Viessmann VITODENS 200, WB2-44/60 Start-up And Service Instructions

Download

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 Heating input NG 55 to 230 MBH

16 to 67 kW

Heating input LP 55 to 214 MBH

16 to 63 kW

Please file in Service Binder

VITODENS 200

Vitodens 200, WB2-44/60 (with preinstalled vent pipe adaptor)

5285 961 v1.3 09/2008

IMPORTANT

Read and save these instructions for future reference.

Page 2

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 manu al can cause product/property damage, severe personal injury,and/orloss 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 c ontractor.

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 Venting 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.

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.

5285 961 v1.3

Page 3

Index

Page

General Information

Initial Start-up and Service

Troubleshooting

Safety, Installation and Warranty Requirements 2...................................

Operating and Service Documentation 2......................................................

Important Regulatory and Installation Requirements 4...........................

About these Start-up/Service Instructions 5................................................

Necessary Tools 6...................................................................................................

Removing and Reinstalling Front Enclosure Panel a nd Cover Panel 7

Procedure (Overview) 8........................................................................................

Steps 9........................................................................................................................

Troubleshooting Steps 27......................................................................................

Diagnosis 27................................................................................................................

Correction 39...............................................................................................................

Additional Information

Overview 45................................................................................................................

Technical Data 46.....................................................................................................

Burner Control Unit LGM 29 47..........................................................................

Control Unit for Weather-Responsive Operation

H with programming unit 48.................................................................................

H jumper assignment and codings 59...............................................................

Replacement of Circuit Board VR20 61............................................................

Replacement of Burner Control Unit LGM 29 62..........................................

Wiring Diagram 65....................................................................................................

Parts Lists

H Vitodens 200, WB2 66

H Installation fittings (models WB2 11-44 and 15-60) 68........................

Alphabetical Index 69..............................................................................................

Maintenance Record 70..........................................................................................

Lighting and Operating Instructions 71............................................................

......................................................................................

5285 961 v1.3

Page 4

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 m ust be performed by a qualified heating c ontractor. 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 70 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 I nformation Manual

- System Design Guidelines

- 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.

5285 961 v1.3

Page 5

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.

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

This symbol indicates that other instructions must be referenced.

5285 961 v1.35285 961 v1.3

Page 6

General Information

Necessary Tools

Special items

H Approved leak detection fluid for

natural gas and propane gas

H Pipe joint sealant

Testing/analysis equipment

H Multimeter to measure 0 - 230 V,

0 - 12 A AC and 0 - 100 μADC

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

Cleaning supplies

H Plastic hand brush H Rags

Use only calibrated equipment.

5285 961 v1.3

Page 7

General Information

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 kind please follow the instructions below carefully when removing or reinstalling the front enclosure panel and cover panel.

To remove front enclosure panel and cover panel proceed as follows:

1. Close main gas supply valve.

2. Open flip-down cover of front enclosure panel (by exerting slight pressure with fingertip). 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.

5. Unlock enclosure panel by giving cover lock a quarter turn.

6. Remove burner cover panel by unlocking the two pull-down latches located on the bottom of the panel, and slide out panel.

7. Attach front enclosure panel.

8. Secure in place by rotating slotted

screw.

5285 961 v1.3

Page 8

Initial Start-up and Service

Procedure (Overview)

Initial start-up steps

Service steps

I I I I I S I S I S I S I S

S I S I S I

1. Fill heating system with water Page 9................................................................................................................

2. Check power supply connection Page 11..............................................................................................................

3. Select language (if required) Page 12.....................................................................................................................

4. Heating contractor address input Page 12...........................................................................................................

5. Select appropriate gas type Page 13......................................................................................................................

6. Measure static pressure and running pressure Page 13.................................................................................

7. How the Vitodens 200 boiler operates... Page 15............................................................................................

8. Check CO2setting Page 16........................................................................................................................................

9. Clock natural gas meter Page 17..............................................................................................................................

10. Check orifice size Page 17..........................................................................................................................................

11. Check all primary and secondary circuit connections for leaks Page 18................................................

12. Perform c ombustion analysis Page 18...................................................................................................................

13. Check venting system for leaks (circular air gap measurement) Page 18..............................................

14. Disassemble burner and check burner gasket Page 19..................................................................................

15. Visually check exterior of burner mesh assembly Page 19...........................................................................

S I S I S I S I S

S I I I

16. Replace burner mesh assembly (if wire mesh is damaged) Page 19........................................................

17. Check and adjust ignition and ionization electrode Page 20........................................................................

18. Check condensate drain Page 20.............................................................................................................................

19. Check neutralization unit (if applicable) Page 21................................................................................................

20. Clean combustion chamber/heat exchanger surfaces, and mount burner Page 21...........................

21. Check diaphragm expansion tank and system pressure Page 22...............................................................

22. Check functioning of safety valves Page 22.......................................................................................................

23. Check electrical connections Page 23....................................................................................................................

24. Check gas pipes and fittings for leaks Page 23.................................................................................................

25. Measure ionization current Page 24........................................................................................................................

26. Verify programming unit system coding addresses Page 24.......................................................................

27. Check extension kit for heating circuit with mixing valve Page 25..........................................................

28. Check Dekamatik-HK Page 26....................................................................................................................................

5285 961 v1.3

Page 9

Steps

Initial Start-up and Service

Initial start-up

Air vent

1. Fill heating system with water

1. Open system isolation valves (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. Optional:

Fill the heating system with w ater at the boiler filling and drain tap and drain air completely from the system at ball valve barb fitting

Max. boiler

operating pressure ......45 psig

Min. boiler

operating pressure ......12 psig

Pressure relief valve ......30 psig

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. 60 ºF/15.6 ºC.

System fill pressure must be approximately 3 psig higher than t he 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 t o the system water to protect the system. Please adhere to the specifications given by the antifreeze m anufacturer. 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 t anks, 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 a lso may contain components which might be negatively affected by antifreeze. Check total system frequently when filled with antifreeze.

5285 961 v1.3

Page 10

Initial Start-up and Service

Steps (continued)

Initial start-up

1. Fill heating system with water (continued)

5. Check system pressure and open

ball valve

6. Shut off the boiler from the heating system on heating water side (close shutoff valve

7. Connect drain hose to drain valve

or .

8. Open drain valve the boiler with system pressure until noise due to the presence of air is eliminated.

9. Close drain valve open ball valve

10. Check system pressure.

11. Ensure proper/adequate fuel supply

exists. Open gas shutoff valve.

or and vent

or and

Water flow

Air vent

5285 961 v1.3

Page 11

Steps (continued)

Initial Start-up and Service

Initial start-up

2. Check power supply connection

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

Voltage range

The voltage at connector 230 V (see wiring diagram).

