Viessmann Vitodens 200-W, Type B2HA, Vitodens 200-W B2HA Installation And Service Instructions Manual

Installation and service
instructions

for contractors

VIESMANN

Vitodens 200-W
Type B2HA, 125 and 150 kW

Wall mounted gas condensing boiler
Natural gas and LPG version

For applicability, see the last page

VITODENS 200-W

5623 520 GB 6/2012

Please keep safe.

2

Please follow these safety instructions closely to prevent accidents and mate­rial losses.

Safety instructions explained

Danger

This symbol warns against the
risk of injury.

!

Please note

This symbol warns against the
risk of material losses and envi­ronmental pollution.

Note

Details identified by the word "Note" con­tain additional information.

Target group

These instructions are exclusively
designed for qualified personnel.

■ Work on gas equipment must only be
carried out by a qualified gas fitter.

■ Work on electrical equipment must
only be carried out by a qualified elec­trician.

■ The system must be commissioned by
the system installer or a qualified per­son authorised by the installer.

Regulations

Observe the following when working on
this system

■ all legal instructions regarding the pre­vention of accidents,

■ all legal instructions regarding envi­ronmental protection,

■ the Code of Practice of relevant trade
associations,

■ all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards,

■ Gas Safety (Installation & Use) Regu­lations
– the appropriate Building Regulation

either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire­land),

– the Water Fittings Regulation or

Water Bylaws in Scotland,

– the current I.E.E. Wiring Regula-

tions.

If you smell gas

Danger

Escaping gas can lead to explo­sions which may result in serious
injury.

■ Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical appli­ances ON or OFF.

■ Close the gas shut-off valve.

■ Open windows and doors.

■ Remove all people from the
danger zone.

■ Notify your gas or electricity
supplier from outside the build­ing.

■ Shut off the electricity supply to
the building from a safe place
(outside the building).

Safety instructions

Safety instructions

5623 520 GB

3

If you smell flue gas

Danger

Flue gas can lead to life-threat­ening poisoning.

■ Shut down the heating system.

■ Ventilate the boiler room.

■ Close all doors leading to the
living space.

Working on the system

■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.

■ Isolate the system from the power sup­ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.

■ Safeguard the system against unau­thorised reconnection.

!

Please note

Electronic modules can be dam­aged by electro-static dis­charges.
Touch earthed objects, such as
heating or water pipes, to dis­charge static loads.

Repair work

!

Please note

Repairing components which ful­fil a safety function can compro­mise the safe operation of your
heating system.
Replace faulty components only
with original Viessmann spare
parts.

Ancillary components, spare and
wearing parts

!

Please note

Spare and wearing parts which
have not been tested together
with the heating system can com­promise its function. Installing
non-authorised components and
non-approved modifications/con­version can compromise safety
and may invalidate our warranty.
For replacements, use only orig­inal spare parts from Viessmann
or those which are approved by
Viessmann.

Safety instructions

Safety instructions

(cont.)

5623 520 GB

4

Installation instructions

Preparing for installation

Product information.............................................................................................. 6

Preparing for installation....................................................................................... 7

Installation sequence

Fitting the boiler and making connections............................................................ 9

Heating water side connection............................................................................. 13

Flue gas connection............................................................................................. 13

Condensate connection........................................................................................ 14

Gas connection.................................................................................................... 15

Opening the control unit casing............................................................................ 15

Electrical connections........................................................................................... 17

Closing the control unit casing and inserting the programming unit..................... 27

Service instructions

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance.......................................... 28

Further details regarding the individual steps....................................................... 30

Code 1

Calling up coding level 1...................................................................................... 66

General/group "1"................................................................................................. 67

Boiler/group "2".................................................................................................... 70

DHW/group "3"..................................................................................................... 70

Solar/group "4"..................................................................................................... 71

Heating circuit 1, heating circuit 2, heating circuit 3/group "5"............................. 73

Code 2

Calling up coding level 2...................................................................................... 80

General/group "1"................................................................................................. 81

Boiler/group "2".................................................................................................... 90

DHW/group "3"..................................................................................................... 92

Solar/group "4"..................................................................................................... 94

Heating circuit 1, heating circuit 2, heating circuit 3/group "5"............................. 98

Diagnosis and service scans

Calling up the service level................................................................................... 107

Diagnosis.............................................................................................................. 108

Checking outputs (relay test)................................................................................ 114

Index

Index

5623 520 GB

5

Troubleshooting

Fault display......................................................................................................... 117

Fault codes........................................................................................................... 119

Repair................................................................................................................... 135

Function description

Constant temperature control unit........................................................................ 143

