Viessmann Vitodens 200-W WB2B 80, VITODENS 200-W WB2B Series, Vitodens 200-W, Vitodens 200-W WB2B 105, WB2B-19 Start-up/service Instructions

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Start-up/Service Instructions

for use by heating contractor

Vitodens 200-W, WB2B Series

Models WB2B 19, 26, 35 Wall-mounted, gas-fired condensing boiler

For operation with natural gas and liquid propane gas Heating input 31 to 125 MBH

9 to 37 kW

Please file in Service Binder

VITODENS200-W



5418 911 v1.6 09/2012

IMPORTANT

Read and save these instructions for future reference.

 This trademark is registered with the U.S. Patent and Trademark Office.

Safety, Installation and Warranty Requirements

Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).

HLicensed professional heating

contractor

The installation, service, and maintenance of this equipment must be performed by a licensed professional heating contractor.

Please see section entitled “Important Regulatory and Installation Requirements” in the Installation Instructions.

HProduct documentation

Read all applicable documentation

before commencing installation. Store documentation near boiler in a readily accessible location for reference in the future by service personnel.

For a listing of applicable literature, please see section entitled “Important Regulatory and Installation Requirements” in the Installation Instructions.

HCarbon monoxide

Improper installation, service and/or maintenance can cause flue products to flow into living space. Flue products contain poisonous carbon monoxide gas.

For information pertaining to the proper installation, service and maintenance of this equipment to avoid formation of carbon monoxide, please see the Installation Instructions of the Vitodens 200-W Direct Vent System.

WARNING

Installers must follow local regulations with respect to installation of carbon monoxide detectors. Follow manufacturer’s maintenance schedule of boiler.

HEquipment venting

Never operate boiler without an installed venting system. An improper venting system can cause carbon monoxide poisoning.

HWarranty

Information contained in this and related product documentation must be read and followed. Failure

to do so renders warranty null and void.

HAdvice to owner

Once the installation work is complete, the heating contractor must familiarize the system operator/ultimate owner with all equipment, as well as safety precautions/requirements, shut-down procedure, and the need for professional service annually before the heating season begins.

Warning

This boiler requires fresh air for safe operation and must be installed with provisions for adequate combustion and ventilation air (in accordance with local codes and regulations of authorities having jurisdiction).

Do not operate this boiler in areas with contaminated combustion air. High levels of contaminants such as dust, lint or chemicals can be found at construction sites, home renovations, in garages, workshops, in dry cleaning/laundry facilities, near swimming pools and in manufacturing facilities.

Contaminated combustion air will damage the boiler and may lead to substantial property damage, severe personal injury and/or loss of life. Ensure boiler/burner is inspected and serviced by a qualified heating contractor at least once a year in accordance with the Start-up/Service Instructions of the boiler.

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. Documentation is to be stored near boiler in a readily accessible location for reference by service personnel.

5418 911 v1.6

Table of Contents

Page

General Information

Initial Start-up and Service

Control Technology

Coding

Safety, Installation and Warranty Requirements 2

Operating and Service Documentation 2

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Important Regulatory and Installation Requirements 4

About these Start-up/Service Instructions 6

Necessary Tools 6

Applicability 7

Product Information 7

Mechanical Room 8

Removing Front Enclosure Panel 9

Steps 11

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Outdoor Reset Programming Unit (Vitotronic 200, HO1) 26

Coding Level 1 37

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Service Scans

Troubleshooting

Additional Information

Coding Level 2 40

Service Level Overview 50

Temperatures, Boiler Coding Card and Brief Scans 51

Checking Outputs (Relay Test) 52

Scanning Operating Conditions and Sensors 53

Diagnostics 54

Corrective Action 60

Control Functions 64

Burner Program Sequence of Operation 67

Wiring Diagrams 68

Parts Lists 70

Maintenance Record 73

Technical Data 74

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5418 911 v1.6

Lighting and Operating Instructions 76

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General Information

Important Regulatory and Installation Requirements

Codes

The installation of this unit shall be in accordance with local codes or, in the absence of local codes, use CAN/CSA-B149.1 or .2 Installation Codes for Gas Burning Appliances for Canada. For U.S. installations use the National Fuel Gas Code ANSI Z223.1. Always use latest editions of codes.

In Canada all electrical wiring is to be done in accordance with the latest edition of CSA C22.1 Part 1 and/or local codes. In the U.S. use the National Electrical Code ANSI/NFPA

70. The heating contractor must also comply with both the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1, and the Installation Code for Hydronic Heating Systems, CSA B214-01, where required by the authority having jurisdiction.

Instructing the system user

The installer of the system is responsible to ensure the system operator/ultimate owner is made familiar with the system functioning, its activation, and its shut-down.

