Viessmann Vitopend 200-W Installation And Service Instructions For Contractors
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Viessmann Vitopend 200-W Installation And Service Instructions For Contractors

Gas fired combi boiler for balanced flue operation natural gas and lpg version
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VIESMANN
Installation and service
instructions
for contractors
Vitopend 200-W
Type WHKA, 10.5 to 29.3 kW
Gas fired combi boiler
for balanced flue operation
Natural gas and LPG version
For applicability, see the last page
VITOPEND 200-W
Please keep safe.
5592 817 GB
3/2007

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  • Page 1 VIESMANN Installation and service instructions for contractors Vitopend 200-W Type WHKA, 10.5 to 29.3 kW Gas fired combi boiler for balanced flue operation Natural gas and LPG version For applicability, see the last page VITOPEND 200-W Please keep safe. 5592 817 GB...
  • Page 2 Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained the Code of Practice of 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 Instal- charge static loads. 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.

  • Page 4: Table Of Contents

    Index Index Installation instructions Preparing for installation Product information ..................Preparing for installation ................Installation sequence Installing the boiler and making all connections ........... Flue gas connection..................10 Gas connection ..................11 Opening the control unit casing ..............12 Electrical connections................. 13 Fitting the programming unit into the control unit..........
  • Page 5 Index Index (cont.) Designs Connection and wiring diagram internal connections ........ 113 Connection and wiring diagram external connections ....... 115 Parts lists ....................117 Commissioning/service reports ............... 123 Specification ..................... 124 Certificates Declaration of conformity ................126 Keyword index ..................127...

  • Page 6: Product Information

    Set up for operation with natural gas E. May be converted with a conversion kit to natural gas LL or LPG. The Vitopend 200-W should generally only be delivered to those countries spe- cified on the type plate. For deliveries to alternative countries, an approved con- tractor, on his own initiative, must arrange an individual approval in accordance with the law of the land.
  • Page 7 Preparing for installation Preparing for installation (cont.) A Heating flow R ¾" E Heating return R ¾" B Hot water R ½" F Fill & drain valve C Gas connection G Cable entry D Cold water R ½" 1. Prepare the water connections. 2.
  • Page 8 Preparing for installation Preparing for installation (cont.) 3. Prepare the electrical connections. Power supply cable: NYM- J 3 x 1.5 mm , fuse max. 16 A, 230 V~, 50 Hz. Accessory cables: NYM with the required number of conductors for the external connections. Allow all cables in area "G"...

  • Page 9: Installation Sequence

    Installation sequence Installing the boiler and making all connections...

  • Page 10: Flue Gas Connection

    Installation sequence Flue gas connection B Parallel boiler flue connection for the vertical and horizontal instal- lation of the flue gas systems 80/ C Coaxial boiler flue connection for the vertical installation of the flue gas systems 60/100 or 80/125 D Boiler connection bend for the horizontal installation of the flue gas system 60/100...

  • Page 11: Gas Connection

    Installation sequence Gas connection 2. Carry out a leak/soundness test. Please note Excessive test pressure may damage the boiler and the gas valve. Max. test pressure 150 mbar. Where higher pressure is required for soundness tests, separate the boiler and the gas valves 1.

  • Page 12: Opening The Control Unit Casing

    Installation sequence Opening the control unit casing...

  • Page 13: Electrical Connections

    Installation sequence Electrical connections Information regarding the connection of accessories For details of accessories, also observe their separate installation instructions provided. Please note Electronic modules can be damaged by electrostatic discharges. Touch earthed objects, such as heating or water pipes, to discharge sta- tic loads to earth.
  • Page 14 Installation sequence Electrical connections (cont.) B Vitotrol 100 UTD (only for con- stant temperature control units) C Vitotrol 100 UTA (only for constant temperature control units) Plug 230 V~ Low voltage plugs fÖ Power supply ! Outside temperature sensor (only for weather-compensated control Danger units)
  • Page 15 Installation sequence Electrical connections (cont.) Routing the connecting cables Please note If connecting cables touch hot components they will be damaged. When routing and securing connecting cables on site, ensure that the maximum permissible temperatures for these cables are not exceeded. A Low voltage connections E Communications module B 230 V connections...

  • Page 16: Fitting The Programming Unit Into The Control Unit

    Installation sequence Fitting the programming unit into the control unit...

  • Page 17: Fitting The Front Panel

    Installation sequence Fitting the front panel...

