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Viessmann Vitodens 200 Start-Up/Service Instructions

Wall-mounted, gas-fired condensing boiler
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Start-up/Service Instructions
for use by heating contractor
Vitodens 200, WB2 Series
Wall-mounted, gas-fired condensing boiler
For natural gas and liquid propane
NG heating input 25 to 124 MBH
7 to 36 kW
LP heating input 25 to 112 MBH
7 to 33 kW
VITODENS
5285 538 - 01
07/2020
200
r
Product may not be exactly as shown
IMPORTANT
Read and save these instructions
for future reference.
Please file in Service Binder

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Summary of Contents for Viessmann Vitodens 200

  • Page 1 Start-up/Service Instructions for use by heating contractor Vitodens 200, WB2 Series Wall-mounted, gas-fired condensing boiler For natural gas and liquid propane NG heating input 25 to 124 MBH 7 to 36 kW LP heating input 25 to 112 MBH 7 to 33 kW...

  • Page 2: Safety, Installation And Warranty Requirements

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

  • Page 3: Table Of Contents

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

  • Page 4: Important Regulatory And Installation Requirements

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

  • Page 5: About These Service Instructions

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

  • Page 6: Cover Panel

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

  • Page 7: Fill Heating System With Water

    4. Fill the heating system with water at the boiler filling and drain tap A and drain air completely from the system at manual air bleed valve B (use supplied key) as per the Vitodens 200 Installation Instructions. Max. boiler operating pressure ..45 psig Min. boiler operating pressure ..12 psig Pressure relief valve ....30 psig...

  • Page 8: Check Power Supply Connection

    The module contains a 120/230 VAC step-up transformer with the latest edition of CSA C22.1 Part 1 and/or local to power the Vitodens 200 with 230 VAC. Refer to the codes. In the U.S. use the National Electrical Code ANSI/ Installation Instructions shipped with the module for NFPA 70.

  • Page 9: Select Language

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

  • Page 10: Select Appropriate Gas Type

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

  • Page 12: How The Vitodens 200 Boiler Operates

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

  • Page 13: Check Co 2 Setting

    IMPORTANT The MatriX burner of the Vitodens 200 is preset for the entire gas group. No adjustment or readjustment of the burner is required.

  • Page 14: Clock Natural Gas Meter

    For example: 1. Ensure all other gas equipment served by the meter A Vitodens 200-W 8-32 boiler (124 000 Btu/h input) is turned off during timing of gas input to the requires 290 seconds to use 10 cu. ft. of natural gas.

  • Page 15: For Leaks

    Maintenance Record on page 80 in this manual. Check Venting System for Leaks (circular air gap measurement) Viessmann strongly recommends that the heating contractor perform a simplified leak test during boiler start-up. For this purpose it is sufficient to measure the B concentration of the combustion air in the coaxial gap of the air intake pipe.

  • Page 16: Disassemble Burner And Check Burner Gasket

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

  • Page 17: Check And Adjust Ignition And Ionization Electrode

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

  • Page 18: Check Neutralization Unit

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

  • Page 19: Check Flow Rate Limiter And Water Flow Switch Filter

    Start-up and Service Vitodens 200 WB2 Service Check Flow Rate Limiter and Water Flow Switch Filter (for Combi boiler only) 1. Loosen threaded connection of the cold water pipe at the water flow switch A. 2. Loosen threaded connection at the cold water connection nipple B.

  • Page 20: Check Functioning Of Safety Valves

    Start-up and Service Vitodens 200 WB2 Service Check Functioning of Safety Valves Ensure proper operation of low water cut-off(s) (if applicable), pressure relief valve, and pump(s). Check pressure gage, air vent and pressure relief valve. Ensure that pressure relief valve does not leak and that it operates in accordance with information provided by the manufacturer.

  • Page 21: Measure Ionization Current

    Start-up and Service Vitodens 200 WB2 Service Measure Ionization Current IMPORTANT Switch off heating system on the control unit before connecting the measuring instrument. 1. Remove burner cover panel (if still installed) as per the removal and reinstallation instructions on page 6 in this manual, and reinstall panel upon completion of service work.