Weather-compensated control unit...................................................................... 144

Internal extensions (accessories)......................................................................... 145

External extensions (accessories)........................................................................ 148

Control functions.................................................................................................. 152

Assigning heating circuits to the remote control................................................... 160

Electronic combustion control unit........................................................................ 160

Designs

Connection and wiring diagram – internal connections ....................................... 162

Connection and wiring diagram – external connections....................................... 163

Parts lists

Ordering parts...................................................................................................... 165

Overview of the assemblies................................................................................. 166

Casing assembly.................................................................................................. 167

Heat cell assembly............................................................................................... 168

Burner assembly.................................................................................................. 169

Hydraulic assembly.............................................................................................. 169

Control unit assembly........................................................................................... 170

Miscellaneous....................................................................................................... 171

Commissioning/service reports

............................................................................................................................. 173

Specification....................................................................................................... 174

Certificates

Declaration of conformity...................................................................................... 175

Manufacturer's certificate according to the 1st BImSchV [Germany]................... 175

Keyword index.................................................................................................... 176

Index

Index

(cont.)

5623 520 GB

6

Vitodens 200-W, B2HA

Preset for operation with natural gas E and LL.
For conversion to LPG P (without conversion kit), see page 37.

Conversion for other countries

The Vitodens 200-W should generally only be delivered to those countries specified
on the type plate. For deliveries to alternative countries, an approved contractor, on
his own initiative, must arrange individual approval in accordance with the law of the
land.

Multi boiler system

In connection with the installation of a multi boiler system observe the installation
instructions of the multi boiler system accessories.

Preparing for installation

Product information

5623 520 GB

7

Dimensions and connections

!

Please note

To prevent equipment damage,

install all pipework free of load
and torque stresses.

165.5

165.5

923

1440

95

689

278

905

600

P

40

200

855

1975

1950

E

L

M

O

K

H

N

A
B

C

G

D

F

70 70

195

A

Safety valve

B

Expansion vessel connection G1

C

Boiler flow 7 54 mm

D

Cylinder flow 7 42 mm

E

Gas connection R 1

F

Cylinder return 7 42 mm

Preparing for installation

Preparing for installation

5623 520 GB

Installation

8

G

Boiler return 7 54 mm

H

Connection sets (accessories,
shown without the thermal insula­tion supplied)

K

Cable entry area at the back

L

Without connection set (accesso­ries)

M

With connection set (accessories)

N

Recommended dimension (single
boiler system without mounting
frame)

O

Recommended dimension (multi
boiler system and single boiler sys­tem with mounting frame)

P

Condensate drain

Preparing for the boiler installation

Note

This boiler (protection IP X4 D) is
approved for installation in wet rooms
inside safety zone 1 according to
DIN VDE 0100 [Germany], if hosed
water can be prevented.
Observe DIN VDE 0100 [or local regula­tions].

1. Prepare the water connections. Thor­oughly flush the heating system.

2. Prepare gas connection to TRGI [or
local regulations].

3. Prepare the electrical connections.

■

Power cable: NYM-J 3 x 1.5 mm2,
max. fuse 16 A, 230 V~.

■ Accessory cables: NYM with the

required number of conductors for
the external connections.

■

Allow all cables in area "K" to pro­trude 1400 mm from the wall.

Preparing for installation

Preparing for installation

(cont.)

5623 520 GB

9

Removing boiler from packaging and levelling

2x

3.

1.

2..

4.

1. Remove packing cushions and keep
them safe.
They are used as a support during
levelling.

2. Undo two screws on the underside.

3. Remove front panel.

4. Push packing cushions onto the

underside of the boiler.

Installation sequence

Fitting the boiler and making connections

5623 520 GB

Installation

10

A

5.

A

7 9 mm drilled holes for attaching
lifting gear

5.

!

Please note

To prevent damage,
do not level boiler without
packing cushions.

Level boiler with pallet.

Installation sequence

Fitting the boiler and making connections

(cont.)

5623 520 GB

11

Fitting the wall mounting bracket

Note

The enclosed screws and rawl plugs are
only suitable for concrete. For other con­struction materials, use fixings that are
suitable for 145 kg loads.

1975

Ø 12

B

C

D

A

2.

1.

A

Reference point: boiler top edge

B

Installation template (included with
the boiler)

C

Top edge finished floor

D

Recommendation

Installation sequence

Fitting the boiler and making connections

(cont.)

5623 520 GB

Installation

12

Hooking the boiler into the wall mounting bracket and levelling
it

1.

3.

2x

3.

2.

