Viessmann Vitogas 200-F GS2 Service Instructions Manual
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Viessmann Vitogas 200-F GS2 Service Instructions Manual

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VIESMANN
Service instructions
for contractors
Vitogas 200-F
Type GS2
Rated heating output 72 to 144 kW
Gas boilers
Natural gas and LPG version
For applicability, see the last page
VITOGAS 200-F
Please keep safe.
5692 704 GB
2/2013

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Summary of Contents for Viessmann Vitogas 200-F GS2

  • Page 1 VIESMANN Service instructions for contractors Vitogas 200-F Type GS2 Rated heating output 72 to 144 kW Gas boilers Natural gas and LPG version For applicability, see the last page VITOGAS 200-F Please keep safe. 5692 704 GB 2/2013...

  • Page 2: Safety Instructions

    Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate- rial losses. Safety instructions explained ■ Codes of practice of the relevant trade associations Danger ■ All current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury.
  • Page 3 If the boiler is operated at Defective components must be the same time, this can lead to reverse replaced with genuine flow of the flue gas. Viessmann spare parts.
  • Page 4 Installing non-author- ised components and making non-approved modifications or conversions can compromise safety and may invalidate our warranty. For replacements, use only orig- inal spare parts supplied or approved by Viessmann.

  • Page 5: Table Of Contents

    Index Index Product information Intended use......................Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance.......... Further details regarding the individual steps............Troubleshooting Diagnosis......................25 Ignition system Time chart and function..................26 Designs Burner connection diagram.................. 28 Parts lists......................30 Commissioning/service reports................ 35 Specification.......................

  • Page 6: Product Information

    Product information Intended use The appliance is only intended to be installed and operated in sealed unven- ted heating systems that comply with EN 12828, with due attention paid to the associated installation, service and operating instructions. It is only designed for the heating of water that is of potable water quality.

  • Page 7: Commissioning, Inspection, Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page • • • 1. Preparing for commissioning and filling the heating system................• •...

  • Page 8: Further Details Regarding The Individual Steps

    Commissioning, inspection, maintenance Further details regarding the individual steps Preparing for commissioning and filling the heating system Fill water ■ An antifreeze additive suitable for heating systems can be Please note added to the fill water. The anti- Unsuitable fill water increases freeze manufacturer must ver- the level of deposits and corro- ify its suitability.

  • Page 9: Checking The Gas Type

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Open any installed check valves. 4. Fill the heating system with water and vent it until the charge pressure at the pressure gauge is higher than the pre-charge pressure of the expan- sion vessel (0.1 to 0.2 bar/10 to 20 kPa).

  • Page 10: Changing The Gas Type (If Required)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. If the details do not match, convert 3. Record the gas type in the report on the burner to the available gas type, page 35. in accordance with the information provided by the gas supply utility or the LPG supplier.
  • Page 11 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 05. Start the boiler. Note During commissioning, the boiler can enter a fault state (several times) because of airlocks in the gas line. To reset, switch the control unit ON/OFF switch OFF and ON again. The ignition process will then be repeated.
  • Page 12 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 11. Open the gas shut-off valve and Danger check top test nipple A for gas Gas escaping from the test tightness. nipple leads to a risk of explosion. Check the test nipple for gas tightness.

  • Page 13: Checking The Nozzle Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the nozzle pressure D Phillips screw (partial load adjust- ment) E 2 plugs a:Ö (modulation coil) F Bottom test nipple: "P.OUT" (out- put) G Nozzle cap H Gas nozzle K Gas manifold Disabling the l.h.
  • Page 14 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 9. Reduce the nozzle pressure at the 08. Pull one of the two plugs a:Ö E l.h. gas train (BV1) with hexagon from the modulation coil on the gas screw C to 0 (no end-stop). train.
  • Page 15 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 05. Adjust the nozzle pressure at the 09. Shut down the boiler and close the l.h. gas train (BV1) with hexagon gas shut-off valve. screw C in accordance with the 10.

  • Page 16: Determining The Flue Gas Values

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Rated heating output Natural gas LL / G25 Pilot gas nozzle 29-2 Nozzle pressure at mbar 13.3 13.3 12.1 12.5 12.5 12.9 12.9 full load 1.33 1.33 1.21 1.25 1.25 1.29 1.29 Nozzle pressure at...

  • Page 17: Checking The Ionisation Current

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the ionisation current 2. Connect the measuring device A as shown in the diagram: ■ Push plug-in adaptor (7 6/4) B into ionisation cable C. ■ Push adaptor cable (7 4/6) F onto ionisation electrode E.

  • Page 18: Checking The Draught

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the draught Check the draught in Pa (100 Pa = 1 mbar, test port behind the draught hood) and record it in the report on page 35. Note Required boiler draught: 3 Pa (0.03 mbar).

  • Page 19: Removing The Burner

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Removing the burner 1. Pull the plug from burner control unit 3. Undo the nuts and screws and care- fully pull burner A forward and out. 2. Undo the fitting on gas supply pipe Checking the burner tubes 1.

  • Page 20: Checking The Pilot Burner

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the pilot burner 1. Check ionisation electrode A, pilot 2. Check the electrode gaps. burner B and ignition electrode C for damage.