Neutral conductor

The electrical power supply must have a neutral conductor.

must be

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 in section entitled ”Additional Information” in this manual.

5285 961 v1.3

Page 12

Initial Start-up and Service

Steps (continued)

Initial start-up

LANGUAGE / LANGUE

>ENGLISH:.................A

>FRANÇAIS:...............B

>BACK / RETOUR: ......D

Initial start-up

HEATING CONTRACTOR INPUT NAME/TEL.:

TEL.: >CHANGE: -/+ >POSITION FORWARD:A

>POSITION BACK: ......B

>INSTALLER SETUP: ...D

3. Select language (if required)

Menu-driven programming unit.

Open cover: Menu option Button

→ SYSTEM ”D” → FACTORY SETTING ”A” → LANGUAGE ”C”

Select language.

4. Heating contractor address input

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 I nstructions) almost immediately after a system fault has occurred.

Open the cover: Menu option Button

→ SYSTEM ”D” → INSTALLER SETUP ”C” → CODE PLEASE: ”B-C-C-B” → DIAGNOSIS ”A” → HEATING

CONTRACTOR ”C” Position cursor as required using the ”A”and”B” buttons. Select the required characters (number, letter, special character) by turning the ”G” selector knob (turn clockwise or counterclockwise).

Sequence of available characters:

0123456789ABCDEF GHIJKLMNOPQRSTUV WXYZ=<>.:k ?,–i/()

Characters already selected can be deleted with the space character ”k”or overwritten with another character.

Upon exiting the input menu (INSTALLER SETUP ”C”), name and telephone number of the heating contractor are automatically stored.

5285 961 v1.3

Page 13

Steps (continued)

Initial Start-up and ServiceInitial Start-up and Service

Initial start-up

The Vitodens 200 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

Service

Initial start-up Service

outlet

5. Select appropriate gas type

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 70.

Natural gas Propane gas

6. Measure static pressure and running pressure

Static pressure

1. To measure static and/or running

pressure remove burner cover panel as per the removal and reinstallation instructions on page 7 in these instructions.

2. Close gas shutoff valve (field supplied).

3. Loosen screw in test nipple ”PE” A on the gas combination valve, do not remove completely. Connect manometer.

970 to 1100 2466 to 2542

IMPORTANT

A CO measurement (see page 16 must be taken before and after working on gas appliances to eliminate risks to health and to guarantee the satisfactory condition of the system.

inlet

Measuring static gas supply pressure, using test nipple “PE”

5285 961 v1.3

4. Open the gas shutoff valve.

5. Measure static pressure. Values

must be:

H 14“w.c.max.forNG H 14“w.c.max.forLP

6. Enter measured value into Maintenance Record on page 70 in this manual.

7. Start up boiler, using the on/off switch on the boiler control.

IMPORTANT

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 propane gas).

After approx. 5 seconds, press the ”EU”

button to reset the burner. The ignition procedure is repeated. This boiler employs a direct spark ignition system.

Page 14

Initial Start-up and Service

Steps (continued)

Initial start-up Service

6. Measure static pressure and running pressure (continued)

Running pressure

8. Measure the running pressure; value

must be:

Running supply pressure with Corrective action Natural gas Propane gas

Hunder 4 ”w.c. (WB2-44) Hunder 7 ”w.c. (WB2-60)

H4 to 14 “w.c. (WB2-44) H7 to 14 “w.c. (WB2-60)

over 14 ”w.c. over 14 ”w.c. Do not attempt adjustment. Call local

9. Enter gas type into Maintenance Record on page 70 in this manual.

10. Switch off t he heating system on/off switch on the boiler control unit (boiler is shut down), close the gas shutoff valve, remove the manometer and re-tighten the screw in the test nipple ”PE” A.

under 11 ”w.c. Do not attempt adjustment. Call local

11 to 14 ”w.c. Start up boiler.

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

gas utility to increase pressure.

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

WARNING

Ensure that there is no open flame in the room.

outlet

inlet

Measuring running gas supply pressure, using test nipple “PE”

11. Open gas shutoff valve and check that the test nipple ”PE” and all gas connections are gas-tight.

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.

5285 961 v1.3

Page 15

Steps (continued)

Initial Start-up and Service

Initial start-up Service

7. 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. Blower speed is automatically increased or decreased based on heat demand and venting system resistances, thereby regulating the amount of combustion air drawn. The pneumatic modulating link between air and gas introduces the required amount of gas for correct combustion to meet the current heat demand, based on a linear relationship between ∆ Pairand∆ Pgas. Optimum combustion air flow rate is recognized and monitored by the differential air pressure sensor (transducer). The output voltage signal of the transducer is analyzed for logic by the LGM 29.XX burner ignition control unit. The LGM 29.XX unit contains pre-programmed performance curves and operational safety parameters unique for every boiler model. See page 47 for sequence of operation.

Flue gas adaptation function

The Vitodens employs a flue gas adaptation function. This unique function records, processes, and reacts in real time to fluctuations in pressure drops in the vent pipe during normal operation caused by partial pipe blockages due to ice formation at the vent termination, debris and/or sudden high winds. Such increase in pressure drop, if not promptly corrected, will reduce the combustion air flow rate, and hence lead to unstable combustion. The differential air pressure sensor (transducer) records such pressure drops and supplies voltage signals to the LGM

29.XX burner ignition control unit which, in turn (based on stored performance curves and safety parameters), initiates prompt adjustment of the blower rotational speed, thus readjusting the combustion air flow rate for optimum combustion. The same automatic adaptation logic applies if combustion air is reduced (or increased) due to slower (or faster) blower speed resulting from line voltage drops (or increases) below (or above) the threshold of 85% (or 110%).

outlet

Do not adjust screws X and Y!

5285 961 v1.3

inlet

WARNING

FOR FACTORY CALIBRATING PURPOSES, THE COMBINATION GAS VALVE IS EQUIPPED WITH ADJUSTMENT SCREWS X AND Y. DO NOT ATTEMPT TO ADJUST OR READJUST THESE SCREWS. ANY ATTEMPT TO TAMPER WITH FACTORY PRE-ADJUSTED SETTINGS WILL LEAD TO UNSTABLE OPERATION AND WILL AFFECT BOILER WARRANTY.

Page 16

Initial Start-up and Service

Steps (continued)

Initial start-up Service

The Vitodens 200 boiler is factory preset for operation with natural gas or propane. It is recommended t hat a CO check be performed at the boiler vent pipe adaptor as part of the initial start-up/maintenance procedure.

IMPORTANT

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

8. Check CO2setting

Depending on the gas type, the CO value lies within the range of H 6.6 to 10.0% for natural gas

H approx. 10.0 % for LP

The CO compared with the above CO ranges of the individual gas type.