  • Page 18: 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. Filling the heating system ..........2.
  • Page 19 Commissioning, inspection, maintenance Steps - commissioning, inspection and . . . (cont.) Commissioning steps Inspection steps Maintenance steps Page 21. Checking the tightness of electrical connections 22. Checking all gas equipment for soundness at operating pressure ............. . . 23.

  • Page 20: Further Details Regarding The Individual Steps

    Only use fill water of potable quality. Soften fill water with hardness exceeding 3.0 mol/m , e.g. using a small softening system for heating water (see Viessmann Vitoset price list). An antifreeze additive suitable for heating systems can be mixed with the fill water.

  • Page 21: Venting The Heating System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Venting the heating system 1. Start the control unit. 3. Check the system pressure. 2. Activate the venting program via code "2F:1". Note To call up coding level 1 and for setting the coding address, see page 53.

  • Page 22: Changing The Language (If Required) Only For Weather-Compensated Control Units

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Changing the language (if required) only for weather-com- pensated control units Note Press the following keys: When the unit is first taken into opera- tion the display is in German (default 1.

  • Page 23: Function Sequence And Possible Faults

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Record the gas type in the service report on page 123. Wobbe index ranges Gas type Wobbe index range kWh/m MJ/m Delivered condition Natural gas E 12.0 to 16.1 43.2 to 58.0 GZ 50 After conversion...
  • Page 24 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Ignition Fault F4 Check ignition module (control voltage 230 V~ across plugs "X2.1" and "X2.2") Gas train opens Fault F4 Check the gas train (control vol- tage 230 V~); check the gas supply pressure Ionisation cur- Fault F4...

  • Page 25: Checking The Static And Supply Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the static and supply pressure Danger CO build-up as a result of an incorrect burner setup can have serious health implications. Carry out a CO test prior to and after work on gas equipment. Operation with LPG 5.
  • Page 26 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 9. Open the gas shut-off valve and start up the boiler. Danger Gas escaping from the test port leads to a risk of explo- sion. Check the test connector for soundness.

  • Page 27: Checking The Nozzle Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the nozzle pressure 4. Select the upper rated output. Constant temperature control unit: K + d press simultaneously: "1" is shown. press: "2" is shown. Weather-compensated control unit: K + d press simultaneously: "Relay test"...
  • Page 28 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 9. Test the nozzle pressure at the 13. Switch OFF the system at the lower rated output. In case of control unit (the boiler shuts deviations from the value down), close the gas shut-off shown in the table below, adjust valve, remove the pressure gauge the nozzle pressure for the lower...

  • Page 29: Setting The Maximum Output

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Setting the maximum output You can limit the maximum output for heating operation. The limit is set via the modulation range. Note The value to be entered is the approximate percentage of the max. rated output: 100 % corresponds to 29 kW rated output.

  • Page 30: Checking The Balanced Flue System For Soundness (Annular Gap Check)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the balanced flue system for soundness (annular gap check) A Combustion air test port (ventila- tion air) The flue pipe is deemed to be sound if If actual CO2 values are higher or O2 the CO2 concentration in the combus- values are lower, then pressure test tion air is no higher than 0.2 % or the...
  • Page 31 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Switch ON the control unit and call up the relay test: Constant temperature control unit: K + d press simultaneously for at least 2 s. press, until "5" is dis- played.

  • Page 32: Checking And Cleaning The Burner

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking and cleaning the burner 1. Switch OFF the ON/OFF switch 4. Release control unit E and pivot on control unit E and the power downwards. supply. 5. Unscrew combustion chamber 2.
  • Page 33 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 8. Pull the ignition cable plug from 11. Clean the burner, if required, with ignition unit D and release from compressed air or with a soapy the air box. solution. Flush with clean water.

  • Page 34: Checking And Cleaning The Flue Gas Heat Exchanger

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking and cleaning the flue gas heat exchanger 1. Pull the plug from boiler water tem- perature sensor B and tempera- ture limiter C. 2. Release plug-in connector clip A from the connecting pipe and release fitting D.

  • Page 35: Checking The Ignition And Ionisation Electrodes

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the ignition and ionisation electrodes 1. Check ignition electrodes A and 3. Check the electrode gaps. ionisation electrode B for wear Replace the electrodes, if the gaps and contamination. are not as specified or the electro- des are damaged.