  • Page 22: Check Extension Kit For Heating Circuit With Mixing Valve

    (see page 50). Note: The extension kit is only recognized when connected via the KM-BUS, not when connected via the Viessmann 2-wire BUS. With standard progamming unit’ 1. Set the heating program selector switch to “T”.

  • Page 23: Check Dekamatik-Hk

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

  • Page 24: Troubleshooting Steps

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

  • Page 25: Diagnosis

    Troubleshooting Vitodens 200 WB2 Service Diagnosis With comfortrol menu driven progamming unit’ Faults with fault display on control unit When a fault message is detected, –––– FAULT–––– flashes in the display of the programming unit with the cover closed. To trace the fault 1.
  • Page 26 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Comfortrol Menu driven programming unit retrieval of fault codes from fault memory 1. Open the cover: Menu option Button   SYSTEM ”D”   INSTALLER SETUP ”C”   CODE PLEASE: ”B-C-C-B”...
  • Page 27 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Sequence of operation and potential faults during each start-up cycle.
  • Page 28 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Diagnostics table: Faults with fault display on control unit...
  • Page 29 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Diagnostics table: Faults with fault display on control unit (continued)
  • Page 30 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Diagnostics table: Faults with fault display on control unit (continued) *1 Displayed when fault codes retrieved from fault memory.
  • Page 31 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Diagnostics table: Faults with fault display on control unit (continued) *1 Displayed when fault codes retrieved from fault memory.
  • Page 32 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Diagnostics table: Faults with fault display on control unit (continued) *1 Displayed when fault codes retrieved from fault memory.
  • Page 33 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued)
  • Page 34 Troubleshooting Vitodens 200 WB2 Service Diagnosis (continued) Diagnostics table: Faults without fault display on control unit System behavior Cause of Fault Corrective action Supply temperature too cold or too warm. Fuse Check fuse (see page 43). Variable speed heating circuit pump Check coding of heating circuit pump Heating system type incorrectly coded Check coding of heating system type Room temperature too cold or too warm.

  • Page 35: Correction

    Troubleshooting Vitodens 200 WB2 Service Correction (continued) Scanning the actual and desired temperatures Check outdoor temperature sensor 1. Disconnect connector ”X6” from the control unit. 2. Measure resistance of outdoor temperature sensor A at the disconnected connector between ”X6.3” and ”X6.4”, and compare with resistance/outdoor...
  • Page 36 Troubleshooting Vitodens 200 WB2 Service Correction (continued) Check DHW outlet temperature sensor or comfort sensor (Combi boiler only) 1. Disconnect cables from the DHW outlet temperature sensor A ( $ sensor) or the comfort sensor B (% sensor). 2. Measure resistance of the sensor and compare with the resistance/temperature curve shown on the left.
  • Page 37 Troubleshooting Vitodens 200 WB2 Service Correction (continued) Check DHW tank temperature sensor or low-loss header temperature sensor 1. Disconnect connector ”X7” from the control unit. 2. Measure resistance of the tank temperature sensor and compare with the curve. 3. If the value measured differs significantly, replace the sensor.
  • Page 38 Troubleshooting Vitodens 200 WB2 Service Correction (continued) Check plate heat exchanger (Combi boiler only) 1. Close shutoff valves on heating water and domestic hot water sides of the boiler and drain. 2. Loosen mounting screws of the control unit and swing down control unit A.
  • Page 39 Troubleshooting Vitodens 200 WB2 Service Correction (continued) With comfortrol menu driven progamming unit Relay test Open cover: Menu option Button ”D” SYSTEM INSTALLER SETUP ”C” CODE PLEASE: ”B-C-C-B” ”A” DIAGNOSIS RELAY TEST ”A” Select required relay to check its function with the menu option CONTINUE ”A”...
  • Page 40 Troubleshooting Vitodens 200 WB2 Service Correction (continued) Relay test (standard programming unit) 1. Set the heating program selector switch to “T“. 2. Select the required position using rotary selector “s“. Function Flashing display Rotary selector “s” Three-way valve drive (DHW cyl.)
  • Page 41 Troubleshooting Vitodens 200 WB2 Service Correction (continued) Check safety fixed high limits (FHL) If the safety fixed high limits cannot be reset after an automatic lockout of the burner control unit, even though the boiler water temperature is below approx. 194ºF / 90ºC, perform the following steps:...
  • Page 42 Troubleshooting Vitodens 200 WB2 Service Correction (continued) Check WS remote control unit (Accessory) Check RS remote control unit (Accessory) The WS remote control unit is used for setting the desired room temperature values from any room in the building. The RS remote control unit is used for setting the desired room temperature values from the main living room (with room temperature dependent control).