1. Connect flue gas analyzer to boiler

2. Open the gas shutoff valve and start

3. Trigger a call for heat by adjusting

4. Select lower end of rated input

value measured must be

vent pipe adaptor measurement opening).

up the boiler.

the setpoint value.

range and check CO

→ SYSTEM ”D” → INSTALLER

SETUP ”C”

→ CODE PLEASE ”B-C-C-B” → DIAGNOSIS ”A” → RELAY TEST ”A”

Select menu option CONTINUE ”A” until code

10: MODULATION

10: <PL.90> CLOSED 10: BURNER 10: <PL.41> ON 10: is displayed

(”Flue gas”

content.

value

If the CO

than 1% outside the stated range for NG, or 0.5% outside the stated range for LP, perform the following steps: H Check that correct orifice was used

(see subsection entitled “Check orifice size” on page 17 and section “Technical Data” on page 46 of this manual).

H Check the venting system for leaks

(see subsection entitled “Check venting system f or leaks” on page 18 of this manual).

value measured lies more

IMPORTANT

Do not use the emissions test switch

”S” to trigger a call for heat.

5. Select top end of rated input range

and check CO

If the value differs by more than one percentage point, replace burner. Select menu option CONTINUE ”A”

until code 11: MODULATION

10: <PL.90> OPEN 10: BURNER 10: <PL.41> ON 10: is displayed

6. Exit the setting mode

H Close cover of programming unit. H Enter the measured values into

Maintenance Record on page 70 in this manual.

H Close flue gas measurement

opening

content

5285 961 v1.3

Page 17

Steps (continued)

Initial Start-up and Service

Initial start-up Service

Clock natural gas meter to verify input

1. Ensure all other gas equipment

served by the meter is turned off during timing of gas input to the Vitodens 200 boiler.

2.Measure the time in seconds it takes for the boiler to use 10 cu. ft. of gas. Divide 3600 x 10 by the number of seconds and you get the number of cu. ft. of gas used per hour. Multiply this number by the heating value of the gas to obtain Btu per hour input.

Service

9. Clock natural gas meter

For example: A Vitodens 200, WB2 11-44 boiler (172 000 Btu/h input) requires 209 seconds to use 10 cu. ft. of natural gas. After contacting the local utility, you will find the heating value is 1000 Btu per cu. ft. Therefore, 3600 x 10/209 x 1000 ≅ 172 000 Btu/h input. Therefore, the boiler input is correct.

Burner input formulas (for low altitude only):

INPUT=(3600 t=TIME (sec.) f or 1 ft.

INPUT=(3600 x .01 x 1000 x 35.31)÷T where T = TIME (sec.) for .01 m

10. Check orifice size

÷t) x 1000 where

natural gas

IMPORTANT

A boiler underfired by 5% is acceptable. Do not overfire the boiler.

CAUTION

Always contact your gas utility to obtain the correct heating value before clocking the meter.

ACB

Stamped identification code

1. Remove burner cover panel (if still installed) as per the removal and reinstallation instructions on page 7 in this manual, and reinstall panel upon completion of service work.

2. Loosen screws A and take the gas orifice holder C out of the fitting.

3. Read orifice size stamped on the orifice body and cross-reference to table below. If wrong orifice is installed, proceed to next step.

4. Push the gas orifice B sideways out of the gas orifice holder C.Snap new and correct gas orifice into gas orifice holder and push into the gas train.

5. Tighten screws A. Tighten to a torque of 1.1 lb.ft./

6. Check all gas connections for leaks

with an approved leak test solution.

Overview of orifices

Boiler model

Natural gas E44 E60

Liquid propane P44 P60

WB2 11-44 WB2 15-60

See section entitled “Technical Data” on page 46 of this manual for information on gas orifices.

IMPORTANT

Place O-ring E in groove on new gas orifice B.

1.5 Nm.

5285 961 v1.3

Page 18

Initial Start-up and Service

Steps (continued)

Initial start-up Service

11. Check all primary and secondary circuit connections for leaks

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

12. Perform c ombustion analysis

IMPORTANT

A CO measurement (see page 16) 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 70 in this manual.

Initial start-up

Combustion air measuring point

13. Check venting system for leaks (circular air gap measurement) For sealed combustion, coaxial vent only.

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 CO the combustion air in the coaxial gap of the air intake pipe. The vent pipe is considered sufficiently leak-proof if a

concentration in the combustion

airnohigherthan0.2%oranO concentration no lower than 20.6% is measured.

concentration of

If higher CO are measured, check venting system thoroughly.

Please note!

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

Please note!

This test is not applicable for single wall venting system (non-sealed combustion).

values or lower O2values

5285 961 v1.3

Page 19

Steps (continued)

Initial Start-up and Service

Service

14. Disassemble burner and check burner gasket

1. Remove burner cover panel (if still

installed) as per the removal and reinstallation instructions on page 7 in this manual, and reinstall panel upon completion of service work.

2. Switch off the heating system switch on the control unit and the power supply.

3. Close gas shutoff valve and secure.

4. Disconnect electrical cables from fan

motor sensor

transformer

5. Remove two screws disconnect gas line from gas valve.

6. Loosen six hexagon socket head cap screws

7. Check burner gaskets for damage and replace if required (see Parts List).

, differential a ir pressure

, combination gas valve

, ionization electrode , ignition

and grounding .

and remove burner.

Do not lay burner on burner mesh assembly (wire mesh)!

CAUTION

5285 961 v1.3

Service

15. Visually check exterior of burner mesh assembly

To check the exterior of the burner mesh assembly for physical damages, such as dents, corrosion and/or abnormally large holes:

1. Remove burner cover panel, if still installed (see page 7). Reinstall panel upon completion of service work.

16. Replace burner mesh assembly (if wire mesh is damaged)

1. Remove electrodes .

3. Turn thermal insulation ring

clockwise and remove.

2. Unsrew the eight Torx screws and remove burner mesh assembly

and assembly gasket .

3. Remove existing burner mesh assembly gasket .

4. Fit new burner mesh assembly with the new gasket and tighten with the eight Torx screws.

IMPORTANT

Do not replace gasket inspecting the exterior of the mesh assembly.

Tighten to a torque of 3.3 lb.ft. /

4.5 Nm

when visually

Page 20

Initial Start-up and Service

Steps (continued)

Service

17. Check and adjust ignition and ionization electrode

1. Remove burner cover panel (if still

installed) as per the removal and reinstallation instructions on page 7 in this manual, and reinstall panel upon completion of service work.

2. Check electrodes for wear and contamination.

3. Clean electrodes with small brush or emery paper.

4. Check clearances. If clearances are

CAUTION

Do not damage wire mesh when cleaning.

not satisfactory or the electrodes are damaged, replace electrodes and gasket A and align. Tighten fastening screws for the electrodes to a torque of 1.5 lb.ft. / 2Nm.