  • Page 36: Flow Limiter

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Secure the combustion chamber cover. Flow limiter 1. Switch OFF the control unit, shut off the cold water supply line and drain the system. 2. Undo Allen screws A. 3.

  • Page 37: Checking The Diaphragm Expansion Vessel And System Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the diaphragm expansion vessel and system pres- sure 1. Pull the leads from air pressure switch A. 2. Secure cover B. 3. Check the diaphragm expansion vessel inlet pressure at test port C and recharge, if required.

  • Page 38: Flue Gas Emissions Test

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Flue gas emissions test Coaxial boiler flue connection Parallel boiler flue connection Coaxial boiler flue connection bend A Flue gas B Ventilation air 1. Connect the flue gas analyser to 4.
  • Page 39 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Select the upper rated output. 8. Press d. Constant temperature control Operation with the upper rated out- unit: put is terminated. K + d press simultaneously: "1" is shown. Maintain limits to EN 483 and EN 297 press: (CO content <...

  • Page 40: Checking The Ionisation Current

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the ionisation current 2. Adjusting the upper output: Constant temperature control unit: K + d press simultaneously: "1" is shown. press: "2" is shown. Weather-compensated control unit: K + d press simultaneously: "Relay test"...

  • Page 41: Matching The Control Unit To The Heating System

    For the selection of an appropriate design, see the following diagrams. For coding steps, see page 53. System version 1 One heating circuit without mixer A1 KW Cold water Vitopend 200-W WW DHW ! Outside temperature sensor (only for weather-compen- sated control units)
  • Page 42 KW Cold water Extension kit for one heating cir- WW DHW cuit with mixer M2 Vitopend 200-W ? M2 Flow temperature sensor ! Outside temperature sensor sÖ M2 Heating circuit pump (only for weather-compen- Plate-type heat exchanger for...
  • Page 43 (injection control) with controller without auxiliary power (three-way version) KW Cold water Temperature limiter for limiting WW DHW the maximum temperature of Vitopend 200-W underfloor heating systems ! Outside temperature sensor Controller without auxiliary (only for weather-compen- power, three-way version (closes...
  • Page 44 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Note Three-way version available from: WSC AG Mess- + Regeltechnik Weismüllerstr. 3 D-60314 Frankfurt/M. Danfoss Antriebs- und Regeltechnik GmbH Carl-Ligien-Str. 8 D-63073 Offenbach/M. Required coding Operation with LPG 1E:1 Internal extension (accessories) 53:2 System version 4 One heating circuit without mixer A1, one heating circuit with mixer M2...

  • Page 45: Adjusting The Heating Curves (Only For Weather-Compensated Control Units)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Vitopend 200-W Extension kit for one heating cir- Outside temperature sen- cuit with mixer M2 sor (only for weather- ? M2 Flow temperature sensor compensated control for heating circuit with...
  • Page 46 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) A Heating curve slope for underfloor B Heating curve slope for low tem- heating systems perature heating systems (according to the Energy Savings Order [Germany])
  • Page 47 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Changing the slope and level 1. Slope: Change with coding address "d3" in code 1. Setting range 2 to 35 (equals slope 0.2 to 3.5). 2. Level: Change with coding address "d4" in code 1.
  • Page 48 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Adjusting the set room temperature 5. Adjust the set day temperature with Standard room temperature rotary selector "ts". The value will be automatically accepted after approx. 2 s. Accordingly, the heating curve is adjusted along set room tempera- ture axis C, which results in modi- fied start/stop characteristics of the...

  • Page 49: Connecting The Control Unit To The Lon System (Only For Weather-Compensated Control Units)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. d to select heating circuit A1 5. E Call up the set night tem- (heating circuit without perature. mixer) 6. a/b Change the value. 3. a "2r" flashes. 7. d Confirm the value.
  • Page 50 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Boiler control unit Vitotronic 200-H Vitotronic 200-H Vitocom Control unit trans- Control unit re- Control unit re- mits outside tem- ceives outside tem- ceives outside tem- perature perature perature Set code "97:2" Set code "97:1"...

  • Page 51: Instructing The System User

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Press the following keys: 4. "Check OK" is displayed during communication between both 1. L + d simultaneously for devices. approx. 2 s. The subscriber check has been initiated. "Check not OK" is displayed if there is no communication 2.
  • Page 52 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. d The service display will be Note cleared (for a weather- An acknowledged service message compensated control unit: can be redisplayed by pressing d "Acknowledge: Yes", (approx. 3 s). reconfirm with d).