Initial start-up

Initial start-up must be performed by a qualified heating contractor. Proper completion of the Maintenance Record by the heating contractor is also required.

Working on the equipment

The installation, adjustment, service, and maintenance of this boiler must be done by a licensed professional heating contractor who is qualified and experienced in the installation, service, and maintenance of hot water boilers.

There are no user serviceable parts on the boiler, burners, or control.

The following topics must be covered: Proper system operation sequence. Explain the equipment. Demonstrate an emergency shut-down, what to do and what not. Explain that there is no substitute for proper maintenance to help ensure safe operation.

The Maintenance Record is located on page 73 of this manual.

Please carefully read this manual prior to attempting start-up, maintenance or service. Any warranty is null and void if these instructions are not followed.

For information regarding other Viessmann System Technology componentry, please reference documentation of the respective product.

Ensure main power supply to equipment, the heating system, and all external controls has been deactivated. Close main gas supply valve. Take precautions in all instances to avoid accidental activation of power during service work.

Technical literature

Literature for the Vitodens boiler:

- Technical Data Manual

- Installation Instructions

- Start-up/Service Instructions

- Operating Instructions and User’s Information Manual

- Instructions of other Viessmann products utilized and installed

- Installation codes mentioned in this manual

We offer frequent installation and service seminars to familiarize our partners with our products. Please inquire.

The completeness and functionality of field supplied electrical controls and components must be verified by the heating contractor. These include low water cut-offs, flow switches (if used), staging controls, pumps, motorized valves, air vents, thermostats, etc.

Leave all literature at the installation site and advise the system operator/ultimate owner where the literature can be found. Contact Viessmann for additional copies.

This product comes with several safety instruction labels attached. Do not remove! Contact Viessmann immediately if replacement labels are required.

5418 911 v1.6

General Information

Important Regulatory and Installation Requirements

For installations on the Commonwealth of Massachusetts, the following modifications to NFPA-54 chapter 10 apply:

Excerpt from 248 CMR 5-08:

2(a) For all side-wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in

whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side-wall exhaust vent termination is less than (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side-wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side-wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professional for the installation of hard-wired carbon monoxide detectors.

a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or an attic,

the hard-wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the

owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

(continued)

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, ”GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side-wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled ”Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side-wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

5418 911 v1.6

General Information

About these Start-up/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

WARNING

Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury or substantial product/property damage.

CAUTION

Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or product/property damage.

IMPORTANT

presence of potential hazards or important product information.

Cautions draw your attention to the presence of potential hazards or important product information.

Helpful hints for installation, operation or maintenance which pertain to the product.

Necessary Tools

Special items

H Approved leak detection fluid for

natural gas and liquid propane gas

H Pipe joint sealant

Testing/analysis equipment

H Multimeter to measure 0 - 230V,

0 - 12A AC and 0 - 100 A DC

H Flue gas analyzer to measure % CO

or O2(i.e. Bacharach fluid samplers or suitable electronic analyzer)

H Manometer to measure gas pressure

0 to 11 ”w.c. (accurately) and up to 28 ”w.c. gas pressure (or a non-electric Magnehelic® manometer may also be utilized)

H Stack thermometer 0 to 500°F /

0 to 260°C

H Bacharach calculator or suitable

tables to calculate efficiency

H Carbon monoxide measuring

equipment 0 to 400 ppm

This symbol indicates that additional, pertinent information is to be found in column three.

This symbol indicates that other instructions must be referenced.

Use only calibrated equipment.

Cleaning supplies

H Plastic hand brush H Rags

5418 911 v1.65418 911 v1.6

5418 911 v1.6

Applicability

CAUTION

The boiler serial number must be provided when ordering replacement parts. Some replacement parts are not reverse compatible with previous versions of the Vitodens 200-W WB2B boiler.

IMPORTANT

When ordering replacement parts, provide either the 16-digit boiler serial number (on the bar code label) or the 12-digit ASME/NB serial number, located as shown underneath boiler front enclosure panel. Refer to page 9 for instructions on how to remove front enclosure panel.

Model No. WB2B 19

Serial No. 7374863 jjjjjjjjj

General InformationGeneral Information

Stainless steel Inox-Radial heat exchanger

12-digit ASME/NB serial number (located on metallic plate riveted to the heat exchanger)

16-digit boiler serial number on white bar code label labelled “Boiler Serial Number” is also located on the bottom of the boiler.

Model No. WB2B 26

Serial No. 7374864 jjjjjjjjj

Model No. WB2B 35

Serial No. 7374865 jjjjjjjjj

Product Information

Fig. 1 Locating boiler serial numbers for ordering replacement parts

Natural gas and liquid propane gas-fired wall-mounted condensing heating boiler for weather-responsive operation in closed loop, forced circulation hot water heating systems for space heating and domestic hot water (DHW) production.