-0

+0.5

-0

-1

Service

18. Check condensate drain

Ensure condensate drains freely (e.g. at siphon trap

If necessary, clean siphon trap.

Discharge tubing Flexible discharge tubing Siphon trap

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)

5285 961 v1.3

Page 21

Steps (continued)

Initial Start-up and Service

Service

19. 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.

3. Add granulate as marked.

IMPORTANT

pH measuring strip must be field supplied.

IMPORTANT

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

Installation Instructions Neutralization Unit

20. Clean combustion chamber/heat exchanger surfaces, and mount burner

1. Remove burner cover panel (if still

installed) as per the removal and reinstallation instructions on page 7 in this manual, and reinstall panel upon completion of service work.

2. If necessary, clean the combustion chamber surfaces with water. Use solvent-free cleaning agents to remove residues: H Remove deposits of soot 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.

3. Mount burner and tighten diagonally to a torque of 3.3 lb.ft. / 4.5 Nm (six hexagon socket head cap screws).

4. Fasten threaded connection for the gas connection hose with a new O-ring.

5. Connect electrical cables to corresponding parts.

and heat exchanger with a brush and/or rinse

Please note:

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

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

WARNING

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

IMPORTANT

Perform leak test.

5285 961 v1.3

Page 22

Initial Start-up and Service

Steps (continued)

Initial start-up Service

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. 60 ºF/15.6 ºC.

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:

........................................

Min. operating pressure:

........................................

45 psig

12 psig

Initial start-up Service

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.

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

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.

5285 961 v1.3

Page 23

Steps (continued)

Initial Start-up and Service

Initial start-up Service

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

WARNING

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

Installation Instructions Power/Pump Module

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).

5285 961 v1.3

Page 24

Initial Start-up and Service

Steps (continued)

Service

25. 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 7 in this manual, and reinstall panel upon completion of service work.

2. Connect a DC μA multimeter in series with the ionization cable as follows: a)Disconnect the socket of the

ionization cable ionization electrode connect to the plug of the multimeter via adaptor

b)Connect additional ionization

measuring cable ionization electrode socket of the multimeter.

3. Start up boiler to its maximum input: Turn emissions test switch ”S”on the control unit to ”h”.

from the

and

to the

and the

Please note:

The m easurement can be made with a multimeter (measuring range 0 to 100 μA).

A C

Initial start-up

4. If the ionization current is less than

5 μA H check the electrode clearance (see

page 20).

H check the power supply

connection of the control unit.

5. After completing the measurement, turn emissions test switch to ”a”.

6. Enter the value measured in the Maintenance Record on page 70 in this manual.

26. Verify programming unit system coding addresses

The control unit must be adjusted according to the system equipment. See H page 48 onwards for programming unit. For details on coding procedure and for an overview of the coding addresses, see H page 50 onwards for programming unit.

Please note:

The minimum ionization current must be at least 5 μA when the flame is formed (approx. 2- 3 seconds after opening the gas combination valve).

5285 961 v1.3

Page 25

Steps (continued)

Initial Start-up and Service

Initial start-up

27. Check extension kit for heating circuit with mixing valve Accessory

1. Check via Scan 1 on the

programming unit whether the connected extension kit is recognized.

Please note:

The third and fourth-placed digits from the left have the following meaning:

(__ 02 _ _ = with burner control unit

Calling up Scan 1

Open the cover: Menu option Button

→ SYSTEM ”D” → OPERATING

STATUS ”B”

→ CONTINUE ”A”

until ”Scan 1” is displayed

(__12 _ _)= additionally with Vitocom

100

(__ 03 _ _ = with burner control unit

and variable speed heat circuit pump

(__13 _ _)= additionally with Vitocom

100

(__ 06 _ _ = with burner control unit

and extension kit for heating circuit with mixing valve

(__16 _ _)= additionally with Vitocom

100

(__ 07 _ _ = with burner control unit,

extension kit for heating circuit with mixing valve and variable speed heating circuit pump

(__17 _ _)= additionally with Vitocom

100

2. If the extension kit is not recognized, check the coding of the heating system type (see page 49).

Please note:

The extension kit is only recognized when connected via the KM-BUS, not when connected via the Viessmann 2-wire BUS.

Rotational direction switch Power supply switch ” ”

5285 961 v1.3

I II

Check mixing valve motor

1. Select rotational direction of the

mixing valve motor. H Switch setting I for boiler return

from left (factory default setting).

Please note:

Please reference Installation Instructions of Mixing Valve Actuator.

H Switch setting II for boiler return

from right.

2. Relay test Switch power supply switch on the motor off and on again. The unit will

perform the following self-test:

H Close mixing valve (150 sec) H Pump ON ( 10 sec) H Open mixing valve ( 10 sec) H Close mixing valve ( 10 sec)

After that normal control mode is resumed.

3. Observe the rotational direction of the mixing valve motor during the automatic relay test of the extension kit. Afterwards, position the mixing valve by hand in t he ”Open” setting.

The supply temperature sensor must now measure a higher temperature. If the temperature is lower, either the rotational direction of t he motor is incorrect or the mixing valve insert is incorrectly fitted.

Page 26

Initial Start-up and Service

Steps (continued)

Initial start-up

141

WHBNGN

21 23

22 24

141

2341

28. Check Dekamatik-HK Accessory

1. Check via Scan 2 on the

programming unit whether the connected expansion module is recognized.

Expansion module

The last-placed digit has the following meaning: 2____0 =Viessmann 2-wire BUS

expansion module not

Calling up Scan 2

Open the cover:

2____1 =Viessmann 2-wire BUS

Menu option Button → SYSTEM ”D”

recognized

expansion module is recognized

→ OPERATING

STATUS ”B”

→ CONTINUE ”A”

until ”Scan 2” is displayed

Dekamatik-HK

The second-placed digit from the left has the following meaning: _2____ =Extension kit for a heating

circuit with mixing valve or Dekamatik-HK1/-HK 2 recognized

_3____ =Dekamatik-HK4 recognized

2. If the expansion module or the Dekamatik is not recognized, check that they were installed correctly.

Please note:

A green LED will flash on the expansion module if the data BUS is intact. If the LED is not lit, the data line ”X5.3”- ”X 5.4” may be incorrectly connected.

Check setting of rotary switch

H Dekamatik-HK1:

The rotary switch on the communication module must be set to ”4”.

H Dekamatik-HK2:

The rotary switch on the circuit board E4 must be set to ”4”.

H Dekamatik-HK 4:

The rotary switch on circuit board E4.1 must be set to ”4” and the rotary switch on circuit board E4.2 to ”5”.

See wiring diagram in section entitled ”Additional Information”.

Please note:

Please reference corresponding installation documentation for Dekamatik-HK.

5285 961 v1.3

Page 27

Troubleshooting Steps

Diagnosis 1. Establish fault message or diagnose behavior of system.

