Viessmann VITODENS 200 Installation Instructions Manual

Installation instructions

VIESMANN

for heating engineers

Vitodens 200

Type WB2A, 8.8 to 26.0 kW

Gas fired wa ll mounted con densing boi ler

Natural gas and LPG version

VITODENS 200

5862 559 GB 2/2004 Dispose after installation

Please follow these safety instructions closely to prevent accidents and

material losses.

Safety instructions explained

!

Important information

This symbol warns against the

risk of material losses and

environmental pollution.

Safety regulations

Installation, initial start-up, inspection,

maintenanc e and re pairs must be car-

ried out by a competent person (heat-

ing engineer/installation contractor).

Observe all current sa fety regulations

as defined by DIN, EN, DVGW, TRGI,

TRF, VDE or all locally applicable

standards.

See a lso the "safety instructions" in

the "Vitotec Technical Guide" folder.

Before working on the equipment/

heating sy stem, isolate the m ains

electrical supply (e.g. by removing a

separate mai ns f use or by means of a

mains electrical isolator) and safe-

guard against unauthorised reconnec-

tion.

Close the main gas shut-off valve and

safeguard against unauthorised

reopening .

Electric al assemblies p rovided on site

must be type-a pproved.

Work on gas equipment

This must only be carried out by an

approved gas fitter.

Observe all commissioning work spe-

cified for gas installations to TRGI or

TRF and all local regulations.

Safety instructions

2

5862 559 GB

Preparing for installation

Product information ................... ................................................................. 4

Preparations for boiler installation............................................................... 5

Installation

Installing the boiler and making all connections ........................................... 7

Flue gas connection .................................................................................... 8

Condensate connection .............................................................................. 8

Gas c onnection ................................................................. ......................... 8

Opening the control unit housing.................... ............................................. 10

Electrical connections............................................................................ ..... 11

&

Routing connecting cables ...... ................................................................. 13

Closing control unit housing and in serting user interface .... ......................... 14

Front panel installation............... ................................................................. 15

Commissioning and adjustments ................................................................. 15

Index

3

5862 559 GB

Vitodens 200, Type WB2A

Set up for operatio n with natural g as E .

The natural gas E version can be converted to natural gas LL or LPG P using a

conversi on kit.

Product information

4

5862 559 GB

For on-site preparation of gas, water and electrical connections, see

installation instructions, installation template or mounting frame.

A Heating flow Rp¾"

B DHW Rp½" (gas fired combination

boiler)

DHW flow G¾" (gas fired boiler)

C Gas connection

D Cold wate r Rp ½" (gas fired com bi-

nation boiler)

DHW return G¾" (gas fired boiler)

E Heating return R p¾"

F Fill & drain valve

G Cable arrang ement area

H Dimension for installation with

DHW cylinder below t he boiler.

K Condensate dr ain

Preparations for boiler installation

5

5862 559 GB

1. Prepare t he water conne ctions.

Thoroughly flush the heating sys-

tem.

2. Prepare the gas con nection

accordingtoTRGIorTRForall

local r egulation s.

3. Prepare t he electrical co nnections.

&

Mainscable:NYM-J3x1.5mm

2

,

fuse max. 16 A, 230 V~, 50 Hz.

&

Accessory cables: NYM with the

required number of conductors

for the external connections.

&

Allcablesinarea"G" shoul d

protrude 1200 mm from the wall.

Preparations for boiler installation (cont.)

6

5862 559 GB

A Heating flow

B DHW (gas fired combination boi-

ler)

DHW flow (gas fired boiler)

C Gas connection

D Cold wa ter (gas fir ed c ombinati on

boiler)

DHW return (gas fired boiler)

E Heating return

F Fill & drain valve

Installing the boiler and making all connections

7

5862 559 GB

Connect the balanc ed fl ue pipe. Flue gas system installation

instructions.

Condensate connection

Connect the condensate drain with a

pipe air vent valve sloping to the pub-

lic sewer.

Gas connection

A Gas connection

Conversion to other gas

types:

Conversion kit installation

instructions

Information regarding operation

with LPG

We recommend the installation of an

external safety solenoid valve when

installing the boiler in rooms below

ground l evel.

