viessmann 2-wire BUS and the data connection to Vitotronic 050 With Comfortrol programming unit 1. Check via Scan 1 on the programming unit whether the connected extension kit is recognized.

  • Page 22: Check Dekamatik-Hk

      OPERATING STATUS ”B”   CONTINUE ”A” until ”Scan 2” is displayed Expansion module The last-placed digit has the following meaning: 2____0 =Viessmann 2-wire BUS expansion module not recognized 2____1 =Viessmann 2-wire BUS expansion module is recognized Dekamatik-HK...

  • Page 23: Troubleshooting Steps

    Troubleshooting Vitodens 200 WB2 Service Check Dekamatik-HK (continued) Check setting of rotary switch Dekamatik-HK1: The rotary switch on the communication module must be set to ”4”. Dekamatik-HK2: The rotary switch on the circuit board E4 must be set to ”4”.

  • Page 24: Diagnosis

    Troubleshooting Vitodens 200 WB2 Service Diagnosis Comfortrol Menu driven programming unit Faults with fault display on control unit Faults with fault display on control unit When a fault message is detected, –––– FAULT–––– flashes in the display of the programming unit with the cover closed.
  • Page 25 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Comfortrol Menu driven programming unit retrieval of fault codes from fault memory 1. Open the cover: Menu option Button   SYSTEM ”D”   INSTALLER SETUP ”C”   CODE PLEASE: ”B-C-C-B”...
  • Page 26 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Sequence of operation and potential faults during each start-up cycle.
  • Page 27 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Diagnostics table: Faults with fault display on control unit...
  • Page 28 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Diagnostics table: Faults with fault display on control unit (continued)
  • Page 29 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Diagnostics table: Faults with fault display on control unit (continued) *1 Displayed when fault codes retrieved from fault memory.
  • Page 30 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Diagnostics table: Faults with fault display on control unit (continued) *1 Displayed when fault codes retrieved from fault memory.
  • Page 31 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Diagnostics table: Faults with fault display on control unit (continued) *1 Displayed when fault codes retrieved from fault memory.
  • Page 32 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued)
  • Page 33 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Diagnostics table: Faults without fault display on control unit System behavior Cause of Fault Corrective action Supply temperature too cold or too warm. Fuse Check fuse (see page 38). Variable speed heating circuit pump Check coding of heating circuit pump Heating system type incorrectly coded Check coding of heating system type Room temperature too cold or too warm.

  • Page 34: Correction

    Troubleshooting Vitodens 200 WB2 Service Correction Scanning the actual and desired temperatures Check outdoor temperature sensor 1. Disconnect connector ”X6” from the control unit. 2. Measure resistance of outdoor temperature sensor A at the disconnected connector between ”X6.3” and ”X6.4”, and compare with resistance/outdoor temperature curve shown below.
  • Page 35 Troubleshooting Vitodens 200 WB2 Service Correction (continued) Check DHW tank temperature sensor or low-loss header temperature sensor 1. Disconnect connector ”X7” from the control unit. 2. Measure resistance of the tank temperature sensor and compare with the curve. If the value measured differs significantly, replace the sensor.
  • Page 36 Troubleshooting Vitodens 200 WB2 Service Correction (continued) Relay test with comfortrol menu driven programming unit Open cover: Menu option Button ”D” SYSTEM INSTALLER SETUP ”C” CODE PLEASE: ”B-C-C-B” ”A” DIAGNOSIS RELAY TEST ”A” Select required relay to check its function with the menu option CONTINUE ”A”...
  • Page 37 Troubleshooting Vitodens 200 WB2 Service Correction (continued) Relay test (standard programming unit) 1. Set the heating program selector switch to “T“. 2. Select the required position using rotary selector “s“. Function Flashing display Rotary selector “s” Three-way valve drive (DHW cylinder)
  • Page 38 Troubleshooting Vitodens 200 WB2 Service Correction (continued) Check safety fixed high limits (FHL) If the safety fixed high limits cannot be reset after an automatic lockout of the burner control unit, even though the boiler water temperature is below approx. 194ºF / 90ºC, perform the following steps:...
  • Page 39 Troubleshooting Vitodens 200 WB2 Service Correction (continued) Check WS remote control unit (Accessory) Check RS remote control unit (Accessory) The WS remote control unit is used for setting the desired room temperature values from any room in the building. The RS remote control unit is used for setting the desired room temperature values from the main living room (with room temperature dependent control).