  • Page 43: Technical Data

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

  • Page 44: Burner Control Unit Lgm 29.Xx

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

  • Page 45: Control Unit For Weather-Responsive Operation

    Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation Functional description Domestic hot water supply Space heating mode with gas-fired space heating boiler The control unit calculates a boiler water setpoint Domestic hot water heating is activated when the tank temperature based on the outdoor or room temperature temperature is 4.5ºF/2.5ºC below the tank temperature...
  • Page 46 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation (continued) With standard progamming unit Legend A Gauge B Display C Time setting D Weekday setting E Scanning temperatures F Heating program selector switch Standby mode Only DHW rw Heating and DHW...
  • Page 47 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation Heating system types The control unit is adjusted to the system equipment. In the factory default setting, the heating system type is coded ”000:000”. The coding is set automatically when a tank temperature sensor is connected (for operation with a DHW tank).
  • Page 48 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) System type ”000:002” Heating system with low-loss header (with temperature sensor) one heating circuit with mixing valve one heating circuit without mixing valve (activation of heating circuit pump via connection expansion board) without domestic hot water heating.
  • Page 49 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) With standard progamming unit Calling Up Coding Level 1 Note: For a summary of the coding addresses of coding / leve/ 1, see page 72.
  • Page 50 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Summary coding level 1 (continued) Coding in the as delivered Function mode Code change Possible change condition Address: value Address: value Boiler (continued) 06:10 Maximum temperature...
  • Page 51 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Summary coding level 1 (continued) Coding in the as delivered Function mode Code change Possible change condition Address: value Address: value DHW cylinder 10:01 The circulation pump starts...
  • Page 52 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Summary coding level 1 (continued) Coding in the as delivered Function mode Code change Possible change condition Address: value Address: value Changeover between summer and winter...
  • Page 53 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Summary coding level 2 (continued) For a sequence of steps to call up coding level 2, see page 72. Coding in the as delivered Function mode...
  • Page 54 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Summary coding level 2 (continued) Modification types coding address 125 “External demand” Coding Heating circuit pump Heating circuit with mixing valve Tank Burner (extension kit)
  • Page 55 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Adjusting heating curves Room temperature set value Designs “04:00” and “04:01”: Heating circuit without mixer Designs “04:02” and “04:03”: Heating circuit with mixer Control unit setting:...
  • Page 56 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) With standard progamming unit Adjusting heating curves (cont.) Heating curve level Designs “04:00” and “04:01”: Heating circuit without mixer Designs “04:02” and “04:03”: Heating circuit with mixer Control unit setting: Designs “04 02”...
  • Page 57 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) With comfortrol menu driven progamming unit Accessing coding addresses The coding of the programming unit is performed by using the ”A”, ”B”, ”C” and ”D” buttons and the ”G” selector knob.
  • Page 58 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Overview of coding addresses Coding addresses not discussed in this section must not be changed. See page 51 for information of how to access coding addresses.
  • Page 59 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Overview of coding addresses (continued) Coding (factory default Function mode Coding change Possible changes setting) Address: Value Address: Value 016:000 Do not change 017:001 Do not change...
  • Page 60 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Overview of coding addresses (continued) Coding (factory default Function mode Coding change Possible changes setting) Address: Value Address: Value 042:070 Boiler water temperature in 000 to 82 Max.
  • Page 61 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Overview of coding addresses (continued) Coding (factory default Function mode Coding change Possible changes setting) Address: Value Address: Value 0A4:___ Do not change 0A5:___ Do not change...
  • Page 62 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Overview of coding addresses (continued) Coding (factory default Function mode Coding change Possible changes setting) Address: Value Address: Value 0A9:098 Circulating pump 0A9:001 Lowest value for rotational speed of Max.
  • Page 63 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Overview of coding addresses (continued) Coding (factory default Function mode Coding change Possible changes setting) Address: Value Address: Value 0C6:000 Do not change 0C7:003 Resetting to summer/winter time...
  • Page 64 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Heating curve The heating curves represent the relationship between the outdoor temperature and the boiler water or supply temperature. Put simply: The lower the outdoor temperature, the higher the boiler water or supply temperature.
  • Page 65 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation (continued) Accessing temperature settingswith Comfortrol menu driven programming unit The following desired and actual temperature values can be accessed and shown on the display of the programming unit: Outdoor temperature...
  • Page 66 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation (continued) Scanning temperatures with standard programming unit The programming unit enables the temperatures of connected sensors to be scanned as set and actual values. Scanning actual temperatures with standard programming unit 1.
  • Page 67 Additional Information Vitodens 200 WB2 Service Control Unit for Weather-Responsive Operation with programming unit (continued) Scanning temperatures (cont.) Scanning set temperatures with standard programming unit Note: For systems with wall-mounting fixture, the programming unit must be plugged into the control unit to be able to scan set temperatures.

  • Page 68: Jumper Assignment And Codings

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

  • Page 69: Replacement Of Circuit Board Vr20

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

  • Page 70: Replacement Of Burner Control Unit Lgm 29

    Additional Information Vitodens 200 WB2 Service Replacement of Burner Control Unit LGM 29 Removing the circuit board 1. Unlock hooks 1 located on both sides of the control unit and remove the control housing 2 of the control unit. 2. Remove pressure gauge 3.
  • Page 71 Additional Information Vitodens 200 WB2 Service Replacement of Burner Control Unit LGM 29 (continued) Setting the dip switch Dip switch setting for Vitodens 200 boiler models WB2-24/32 Boiler model no. Dip switch setting WB2 6-24C WB2 6-24 WB2 8-32 Installing the replacement circuit board 1.

  • Page 72: Wiring Diagram

    Additional Information Vitodens 200 WB2 Service Wiring Diagram...

  • Page 73: Parts Lists

    Please provide boiler Model and Serial Number from 042 Gas valve (w.o. orifice) rating plate when ordering replacement parts. 043 Gas connection (non replaceable) Order replacement components from your Viessmann 044 Orifice, NG distributor. 046 Orifice, LP 055 Vent pipe adaptor...
  • Page 74 Additional Information Vitodens 200 WB2 Service Parts Lists (continued) Parts 001 Automatic air vent 022 Condensate hose 002 Connecting pipe (supply) 031 Extension pipe 003 Fixed high limit switch 032 Bushing (set) 004 Temperature sensor 047 Heat exchanger (DHW)*1 005 Gasket set...
  • Page 75 Additional Information Vitodens 200 WB2 Service Parts Lists (continued) Parts 171 Flat cable, 26-pole 029 Pressure gage 174 Fuse, 6.3A 048 Hood for control unit 177 Programming unit 141 Control housing 179 Pressure gage insert 142 Mounting plate 200 Fastening bracket...
  • Page 76 Additional Information Vitodens 200 WB2 Service Parts Lists (continued) Installation fittings (model WB2 6-24 Combi) 010 Spring clips (set) 011 Steel nipple, ¾ in. Parts 012 Brass adaptor, ½ in. 001 Installation fittings bracket 013 Pressure bypass valve 002 Boiler supply/return connects 020 Compression fittings, ½...
  • Page 77 Additional Information Vitodens 200 WB2 Service Parts Lists (continued) Installation fittings (models WB2 6-24 and 8-32) 010 Spring clips (set) 011 Steel nipple, 3/4 in. Parts 012 Brass adaptor, 3/4 in. 001 Installation fittings bracket 013 Pressure bypass valve 002 Boiler supply/return connects 021 Compression fittings, ¾...

  • Page 78: Maintenance Record

    Additional Information Vitodens 200 WB2 Service Maintenance Record...

  • Page 79: Lighting And Operation Instructions

    Additional Information Vitodens 200 WB2 Service Lighting and Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING W A R N I N G: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
  • Page 80 Vitodens 200 WB2 Service...

This manual is also suitable for:

Wb2 6-24cWb2 6-24Wb2 8-32

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