Installation sequence

Fitting the boiler and making connections

(cont.)

5623 520 GB

13

A

B

C

D

E

A

Expansion vessel connection

B

Boiler flow

C

Cylinder flow

D

Cylinder return

E

Boiler return

Note

Residual water may escape when undo­ing the locking caps.

Flue gas connection

Note

The labels "System certificate" and "Sko­berne GmbH flue system" enclosed with
the technical documentation may only be
used in conjunction with the Viessmann
flue system made by Skoberne.

Installation sequence

Heating water side connection

5623 520 GB

Installation

14

A

1. Only for open flue operation:
Remove outer gasket A (ventilation
air).

2. Connect flue pipe or flue ventilation
air pipe.

Flue system installation instruc­tions.

Condensate connection

Connect the condensate hose with a
constant fall and a pipe vent to the public
sewage system or to a neutralising sys­tem.

Installation sequence

Flue gas connection

(cont.)

5623 520 GB

15

A

Information on operation with LPG

We recommend the installation of an
external safety solenoid valve when
installing the boiler in rooms below
ground level.

1.

Seal in gas shut-off valve A into the
gas supply pipe.

2. Carry out a tightness test.

Note

Only use suitable and approved leak
detecting agents (EN 14291) and
devices for the tightness test. Leak
detection agents with unsuitable con­stituents (e.g. nitrites, sulphides) can
cause material damage.
Remove residues of the leak detec­tion agent after testing.

!

Please note

Excessive test pressure may
damage the boiler and the gas
valve.
Max. test pressure 150 mbar.
Where higher pressure is
required for tightness tests,
disconnect the boiler and the
gas valves from the gas sup­ply pipe (undo the fitting).

3. Vent the gas line.

Conversion to other gas types:
Service instructions

Opening the control unit casing

!

Please note

Electronic assemblies can be
damaged by electrostatic dis­charge.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.

Installation sequence

Gas connection

5623 520 GB

Installation

16

3.

2.

2x

1.

4.
4x

5.

Installation sequence

Opening the control unit casing

(cont.)

5623 520 GB

17

L N

230V~ 230V~

5

96

40

40962035100

1LN

X4

2 1

2

1

32 15 4

X3

LN

21

M

1~

X19

X14

A

B

21

20

L 1

C

D

145

145

LN

M

1~

A

Radio clock receiver

B

Heating circuit pump or boiler circuit
pump

C

Vitotrol 100 UTDB (only for constant
temperature control)
When making this connection,
remove jumper between "1" and
"L".

D

Vitotrol 100 UTA (only for constant
temperature control)
or
Vitotrol 100 UTDB-RF radio clock
receiver
When making this connection,
remove jumper between "1" and
"L".

Installation sequence

Electrical connections

5623 520 GB

Installation

18

Connections at plug 230 V~

sÖ

Boiler circuit pump or heating circuit
pump, variable speed with 0 - 10 V
connection

sA

Circulation pump, optional connec­tion:

■ DHW circulation pump

■ External heating circuit pump

■ Circulation pump for cylinder
heating

fÖ

Power supply

lH

■ Power supply for accessories

■ External demand/blocking

■ Vitotrol 100 UTA

■ Vitotrol 100 UTDB

■ Vitotrol 100 UTDB-RF

Connections at LV plug

!

Outside temperature sensor

?

Flow temperature sensor for low
loss header (accessories)

%

Cylinder temperature sensor (part
of the DHW cylinder connection
set)

aVG

KM BUS subscriber (accessory)

■ Vitotrol 200A or 300A remote
control

■ Vitocom 100

■ Extension kit for one heating cir­cuit with mixer

■ Solar control module, type SM1

■ Vitosolic

■ Extension AM1

■ Extension EA1

■ Wireless base station

Information on connecting
accessories

When connecting accessories
observe the separate installation
instructions provided with them.

Circulation pump at plug sÖ:

A

1~

M

sÖ

L

N

?

x4

B

A

Circulation pump

B

Only with variable speed heating cir­cuit pump:
Plug in 0 - 10 V connection at X4.

Rated current 2(1) A~
Rated voltage 230 V~

Installation sequence

Electrical connections

(cont.)

5623 520 GB

19

Circulation pump at plug sA:

A

1~

M

sA

L

N

?

A

Circulation pump

Rated current 2(1) A~
Rated voltage 230 V~

Set function of connected component
in coding address "39"
Function Code

DHW circulation pump 39:0
Heating circuit pump for
heating circuit without mixer
A1

39:1

Circulation pump for cylinder
heating (delivered condi­tion)

39:2

External demand via switching contact

Connection options:

■ Extension EA1 (accessory, see sepa­rate installation instructions).