The Vitodens 200-W, WB2B series boiler comes factory set for operation with natural gas. For a fuel conversion to liquid propane gas no conversion kit is required (see page 14).

Boiler model must be selected based on an accurate heat loss calculation of the building. Ensure boiler model is compatible with connected radiation.

5418 911 v1.6

Vitodens 200-W, WB2B series boilers are factory-tested and calibrated. Further gas valve adjustments are not typically required during field start-up.

Follow the Vitodens Venting System Installation Instructions to vent this boiler.

General Information

Mechanical Room

During the early stages of designing a new home, we recommend that proper consideration be given to constructing a separate mechanical room dedicated to the gas- or oil-fired heating equipment and domestic hot water storage tank(s).

The boiler must be located in a heated indoor area, near a floor drain, and as close as possible to a wall. Whenever possible, install the boiler near an outside wall so that it is easy to duct the venting system to the boiler.

Locate the boiler on a wall capable of supporting the weight of the boiler filled with water (see section entitled “Technical Data” on page 74 for information required for total boiler weight calculation). Ensure that the boiler location does not interfere with the proper circulation of combustion and ventilation air of other fuel burning equipment within the mechanical room (if applicable).

The maximum room temperature of the mechanical room where the boiler is located must not exceed 104ºF / 40ºC.

Installation area conditions

WARNING

Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk.

H Ensure ambient temperatures are

higher than 32°F / 0°C and lower than 104°F / 40°C.

H Prevent the air from becoming

contaminated by halogenated hydrocarbons (e.g. as contained in paint solvents or cleaning fluids) and excessive dust (e.g. through grinding or polishing work). Combustion air for the heating process, and ventilation of the boiler room must be free of corrosive contaminants. To that end, any boiler must be installed in an area that has no chemical exposure. The list to the right indicates the main, currently known sources.

H Avoid continuously high levels of

humidity (e.g. through frequent drying of laundry).

H Never close existing ventilation

openings.

WARNING

If you notice fire coming from the appliance, call the fire department immediately! Do not attempt to extinguish the fire unless qualified to do so.

WARNING

Fire causes a risk of burns and explosion!

HHHH Shut down the boiler HHHH Close fuel shut-off valves HHHH Use a tested fire extinguisher,

class ABC.

Sources of combustion and ventilation air contaminants

Areas likely to contain contaminants:

HNew building construction HSwimming pools HRemodelling areas, hobby rooms HGarages with workshops HFurniture refinishing areas HDry cleaning/laundry areas and

establishments

HAuto body shops HRefrigeration repair shops HMetal fabrication plants HPlastic manufacturing plants HPhoto processing plants HBeauty salons

Products containing contaminants:

HChlorine-type bleaches, detergents

and cleaning solvents found in household laundry rooms

HPaint and varnish removers HHydrochloric acid, muriatic acid HChlorine-based swimming pool

chemicals

HSpray cans containing

chlorofluorocarbons

HChlorinated waxes and cleaners HCements and glues HRefrigerant leaks HCalcium chloride used for thawing HSodium chloride used for water

softening salt

HPermanent wave solutions HAdhesives used to fasten building

products and other similar items

HAntistatic fabric softeners used in

clothes dryers

Boiler operation in marine environments (damp, salty coastal areas)

IMPORTANT

The service life of the boiler’s exposed metallic surfaces, such as the casing and fan housing, is directly influenced by proximity to damp and salty marine environments. In such areas, higher concentration levels of chlorides from sea spray, coupled with relative humidity, can lead to degradation of the exposed metallic surfaces mentioned above. Therefore, it is imperative that boilers installed in such environments not be installed using direct vent systems which draw outdoor air for combustion. Such boilers must be installed using room air dependent vent systems; i.e. using room air for combustion. The indoor air will have a much lower relative humidity and, hence, potential corrosion will be minimized.

5418 911 v1.6

Removing Front Enclosure Panel

Fig. 2 Accessing the control to switch off the boiler

General Information

Some of the following start-up/service steps require the removal of the front enclosure panel. To avoid personal injury and/or product damage of any kind please follow the instructions below carefully when removing the front enclosure panel.

1. Close main gas supply valve.

2. Access the control unit by lifting and

pivoting the control cover and switch off system on/off switch.

3. Turn off power supply to boiler and ensure that power supply cannot be activated during the duration of the start-up/service work.

4. Loosen the screws at the bottom of the boiler as shown (do not remove completely).

Fig. 3 Removing front enclosure panel

5. Slide out and remove front enclosure panel .

5418 911 v1.6

Initial Start-up and Service

Steps

nitial start-up

C DA E

Fig. 4

F Automatic air vent

1. Bleed air from boiler heat exchanger

1. Connect hose to boiler filling tap E

and other end to a fresh water supply (or heating medium).