  • Page 40: Technical Data

    Additional Information Vitodens 200 WB2 Service Technical Data Rated voltage: .....230 VAC Setting of fixed high limit Rated frequency: ..60 Hz safety cut-out: .....210ºF Rated current: .....2.5 A~ (fixed setting) ....99ºC Max. ambient temperature Main fuse: max. 16A at operation: ....32 to 104ºF (–0 to +40ºC) when storing and transporting: ..–4 to +149ºF...

  • Page 41: Burner Control Unit Lgm 29.Xx

    Additional Information Vitodens 200 WB2 Service Burner Control Unit LGM 29.XX Program sequence Test time Standby Auto reset is the end of the shutdown phase after Waiting time until next call for heat start. Differential air controlled switch-off. Auto reset also takes place after...

  • Page 42: Control Unit For Weather-Responsive Operation

    Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit Functional description Domestic hot water supply Space heating mode with gas-fired space heating boiler The control unit calculates a boiler water setpoint Domestic hot water heating is activated when the tank temperature based on the outdoor or room temperature temperature is 4.5ºF/2.5ºC below the tank temperature...
  • Page 43 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Standard programming unit Legend A Gauge B Display C Time setting D Weekday setting E Scanning temperatures F Heating program selector switch Standby mode Only DHW...
  • Page 44 ”044, 045 and 046” must each be set to the value ”001”. Refer to the Vitodens 200 Installation Instructions for piping layout details. System type ”000:000” Heating system with one heating circuit without mixing valve, without DHW heating.
  • Page 45 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Calling Up Coding Level 1 1. Calling up the coding level Simultaneously press the red key “w” and the blue key “M”. Hold the keys down until after approx. 5 seconds “01:00”...
  • Page 46 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Summary coding level 1 (continued) Coding in the as delivered Function mode Code change Possible change condition Address: value Address: value Boiler (continued) 06:10 Maximum temperature...
  • Page 47 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Summary coding level 1 (continued) Coding in the as delivered Function mode Code change Possible change condition Address: value Address: value DHW cylinder 10:01 The circulation pump starts...
  • Page 48 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Summary coding level 1 (continued) Coding in the as delivered Function mode Code change Possible change condition Address: value Address: value Changeover between summer and winter...
  • Page 49 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Calling Up Coding Level 2 Note: For systems with wall mounting fixtures, the programming unit must be plugged into the control unit, if coding is to be carried out at coding level 2.
  • Page 50 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Summary coding level 2 (continued) Modification types - coding address 108 “External blocking” Coding Heating circuit pump Heating circuit with mixing valve Tank Burner (extension kit)
  • Page 51 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Coding in the as delivered Function mode Code change Possible change condition Address: value Address: value Heating circuit pump 044:020 Minimum heating 044:001 Lowest value for the...
  • Page 52 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Heating curve The heating curves represent the relationship between the outdoor temperature and the boiler water or supply temperature. Put simply: The lower the outdoor temperature, the higher the boiler water or supply temperature.
  • Page 53 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Adjusting heating curves Room temperature set value Designs “04:00” and “04:01”: Heating circuit without mixer Designs “04:02” and “04:03”: Heating circuit with mixer Control unit setting: Heating curve slope Designs “04:00”...
  • Page 54 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Adjusting heating curves (cont.) Heating curve level Designs “04:00” and “04:01”: Heating circuit without mixer Designs “04:02” and “04:03”: Heating circuit with mixer Control unit setting: Designs “04 02”...
  • Page 55 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Maximum temperature limit Heating circuit without mixer Setting of coding address “06” Setting range 0 for max. temp. from “06:01” == 40ºC to “06:15” == 110ºC (Change per step: 5 K) As delivered 0condition: “06:10”...
  • Page 56 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Overview of coding addresses Coding addresses not discussed in this section must not be changed. See page 50 for information of how to access coding addresses.
  • Page 57 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Overview of coding addresses (continued) Coding (factory default Function mode Coding change Possible changes setting) Address: Value Address: Value 016:000 Do not change 017:001 Do not change...
  • Page 58 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Overview of coding addresses (continued) Coding (factory default Function mode Coding change Possible changes setting) Address: Value Address: Value 042:070 Boiler water temperature in 000 to 82 Max.
  • Page 59 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Overview of coding addresses (continued) Coding (factory default Function mode Coding change Possible changes setting) Address: Value Address: Value 0A4:___ Do not change 0A5:___ Do not change...
  • Page 60 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Overview of coding addresses (continued) Coding (factory default Function mode Coding change Possible changes setting) Address: Value Address: Value 0A9:098 Circulating pump 0A9:001 Lowest value for rotational speed of Max.
  • Page 61 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Overview of coding addresses (continued) Coding (factory default Function mode Coding change Possible changes setting) Address: Value Address: Value 0C6:000 Do not change 0C7:003 Resetting to summer/winter time...
  • Page 62 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Accessing temperature settings (with comfortrol menu driven programming unit) The following desired and actual temperature values can be accessed and shown on the display of the...
  • Page 63 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Scanning temperatures The programming unit enables the temperatures of connected sensors to be scanned as set and actual values. Scanning actual temperatures 1. Select the ID of the respective temperature from the table.
  • Page 64 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Scanning temperatures (cont.) Scanning set temperatures Note: For systems with wall-mounting fixture, the programming unit must be plugged into the control unit to be able to scan set temperatures.

  • Page 65: Jumper Assignment And Codings

    With ”External burner disable” function. Plug-in jumpers ”X2”-”X4” Factory default setting without Viessmann 2-wire BUS expansion module: Two plug-in jumpers connected as shown. With Viessmann 2-wire BUS expansion module: Both plug-in jumpers removed. External switching of the heating program (telephone contact) With programming unit Change coding address ”011:000”...

  • Page 66: Replacement Of Circuit Board Vr20

    Additional Information Vitodens 200 WB2 Service Replacement of Circuit Board VR20 Before replacing circuit board VR20, record actual system addresses (in particular coding addresses 000, 0B8, 042, 045, 015, 017, 0A2) and their corresponding values, heating curves and DHW settings.

  • Page 67: Replacement Of Burner Control Unit Lgm 29

    Additional Information Vitodens 200 WB2 Service Replacement of Burner Control Unit LGM 29 Removing the circuit board 1. Unlock hooks 1 located on both sides of the control unit and remove the control housing 2 of the control unit. 2. Remove pressure gauge 3.
  • Page 68 Additional Information Vitodens 200 WB2 Service Replacement of Burner Control Unit LGM 29 (continued) Setting the dip switch Boiler model no. Dip switch setting WB2 11-44 WB2 15-60 Installing the replacement circuit board 1. Install new circuit board LGM 29.55 qP.

  • Page 69: Wiring Diagram

    Additional Information Vitodens 200 WB2 Service Wiring Diagram...

  • Page 70: Parts Lists

    Additional Information Vitodens 200 WB2 Service Parts Lists Model No. Serial No. 044 Flow sensor WB2 11-44 7188578 050 Condensate hose  WB2 15-60 7188577  055 Differential pressure sensor 056 Gas valve without orifice Ordering Replacement Parts: 057 Sealing grommet...
  • Page 71 200 Fastening bracket (10 pack) 210 Flow check valve DN25 061 Accessory pack, front panel 205 Cap G 3/4 SW30 305 Drain valve kit, ¾ in. hardware 306 Power conditioner 307 Accessory pack (strain reliefs) 400 Service tool set ”Vitodens 200”...
  • Page 72 Additional Information Vitodens 200 WB2 Service Parts Lists (continued) Installation fittings Parts Parts (not illustrated) 110 Gasket, 32 x 44 x 2 mm 130 Accessory pack (metal stud mounting kit) 111 Adaptor (pair with gasket) 1½ in. - 1¼ in.

  • Page 73: Maintenance Record

    Additional Information Vitodens 200 WB2 Service Maintenance Record...

  • Page 74: Lighting And Operation Instructions

    Additional Information Vitodens 200 WB2 Service Lighting and Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING W A R N I N G: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 75 Vitodens 200 WB2 Service...
  • Page 76 Vitodens 200 WB2 Service...

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