  • Page 53: Coding

    Coding Code 1 Calling up code 1 Note 2. a/b for the required coding On weather-compensated control address; the address units, codes are displayed as plain flashes. text. Codes that are irrelevant due to the 3. d to confirm. system equipment level or the set- ting of other codes will not be dis- 4.
  • Page 54 Coding Code 1 (cont.) Coding in the delivered condition Possible change Max. boiler water temp. 06:... Maximum limit of the 06:20 Maximum limit of the boil- boiler water tempera- er water temperature ture, defaulted in °C by 06:127 within the ranges de- the boiler coding card faulted by the boiler Gas type...

  • Page 55: Code 2

    Coding Code 1 (cont.) Coding in the delivered condition Possible change Slope A1/M2 d3:14 Heating curve slope = d3:2 Heating curve slope ad- 1.4 (only for weather- justable from 0.2 to 3.5 compensated control d3:35 (see page 45) units) Level A1/M2 d4:0 Heating curve level = 0 d4: 13...
  • Page 56 Coding Code 2 (cont.) The areas are scanned in the following sequence with a/b: Function area Coding addresses System design Boiler/burner 06 to 54 56 to 73 General 76 to 9F Heating circuit A1 (heating circuit without A0 to Fb mixer) Heating circuit with mixer M2 A0 to Fb...
  • Page 57 Coding Code 2 (cont.) Coding in the delivered condition Possible change 23:0 No time interval for 23:1 Interval adjustable from 1 burner service selected to 24 months 23:24 24:0 The service display is 24:1 Service display (value reset displayed automatically) 25:0 With outside tempera- 25:1...
  • Page 58 Coding Code 2 (cont.) Coding Internal cir- Heating circuit Heating circuit pump culation pump Heating circuit with pump Heating circuit mixer without mixer Control funct. Control funct. Coding in the delivered condition Possible change Boiler/burner 34:0 Influence of the signal 34:1 Influence of the signal "External demand"...
  • Page 59 Coding Code 2 (cont.) Coding Internal circula- Heating circuit Heating circuit tion pump pump pump Heating circuit Heating circuit with without mixer mixer Control funct. Control funct. Control funct. Coding in the delivered condition Possible change Boiler/burner 52:0 Without flow tempera- 52:1 With flow temperature ture sensor for low loss...
  • Page 60 Coding Code 2 (cont.) Coding in the delivered condition Possible change 77:1 LON subscriber number 77:2 LON subscriber number, (only for weather-com- adjustable from 1 to 99: pensated control units) 77:99 1 - 4 = Boiler 5 = Cascade 10 - 98 = Vitotronic 200-H 99 = Vitocom Note Allocate each number...
  • Page 61 Vitotronic 200-H ternally (only for weath- er-compensated control units) 98:1 Viessmann system 98:1 System number adjusta- number (in conjunction ble from 1 to 5 with monitoring several 98:5 systems via the...
  • Page 62 Coding Code 2 (cont.) Coding in the delivered condition Possible change 9C:20 Monitoring LON sub- 9C:0 No monitoring scribers. 9C:5 The time is adjustable If a subscriber fails to from 5 to 60 min respond, the values de- 9C:60 faulted inside the con- trol unit will be used after 20 min;...
  • Page 63 Coding Code 2 (cont.) Parameter Heating circuit pump -5 °C -3 °C -4 °C -2 °C -3 °C -1 °C -2 °C 0 °C -1 °C 1 °C 0 °C 2 °C 1 °C 3 °C 14 °C 16 °C Coding in the delivered condition Possible change Boiler circuit, mixer circuit...
  • Page 64 Coding Code 2 (cont.) Parameter address With heating circuit pump logic function: Heating A5:... circuit pump "OFF" AT > RT + 2 K AT > RT + 1 K AT > RT AT > RT - 1 K AT > RT - 9 K Coding in the delivered condition Possible change...
  • Page 65 Coding Code 2 (cont.) Coding in the delivered condition Possible change A8:1 Heating circuit with A8:0 Heating circuit with mixer mixer M2 creates a de- M2 creates no demand mand for the internal for the internal circulation circulation pump (only pump for weather-compen- sated control units)
  • Page 66 Coding Code 2 (cont.) Coding in the delivered condition Possible change b5:0 With remote control: No b5:1 Heating circuit pump room temperature-de- logic function, see the fol- pendent heating circuit b5:8 lowing table: pump logic function (only for weather-com- pensated control units; change the coding only for the heating circuit with mixer M2)
  • Page 67 Coding Code 2 (cont.) Coding in the delivered condition Possible change d4:0 Heating curve level = 0 d4: 13 Heating curve level ad- (only for weather-com- justable from 13 to 40 pensated control units) d4:40 (see page 45) d5:0 With external heating d5:1 The external heating pro- program changeover:...
  • Page 68 Coding Code 2 (cont.) Coding in the delivered condition Possible change E7:20 Minimum speed of the E7:0 Minimum speed adjusta- external variable speed ble from 0 to 100 % of heating circuit pump: E7:100 max. speed 20 % of the maximum speed (only for weath- er-compensated control units)
  • Page 69 Coding Code 2 (cont.) Coding in the delivered condition Possible change F5:8 Run-on time of the inter- F5:0 No run-on time of the in- nal circulation pump in ternal circulation pump heating mode 8 min F5:1 Run-on time of the inter- (only for constant tem- nal circulation pump ad- perature control units)

