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Viessmann Vitodens 200 Service Instructions Manual

48.6 to 66.3/44 to 60kw wall-mounted gas fired condensing boiler with integral boiler control unit

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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 for heating engineers 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 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 22. Checking all gas components for leaks at operating pressure 23. Checking the ionisation current 24. Checking the external LPG safety valve 25. Matching up the coding addresses (control unit for weather-compensated mode)
Page 6 Further details regarding the individual steps Filling the heating system...
Page 7: Further Details Regarding The Individual Steps
Further details regarding the individual steps Changing the language (if necessary) only with Comfortrol menu-assisted programming unit SPRACHE/LANGUAGE ³ ³ ³ >DEUTSCH:..A >ENGLISH:..B >ZURÜCK/BACK:..D Check the gas type ¨ Safety instruction The natural gas version cannot be converted to LPG. Please note: In the as delivered condition, See separate conversion kit...
Page 8 Further details regarding the individual steps Checking the idle 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) measure the supply pressure. Use suitable test equipment with a resolution of at least 0.1 mbar to Supply pressure (flow pressure) for Check natural gas 10. ¨ Safety instructions Open the gas shut-off valve and check for leaks on test nipples "PE", "PG"...
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 Further details regarding the individual steps Check 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 the upper 6. Terminate rated thermal load rated thermal the setting and check the load and check mode content the CO content Control unit type Control unit for constant temperature mode...
Page 14 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 Control pressure Rated output relative to T 75/60 ºC, 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). ¨ Generally, replace the burner gasket every two years.
Page 18 Further details regarding the individual steps Checking the burner gauze assembly Torque: 4.5 Nm Checking and adjusting the ignition and ionisation electrodes ¨ Ensure that wire mesh is not damaged.
Page 19 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 20 Further details regarding the individual steps Checking the condensate drain Checking the neutralizing system The granulate is used up as it neutralises the condensate. The red marker strip indicates the Please note: minimum fill height. Part no. for pH test strips: 9517 678.
Page 21 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 22 Further details regarding the individual steps Matching coding addresses to the heating system The control unit must be matched to the system equipment. Standard Comfortrol programming programming unit unit control control As delivered condition Design "04:00" Design "000:000"...
Page 23 Further details regarding the individual steps Adjusting the heating system design H For selection of an appropriate design, see the following diagram. H Coding steps with standard programming unit, see page 62, with Comfortrol programming unit, see page 81. Please note: If there is no directly connected heating circuit without mixer, set the coding address to "22:01"...
Page 24 Further details regarding the individual steps Standard Comfortrol programming programming unit unit control control Design "04:02" Design "000:002" Design "04:03" Design "000:003" For further adjustments, see coding summary H with standard programming unit from page 67, H with Comfortrol programming unit from page 84.
Page 26 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 27 ³ Cause Check...
Page 28 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 29 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 Call up display of fault codes from the fault memory.
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 Repairs Scanning the actual and set temperatures for: H Control unit for constant temperature mode, see page 59. H Control unit for weather-compensated mode with standard programming unit, see page 77, Comfortrol programming unit, see page 95. Checking the outside temperature sensor º...
Page 39 Repairs Checking the boiler temperature sensor, DHW cylinder temperature 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 40 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 41 Repairs Relay test Function Rotary Flashing display selector "s"...
Page 42 Repairs Relay test Please note: The programming unit must be ³ plugged into the control unit before a ³ relay test can be carried out. ³ B C C B Relays which have not been ³ mentioned are not relevant. ³...
Page 43 Repairs Checking the safety chain º...
Page 44 Repairs Checking fuses...
Page 45 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 46 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 47 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 48 Repairs Check the rotary selector setting on the communication module of Vitotronic 050 Please note: Please observe the respective installation documents for Vitotronic 050.
Page 49 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 "0C5"...
Page 50 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 51 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 52 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 53 Function description Heating mode º º º...
Page 54 Test settings "T 1" and "T 2" T 1 Heating mode with lower rated output T 2 Heating mode with maximum 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 55 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 54. 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 54.
Page 56 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 54. 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 57 Changing parameters in service positions "S 1" to "S 7" S 6 Limited system frost protection For setting steps, see page 54. Parameter Switching cycle S 7 M clock thermostat For setting steps, see page 54. Parameter Pump function Please note: For settings 1 to 9, the link on the M clock thermostat must be open (as delivered condition).
Page 58 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 59 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 60 Function description Heating mode Supplementary DHW heating You can set the temperature value for supplementary heating in coding address "107". º º º...
Page 61 Function description...
Page 62 Calling up coding level 1 Please note: For a summary of the coding addresses of coding level 1, see page 67. 1. Calling up the coding level 01:00 2. Coding address selection 3. To change the coding address value 4. Terminating coding...
Page 63 Heating curves Settings in as delivered condition: H Slope "n" = 1.4 H Level "N" = 0 º...
Page 64 Adjusting heating curves Set room temperature without with º Heating curve slope without with º without...
Page 65 Adjusting heating curves Heating curve level without with º º 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 º temperature on Vitotronic 050 appropriately lower.