2. Open fresh water supply valve and

then the boiler filling tap E slowly (isolation valves connected to C and D must be closed during fill/bleed process).

3. Flush boiler heat exchanger via boiler supply and return (for at least 10 min.) until all air is removed from the boiler.

4. When drain valve A begins to bleed water, close boiler drain valve A, then boiler fill valve E and open system isolation valves.

5. If the control unit has not been

switched ON prior to filling the system, switch the control to ON, and activate the air bleed program by setting coding address “2F” to “1” (boiler pump sÖ will be switch ON and OFF for 30 sec. at a time over a period of 20 minutes. The program is automatically disabled after 20 minutes, and coding address “2F” is set back to “0”).

To access coding level 1 and setting the coding address see page 37. For function and sequence of the air bleed program, see page 65. While the air bleed program is running, the display will show ”Entlüftung” (bleeding air).

nitial start-up

6. Check system pressure.

7. Ensure adequate fuel supply exists

and open gas shutoff valve.

2. Fill siphon with water

1. Remove retaining clip A and

siphon B.

2. Fill siphon B with water.

3. Re-attach siphon B and secure

with retaining clip A.

Max. operating pressure...45 psig Min. operating pressure...14 to 23 psig

Pressure relief valve......30 psig

5418 911 v1.6

Initial Start-up and Service

Steps

nitial start-up

Fig. 5

c System supply D System return

(continued)

C DA E

CAUTION

Unsuitable fill water increases the level of deposits and corrosion, and may lead to damage to the equipment.

H Thoroughly flush the entire heating

system prior to filling with water.

H Only use water of potable quality.

H The water will have have to be

softened if it is harder than 8.77 grains / 150 ppm total dissolved solids.

H Inhibitors or antifreeze additives

suitable for heating systems may be added manually.

3. Fill heating system with water

1. Open system isolation valves at C

and D (if installed).

2. Check inlet pressure of the diaphragm expansion tank.

3. To remove debris and/or sludge ensure that the system piping is flushed out. Failure to do so could cause settlement in the boiler causing overheating and damage not covered by warranty.

4. Fill the heating system with water at the boiler filling tap E and drain air completely from the drain tap A.

5. If the control unit has not been switched ON prior to filling the system, switch the control to ON, and activate the filling program by setting coding address “2F” to “2” (boiler pump sÖ starts and the burner shuts down if this function is enabled. The program is automatically disabled after 20 minutes, and coding address “2F” is set back to “0”).

Please note:

Before filling the heating system with water, check that all necessary flow check valves are installed.

If the nitrogen pressure of the precharged expansion tank is less than the static pressure of the system, inflate membrane pressure to slightly exceed pressure of system. The static pressure required at the tank is based upon the static height of the system. The system fill pressure value must be equal to the expansion tank pressure value at approx. 60ºF / 15.6ºC.

System fill pressure must be approximately 3 psig higher than the static head when the system is cold.

Water treatment should be considered in areas where it is known that boiler feed water contains a high mineral content and hardness. In areas where freezing might occur, an antifreeze may be added to the system water to protect the system. Please adhere to the specifications given by the antifreeze manufacturer. Do not use automotive silicate-based antifreeze. Please observe that an antifreeze/water mixture may require a backflow preventer within the automatic water feed and influence components such as diaphragm expansion tanks, radiation, etc. A 40% antifreeze content will provide freeze-up protection to -10°F /

-23°C. Do not use antifreeze other than specifically made for hot water heating systems. System also may contain components which might be negatively affected by antifreeze. Check total system frequently when filled with antifreeze.

5418 911 v1.6

Max. operating pressure...45 psig Min. operating pressure...14 to 23 psig

Pressure relief valve......30 psig

Initial Start-up and Service

Steps

nitial start-up

(continued)

4. Check power supply connection

A power/pump module is supplied with the Vitodens 200-W, WB2B boiler, which requires a 120VAC power supply from a wall receptacle. The module contains a 120/230VAC step-up transformer to power the boiler with 230VAC. Refer to the Installation Instructions shipped with the module for wiring details and/or the Installation Instructions of the boiler.

Voltage range

The voltage at connector fÖ of the boiler control must be 230V (see wiring diagram).

Neutral conductor

The electrical power supply must have a neutral conductor.

IMPORTANT

In Canada all electrical wiring is to be done in accordance with the latest edition of CSA C22.1 Part 1 and/or local codes. In the U.S. use the National Electrical Code ANSI/NFPA

70. The heating contractor must also comply with both the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI, ASME CSD-1.