  • Page 70: Resetting Codes To Their Delivered Condition

    Coding Code 2 (cont.) Coding in the delivered condition Possible change FA:20 Raising the set boiler FA:0 Temperature rise adjusta- water temperature or ble from 0 to 50 % the set flow temperature FA:50 when changing from op- eration with reduced room temperature to op- eration with standard room temperature by...

  • Page 71: Service Scans

    Service scans Service level overview Function Key combination Exit Page Temperatures, boiler cod- Press K and G simulta- Press d ing card and brief scans neously for approx. 2 s Relay test Press K and d simulta- Press d neously for approx. 2 s Max.

  • Page 72: Temperatures, Boiler Coding Card And Brief Scans

    Service scans Temperatures, boiler coding card and brief scans Constant temperature control unit Press the following keys: 2. a/b for the required scan. 1. K + G simultaneously for 3. d Scanning is completed. approx. 2 s. The following values can be scanned, subject to the actual system equip- ment level: Brief scan Display screen...
  • Page 73 Service scans Temperatures, boiler coding card and brief scans (cont.) Brief scan Display screen Variable Software speed version pump Variable 0 w/o speed pump 1 Wilo 0: no vari- 2 Grundfos able speed pump Weather-compensated control unit Press the following keys: 2.
  • Page 74 Service scans Temperatures, boiler coding card and brief scans (cont.) Brief Display screen scan Software version Equipment version Burner control unit Control unit version System designs 01 Number Maximum demand temperature to 06 of KM subscri- bers Flow Software Software Software Software switch...

  • Page 75: Checking Outputs (Relay Test)

    Service scans Temperatures, boiler coding card and brief scans (cont.) Brief Display screen scan Internal circulation Heating circuit pump to connection ex- pump tension Variable Software Variable Software speed version speed version pump Variable pump Variable 0: w/o speed 0: w/o speed 1: Wilo pump...

  • Page 76: Scanning Operating Conditions And Sensors

    Service scans Checking outputs (relay test) (cont.) Weather-compensated control unit Press the following keys: 2. a/b for the required relay out- put. 1. K + d simultaneously for approx. 2 s. 3. d Relay test is completed. The following relay outputs can be controlled subject to system design: Display screen Explanation Base load...
  • Page 77 Service scans Scanning operating conditions and sensors (cont.) Display screen Explanation Burner hours run (after a service, reset with e to "0") 263572 Burner starts (after a service, reset with e to "0") 030529 Weather-compensated control unit Press the following keys: 3.
  • Page 78 Service scans Scanning operating conditions and sensors (cont.) Display screen Explanation Htg.cir.pump Off/On If an external extension or extension kit for one heating circuit with mixer is installed Centr.fault ind.Off/On If an external extension is installed Mix.valve open/closed If an extension kit for one heating circuit with mixer is installed Various languages The respective languages can be selected as...

  • Page 79: Troubleshooting

    Troubleshooting Fault display Fault display layout A Fault display C Fault number B Fault symbol D Fault code The red fault indicator flashes for A fault in the burner control unit every fault. causes the display to show "E". Constant temperature control unit In case of faults, the fault code and fault symbol flashes on the program- ming unit display...
  • Page 80 Troubleshooting Fault display (cont.) Remote control Fault participant Checking and acknowledging faults Note If an acknowledged fault is not removed, the fault message will be re- displayed: With a constant temperature control unit after 24 h With a weather-compensated con- trol unit at 7:00 h the next day Constant temperature control unit Press the following keys:...