■

Plug lH.

Connection

!

Please note

'Live' contacts lead to short cir­cuits or phase failure.
The external connection must be
floating.

Installation sequence

Electrical connections

(cont.)

5623 520 GB

Installation

20

Plug lH

Extension EA1

A

lH

N

?

1

L

A

Floating contact
When making this connec­tion, remove jumper be­tween 1 and L.

B

[{S

DE

[{D

DE

[{A

DE

A

A

Floating contact

B

Extension EA1

Burner operation is load-dependent if the contact is closed. The boiler water is heat­ed to the value set in coding address "9b" in group "General"/"1". The boiler water
temperature is limited by this set value and the electronic maximum limit (coding
address "06" in group "Boiler"/"2").

Codes

Plug lH

Extension EA1

"4b:1" in group "General"/"1" Set "3A" (DE1), "3b" (DE2) or "3C" (DE3) in

group "General"/"1" to 2.

■ Select effect of the function on the relevant heating circuit pump in coding address
"d7" in group "Heating circuit"/"5".

■ Select effect of the function on the circulation pump for cylinder heating in coding
address "5F" in group "DHW"/"3".

External demand via 0 – 10 V input

Connection at 0 – 10 V input to exten­sion EA1.

Ensure DC separation between the earth
conductor and the negative pole of the
on-site voltage source.

Installation sequence

Electrical connections

(cont.)

5623 520 GB

21

L

?

N

L

?

N

fÖ

S

P

aBJ

230 V~

Ö

[{{]

0-10V

f-]

A

=

0-10 V



+

1 2

0 – 1 V

≙ no default set boiler water
temperature

1 V

≙ Set value 10 °C

10 V

≙ Set value 100 °C

External blocking via switching contact

Connection options:

■

Plug lH.

■ Extension EA1 (accessory, see sepa­rate installation instructions).

!

Please note

'Live' contacts lead to short cir­cuits or phase failure.
The external connection must be
floating.

Installation sequence

Electrical connections

(cont.)

5623 520 GB

Installation

22

Plug lH

Extension EA1

A

lH

N

?

1

L

A

Floating contact
When making this connection, re­move jumper between 1 and L.

B

[{SDE[{D

DE

[{A

DE

A

A

Floating contact

B

Extension EA1

The burner is switched off if this contact is closed. The heating circuit pump and
circulation pump for cylinder heating are switched according to the set code (see the
following table "Codes").

!

Please note
When blocked, there is no frost
protection for the

heating system.

Codes

Plug lH

Extension EA1

"4b:2" in group "General"/"1" Set "3A" (DE1), "3b" (DE2) or "3C" (DE3) in

group "General"/"1" to 3 or 4.

■ Select effect of the function on the heating circuit pump in coding address "d6" in
group "Heating circuit"/"5".

■ Select effect of the function on the circulation pump for cylinder heating in coding
address "5E" in group "DHW"/"3".

Outside temperature sensor

!

Fitting outside temperature sensor RF
(wireless accessory):

Wireless base station

Installation sequence

Electrical connections

(cont.)

5623 520 GB

23

Fitting location for outside tempera­ture sensor

■ North or north-westerly wall, 2 to

2.5 m above ground level; in multi
storey buildings, in the top half of the
second floor

■ Not above windows, doors or vents

■ Not immediately below balconies or
gutters

■ Never render over

Outside temperature sensor connec­tion

2-core lead, length up to 35 m with a
cross-section of 1.5 mm

2

Power supply for accessories at plug

lH

230 V~
Where the boiler is installed in a wet
area, the connection of accessories to
the power supply must not be carried out
at the control unit. The power supply
connection for accessories can be made
immediately at the control unit, if the
boiler is installed outside wet areas. This
connection is switched directly with the
ON/OFF switch of the control unit.

If the total system current exceeds 6 A,
connect one or more extensions via an
ON/OFF switch directly to the mains sup­ply (see next chapter).

Installation sequence

Electrical connections

(cont.)

5623 520 GB

Installation

24

Connection of accessories

Power supply of all accessories via the boiler control unit

145

145

40 A

40

145

145

40 A

40

B C

145

40

96

A

145

145

40 A

40

D

E

Some accessories with direct power supply

145

145

40 A

40

145

145

40 A

40

B C

145

40

96

A

145

145

40 A

40

D

E

A

Boiler control unit

B

Extension kit for heating circuit with
mixer M2

C

Extension kit for heating circuit with
mixer M3

D

Extension AM1, EA1 and/or solar
control module, type SM1

E

ON/OFF switch

If the current flowing to the connected
working parts (e.g. circulation pumps) is
higher than the safety level of the acces­sory, the output concerned should only
be used to control an on-site relay.