Please note:

The outer conductor ”L” and the neutral conductor ”N” must not be interchanged. See wiring diagram on page 68 in section entitled ”Additional Information”.

nitial start-up

Uhrzeit

Datum

00004444....00008888....00007777

5. Set time and date

See page 26 in these instructions for an overview of controls and indicators of the boiler control.

H During commissioning or after a

prolonged time not in use, it may be necessary to reset the time and date if the time flashes in the display.

H When the boiler is started up for the

first time the display appears in German (factory default setting). Refer to following subsection on how to select the correct language.

1. Press “⊕ /  to adjust to the

current time.

2. Press “ ” to confirm. The word “Datum” is displayed.

3. Press “⊕ / “ to set the current date.

Please note:

If any fault exists during the initial start-up “storung” (fault) appears on the screen. Read and record the fault. Press “ i ” and read the fault. “Quittieren? Ja” (acknowledge? Yes). Press “ ” then proceed with setting the time and date.

4. Press “ ” to confirm.

5418 911 v1.6

Initial Start-up and Service

Steps

nitial start-up

Außentemperatur

(continued)

55550000

ºF

6. Select language

H When the boiler is started up for the

first time the display appears in German (factory default setting).

1. Press “i”. “Heizkreis wählen”

appears on display.

2. Press “ ” to confirm and wait for approx. 4 sec.

3. Press “i” again and “Außentemperatur” (outdoor temperature) is displayed.

4. Press ““ to select required language.(language can be selected at any time by pressing “i” then ““).

5. Press “ ” to confirm your selection.

Please note:

At any time after the initial start-up, to select a language:

- with two heating circuits A1, M2

- Press “i”

- choose heating circuit 1 or 2

using “⊕ / ”

- Press “ ”

- Press “i” again

- Press “” until English comes up

- Press “ ”

- With one heating circuit

- Press “i”

- Press “” until English comes up

- Press “ ”

nitial start-up

The Vitodens 200-W boiler is for use with gases whose characteristics fall within the following ranges. Do not use any other types of gas.

Heating value (gross) Btu/ft

Specific gravity 0.57 to 0.70 1.522 to 1.574

Ultimate carbon dioxide (CO2) % 11.7 to 12.2 13.73 to 13.82

7. Select gas type

H Please note that the Vitodens 200-W,

WB2B boiler is factory set to operation with natural gas . See following subsection for conversion instructions to liquid propane gas.

1. Ensure that the fuel type listed on the boiler rating plate is the correct type for the installation being attempted.

2. Record fuel type in Maintenance Record on page 73.

Natural gas Liquid propane gas

970 to 1100 2466 to 2542

5418 911 v1.6

Initial Start-up and Service

Fig.7

Steps

nitial start-up

(continued)

8. Convert fuel type to liquid propane gas

1. Set adjusting screw A at the gas

valve to “2” (using a hex key, 2.5 mm).

2. Switch ON/OFF switch “8” to ON.

3. Call up coding level 2.(see page 40)

4. In coding address “11” select value

“9”. The green LED flashes.

5. In coding address “82” select value “1” (operation with liquid propane gas).

6. Go back to coding address “11” and select any value (except “9”)

7. Terminate coding level 2 and open gas shut-off valve.

8. Apply supplied fuel conversion labels.

The Vitodens 200-W, WB2B boiler comes factory adjusted for operation with natural gas. Coding address “82” is set to “0” (operation with natural gas) in the factory default setting.

Note:

The system automatically terminates the parameter change after approx. 25 min., if setting the parameters is not concluded via coding address 11.

Fig. 6

nitial start-up

9. Convert to high altitude

In the factory default setting, the boiler is equipped to operate in altitudes of up to 5,000 ft. / 1,500 m. For operation in higher altitudes, the existing coding card must be replaced with a high altitude coding card. See table below or the Viessmann Price List for order information.

1. Pull out the factory installed coding card, cut and remove it from the cable tie. Insert the high altitude coding card into the boiler control board.

2. Install cover.

Coding card number

Boiler Model (base serial #) 0 - 5,000 ft. /

0 - 1,500 m

WB2B 19 (7374863....) 7832 264

7833 221

WB2B 26 (7374864....) 7832 265

7833 223

WB2B 35 (7374865....) 7832 266

7833 225

*1Factory installed

5,000 - 10,000 ft. / 1,500 - 3,000 m

7425 953 or 7424 902

7425 954 or 7424 903

7425 955 or 7424 904

5418 911 v1.6

Initial Start-up and Service

Steps

nitial start-up

inlet

(continued)

ervice

outlet

10.Measure static pressure and running pressure

1. To measure static and/or running

pressure remove boiler enclosure panel as indicated page 9 in these instructions.