  • Page 21: Cleaning The Heating Surfaces (If Required)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the heating surfaces (if required) 1. Undo self-tapping screws A and 3. Undo the screw and remove the front remove top panel B. panel. 4. Bend the locking tab down, unhook 2.

  • Page 22: Fitting The Burner

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 5. Undo cleaning cover D. 7. Remove residues from the bottom plate. 6. Clean the heating surfaces of the 8. Refit in reverse order. boiler body (with the burner removed) with the cleaning brush supplied.

  • Page 23: Checking The Flue Gas Monitoring Device

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the flue gas monitoring device 1. Switch ON/OFF switch OFF. 5. The flue gas monitoring device must shut down the burner within 2 min. 2. Pull the flue pipe from the draught The burner will then be locked out for hood.

  • Page 24: Instructing The System User

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. ■ Check the position of flue gas mon- 7. Shut down the boiler. itoring sensor A if the flue gas monitoring device takes longer 8. Remove the cover, and push the flue pipe on to the draught hood.

  • Page 25: Troubleshooting

    Troubleshooting Diagnosis System char- Cause Action acteristics The boiler will No voltage Check the MCB/fuse and power cable not start connections. Check the setting of the switch on the control unit. Boiler water tempera- Wait until the boiler water temperature ture too high has dropped by approx.

  • Page 26: Ignition System

    Ignition system Time chart and function Time chart Standard mode operation with heat demand T1 T2 A Heat demand F Ionisation current B External LPG valve G Main gas valve C Gas pressure switch H Modulation valve D Ignition K Flue gas monitoring device E Pilot gas valve Intervals Waiting period...
  • Page 27 Ignition system Time chart and function (cont.) Function Pilot gas valve E and external LPG valve B (if installed) open after a heat demand A is issued. The gas pressure switch C (if installed) is switched on. Gas flows to the pilot burner; at the same time, ignition D is switched on.

  • Page 28: Designs

    Designs Burner connection diagram A Burner control unit C Flue gas monitoring sensor (plug B Gas pressure switch (plug CN3), if CN2) installed Plug with resistance D Modulation coil to BV1 (plug CN6/ a:Ö)
  • Page 29 Designs Burner connection diagram (cont.) E Modulation coil to BV2 (plug CN6/ L Gas solenoid valve BV2 (plug a:Ö) CN10/dH) F Ignition cable M Gas solenoid valve BV1 (plug CN9/ G Ionisation cable N Burner cable (plug CN1/fA) H External LPG valve BV EXT (plug CN4) O Burner cable (plug CN7/lÖ) K Pilot burner...

  • Page 30: Parts Lists

    Parts lists Parts lists When ordering spare parts: Edge protector Quote the part number and serial no. Spring hook (see type plate) and the item no. of the Control unit fascia required part (as per this parts list). Standard parts are available from your Wearing parts local supplier.
  • Page 31 Parts lists Parts lists (cont.) 327 Retrofit kit, gas pressure switch for A Type plate 328 Installation instructions B Boiler control unit Vitotronic 100, 329 Service instructions type GC1B, see separate installa- tion and service instructions C Boiler control unit Vitotronic 100, type KC4B or Vitotronic 200, type KO2B;...
  • Page 32 Parts lists Parts lists (cont.)
  • Page 33 Parts lists Parts lists (cont.)
  • Page 34 Parts lists Parts lists (cont.)

  • Page 35: Commissioning/Service Reports

    Commissioning/service reports Commissioning/service reports Settings and actual val- Set value Commis- Mainte- sioning nance/Serv- Date Static pressure mbar max. 57.5 max. 5.75 Supply pressure (flow pressure) Tick gas type = for natural gas E mbar 17.4 - 25 1.74 - 2.5 = for natural gas LL mbar 17.4 - 25...

  • Page 36: Specification

    Specification Specification Specification and product characteristics (to EnEV [Germany]) Rated heating output Full load Partial load 46.8 54.6 62.4 70.2 78.0 85.8 93.6 Flue pipe 7 (internal diameter) Required draught mbar 0.03 0.03 0.03 0.03 0.03 0.03 0.03 Flue gas Temperature (gross) Full load °C...

  • Page 37: Certificates

    Certificates Declaration of conformity Declaration of Conformity for Vitogas 200-F We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm as sole respon- sible body that the product Vitogas 200-F complies with the following standards: EN 297 EN 55 014 EN 60 335...
  • Page 38 Certificates Manufacturer's certificate according to the 1st… (cont.) Allendorf, 01 September 2012 Viessmann Werke GmbH&Co KG Authorised signatory Manfred Sommer...

  • Page 39: Keyword Index

    Keyword index Keyword index Burner control unit......19 Ignition system........26 Ionisation current.......17 Changing the gas type.......10 Checking the burner tubes....19 Manufacturer's certificate....37 Checking the flue gas monitoring Minimum system pressure....9 device..........23 Checking the gas type......9 Checking the nozzle pressure....13 Nozzle pressure table......15 Checking the pilot burner....20 Cleaning the heating surfaces...21 Commissioning........8...
  • Page 40 7247593 7247594 7247595 7247596 7247597 7247598 7247599 7247600 7247601 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040...

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