Accessories Internal fuse

protection

Extension kit for heat­ing circuit with mixer

2 A

Extension AM1 4 A
Extension EA1 2 A
Solar control module,
type SM1

2 A

Installation sequence

Electrical connections

(cont.)

5623 520 GB

25

Power supply fÖ

Danger

Incorrect core allocation can
result in serious injury and dam­age to the appliance.
Take care not to interchange
wires "L1" and "N".

■ Install an isolator in the power cable
which simultaneously separates all
non-earthed conductors from the
mains with contact separation of at
least 3 mm.
Furthermore, we recommend instal­ling an AC/DC-sensitive RCD (RCD
class B ) for DC (fault) currents
that can occur with energy efficient
equipment.

■ Max. fuse rating 16 A.

Installation sequence

Electrical connections

(cont.)

5623 520 GB

Installation

26

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.

5

A

Low voltage connections

B

230 V connections

C

Internal extension

D

Main PCB

E

Communication module

F

Cable grommet for power cable

%

Plugs for connecting the cylinder
temperature sensor to the cable har­ness

Remove the existing cable grommet
when using larger cross-sections (up to

7

14 mm). Secure the cable with the
cable grommet plugged into the lower
casing section F (black).

Installation sequence

Electrical connections

(cont.)

5623 520 GB

27

1.

3.

2x

2.

4.

4.

6.

Insert programming unit (packed sepa­rately) into the control unit support.

Note

The programming unit can also be
housed in a wall mounting base (acces­sory) near the boiler.

Wall mounting base installation
instructions

Installation sequence

Closing the control unit casing and inserting the programming unit

5623 520 GB

Installation

28

For further information regarding the individual steps, see the page indicated

Commissioning steps

Inspection steps

Maintenance steps Page

• • •

1. Opening the boiler.......................................................... 30

•

2. Filling the heating system.............................................. 31

•

3. Selecting the language (if necessary) - only for

weather-compensated control units............................. 32

• •

4. Setting the time and date (if required) - only for

weather-compensated control units............................. 33

•

5. Venting the boiler........................................................... 34

•

6. Venting the heating system........................................... 35

•

7. Filling the siphon with water......................................... 35

• • •

8. Checking all connections on the heating water side
and DHW side for leaks

•

9. Checking the power supply

•

10. Designating heating circuits - only for weather-

compensated control units............................................ 36

• •

11. Checking the gas type.................................................... 36

•

12. Gas type conversion (only for operation with LPG).... 37

• • •

13. Function sequence and possible faults....................... 37

• • •

14. Checking the static and supply pressure..................... 39

•

15. Maximum output setting................................................ 41

•

16. Checking the balanced flue system for tightness

(annular gap check)........................................................ 42

• •

17. Removing the burner and checking the burner gasket 43

• •

18. Checking the burner gauze assembly & replacing if

required........................................................................... 44

• •

19. Checking the flue gas non-return device..................... 45

• •

20. Checking and adjusting the ignition and ionisation

electrodes........................................................................ 46

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5623 520 GB

29

Commissioning steps

Inspection steps

Maintenance steps Page

• •

21. Cleaning the combustion chamber/heat exchanger

and installing the burner................................................ 47

• •

22. Checking the condensate drain and cleaning the

siphon.............................................................................. 48

• •

23. Checking the neutralising system (if installed)

• •

24. Checking the diaphragm expansion vessel and

system pressure............................................................. 48

• • •

25. Checking the function of safety valves

• • •

26. Checking firm seating of electrical connections

• • •

27. Checking all gas equipment for tightness at operating

pressure .......................................................................... 49

• • •

28. Checking combustion quality........................................ 49

• • •

29. Checking the flue system for unrestricted flow and
tightness

• • •

30. Checking the external LPG safety valve (if installed)

•

31. Matching the control unit to the heating system ........ 51

•

32. Adjusting the heating curves (only for weather-

compensated control units)........................................... 58

•

33. Connecting the control unit to the LON....................... 61

•

34. Calling up and resetting the "Service" display............ 62

• • •

35. Fitting the front panel..................................................... 64

•

36. Instructing the system user........................................... 65

Commissioning, inspection, maintenance

Steps - commissioning, inspection and…

(cont.)

5623 520 GB

Service

30

Opening the boiler

2x

2.

1.

4.

3.

Commissioning, inspection, maintenance

Further details regarding the individual steps

5623 520 GB