2. Look for corresponding cause of fault in the diagnostics table. Diagnosis H for faults with fault display on control unit (see below).

Please note:

See page 28 for retrieval of fault codes from the fault memory.

H for faults without fault display on control unit (page 38).

3. Find corrective action in the table.

Correction 4. Perform corrective action (page 39).

Diagnosis

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.

Troubleshooting

FAULT SEARCH

FAULT:

OUTDOOR TEMP. SENSOR

>HEATG. CONTRACTOR: >ACKNOWLEDGE: A

DIAGNOSIS/SENSORS

01: OUTDOOR TEMP.

HC A 01: OPEN CIRCUIT

>CONTINUE:..............A

>BACK: ...................B

>INSTALLER SETUP: ..D

To trace the fault

1. Open cover:

→ FAULT SEARCH ”A”. Fault code is displayed.

2. Close the cover.

To reset the burner

If red light is on or flashing:

1. Press the ”EU” button once to reset

the burner.

Display window Reset button Burner fault indicator

Find nature of sensor fault in plain language

Open the cover: Menu option Button

→ MAIN MENU ”D” → SYSTEM ”D” → INSTALLER SETUP ”C” → CODE PLEASE: ”B-C-C-B” → DIAGNOSIS ”A” → SCAN SENSORS ”B”

Please note:

The fault message is cleared when ”ACKNOWLEDGE” is selected. If an acknowledged fault is not corrected by 24:00 hrs on the same day, the fault message will reappear. The acoustic alarm system (only with optional expansion board installed), is not reactivated. The meaning of the fault codes is explained in the table starting on page 30.

Please note:

Please refer to the diagnostics table starting on page 30 for details on required action.

5285 961 v1.35285 961 v1.3

Select defective sensor with the menu option CONTINUE ”A”.

Page 28

Troubleshooting

Diagnosis (continued)

Retrieval of fault codes from the fault memory

1. Open the cover:

Menu option Button

→ SYSTEM ”D” → INSTALLER SETUP ”C” → CODE PLEASE: ”B-C-C-B” → CODING 2 ”C”

2. H Select coding address ”0B2” by pressing button ”A” (CONTINUE) or ”B”(BACK).

H With the ”G” selector knob

Please note:

All settings are made in the ”Installer Setup” menu, containing ”Coding 1” (the main coding addresses in plain language) and ”Coding 2” (all coding addresses).

Changes which are made and confirmed in Coding 1 are automatically transferred t o Coding 2 and vice versa.

(CHANGE), set the value of the coding address to ”001”.

H Confirm the change with

button ”D”.

3. Select coding address ”0B3”. The value which appears is the most

recent fault code (value in brackets () in the diagnostics table).

4. Repeat step 2, but set value of

“0B2” coding address to ”002”. The

Please note:

10 fault codes can be scanned.

new value which appears under coding address ”0B3” is the next fault code.

Fault code displayed on programming unit

Fault history code displayed

Fault: F9 249

Fault: FD 253

Fault: FE 254

Fault: 02 002

Fault: 04 004

Fault: 05 005

Fault: 06 006

Fault: 07 007

Fault: 08 008

Fault: 14 020

Fault: 15 021

Fault: 0A 010

Fault: 0B 011

Fault: 0C 012

Fault: 0D 013

Fault: 0E 014

Fault: 0F 015

Fault: CC 204

5285 961 v1.3

Page 29

Diagnosis (continued)

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

Check water flow switch. Replace

if necessary.

Check cabling and plug-in connectors of the

blower , as well as blower itself.

Check differential air pressure sensor.

Seepage34.

Troubleshooting

Fault 06

Display message

5285 961 v1.3

Water flow switch activates

plug 33.

after approx. 70 seconds

Fault 94

see page 34

Page 30

Troubleshooting

Diagnosis (continued)

Display window

Reset button

Burner fault indicator

Control unit for weather-responsive operation with programming unit

Diagnostics table: Faults with fault display on control unit

Fault message in display window

Control unit for weather-responsive operation with programming unit

FAULT: OUTDOOR TEMP. SENSOR

FAULT: SUPPLY TEMP. SENSOR

FAULT: BOILER TEMP. SENSOR

FAULT: SUPPLY TEMP. SENSOR

FAULT: TANK TEMP. SENSOR

Burner System behavior fault indicator (red)

OFF Boiler operates based on 32 ºF/0 ºC outdoor temperature.

OFF Supply temperature of heating circuits too low.

OFF Boiler cools down.

OFF Mixing valve is opened.

OFF Mixing valve is closed.

OFF DHW tank cools down.

FAULT: TANK TEMP. SENSOR

FAULT: EXT.PROG.2

OFF DHW tank cools down.

ON Boiler cools down

5285 961 v1.35285 961 v1.3

Page 31

Cause of fault Corrective action

Troubleshooting

Short circuit – outdoor temperature sensor Check outdoor temperature sensor (see page 40).

Open circuit – outdoor temperature sensor Check outdoor temperature sensor (see page 40).

Short circuit – low-loss header temperature sensor Check supply temperature sensor (see page 40).

Open circuit – low-loss header temperature sensor Check supply temperature sensor (see page 40).

Short circuit – boiler temperature sensor Check boiler temperature sensor (see page 40).

Open circuit – boiler temperature sensor Check boiler temperature sensor (see page 40).

Short circuit – supply temperature sensor See Installation Instructions Mix. Valve Actuator.

Open circuit – supply temperature sensor See Installation Instructions Mix. Valve Actuator.

Short circuit – tank temperature sensor Check tank temperature sensor (see page 41).

See coding address “000” (see page 49). See coding address “0B8” (see page 56).

Open circuit – tank temperature sensor Check tank temperature sensor (see page 41).

See coding address “000” (see page 49). See coding address “0B8” (see page 56).

Internal BUS fault Replace VR20 (see page 61).

Replace LGM 29 (see page 62). Replace entire control console.

See coding address “000” (see page 49). See coding address “0B8” (see page 56).

5285 961 v1.3

Page 32

Troubleshooting

CONTROLUNIT

Diagnosis (continued)

Diagnostics table: Faults with fault display on control unit (continued)

Fault message in display window

Burner fault

System behavior

indicator (red)

FAULT: 70 RS

/WS REMOTE

CONTROL FAULT: 78

/WS REMOTE

CONTROL FAULT: A1

KM-BUS BURNER CONTROL UNIT

OFF Operates based on 68 ºF/20 ºC desired daytime

temperature, 58 ºF/14 ºC desired nighttime temperature.

OFF Operates based on 68 ºF/20 ºC desired daytime

temperature, 58 ºF/14 ºC desired nighttime temperature.

Flashes Boiler operates in emergency mode

(after approx. 30 min. BUS fault).