  • Page 81: Fault Codes

    Troubleshooting Fault display (cont.) Calling up fault codes from the fault memory (fault history) The 10 most recent faults are saved Press the following keys: and may be scanned. The faults are ordered by date, thus 1. G + d simultaneously for the most recent fault is fault number 1.
  • Page 82 Troubleshooting Fault codes (cont.) Fault Const. Weath.- System char- Cause Measures code comp. acteristics on the display Regulates System flow Check the low without flow temperature loss header sen- temperature sensor lead sor (see page 91) sensor (low broken loss header) Burner Boiler water Check the boiler...
  • Page 83 Troubleshooting Fault codes (cont.) Fault Const. Weath.- System char- Cause Measures code comp. acteristics on the display Control mode Faulty pro- Replace program- as per the de- gramming ming unit livered condi- unit tion Control mode Communica- Check connec- as per the de- tion fault, tions and replace livered condi-...
  • Page 84 Troubleshooting Fault codes (cont.) Fault Const. Weath.- System char- Cause Measures code comp. acteristics on the display Control mode Vitotrol re- Check remote mote control control DIP switch incorrectly setting (see programmed page 111) Control mode Incorrect Replace the LON LON com- communication munication...
  • Page 85 Troubleshooting Fault codes (cont.) Fault Const. Weath.- System char- Cause Measures code comp. acteristics on the display Control mode Room tem- Check the room without room perature temperature sen- influence sensor, heat- sor, heating cir- ing circuit A1 cuit A1 shorted out Control mode Room tem-...
  • Page 86 Troubleshooting Fault codes (cont.) Fault Const. Weath.- System char- Cause Measures code comp. acteristics on the display Burner Internal fault Replace the con- blocked trol unit Burner in a The tem- Check the heating fault state perature lim- system fill level, iter has the circulation responded...
  • Page 87 Troubleshooting Fault codes (cont.) Fault Const. Weath.- System char- Cause Measures code comp. acteristics on the display Burner control The gas Check gas pres- unit fault pressure sure switch, gas switch is pressure and gas closed dur- train ing the burn- er start or is not closed at the end of...
  • Page 88 Troubleshooting Fault codes (cont.) Fault Const. Weath.- System char- Cause Measures code comp. acteristics on the display Burner Fault at the Check ignition blocked burner con- electrodes and trol unit connecting cables. Check whether a strong interference (EMC) field exists near the equip- ment.

  • Page 89: Repairs

    Troubleshooting Repairs Checking the plate-type heat exchanger F Cold water K Heating flow G Heating return H DHW 1. Shut off and drain the boiler on its 3. Pull the leads from comfort heating water and DHW side. sensor B. 2.
  • Page 90 Troubleshooting Repairs (cont.) 5. Undo screws D and pull out plate- 7. Check the heating water connec- type heat exchanger C to the tions for contamination and, if front. required, flush via central heating return G (flushing system for 6. Check the DHW connections for plate-type heat exchanger, see pri- scaling and, if required, replace the celist).
  • Page 91 Troubleshooting Repairs (cont.) 3. Where actual values strongly devi- 4. Subject to result, replace the lead ate from the curve values, discon- or the outside temperature sensor. nect the wires at the sensor and repeat test immediately at the sen- sor.
  • Page 92 Troubleshooting Repairs (cont.) Boiler water temperature sen- Pull the leads off the boiler tem- perature sensor and check the resistance. Comfort sensor Pull plug % from the cable har- ness at the control unit and check the resistance. Flow temperature sensor Pull plug "X3"...
  • Page 93 Troubleshooting Repairs (cont.) Checking the outlet temperature sensor A Outlet temperature sensor 1. Pull the leads off the outlet tem- perature sensor. 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in case of severe deviation.
  • Page 94 Troubleshooting Repairs (cont.) Checking the temperature limiter Check the temperature limiter if the burner control unit cannot be reset after a fault shutdown, although the boiler water temperature is below approx. 90 °C (display "E"). 1. Pull the leads from the temperature limiter.
  • Page 95 Troubleshooting Repairs (cont.) Checking the fuse 1. Switch OFF the power. 3. Remove cover A. 2. Release the side closures and 4. Check fuse F1 (see connection and pivot the control unit down. wiring diagram). Extension kit for heating circuit with mixer Checking the rotational direction of the mixer motor 1.
  • Page 96 Troubleshooting Repairs (cont.) Then standard control mode 2. Note the rotational direction of the resumes. mixer motor during its self-test. Then set the mixer manually to "Open" again. Note The flow temperature sensor must now capture a higher temperature. If the temperature drops, either the motor is turning in the wrong direc- tion or the mixer set is incorrectly fitted.
  • Page 97 Troubleshooting Repairs (cont.) 2. Change over the rotational direc- tion switch: Switch position I for central heating return from the left (delivered con- dition). Switch position II for central heat- ing return from the right. Checking the Vitotronic 200-H (accessories) The Vitotronic 200-H is connected to the control unit via the LON cable.

  • Page 98: Function Description

    Function description Constant temperature control unit Control and display elements A Pressure gauge D ON indicator (green) B Fault indicator (red) E Reset button C Optolink interface F User interface only in conjunction with the diag- G ON/OFF switch nostic adaptor (accessory) and Vitosoft (accessory) Keys at the user interface: Set boiler water tempera-...

  • Page 99: Weather-Compensated Control Unit

    Function description Constant temperature control unit (cont.) DHW heating The burner, circulation pump and The burner modulates to reach the three-way valve are started or chan- DHW outlet temperature and is limited ged over if the flow switch detects that on the boiler side by the temperature water is drawn off (>3 l/min).
  • Page 100 Function description Weather-compensated control unit (cont.) Heating mode The control unit determines the set From the set and actual boiler water boiler water temperature subject to temperatures, the burner control unit the outside temperature or room tem- calculates the modulation level and perature (if a room temperature- regulates the burner accordingly.

  • Page 101: Extensions For External Connections (Accessories)

    Function description Extensions for external connections (accessories) Internal extension H1 The internal extension is integrated Central fault message (coding into the control unit casing. The fol- address "53:0") lowing alternative functions can be Heating circuit pump for heating cir- connected to relay output sK. The cuit without mixer (coding address function is allocated via coding "53:2")
  • Page 102 Function description Extensions for external connections . . . (cont.) Internal extension H2 The internal extension is integrated Central fault message (coding into the control unit casing. The fol- address "53:0") lowing alternative functions can be Heating circuit pump for heating cir- connected to relay output sK.
  • Page 103 Function description Extensions for external connections . . . (cont.) External extension H1 The external extension is connected External blocking to the boiler control unit via the KM (terminals 2 - 3) BUS. The following functions can be External demand controlled or processed simulta- (terminals 1 - 2) neously via the extension:...
  • Page 104 Function description Extensions for external connections . . . (cont.) External extension H2 The external extension is connected External blocking to the boiler control unit via the KM (terminals 2 - 3) BUS. The following functions can be External demand controlled or processed simulta- (terminals 1 - 2) neously via the extension:...

  • Page 105: Control Functions

    Function description Control functions External heating program changeover The "External heating program chan- geover" function is connected via external extension input "aVD". You can select which heating circuits the heating program changeover affects in coding address "91": Heating program changeover Coding No changeover 91:0...
  • Page 106 Function description Control functions (cont.) External blocking The "External blocking" function is In coding address "32" you can select connected via the external extension the influence the "Ext. blocking" sig- input "aVD". nal should have on the connected cir- culation pumps. External demand The "External demand"...
  • Page 107 Function description Control functions (cont.) Filling with the control unit switched ON If the system is to be filled with the The burner shuts down if this function control unit switched ON, the diverter is enabled via coding address "2F". valve will be moved to its central posi- The program is automatically disabled tion via code "2F:2"...
  • Page 108 Function description Control functions (cont.) Temperature profile 2: (ZV parquet and flooring technology) code "F1:2" Temperature profile 3: Code "F1:3" Temperature profile 4: Code "F1:4" Temperature profile 5: Code "F1:5"...
  • Page 109 Function description Control functions (cont.) Temperature profile 6 (delivered condition): Code "F1:6" Raising the reduced room temperature During operation with reduced room The outside temperature limits for the temperature, the reduced set room start and end of the temperature rais- temperature can be automatically ing can be adjusted via coding raised subject to the outside tempera-...
  • Page 110 Function description Control functions (cont.) Example using the settings in the delivered condition A Heating curve for operation with B Heating curve for operation with standard room temperature reduced room temperature Reducing the heat-up time During the transition from operation The value and duration of the addi- with reduced room temperature to tional increase of the set boiler water...