2. Close gas shutoff valve (field supplied).

3. Loosen screw at inlet gas pressure port A on the gas combination valve, do not remove completely. Connect manometer.

IMPORTANT

A CO measurement (see page 24) must be taken before and after working on gas appliances to eliminate risks to health and to guarantee the satisfactory condition of the system.

IMPORTANT

4. Open the gas shutoff valve.

5. Measure static pressure. Values

must be:

H 14 “w.c. max. for NG H 14 “w.c. max. for LPG

6. Enter measured value into Maintenance Record on page 73 in this manual.

7. Start up boiler, using the ON/OFF switch “8” on the boiler control.

The burner is automatically ignited and starts operation after a safety time has elapsed. During initial start-up, the unit may indicate a fault because of air in the gas supply pipe (especially for liquid propane gas). After approx. 5 seconds, press the ”EEEE” button to reset the burner. The ignition procedure is repeated. This boiler employs a direct spark ignition system.

Fig. 8 Measuring gas supply pressure

at inlet gas pressure port

5418 911 v1.6

8. Measure the running pressure; value must be:

Running supply pressure with Corrective action

Natural gas Liquid propane gas

under 4 ”w.c. under 10 ”w.c. Do not attempt adjustment. Call local gas utility

4 to 14 “w.c. 10 to 14 ”w.c. Start up boiler. over 14 ”w.c. over 14 ”w.c. Do not attempt adjustment. Call local gas utility

9. Enter gas type into Maintenance Record on page 73 in this manual.

10. Switch off the ON/OFF switch “8”

on the boiler control, close the gas shut-off valve, remove the manometer and re-tighten the screw at inlet gas pressure port A.

WARNING

Ensure that there is no open flame in the room.

Use suitable measuring instruments calibrated with a minimum resolution of 0.04 “w.c. for measuring the running pressure.

to increase pressure.

to decrease pressure. Boiler valve must not be exposed to pressure over 14 ”w.c.

WARNING

Never purge a gas line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for purpose of checking leakage. Use a soap-and-water solution to check for leakage. A failure to follow this warning could result in fire, explosion, personal injury, or death.

Initial Start-up and Service

Steps

Sequence of operation and potential faults during each start-up cycle

Call for heat by control.

Blower starts up.

Ignition.

(continued)









yes









Display message

Fault F9 after approximately 51 seconds.

Fault F4/EE













Corrective action

Increase boiler water set-point temperature and ensure that there is heat demand.

Check cabling and plug-in connectors of the blower, as well as the blower itself. Check proper power supply to the blower.

Check ignition transformer (control voltage 230 V across plugs “X2.1” and “X2.2”).

yes





Gas combination valve opens.

yes





Ionization current builds up / flame established (symbol A appears).

yes





Burner is operating.

yes





Automatic calibration of the combustion unit.

















Fault F4/EE

Burner shuts off when the boiler temperature is below the selected boiler set-point temperature and immediately starts up again (cycles).

Fault Eb

















Check gas combination valve 230VRAC (plug 35).Check gas supply pressure.

Check electrode settings, purge gas supply line. Check condensate line and flue gas system for leaks.

Check flue gas system for leakage (flue gas recirculation), check running gas pressure.

Check the connecting cable and the ionization electrode, check the flue gas system (flue gas recirculation). Press “Reset”

For further details regarding faults, see page 56.

5418 911 v1.6

Initial Start-up and Service

Steps

nitial start-up

(continued)

11. Set maximum input

H The maximum input (or output) for

heating operation can be limited. The limit is set via the modulation range. The maximum adjustable heating input (or output) is limited upwards by the boiler coding card.

1. Start up boiler.

2. Press “9“ and “ttttwwww“ simultaneously

until a value flashes on the display (e.g. “85”), and “A” and “Max. output” appear. In the factory default setting this value represents 100% of the rated input (or output).

3. With buttons “⊕ / “ select the

required value in % of the rated input (or output) as maximum input (or output).

The input for DHW production can be limited as well. To do so, change coding address “6F” in coding level 2.

nitial start-up

ervice

4. Confirm the set value with “ ”.

12. Check all primary and secondary circuit connections for leaks

Check heating system and domestic hot water connections (if applicable). Ensure all connections are pressure tight. Correct any leaks found on fittings, pumps, valves, etc.

13. Perform combustion analysis

IMPORTANT

A CO measurement (see page 24) must be taken before and after working on gas appliances to eliminate risks to health and to guarantee the satisfactory condition of the system.

Record the measured combustion values in the sequence stated in the Maintenance Record on page 73 in this manual.

5418 911 v1.6

Initial Start-up and Service

Steps

nitial start-up

Fig. 9

(continued)

Combustion air measuring port

ervice

14. Check coaxial 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 CO2concentration of the combustion air in the coaxial gap of the air intake pipe. The vent pipe is considered sufficiently leak-proof if a CO2concentration in the combustion air no higher than 0.2% or an O concentration no lower than 20.6% is measured. If higher CO2values or lower O2values are measured, check venting system thoroughly.