OFF Boiler cools down.

FAULT: A2 OFF –– FAULT: A5

KM-BUS MIXING VALVE

OFF ––

FAULT: B1 OFF DIP switches A and B on back of are switched

(e.g. A-A or B-B).

FAULT: B2 OFF Boiler cools down.

FAULT: B3 OFF Setting via service level not possible. FAULT: B6

BURNER CONTROL UNIT DEFECTIVE

FAULT: CC

(204

)

OFF Boiler cools down.

ON Burner control unit switches to lockout

(due to large line voltage fluctuations). FAULT: C8 OFF Boiler does not activate. FAULT: C0 OFF Boiler does not activate. FAULT: E4 or E... OFF ––

FAULT: F2 OFF –– FAULT: F5 OFF ––

FAULT: F9

(249

)

FAULT: FB Flashes ––

FAULT: FD

(253

)

Displayed when fault codes retrieved from fault memory.

OFF/ON Burner control switches to lockout.

ON Burner control switches to lockout.

5285 961 v1.3

Page 33

Troubleshooting

fieldsuppliedconnections(byprocessofeliminationif

Cause of fault Corrective action

Short circuit – WS/RS remote control unit Check WS/RS remote control unit (see page 44).

Open circuit – WS/RS r emote control unit or wrong coding

Internal BUS fault

Open circuit – internal BUS connection

Check WS/RS remote control unit (see page 44).

Check proper system coding.

Verify connections X5.3 and X5.4 for mixing valve (if applicable). Check that circuit board VR20 is inserted properly and check field su required). Check coding of LGM 29 c omponent part. Replace circuit board VR20 or circuit board of burner control unit LGM 29 (see page 61).

lied connections (b

rocess of elimination if

KM-BUS fault to Vitocom Check connection to Vitocom or Vitocom defective. Short circuit/open circuit – BUS connection to extension

kit for heating circuit with mixing valve

Check connection of extension kit for heating circuit with mixing valve (see page 25). Check coding for system with a mixing valve. Mixing valve might be defective.

Set DIP switches to factory default setting. See symbols on back of programming unit.

Sensor inputs are not read correctly. Check correct connection of sensors.

Data points are not stored; internal fault VR20. Replace circuit board VR20 AD-converter of burner control unit defective;

internal fault LGM 29

Check for damage on wiring harnesses. Check whether circuit board VR20 is defective. If required, replace circuit board VR20

Replace burner control unit LGM 29

Differential air pressure sensor / open circuit Check wiring, replace sensor.

Differential air pressure sensor / short circuit Check wiring, replace sensor. Internal fault or fault with internal data protection Reset burner control unit. Fault in Dekamatik-HK heating circuit control unit

connected downstream

Check Dekamatik-HK heating circuit control unit connected downstream and data transmission circuit. Check wiring con-

nections. Error message to Vitocom communication unit Check Vitocom communication unit. Error message extension kit for heating circuit with mixing

valve

Check coding for extension kit and the extension kit itself.

Check sensor of mixing valve.

Parameterization of burner control defective Replace circuit board of burner control unit LGM 29

Emergency operation LGM 29 Check plug-in connection and circuit board VR20.

Parameterization of burner control defective Replace circuit board of burner control unit LGM 29

5285 961 v1.3

Replace circuit board VR20 if necessary.

Page 34

Troubleshooting

Diagnosis (continued)

Diagnostics table: Faults with fault display on control unit (continued)

Fault message in display window

FAULT: FE

(254

)

FAULT: 02

(002

)

FAULT: 04

)

(004

FAULT: 05

)

(005 FAULT: 06

)

(006

FAULT: 07

)

(007 FAULT: 08

)

(008 FAULT: 09

)

(008 FAULT: 14

)

(020

Burner fault

System behavior

indicator (red)

ON Burner control switches to lockout

ON Burner control switches to lockout.

FAULT: 0A

)

(010 FAULT: 0B

)

(011 FAULT: 0C

)

(012 FAULT: 0D

)

(013

Displayed when fault codes retrieved from fault memory.

ON Burner control switches to lockout.

Fan does not idle after auto reset (incorrect fan rpm).

ON Burner control switches to lockout.

5285 961 v1.3

Page 35

Cause of fault Corrective action

Troubleshooting

Internal fault burner control unit or interference Check electrode settings.

Safety chain w as activated (fixed high limit) Check fixed high limit (see page 43). Bleed air from the

Fan speed too high at start (maximum fan rpm exceeded). Fan or fan electronics defective.

Fan speed too low at start (incorrect fan rpm). Check fan and flue gas system.

Air pressure threshold for ignition level is not reached. Feedback voltage signal to LGM 29 not available.

Fan speed incorrect. Check fan and flue gas system.

Fan speed too high prior to ignition (incorrect fan rpm). Check fan and flue gas system.

Fault fan speed Check fan and flue gas system.

No flame signal Check electrical connections (see page 11).

Basic level of air pressure threshold in standby mode not correct.

Severe wind conditions in vent system. Protect outside wall vent termination from severe winds.

Check wiring harness plug X13 for proper connection or

damage.

Check whether flue gas system is leak-tight.

If after corrective action fault “FE” still appears on display

replace LGM 29.

heating system.

Replace RLS 154 electric fan control.

Replace LGM 29 and/or burner assembly.

Check fan plug, fan, differential pressure sensor (see page 41)

and inlet air damper (flapper).

Check flue gas system for proper sizing and functioning.

Purge air from gas line (for LP gas, purge air several times).

Measure ionization current (see page 24).

Check gas pressure (see page 13).

Check gas combination valve (see page 13).

Check ignition transformer.

Check ignition electrodes (see page 20).

Check condensate drain (see page 20).

Check power supply polarity (L,N,G).

Check proper grounding.

Check #158 plug on (replacement) LGM 29 is installed

Check differential air pressure sensor (see page 41).

Check wiring harness and connection to air pressure sensor.

Flame signal still present after switching off. Check gas combination valve (see page 13).

Reset button “EU“ pressed repeatedly or while burner is running.

5285 961 v1.3

Check electrode block (see page 20).

Power ON/OFF boiler / acknowledge fault.

Press reset button ”EU” once.

Page 36

Troubleshooting

Diagnosis (continued)

Diagnostics table: Faults with fault display on control unit (continued)

Fault message in display window

FAULT: 25 OFF Boiler operates with high boiler water temperature.

FAULT: 26 OFF Boiler operates with continuous relay test.

FAULT: 35 OFF Boiler does not activate.

FAULT: 94 OFF Boiler does not activate.

FAULT: 95 OFF Boiler does not activate. FAULT: 51 OFF No DHW function.

FAULT: 59 OFF No DHW function.

Burner fault indicator (red)

System behavior

5285 961 v1.3

Page 37

Cause of fault Corrective action

Troubleshooting

Emissions test switch ”S” turned to ”h” f or 30 minutes already.