Flue gas connection

8

5862 559 GB

1. Carry out a leak test.

!

Important information

Excessive test pressure

leadstodamageonboiler

and gas train.

Max. test pressure

150 mbar. If a higher pres-

sure is requi red fo r l eak

tests, separate the boiler

and the gas train from the

mains gas supply (undo fit-

tings).

2. Purge th e ga s s upply pipe.

Gas connection (cont.)

9

5862 559 GB

Opening the control unit housing

10

5862 559 GB

Notes regarding the connection o f accessories

For details o f acce ssories also obs erve the separate i nstallation ins truc-

tions provided.

A Radio clock co nnection B Vitotrol 100 UTD (only for c ontrol

units operating with a constant

temperatu re)

C Vitotrol 100 UTA (only for control

units operating with a constant

temperatu re)

Electrical connections

11

5862 559 GB

Plug 230 V~

fÖ Power supply

&

Never interchange cores "L1"

and "N".

&

Install an isolator in the mains

supply line which simulta-

neously separates all non-

earthed conductors from the

mains with at least 3 mm contact

separation.

&

Max. fuse rating 16 A.

lH

&

Mains s upply - acces sories

(230 V ~ 50 Hz). Where the boi-

ler is installed in a bathroom or

shower room, the mains supply

of access ories outsi de the wet

area must not be connected to

the control unit. The p ower sup-

ply connection for accessories

canbemadeimmediatelyatthe

control unit, if the boiler is

installed outside damp areas.

This connection is directly con-

trolled with the system ON/OFF

switch (max. 3A).

&

Vitotrol 100 UTA

&

Vitotrol 100 UTD

Low voltage plug

! Outside temperature sensor

(only for weather -compensated

mode)

Installation

&

North or n orthwestern wall, 2

to2.5mabovegroundlevel.In

multi-storey buildings, in the

upper half of the second floor

&

Not above windows, d oors or

ventilation outlets

&

Not immediately below balcony

or gutter

&

Do not render over

&

Twocorecablewithamaxi-

mum length of 35 m and a

cross-section of 1.5 mm

2

? Flow temperatu re s ensor for low

loss header (accessories)

% Cylinder temperature sensor

(part of the DHW cyli nder con-

nection set)

aVG KM BUS user (accessory)

&

Vitotrol 200 or 300 rem ote c on-

trol

&

Vit oco m 1 00

&

Extension kit for one heating

circuit with mixer

&

Vitosolic

&

External extension H 1 or H2

Electrical connections (cont.)

12

5862 559 GB

Routing connecting cables

!

Important information

Connecting cables are damaged if they touch hot components.

When routi ng a nd securing co nnecting cable s on site, ensur e that the

maximum permissible cable temperatures are not exceeded.

A Low voltage connections

B 230 V connections

C Internal extension

D Main PCB

E Communication s modu le

Electrical connections (cont.)

13

5862 559 GB

Closing control unit housing and inserting user interface

14

5862 559 GB

Commissioning and adjustments

For commissioning and adjustment, see service instructions.

Front panel installation

15

5862 559 GB

16

Printed on environmentally-friendly,

chlorine-free bleached paper

5862 559 GB Subject to technical modifications

Viessmann Limited

Hortonwood 30, Tel ford, TF1 7Y P, GB

Telephone: +44 1952 675000

Fax: +44 195 2 6 75040

www.viessmann.co.uk

VIESMANN

Service instructions

for heating engineers

Vitodens 200

Type WB2A, 8.8 to 26.0 kW

Gas fired wa ll mounted con densing boi ler

natural gas and LPG version

See applicability on the last page

VITODENS 200

5692 573 GB 6/2004 Please k eep safe

Please follow these safety instructions closely to prevent accidents and

material losses.

Safety instructions explained

Danger

This symbol warns against the

risk of injury.

!

Important information

This symbol warns against the

risk of material losses and

environmental pollution.

Note

Details identified by the words "Note"

contain addit ional information .

Wa rranty

All warranty rights are void if these

service instructions are not observed.

Target group

These service instructions are exclu-

sively designed for qualified person-

nel.