15. Remove burner assembly

1. Switch the main power supply and

the ON/OFF switch “8” on the boiler control to OFF.

The vent pipe adaptor comes with two measurement ports, one for combustion air-intake measurement and one for flue gas measurement.

D C

2. Shut off the gas valve.

3. Pull the cables from the fan motor

A, gas valve B, ionization electrode C, ignition module D and grounding wire E.

4. Release gas supply pipe fitting F.

5. Loosen the four Torx (T-30) screws

G and remove burner.

Note the gasket between the gas valve and the fitting.

CAUTION

To avoid damage to the burner, do not lay burner on its cylindrical burner tube. Failure to heed this caution may cause damage to the burner tube, which may lead to improper operation.

Fig. 10 Removing burner assembly

5418 911 v1.6

Initial Start-up and Service

Steps

(continued)

ervice

16. Check burner gasket and cylinder assembly

Check the burner gasket A and cylinder burner assembly E for damage and replace if necessary.

CADE 3xFB

1. Remove electrode block and

ionization electrode B.

2. Undo the three retaining clips C at the refractory ring D and remove refractory ring D.

3. Loosen the four Torx screws and remove cylinder burner assembly E and assembly gasket F.

4. Fit and secure new cylinder burner assembly E and new assembly gasket F. Tighten to a torque of

2.6 lb.ft. / 3.5 Nm using a calibrated torque wrench.

5. Reinstall refractory ring D.

Fig. 11 Checking burner gasket and cylinder assembly

ervice

17. Check and adjust ignition and ionization electrodes

+0,5

A B

6. Reinstall electrode block and ionization electrode B. Tighten to a torque of 2.6 lb.ft. / 3.5 Nm using a calibrated torque wrench.

1.Check the ignition electrodes A and ionization electrode B for wear and

contamination.

2. Clean electrodes with small brush (not a wire brush) or emery paper.

3. Check electrode gaps. If the gaps are not as specified, or the electrodes are damaged, replace and align the electrodes with new gaskets. Tighten the electrode fixing screws to a torque of 1.85 lb.ft. /

2.5 Nm using a calibrated torque wrench.

5418 911 v1.6

Initial Start-up and Service

Steps

Fig. 12 Cleaning the combustion

(continued)

ervice

chamber and heat exchanger

18. Clean combustion chamber/heat exchanger surface

1. Remove front enclosure panel (if still

installed) as per the instructions on page 9 in this manual, and reinstall panel upon completion of service work.

2. Remove burner assembly as per instructions on page 18.

3. If necessary, clean the combustion chamber and heat exchanger surface A with a brush and/or rinse with water.

Use solvent-free cleaning agents to remove residues: H Remove deposits of combustion

by-products with alkaline agents containing tenside.

H Remove coatings and (yellowish

brown) surface discoloration with phosphoric acid-based “Antox 75 E Plus”, or citric acid-based CitriSurft 3050 by Stellar Solutions Inc.

H Rinse thoroughly with water.

4. Mount burner and tighten diagonally to a torque of 2.8 lb.ft. / 4 Nm (four flange locknuts).

Please note:

Be careful not to scratch parts which are in contact with flue gas. Use plastic brushes, not wire brushes!

Follow Material Safety Data Sheet (MSDS) of the cleaning agent manufacturer.

The cleaning agents must not contain hydrocarbon-based solvents or potassium.

WARNING

Follow cleaning agent manufacturer’s safety instructions and wear appropriate protective equipment.

5. Install burner assembly.

6. Fasten threaded connection for the

gas connection hose with a new gasket or O-ring.

7. Connect electrical cables to corresponding parts.

IMPORTANT

Perform leak test.

5418 911 v1.6

Initial Start-up and Service

Steps

(continued)

ervice

19. Check condensate drain

1. Check that condensate can drain

freely at the siphon trap B.

2. If necessary clean siphon trap B by removing retaining clip A and siphon trap B.

3. After cleaning the siphon trap B, fill it with water, re-attach it and secure with retaining clip A.

IMPORTANT

If the condensate does not drain freely, condensate will accumulate in bottom part of boiler resulting in a burner shut-down (fault message).

Installation Instructions Neutralization Unit (if applicable)

Fig. 13

B Siphon trap C Flexible discharge tubing D Discharge tube

ervice

20. Check neutralization unit (if applicable) Accessory

1. Check the pH value of the

condensate with pH measuring strip. If the pH value is less than 6.5, replace granulate.

2. If contaminated: Rinse neutralization unit with tap water.

IMPORTANT

pH measuring strip must be field supplied.