Setting mode for maximum or minimum rated input active for 30 minutes already.

Reset button ”EU” pressed while burner is off with emissions test switch ”S” turned to ”h”.

Basic level of air pressure threshold in standby mode not correct.

Start-up prevented. Check wiring, water and gas pressures. DHW outlet sensor / short circuit Check sensor/wiring.

DHW outlet sensor / open circuit Check sensor/wiring.

Turn emissions test switch ”S”to”a”.

Set heating program selector switch to required operating

mode or close cover on programming unit.

Turn emissions test switch ”S”to”a” and press reset

button ”EU” once.

Check differential air pressure sensor (see page 41).

Check wiring harness and connection to air pressure sensor.

Fault will clear if output signal of air pressure sensor is

correct.

See coding address “000” (page 49).

See coding address “0B8” (page 54).

See coding address “000” (page 49).

See coding address “0B8” (page 54).

5285 961 v1.3

Page 38

Troubleshooting

Diagnosis (continued)

Diagnostics table: Faults without fault display on control unit

System behavior

Supply temperature too cold or too warm. Fuse Check fuse (see page 43).

Room temperature too cold or too warm. Thermostatic radiator valves Check thermostatic radiator

Domestic hot water temperature too cold or too warm.

Boiler constantly switches on and off. Flue gas system leaking Check flue gas system for leaks

Diagnostics table: Faults on power module

System behavior

Boiler has no power Main power on/off switch Check switch position

(main power on/off switch on boiler is in ”ON” position)

Heating pump does not operate

Cause of fault Corrective action

Variable speed heating circuit pump

Heating system type incorrectly coded

Circulating pump Check circulating pump.

Cause of fault Corrective action

Power supply or boiler is not electrically connected

Fuse F1 (located in the Power/Pump Module)

Electrical connection(s) has/have been made incorrectly.

Check coding of heating circuit pump (see page 52).

Check coding of heating system type (see page 49).

valves (see page 43).

and perform leak test.

Ensure that power cord and power supply cable to the boiler are plugged in properly.

Replace fuse with same type and of same rating (T2A/250 V, slow blow)

Ensure that – connections , , and on the mother board – connections ..., , and in the boiler junction box are made correctly.

20A

Fuse F2A (located in the Power/Pump Module)

Replace fuse with the same type and of same rating (T10A/250 V, slow blow)

5285 961 v1.3

Page 39

Correction

Troubleshooting

Page

Sensors

Check outdoor temperature sensor 40

Check boiler temperature sensor 40.................................................................

Check DHW tank temperature sensor or low-loss header temperature sensor 41

.............................................................................................

Check and replace differential air pressure sensor 41...............................

Control components

Relay test 42

...............................................................................................................

Check safety fixed high limits 43........................................................................

Check fuse 43.............................................................................................................

Check thermostatic radiator valves 43............................................................

Accessories

Control unit for weather-responsive operation

H Check WS remote control unit (Accessory) 44

H Check RS remote control (Accessory) 44...................................................

.............................................................

..........................................

5285 961 v1.3

Page 40

Troubleshooting

Correction (continued)

Scanning the actual and desired t emperatures

Check outdoor temperature sensor

1 2 43

Outdoor temperature sensor

600

580

560

540

520

500

480

460

440

420

400

Resistance in Ω

-40 -22 -04 +50+68+86

-40 Outdoor temperature in ºF/ºC

+14

-10 0 +10+20+30-30 -20

+32

Check boiler temperature sensor

1. Disconnect connector ”X6” from the

control unit.

2. Measure resistance of outdoor temperature sensor at the disconnected connector between ”X6.3” and ”X6.4”, and compare with resistance/outdoor temperature curve shown on the left.

3. If the value measured differs significantly from the curve, disconnect wires from the sensor and repeat the measurement directly on the sensor.

4. Depending on the result, replace cable or the outdoor temperature sensor.

8 6

Ω

0.8

0.6

0.4

0.2

Resistance in k

50 86 122 158 194 230

68 104 140 176 212 248

10 30 50

20 40 60

Boiler water temperature in ºF/ºC

70 90 110

80 100 120

1. Disconnect cables from boiler temperature sensor A.

2. Measure resistance of the boiler temperature sensor and compare with resistance/boiler water temperature curve shown on the left.

3. If the value measured differs significantly, replace the sensor.

IMPORTANT

As the sensor is in direct contact with the boiler water, the boiler must be drained before changing the sensor.

5285 961 v1.3

Page 41

Correction (continued)

Troubleshooting

Check DHW tank temperature sensor or low-loss header temperature sensor

3 421

A DHW tank temperature sensor B Low-loss header temperature sensor

1. Disconnect connector ”X7” from the control unit.

8 6

2. Measure resistance of the tank temperature sensor and compare with the curve.

3. If the value measured differs significantly, replace the sensor.

4. Repeat above steps 1 - 3 for checking the low-loss header

Ω

0.8

0.6

0.4

0.2

Resistance in k

50 86 122 158 194 230

68 104 140 176 212 248

10 30 50 70 110

20 40 60

Tank temperature in ºF/ºC

80 100 120

temperature sensor.

Check and replace differential air pressure sensor

B D

5285 961 v1.3

C D

In case of fault messages regarding the differential a ir pressure sensor, check that

H the sensor was installed correctly. H the electrical connections were made correctly. H the O-rings in the adaptor are correctly positioned. H the test nipples have been sealed with plugs.

If the error message persists, replace sensor.

To check O-rings:

Transducer power supply

X14.3 Red................

1. Disconnect electrical plug-in

164

connection

2. Remove sensor B by pulling off in

an upward direction.

3. Check that the two O-rings C are

correctly located in the m ountings D of the adaptor.

X14.4 Yellow................

X14.5 Black................

Between red and black:

24VDC.......................

Between black and yellow:

at standby 0.2 to 0.3VDC........

at ignition 0.7 to 1.0VDC.........

at low fire 0.5 to 0.6 VDC........

4. Insert connection nipples of the

at high fire 3.5VDC........

sensor in the adaptor of the gas combination valve and snap into place.

5. Reconnect the electrical plug-in connection on the sensor.

Page 42

Troubleshooting

Correction (continued)

Relay test

DIAGNOSIS/RELAYS

02: HEATING C IRCUIT PUMP A

02: <PL. 20> ON

>CONTINUE:................. A

>BACK:........................ B

>INSTALLER SETUP:...... C

Open cover: Menu option Button

→ SYSTEM ”D” → INSTALLER SETUP ”C” → CODE PLEASE: ”B-C-C-B” → DIAGNOSIS ”A” → RELAY TEST ”A”

Select required relay to check its function with the menu option CONTINUE ”A”(seebelow).