  • Page 111: Remote Control Dip Switches

    Function description Control functions (cont.) Example using the settings in the delivered condition A Start of operation with standard C Set boiler water or flow tempera- room temperature ture in accordance with coding B Set boiler water or flow tempera- address "FA": ture in accordance with the 50 °C + 20 % = 60 °C...
  • Page 112 Function description Remote control DIP switches (cont.) Remote control DIP switch setting The remote control affects the heating circuit without mixer A1 The remote control affects the heating circuit with mixer M2 When connecting a separate room temperature sensor, set DIP switch "3" to "ON".

  • Page 113: Designs

    Designs Connection and wiring diagram internal connections...
  • Page 114 Designs Connection and wiring diagram internal . . . (cont.) § Boiler water temperature sen- Ignition unit a-Ö Fan motor for burner Outlet temperature sensor a-ÖA Fan control Ionisation electrode Gas pressure switch dÖ Stepper motor for diverter Air pressure switch valve Flow switch Thermocouple...

  • Page 115: Connection And Wiring Diagram External Connections

    Designs Connection and wiring diagram external connections Main PCB Burner control unit Power supply unit Programming unit Optolink Coding card...
  • Page 116 Designs Connection and wiring diagram external . . . (cont.) Connection adaptor Comfort sensor LON communication module sÖ Internal circulation pump (Vitotronic 200) Gas solenoid valve Internal extension H1 or H2 fÖ Power supply ON/OFF switch Power supply accessories and Reset button Vitotrol 100 Outside temperature sensor...

  • Page 117: Parts Lists

    Parts lists Parts lists When ordering spare parts 035 Rear panel lid gasket Quote the part number and serial no. 036 Rear panel lid with gasket (see type plate) and the item no. of 037 Compensation hose the required part (as per this parts 038 Gas manifold natural gas E list).
  • Page 118 Parts lists Parts lists (cont.) 094 Programming unit for constant 057 Conversion kit for LPG to natural temperature mode with time gas E switch 058 Installation and service instruc- 095 Locking bracket tions 110 Outside temperature sensor 097 Cable harness X8/X9/auxiliary 114 Access guard earth 120 Locking handle...
  • Page 119 Parts lists Parts lists (cont.)
  • Page 120 Parts lists Parts lists (cont.)
  • Page 121 Parts lists Parts lists (cont.)
  • Page 122 Parts lists Parts lists (cont.)

  • Page 123: Commissioning/Service Reports

    Commissioning/service reports Commissioning/service reports Setting and test va- Set value Initial Service lues start-up Date: Static pressure mbar max. 57.5 mbar Supply pressure (flow pressure) = for natural gas E mbar 17.4-25 mbar = for natural gas LL mbar 17.4-25 mbar = for LPG mbar 42.5-57.5 mbar...

  • Page 124: Specification

    Specification Specification Rated voltage 230 V~ Electronic temperature limiter setting Rated frequency 50 Hz~ during heating Rated current 6 A~ operation 84 °C Protection class for DHW heating 85 °C Protection IP X 4 D to Temperature limiter EN 60529 setting 100 °C (fixed) Permissible ambient temperature...
  • Page 125 Specification Specification (cont.) Product characteristics (to EnEV [Germany]) Rated output range for central heating 10.5 - 29 Efficiency µ at 100 % of rated output 91.3 30% of rated output 91.8 Standby loss q B,70 Power consumption 100 % of rated output 30 % of rated output Max.

  • Page 126: Certificates

    (92/42/EEC) for Low temperature boilers (LT). The product characteristics determined as system values for the product Vitopend 200-W as part of EC type testing according to the Efficiency Directive (see specification table), can be utilised to assess the energy con- sumption of heating and ventilation equipment to DIN V 4701 10 specified by the EnEV [Germany].

  • Page 127: Keyword Index

    Keyword index Keyword index Acknowledging a fault display Electrode ......... . . Annular gap check Emissions test .
  • Page 128 Keyword index Keyword index (cont.) Heating curve Reduced room temperature .......
  • Page 129 Keyword index Keyword index (cont.) Upper rated output 27, 39 Wiring diagram ..........Venting program .
  • Page 132 Gas fired combi boiler Type WHKA Balanced flue operation 10.5 to 29.3 kW Serial number 7196 029 ... 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...

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WhkaVitopend 200

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