Page 66 Adjusting heating curves Maximum temperature limit without º º º with º º º º...
Page 67 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 62. Coding in the Function mode Code Possible change as delivered change condition...
Page 68 Summary coding level 1 Coding in the Function mode Code Possible change as 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 69 Summary coding level 1 Coding in the Function mode Code Possible change as delivered change condition Address:value Address:value Heating circuits DHW cylinder º º º Only for heating system designs "04:02" and "04:03".
Page 70 Summary coding level 1 Coding in the Function mode Code Possible change as delivered change condition Address:value Address:value Heating circuit pump Remote control The address is automatically set and must be manually reset. Do not adjust in the RS remote control connection.
Page 71 Summary coding level 1 Coding in the Function mode Code Possible change as delivered change condition Address:value Address:value Changeover between summer and winter...
Page 72 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 73. 1.
Page 73 Summary coding level 2 For a sequence of steps to call up coding level 2, see page 72. Coding in the Function mode Code Possible change as delivered change condition Address:value Address:value Boiler º º º º Modification types coding address 108 "External blocking" Coding Heating Heating circuit with mixer...
Page 74 Summary coding level 2 Coding in the Function mode Code Possible change as delivered change condition Address:value Address:value Boiler Modification types coding address 125 "External demand" Coding Heating Heating circuit with mixer Boiler water Circulation circuit (extension kit) temperature pump for pump DHW cylinder loading...
Page 75 Summary coding level 2 Coding in the Function mode Code Possible change as delivered change condition Address:value Address:value Heating circuit pump DHW cylinder º º º º Each step represents approx. 20 rpm Only effective with coding 14:00. Please note:...
Page 76 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 77 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 78 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 display, the LED "Reduced room temperature" and the LED "DHW heating"...
Page 79 Function description Heating mode Supplementary DHW heating You can set the temperature value for supplementary heating in coding address "0A7". º º º...
Page 80 Function description...
Page 81 Calling up coding address ³ ³ ³ B C C B ³ All setting are implemented in the menu "Contractor adjustment", where you will find "Code 1" (the most important coding addresses in plain text) and "Code 2" (all coding addresses).
Page 82 Heating curves Settings in the as delivered condition: H Slope = 1.4 H Level...
Page 83 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 º Heating curve level ³ ³ ³ º...
Page 84 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 81. Coding in the Function mode Coding Possible change as delivered change condition...
Page 85 Summary of coding addresses Coding in the Function mode Coding Possible change as delivered change condition Address:value Address:value Boiler Modification options coding address 0A8 "External blocking" Coding Heating Heating circuit with mixer Burner Circulation circuit (extension kit) pump for DHW cylinder pump Heating circuit Mixer...
Page 86 Summary of coding addresses Coding in the Function mode Coding Possible change as 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 87 Summary of coding addresses Coding in the Function mode Coding Possible change as delivered change condition Address:value Address:value Boiler Modification options coding address 0C5 "External demand" Coding Heating Heating circuit with mixer Boiler water Circulation circuit (extension kit) temperature pump for DHW cylinder pump Heating circuit...
Page 88 Summary of coding addresses Coding in the Function mode Coding Possible change as 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 89 Summary of coding addresses Coding in the Function mode Coding Possible change as delivered change condition Address:value Address:value DHW cylinder º º Warning º º º º º Only effective with coding 028:000.
Page 90 Summary of coding addresses Coding in the Function mode Coding Possible change as delivered change condition Address:value Address:value Heating circuit pump Each step represents approx. 20 rpm...
Page 91 Summary of coding addresses Coding in the Function mode Coding Possible change as 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 92 Summary of coding addresses Coding in the Function mode Coding Possible change as 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 93 Summary of coding addresses Coding in the Function mode Code Possible change as delivered change condition Address:value Address:value Programming unit or remote control unit º º º º Changeover between summer and winter...
Page 94 Brief scan Calling up brief scan 1 ³ ³ ³ 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 95 Scanning temperatures ³ ³ ³ ³ ³ ³...
Page 97 Connection and wiring diagram power supply and pump connections Circulation pump optionally with and without BUS connection. DHW circulation pump in the as delivered condition. Optional use of the boiler circuit pump, subject to system design; observe coding. 97/98...
Page 98 Connection and wiring diagram heating components Only for constant temperature mode; only one clock thermostat may be connected. Only for weather-compensated mode. Communication module required (accessory). Internal reference potential. Remove jumper X 4.1 X 4.2 when making this connection. Observe the coding address settings. Only with low loss header.
Page 100: Parts List
Parts list When ordering spare parts: Parts º...
Page 101 Parts list 103/104...
Page 102 Parts list 105/106...
Page 103 Parts list Parts...
Page 104 Commissioning/service report Setting and test values Set value Initial start-up Date: Idle 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 105 Maint./service Maint./service Maint./service Maint./service...
Page 106 Commissioning/service report Setting and test values Set value Maint./service Date: Idle 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 107 Maint./service Maint./service Maint./service Maint./service...
Page 108 Commissioning/service report Setting and test values Set value Maint./service Date: Idle 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 109 Maint./service Maint./service Maint./service Maint./service...
Page 110 Specification º º º º...
Page 111 Specification Gas-fired boiler, category I (natural gas version) 2ELL category II (LPG version) 2ELL3 P Rated output range º º º Rated thermal load range Connection values 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 112 Gas restrictors Boiler Rated output range º...
Page 113 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 114 Index...
Page 115 Key word index...

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Vitodens 200 wb2