Work on gas equ ipment must on ly b e

carried out by a registered gas fitter.

Only approved contractors may mod-

ify this equipment for countries other

than those designated o n the type

plate. That contractor will then

arrange for the relevant approval in

that country.

Electric al work must on ly be carrie d

out by a qualified electrician.

The system must be commissioned by

the system installer or a qualified per-

son authorised by the installer.

Regulations

Observe the following during service

work:

&

all legal instructions regarding the

prevention of accidents,

&

the TRGI, TRF and special regula-

tions, e.g. those of the BDH,

a ÖVGW-TR Gas, ÖVGW-TRF,

c SVGW,

&

all legal instructio ns re garding

environmental protection,

&

the Code of P ractice by rel evant

trade assoc iations and all local reg-

ulations.

If you notice a smell of gas

Danger

Escapin g ga s can cause exp lo-

sionswhichmayleadtoser-

ious injury.

&

Do not smoke. P revent

naked flames and sparks.

Never switch electrical lights

or equipm ent.

&

Open windows and doors.

&

Close the gas s hut-off valve.

&

Remove all per sonnel from

the danger zone.

&

Observe the safety regula-

tions of your local gas sup-

plier which can b e f ound on

the gas meter.

&

Notify your he ating contrac-

tor from outs ide th e bui lding.

Safety instructions

2

Safety instructions

5692 573 GB

If you smell flue gas

Danger

Flue gas may lead to life-threa-

tening po isoning.

&

Shut down the heating sys-

tem.

&

Ventilate the boiler room.

&

Close all doors leading to liv-

ing areas.

Repair work

It is not permitted to carry out repairs

on parts that fulfil a safety function.

Use only ori ginal Viessmann spare

parts, or equivalent parts that have

been appr oved by Viessman n.

Service work on the heating system

&

Isolate the sy stem from mains sup -

ply and check that it is no longer

"live", e.g . by re moving a separat e

fuse or by means of a mains electri-

cal isolator.

&

Safeguard the system against

unauthorised reconnection.

&

When usin g g as as fuel, also c lose

the main gas shut-off valve and

safeguard against unauthorised

reopening.

Ancillary components, spare and

wearing parts

!

Important information

Components which are not

tested with the heating system,

the installation of non-

approved spare parts and

unauthor ised conver sion may

lead to damage to the heating

system, which may affect their

function and limi t our wa rranty.

For conversions or replace-

ments, use onl y or iginal parts

from Viessmann or those spare

parts which are approved by

Viessmann.

Safety instructions (cont.)

3

Safety instructions

5692 573 GB

Initial s tart-up, inspection, maintenance

Steps - initial start -up, inspection and maintenance ..................................... 5

Further details regarding the individual steps . ............................................. 7

Coding

Code 1............................................................................... ......................... 39

Code 2............................................................................... ......................... 42

Resetting the coding to the as delivered condition .................................. ..... 62

Service scans

Service level summary........................................................................... ..... 63

Temperatures, boiler c oding card and brief scans........................................ 64

Checking outputs (relay test) ................................................................. ..... 68

Scanning operating condit ions and sensors ... ............................................. 69

Troubleshooting

Downloading fault codes history ......................................... ......................... 72

Call up current fault codes ............................. ............................................. 72

Checking and acknowledging faults ............................................................ 74

Repairs ......................................................... ............................................. 84

Function description

Constant temperature control unit ...................................... ......................... 96

Weather-compensated control unit ..................................... ......................... 98

Extensions for e xternal conne ctions (accessory)......................................... 100

Control functions ... ..................................................................................... 104

Designs

Connection and wiring diagrams – internal connections...... ......................... 109

Connection and wiring diagrams – external connections.............................. 111

Parts lists ......................................................................... ......................... 113

Commissioning/service reports............................................................... 120

Specification............................ ................................................................. 126

Certificates

Declaration of conformity ....................................................................... ..... 127

Manufacturer's certificate according to the 1st BImSchV [Germany]........ ..... 128

Keyword index .......................................................................................... 129

Index

4

Index

5692 573 GB

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Viessmann VITODENS 200 Installation Instructions Manual

Viessmann VITODENS 200 Installation Instructions Manual

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