5418 911 v1.6

3. Add granulate as marked.

IMPORTANT

The granulate is consumed as it neutralizes the condensate. The red marking indicates the min. filling level.

Installation Instructions Neutralization Unit

Initial Start-up and Service

Steps

nitial start-up

(continued)

ervice

21. Check diaphragm expansion tank and system pressure

Perform check with the system cold.

1. Drain boiler/system and reduce pressure until the manometer reading is ”0”.

2. If the nitrogen pressure of the precharged expansion tank is less than the static pressure of the system, inflate membrane pressure to slightly exceed pressure of system. The static pressure required at the tank is based upon the static height of the system. The system fill pressure value must be equal to the expansion tank pressure value at approx. 60ºF / 15.6ºC.

3. Top up with water until filling pressure is higher than the inlet pressure of the diaphragm expansion tank.

Example

Static head of 33 ft. / 10 m (distance between boiler and topmost heat emitter surface) corresponds to a static pressure of 1 bar/15 psig.

With the system cold, the filling pressure must be approx. 3 psig higher than the static pressure. Max. operating pressure: 45 psig Min. operating pressure: 14 psig

nitial start-up

ervice

4. When starting up the system for the

first time, mark this value as the minimum filling pressure on the manometer.

22. 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.

Refer to maintenance instructions supplied with low water cut-offs, pumps, etc.

A lower manometer reading usually indicates loss of water due to leakage. All leaks must be repaired.

Follow local regulations with respect to backflow preventers.

If oil-lubricated pumps are used, ensure proper lubrication.

If motorized zone valves are used, refer to maintenance instructions provided with zone valves.

Flush float water type low water cut-offs (if used).

5418 911 v1.6

Initial Start-up and Service

Steps

nitial start-up

(continued)

ervice

23. Check electrical connections

Ensure all plug-in connectors and strain reliefs make positive contact and are seated properly.

24. Check gas pipes and fittings for leaks

Installation Instructions Power/Pump Module

WARNING

The gas supply piping must be leak tested before placing the boiler in operation.

CAUTION

Ensure all joints of gas line are pressure tight and that gas valves do not leak when under normal operating pressure (use approved leak detection liquid).

5418 911 v1.6

Initial Start-up and Service

Steps

nitial start-up

Fig. 14

(continued)

ervice

25. Check CO2setting

The Vitodens 200-W, WB2B boiler is equipped with the Lambda Pro Combustion Management System developed by Viessmann which ensures optimal combustion quality independent of gas quality and type. (For a description of the Lambda Pro Combustion Management System, see page 27 in this manual.) During initial start-up and maintenance you will only need to check the CO2and O2content at the boiler vent pipe adaptor. .

Please note!

The Vitodens 200-W, WB2B boiler comes factory set to operation with natural gas. (For instructions on how to convert to operation with liquid propane gas, see page 14.) For high-altitude operation (above 5,000 ft. / 1,500 m), see page

14. The MatriX cylinder burner of this boiler is preset for the entire gas group. No adjustment or readjustment of the burner is required.

1. Connect a flue gas analyzer to test port A at boiler vent pipe adaptor.

2. Open gas shut-off valve, start up boiler and create heat demand.

3. Set boiler to low-fire by pressing buttons “9“ and “ ” at the same time. “Relay test” and then “Base

load” is shown on display.

4. Measure CO2and O2content at

boiler vent pipe adaptor. If the measured values deviated by more than 1% from the acceptable ranges for the respective fuel type listed in the right column or in the table on page 27. H check the venting system for leaks

(see subsection on page 18).

H check that the boiler is set for the

gas type used (see subsection on page 13).

5. Enter measured values into the Maintenance Record on page 73.

6. Set boiler to full-fire by pressing “⊕“. “Full load” is displayed.

7. Measure CO2and O2content at boiler vent pipe adaptor. If the measured values deviated by more than 1% from the acceptable ranges listed in the right column or in the table on page 27. H check the venting system for leaks

(see subsection on page 18).

H check that the boiler is set for the

gas type used (see subsection on page 13).

Acceptable CO2content range:

H 7.7 to 9.2% for natural gas H 9.3 to 10.9 % for LPG

Acceptable O2content range:

H 4.4 to 6.9% for all gas types

Acceptable CO2content range:

H 7.7 to 9.2% for natural gas H 9.3 to 10.9 % for LPG

Acceptable O2content range:

H 4.4 to 6.9% for all gas types

8. Press “ ” after testing and enter measured values into the Maintenance Record on page 73.

5418 911 v1.6

+ 56 hidden pages

Viessmann Vitodens 200-W WB2B 80, VITODENS 200-W WB2B Series, Vitodens 200-W, Vitodens 200-W WB2B 105, WB2B-19 Start-up/service Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual