Viessmann Vitodens 200 Service Manual
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Viessmann Vitodens 200 Service Manual

4.5 to 35.0/4 to 32 kw wall-mounted gas-fired condensing boiler with integral boiler control unit natural gas and lpg version
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See also: Service Manual , Start-up and Service Instructions
for heating engineers
Vitodens 200
type WB2,
See notes on applicability, page 2.
VITODENS 200
Please keep safe

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Summary of Contents for Viessmann Vitodens 200

  • Page 1 Vitodens 200 type WB2, See notes on applicability, page 2. VITODENS 200 Please keep safe...

  • Page 2: Safety Instructions

    Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Work on the equipment Repair work Initial start-up Instructing the system user Work on gas equipment ¨ Safety instruction In this instruction manual, this heading denotes information which must be observed to prevent accidents and material losses.
  • Page 3 Index General information Initial start-up, inspection and maintenance Troubleshooting Control unit for constant temperature mode Control unit for weather-compensated mode with standard programming unit Control unit for weather-compensated mode with Comfortrol programming unit Connection and wiring diagrams Parts lists Appendix...

  • Page 4: Steps Initial Start-Up, Inspection And Maintenance

    Steps initial start-up, inspection and maintenance For further instructions concerning the individual steps see pages indicated. 1. Filling the heating system 2. Checking the electrical mains connection 3. Changing the language (if necessary) 4. Checking the gas type 5. Changing the gas type 6.
  • Page 5 Steps initial start-up, inspection and maintenance 21. Checking the function of all safety valves 22. Checking the tightness of electrical connections 23. Checking all gas components for leaks at operating pressure 24. Checking the ionisation current 25. Checking the external LPG safety valve 26.
  • Page 6 Further details regarding the individual steps Filling the heating system...

  • Page 7: Further Details Regarding The Individual Steps

    The natural gas version cannot be converted to LPG. Please note: In the "as delivered condition", See separate conversion Vitodens 200 is set up for natural kit installation instructions. gas E or LPG P . Natural gas E version: After conversion from...

  • Page 8: Checking The Static And The Supply Pressure

    Further details regarding the individual steps Checking the static and the supply pressure ¨ Safety instruction Measure the CO value before and after any work on gas appliances, to prevent any health hazards and to ensure the perfect operational condition of the system.
  • Page 9 Further details regarding the individual steps Gas supply pressure (flow pressure) Use suitable test equipment with a resolution of at least 0.1 mbar to measure the supply pressure. Supply pressure (flow pressure) Check natural gas 8. ¨ Safety instructions Open the gas shut-off valve and check for leaks on test nipple "PE", and all gas connections.
  • Page 10 Further details regarding the individual steps Function sequence and possible errors during the initial start-up Display screen Check Fault Fault...
  • Page 11 Further details regarding the individual steps Display screen Check Fault Fault Fault...

  • Page 12: Checking The Co 2 Settings

    Further details regarding the individual steps Checking the CO settings Vitodens 200 is, depending on version, set up in the factory for natural gas E or LPG P . In case of initial start-up or maintenance, check the CO level on the boiler connection fitting.
  • Page 13 Further details regarding the individual steps Steps 4. Select the lower 5. Select upper rated 6. Terminate rated output and output and check the setting check the CO content mode content Control unit type Control unit for constant temperature mode Control unit for weather- compensated...

  • Page 14: Max. Output

    Further details regarding the individual steps Max. output The max. output can be limited for the heating operation. You set this limit via the modulation range. The control pressure acts as standard value for setting the required output. Please note: Control pressure = differential pressure.
  • Page 15 Further details regarding the individual steps – Please note: Whilst checking the pressure, wait approx. 5 minutes, until the pressure has stabilised. Rated output Rated thermal load Control pressure Rated output or rated thermal load relative to gas G 20/G 25 and 8.5 % CO content.
  • Page 16 Further details regarding the individual steps Leak testing the BF system (checking the circular gap) For balanced flue systems tested together with the gas-fired wall-mounted boilers, some Federal States (e.g. Nordrhein Westfalia) waive the leak test (overpressure test) during commissioning by the district chimney sweep. We recommend that your heating engineer carries out a simple leak test during the initial start-up of your system.
  • Page 17 Further details regarding the individual steps Removing the burner and checking the burner gasket for leaks ¨ Do not rest the burner on the gauze assembly (wire mesh). ¨ Replace the burner gasket every 2 years as standard. Checking the burner gauze assembly Torque: 3.5 Nm...
  • Page 18 Further details regarding the individual steps Checking and adjusting the ignition and ionisation electrodes +0.4 +0.3 –1 +0.5 ¨ Ensure that wire mesh is not damaged.
  • Page 19 Further details regarding the individual steps Checking the condensate drain...

  • Page 20: Cleaning The Combustion Chamber/Heating Surfaces And Installing The Burner

    Further details regarding the individual steps Cleaning the combustion chamber/heating surfaces and installing the burner Please note: Fauch 600 and Antox 75 E are supplied by Hebro Chemie GmbH Rostocker Straße 40 D 41199 Mönchengladbach Intec Bassersdorf AG Grindelstrasse 12 Postfach CH 8303 Bassersdorf ¨...
  • Page 21 Further details regarding the individual steps Checking the flow limiter and the flow switch filter Lubricate the gasket with instrument grease. A C B...

  • Page 22: Checking The Ionisation Current

    Further details regarding the individual steps Checking the ionisation current ¨ Safety instruction Switch OFF the system ON/OFF switch on the control unit before connecting the test equipment. The minimum ionisation current should be at least 5 mA as soon as the flame is established (approx.
  • Page 23 Further details regarding the individual steps Matching coding addresses to the heating system The control unit must be matched to the system equipment. Control unit with Control unit with standard Comfortrol programming unit programming unit Design "04:00" Design "000:000" As delivered condition Adjusting the heating system design H For selection of an appropriate design, see the following diagram.
  • Page 24 Further details regarding the individual steps Control unit Control unit with with standard Comfortrol programming programming unit unit Design "04:02" Design "000:002" Design "04:02" Design "000:002" Set coding addresses "044, 045 and 046" respectively to "001". Design "04:03" Design "000:003"...
  • Page 25 Further details regarding the individual steps Control unit Control unit with with standard Comfortrol programming programming unit unit Design "04:03" Design "000:003" Set coding addresses "044, 045 and 046" respectively to "001".
  • Page 26 Further details regarding the individual steps Heating systems with low loss header Control unit with Control unit with standard Comfortrol programming unit programming unit Design "04:02" Design "000:002" Adjustment Set coding Set coding address "03" address "0B8" to "00". to "000". Notes The integral circulation pump acts as boiler circuit pump and runs always...
  • Page 27 Further details regarding the individual steps Heating systems with low loss header Control unit with Control unit with standard Comfortrol programming programming unit unit Design "04:03" Design "000:003" Adjustment Set coding address Set coding address "03" either "0B8" either to "01" or "02". to "001"...
  • Page 28 Diagnosis using the control unit Diagnosis table: Faults with fault display on the control unit Fault message System characteristics Display burner Control Control unit for weather- fault, unit for compensated mode with constant standard Comfortrol temp. programming programming mode unit unit º...
  • Page 29 ³ Cause Check...
  • Page 30 Diagnosis using the control unit Fault message System characteristics Display burner Control Control unit for weather- fault, unit for compensated mode with constant standard Comfortrol temp. programming programming mode unit unit º º º º...
  • Page 31 Cause Check...
  • Page 32 Diagnosis using the control unit Fault message System characteristics Display burner Control Control unit for weather- fault, unit for compensated mode with constant standard Comfortrol temp. programming programming mode unit unit Call up display of fault codes from the fault memory.
  • Page 33 Cause Check...
  • Page 34 Diagnosis using the control unit Fault message System characteristics Display burner Control Control unit for weather- fault, unit for compensated mode with constant standard Comfortrol temp. programming programming mode unit unit Call up display of fault codes from the fault memory.
  • Page 35 Cause Check...
  • Page 36 Diagnosis using the control unit Fault message System characteristics Display burner Control Control unit for weather- fault, unit for compensated mode with constant standard Comfortrol temp. programming programming mode unit unit Call up display of fault codes from the fault memory.
  • Page 37 Cause Check...
  • Page 38 Diagnosis using the control unit Fault message System characteristics Display burner Control Control unit for weather- fault, unit for compensated mode with constant standard Comfortrol temp. programming programming mode unit unit Call up display of fault codes from the fault memory.
  • Page 39 Cause Check...

  • Page 40: Checking The Outside Temperature Sensor

    Repairs Scanning the actual and set temperatures: H Control unit for constant temperature mode, see page 64. H Control unit for weather-compensated mode standard programming unit, see page 83, Comfortrol programming unit, see page 101. Checking the outside temperature sensor...
  • Page 41 Repairs Checking the boiler temperature sensor, DHW cylinder temp- erature sensor or the low loss header flow temperature sensor ¨ Safety instruction The boiler temperature sensor is immersed in the heating water. Drain the boiler before replacing the sensor.
  • Page 42 Repairs Checking the outlet or comfort sensor ¨ Safety instruction draw-off temperature sensor The sensor is immersed into the DHW connecting flange. Before replacement: H Close the cold water shut-off valve. H Drain DHW pipe and plate-type heat exchanger (secondary side). Room temperature sensor Insert the sensor into the heat exchanger straps during the...
  • Page 43 Repairs Checking and replacing the pressure differential sensor In case of fault messages concerning the pressure differential sensor, check the sensor: H for correct installation H for correct electrical connection H for correct position of the O rings in the adaptor H for closure of the test nipples with plugs.
  • Page 44 Repairs Checking the plate-type heat exchanger During removal, small amounts of water may trickle from the removed plate-type heat exchanger. C DE F...
  • Page 45 Repairs Relay test Function Rotary Flashing display selector "s"...

  • Page 46: Relay Test

    Repairs Relay test ³ Please note: ³ Relays which have not been ³ B C C B mentioned are not relevant. ³ The burner stays off during the relay ³ test, if there is no heat demand. Display Meaning Only with mixer extension kit, part no. 7450 058. Only with the connection extension, part no.
  • Page 47 Repairs Checking the safety chain º...
  • Page 48 Repairs Checking fuses...

  • Page 49: Extension Kit For One Heating Circuit With Mixer

    Repairs Extension kit for one heating circuit with mixer Checking the rotational direction of mixer motor The flow temperature sensor must now sense a higher temperature. If the temperature falls, either the motor is turning in the wrong direction or the mixer set is incorrectly fitted.
  • Page 50 Repairs Checking Vitotronic 050 To select a Vitotronic 050, the Viessmann 2 wire BUS extension module is required in the boiler control unit, plus an additional communication module in Vitotronic 050. Checking the Viessmann 2 wire BUS and the data connection to Vitotronic 050...
  • Page 51 With menu-guided Comfortrol programming unit Expansion module Here, the final digit means: 2 _ _ _ _ 0 = No expansion module Viessmann 2 wire BUS recognised Calling up brief scan 2 2 _ _ _ _ 1 = Expansion module...
  • Page 52 Repairs Checking rotary selector setting on communication module of Vitotronic 050 Please note: Please observe the respective installation documents for Vitotronic 050.

  • Page 53: External Demand

    Strapping plug configuration and coding Strapping plug configuration on circuit board VR 20 Strapping plug "X 6" Strapping plugs "X 2" "X 4" External demand With standard programming unit Please note: The boiler is started according to the setting of coding address "125" (standard programming unit) or With Comfortrol programming unit "0C5"...
  • Page 54 Strapping plug configuration and coding External blocking Please note: The boiler is shut down according to the setting of coding address "108" (standard programming unit) or "0A8" (Comfortrol programming unit).
  • Page 55 Strapping plug configuration and coding External heating program changeover (telephone contact) An auxiliary device (e.g. Vitocom 300) must be connected for this function. With standard programming unit Preselected heating program Changed heating program...
  • Page 56 Strapping plug configuration and coding With Comfortrol programming unit Please note: If the heating circuit has been changed over via telephone, the display will show the additional text (with the flap closed): "TELE.PROG.". Preselected heating program Changed heating program...

  • Page 57: Function Description

    Function description Heating mode Instantaneous water heating with gas-fired combination boilers º º º º º Instantaneous water heating with gas-fired boilers º º...
  • Page 58 Function description...
  • Page 59 Test settings "T 1" and "T 2" T 1 Heating operation with lower rated output T 2 Heating operation with max. set output Please note: In test position "T 2", the fault memory will also be displayed. Changing parameters in service positions "S 1" to "S 7" Changing parameters in service positions "S 1"...
  • Page 60 Changing parameters in service positions "S 1" to "S 7" S 1 Pump run-on time when using a clock thermostat For setting steps, see page 59. Parameter Circulation pump behaviour S 2 External blocking Please note: Change strapping plug "X 6" on circuit board VR 20 to For setting steps, see page 59.
  • Page 61 Changing parameters in service positions "S 1" to "S 7" S 3 Max. boiler water temperature if DHW is heated º For setting steps, see page 59. Control unit setting range 50 to 125 ºC, limited by the thermostat to 84 ºC. To optimise control characteristics, only select boiler water temperatures up to a maximum of 78 ºC.
  • Page 62 Changing parameters in service positions "S 1" to "S 7" S 6 Limited system frost protection For setting steps, see page 59. Parameter Switching cycle S 7 M clock thermostat For setting steps, see page 59. Parameter Pump function Please note: For settings 1 to 9, the link on the M clock thermostat must be open (as delivered condition).
  • Page 63 Changing parameters in service positions "S 1" to "S 7" S 7 M clock thermostat Parameter Pump function º º Please note: For settings 11 to 20 the link on For settings 11 to 20, the link on the M clock thermostat must be the M clock thermostat must be closed.

  • Page 64: Scanning Temperatures

    Scanning temperatures The display can show the set and actual values for the H boiler water temperature, and the H DHW temperature. Scanning actual temperatures Rotary selector "w" must not be turned fully anticlockwise. Scanning and changing set temperatures...
  • Page 65 Function description Heating mode Instantaneous water heating with gas-fired boilers º Supplementary DHW heating º º Instantaneous water heating with gas-fired combination boilers You can set the temperature value for supplementary heating in coding address "107". º º º...
  • Page 66 Function description...
  • Page 67 Calling up coding level 1 Please note: For a summary of the coding addresses of coding level 1, see page 72. 1. Calling up the coding level 01:00 2. Coding address selection 3. Changing the coding address 1-7" 4. Terminating coding...

  • Page 68: Heating Curves

    Heating curves Settings in the as delivered condition: H Slope "n" = 1.4 H Level "N" = 0...
  • Page 69 Adjusting heating curves Room temperature set value without with Heating curve slope without with without...

  • Page 70: Adjusting Heating Curves

    Adjusting heating curves Heating curve level without with Differential temperature Please note: If Vitotronic 050 is connected, the set differential temperatures add up (as delivered condition respectively 8 K). Therefore set the differential temperature on Vitotronic 050 appropriately lower.
  • Page 71 Adjusting heating curves Maximum temperature limit without º º º with º º º...
  • Page 72 Summary coding level 1 ¨ Safety instruction Coding addresses that are not described here must not be changed. For a sequence of steps to call up coding level 1, see page 67. Coding in the Function mode Coding Possible change delivered change condition...
  • Page 73 Summary coding level 1 Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Boiler º º Heating circuits º º For systems without mixer, the address without mixer and with recognition of the DHW heating will be set automatically, and therefore must be manually reset. Only for heating system designs "04:02"...
  • Page 74 Summary coding level 1 Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Heating circuits DHW cylinder º º º Heating circuit pump Only for heating system designs "04:02" and "04:03".
  • Page 75 Summary coding level 1 Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Heating circuit pump Remote control Changeover between summer and winter The address is automatically set and must be manually reset. Do not adjust in the RS remote control connection.
  • Page 76 Summary coding level 1 Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Changeover between summer and winter time...

  • Page 77: Calling Up Coding Level 2

    Calling up coding level 2 Please 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. For a summary of the coding addresses of coding level 2, see page 78. 1.
  • Page 78 Summary coding level 2 For a sequence of steps to call up coding level 2 see page 77. Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Boiler º º º º Modification types coding address 108 "External blocking" Coding Heating Heating circuit with...
  • Page 79 Summary coding level 2 Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Boiler Modification types coding address 125 "External demand" Coding Heating Heating circuit with Boiler water Circulation circuit mixer (extension kit) temperature pump for DHW cylinder pump Heating circuit...
  • Page 80 Summary coding level 2 Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Heating circuit pump Each step represents approx. 20 rpm.
  • Page 81 Summary coding level 2 Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value DHW cylinder º º º º Only effective with coding 14:00. Please note:...

  • Page 82: Brief Scan

    Brief scan 00:15 For systems with wall mounting fixture, plug the programming unit into the control unit. The system only recognises the extension kit if it is connected via the KM BUS. Not if connected via the 2-wire Viessmann BUS.

  • Page 83: Scanning Temperatures

    Scanning temperatures The programming unit enables the temperatures of connected sensors to be scanned as set and actual values. Scanning actual temperatures Meaning of the display Actual temperature in ºC (display example) º º º º º º The display value takes weather conditions into consideration, such as wind, solar radiation and the wall temperature of the building.
  • Page 84 Scanning temperatures Scanning set temperatures Please note: For systems with wall-mounting fixture, the programming unit must be plugged into the control unit to be able to scan set temperatures. The LEDs "Reduced room temperature" and "DHW heating" flash in the display. Meaning of the display Set temperature in ºC...
  • Page 85 Function description Heating mode Instantaneous water heating with gas-fired boilers º Supplementary DHW heating º º Instantaneous water heating with gas-fired combination boilers You can set the temperature value for supplementary heating in coding address "0A7". º º º...
  • Page 86 Function description...
  • Page 87 Calling up coding address ³ ³ ³ B C C B ³ All settings are implemented in the menu "Installer setup", where you will find "Code 1" (the most important coding addresses in plain text) and "Code 2" (all coding addresses).
  • Page 88 Heating curves Settings in the as delivered condition: H Slope = 1.4 H Level...

  • Page 89: Adjusting Heating Curves

    Adjusting heating curves Please note: Heating circuit A = Heating circuit without mixer Heating circuit B = Heating circuit with mixer Heating curve slope ³ ³ ³ Heating curve level ³ ³ ³...
  • Page 90 Summary of coding addresses ¨ Safety instruction Coding addresses that are not described here must not be changed. For a sequence of steps to call up the coding addresses, see page 87. Coding in the Function mode Coding Possible change delivered change condition...
  • Page 91 Summary of coding addresses Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Boiler Modification options coding address 0A8 "External blocking" Coding Heating Heating circuit with Burner Circulation circuit mixer (extension kit) pump for DHW cylinder pump Heating circuit Mixer...
  • Page 92 Summary of coding addresses Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Boiler Days Automatic adjustment, if a DHW cylinder temperature sensor is connected; can be manually changed to "001". After this function is completed, the system automatically changes over to the operating mode "Heating and DHW".
  • Page 93 Summary of coding addresses Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Boiler Modification options coding address 0C5 "External demand" Coding Heating Heating circuit with Boiler water Circulation circuit mixer (extension kit) temperature pump for DHW cylinder pump Heating circuit...
  • Page 94 Summary of coding addresses Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Boiler Heating circuits DHW cylinder The coding for systems with DHW heating is automatically recognised. These codings also apply to one heating circuit without mixer and one heating circuit with mixer.
  • Page 95 Summary of coding addresses Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value DHW cylinder º º Warning º º º º º Only effective with coding 028:000.
  • Page 96 Summary of coding addresses Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Heating circuit pump Each step represents approx. 20 rpm.
  • Page 97 Summary of coding addresses Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Heating circuit pump Programming unit or remote control unit Each step represents approx. 20 rpm. This conversion is only appropriate if the programming unit is set into the wall mounting fixture.
  • Page 98 Summary of coding addresses Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Programming unit or remote control unit This conversion is only appropriate if the programming unit is set into the wall mounting fixture. The address is automatically set and must be manually reset.
  • Page 99 Summary of coding addresses Coding in the Function mode Coding Possible change delivered change condition Address:value Address:value Programming unit or remote control unit º º º º Changeover between summer and winter...
  • Page 100 Brief scan Calling up brief scan 1 ³ ³ ³ Recognition only follows if the extension kit has been connected via KM BUS. Not if connected via the 2-wire Viessmann BUS.

  • Page 101: Scanning Temperatures

    Scanning temperatures ³ ³ ³ ³ ³ ³...
  • Page 103 Connection and wiring diagram power supply 103/104...
  • Page 104 Connection and wiring diagram operating components 105/106...
  • Page 106 Parts list When ordering spare parts: Parts...
  • Page 107 Parts list 109/110...
  • Page 108 Parts list 111/112...

  • Page 109: Parts List

    Parts list Parts º Only for serial no. 7170312 2 00101 kkk and 7170314 2 00101 kkk...
  • Page 110 Parts list Parts Weather-compensated mode only. Constant temperature mode only. Only for serial no. 7170312 2 00101 kkk and 7170314 2 00101 kkk Only for serial no 7170309 2 00101 kkk 7170310 2 00101 kkk 7170311 2 00101 kkk, 7170313 2 00101 kkk, 7170315 2 00101 kkk and 7170316 2 00101 kkk...
  • Page 111 Parts list 115/116...
  • Page 113 Commissioning/service report Setting and test values Set value Initial start-up Date: Static pressure mbar Supply pressure (flow pressure) mbar mbar mbar Tick gas type Carbon dioxide content CO % by vol. % by vol. Oxygen content O % by vol. % by vol.
  • Page 114 Maint./service Maint./service Maint./service Maint./service...

  • Page 115: Commissioning/Service Report

    Commissioning/service report Setting and test values Set value Maint./service Date: Static pressure mbar Supply pressure (flow pressure) mbar mbar mbar Tick gas type Carbon dioxide content CO % by vol. % by vol. Oxygen content O % by vol. % by vol. Carbon monoxide content CO Ionisation current...
  • Page 116 Maint./service Maint./service Maint./service Maint./service...
  • Page 117 Commissioning/service report Setting and test values Set value Maint./service Date: Static pressure mbar Supply pressure (flow pressure) mbar mbar mbar Tick gas type Carbon dioxide content CO % by vol. % by vol. Oxygen content O % by vol. % by vol. Carbon monoxide content CO Ionisation current...
  • Page 118 Maint./service Maint./service Maint./service Maint./service...

  • Page 119: Specification

    Specification º º º º...
  • Page 120 Specification Gas-fired boiler, category I (natural gas version) 2ELL category II (LPG version) 2ELL3 P Rated output range º º Rated output range Connection values Product ID Product characteristics Efficiency η Standby losses Power consumption The connection values are only for reference (e. g. in the gas contract application) or to roughly check the supplementary volumetric settings.
  • Page 121 Gas restrictors Boiler for Rated output range H Central heating º H DHW heating...
  • Page 122 Declaration of conformity for Vitodens 200 Vitodens 200 conforms to the following This product is identified in standards: accordance with the following guidelines: as follows: _ 0085 Condensing boilers product characteristics determined Vitodens 200 as part of EC type testing acc. to the Efficiency Guideline Manufacturer's certificate acc.

  • Page 123: Keyword Index

    Keyword index...
  • Page 124 Keyword index...

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