Please note:

Those relays which are not mentioned have no significance. When the relay is selected, only the corresponding unit is addressed. If no call for heat is present, the burner is omitted from the relay test.

For installations with Dekamatik-HK mixing valve control, refer to the Dekamatik-HK control manual.

Display Meaning

01 – 1st stage burner Without function

<PL41> ON (Burner on, pump not running)

02 – Heating circuit pump A Circulating pump

<PL20> ON

03 – Heating circuit pump B Heating circuit pump

<PL20B> ON with extension kit with mixing valve

04 – DHW pump DHW heating pump

<PL21> ON

05 – Not assigned

06 – Not assigned

07 – Mixing valve HC B Mixing valve CLOSED

<PL52B> CLOSED

08 – Mixing valve HC B Mixing valve OPEN

<PL52B> OPEN

10 – Modulation Burner (min. input)

<PL90> CLOSED Circulating pump Burner <PL41> ON

11 – Modulation Burner (max. input)

<PL90> OPEN Circulating pump Burner <PL41> ON

13 – Additional heating pump Additional heating pump or

<PL28> ON DHW recirculation pump

14 – Alarm output Alarm output

<PL56> ON

Only in conjunction with mixing valve extension kit

If no low-loss header is installed, pump will be operated as a DHW recirculating pump (see coding addresses “099” and “0B8”). If a low-loss header is installed, the pump will operate as a boiler pump (see coding address “0B8”).

Only in conjunction with expansion board (optional)

5285 961 v1.35285 961 v1.3

Page 43

Correction (continued)

Troubleshooting

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. 194 ºF/90 ºC, perform the following steps: H Disconnect the cables from the fixed

high limit switch A.

H Check continuity of the fixed high

limit switch with a multimeter.

H Remove defective limit switch. H Coat new limit switch with heat

conductive paste and install.

H After start-up, press the reset button

”EU” on the control unit.

5285 961 v1.3

Check fuse

1. Disconnect connector fÖ A in the

control unit.

2. Remove fuse F 3 (6.3 A) B by holding its grip and pulling out of the base.

3. Check continuity of fuse with a multimeter.

Check thermostatic radiator valves

Check operation and setting.

IMPORTANT

The thermostatic radiator valves must not be activated in a room in which the room temperature sensor is installed for room temperature dependent operation. In case of a weather-responsive control, with a room temperature sensor via the RS remote control unit, keep the thermostatic radiator valves fully open.

Page 44

Troubleshooting

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 f or setting the desired room temperature values from the main living room (with room temperature dependent control).

Functionality check

IMPORTANT

Resistance measurement and control unit response test. If the presence of a fault is suspected in the customer’s connecting cable, temporarily connect the remote control directly to the control unit and perform test.

To calculate total r esistance (NTC), add the actual value and the current resistance setpoint value.

In most cases, faulty behavior of the control unit is due to the installation of the RS remote control unit in an unsuitable location. This can lead to draft phenomena caused by cavities behind the remote control or by the stack effect of empty pipes.

Wiring diagram: see section e ntitled ”Additional Information”.

310

Ω

300

290

280

Resistance in

54 61 68 75 82

12 20 24 2816

Setpoint value

ºF ºC

WS remote control s– Setpoint value between terminal

”9” and ”10”

m – Setpoint value between terminal

”9” and ”11”

240

220

200

Ω

180

160

140

Resistance in

8 1216202428

Actual value

54 68 75 82

ºF ºC

RS remote control Room temperature sensor (NTC) curve between terminal ”9” and ”13”

172 152 145

Ω

138 119 108

84 59

Resistance in

46 54 61 68 75

50 57

812

Setpoint value

64 72 79

16 20 24

14 18 22

ºF

ºC

RS remote control s– Setpoint value between terminal

”10” and ”14”

m – Setpoint value between terminal

”11” and ”14”

5285 961 v1.3

Page 45

Overview

Additional Information

Page

Technical Data 46.....................................................................................................

Burner Control Unit LGM 29.XX 47..................................................................

Control Unit for Weather-Responsive Operation with Programming Unit 48

Functional description 48...................................................................................

Heating system types 49....................................................................................

Accessing coding addresses 50......................................................................

Heating curve 51....................................................................................................

Overview of coding addresses 52..................................................................

Accessing temperature settings 58................................................................

Jumper Assignment and Codings 59................................................................

Assignment of plug-in jumper on circuit board VR20 59.....................

External switching of the heating program 59..........................................

External heat demand 59.....................................................................................

External disable 60.................................................................................................

....................................................................................

Replacement of Circuit Board VR20 61............................................................

Replacement of Burner Control Unit LGM 29 62..........................................

Wiring Diagram 64....................................................................................................

Parts Lists 66...............................................................................................................

Vitodens 200, WB2 66...................................................................................

Installation fittings (models WB2 11-44 and 15-60) 68.....................

Alphabetical Index 69..............................................................................................

Maintenance Record 70..........................................................................................

Lighting and Operating Instructions 71............................................................

5285 961 v1.3

Page 46

Additional Information

Technical Data

Rated voltage: 230 VAC Rated frequency: 60 Hz Rated current: 2.5 A~

Max. ambient temperature H at operation: 32 to 104 ºF

Setting of fixed high limit safety cut-out: 210 ºF (fixed setting) 99 ºC

–0 to +40 ºC

H when storing

Main fuse: max. 16 A

and transporting: –4 to +149 ºF

–20 to +65 ºC Setting of adjustable electronic high limit 167 ºF

Power consumption

H Burner: max. 105 W H Control unit: max. 10 VA

75 ºC

WARNING

Always ensure the correct orifices are installed in the boiler. See table below. The boiler must achieve the output stated on the rating plate. Do not overfire the boiler.

Standard heating boiler

Boiler Model Model No. WB2 11-44 WB2 15-60

Natural gas

CSA input

CSA output/DOE heating capacity

Net I=B=R rating

Propane gas

CSA input

CSA output/DOE heating capacity

Net I=B=R rating

Min. gas supply pressure

Natural gas Propane gas

Max. gas supply pressure

Natural gas Propane gas

Flue gas

Temperature (at boiler return water temp. of 86 ºF/30 ºC) – at rated full load – at rated partial load

Temperature (at boiler water return temp. of 140 ºF/60 ºC)

Max. natural gas flow rate ft3/h

Max. propane gas flow rate ft3/h

Burner orifices diameter

Natural gas Propane gas

Net I=B=R rating based on piping and pick-up allowance of 1.15. If the gas supply pressure exceeds the maximum gas supply pressure value, a separate gas pressure regulator must be installed upstream of the

heating system.

Measured flue gas temperature with combustion air temperature of 68 °F/20 °C.

MBH kW MBH kW

MBH 133 178

MBH kW MBH kW

MBH 120 166

“w.c. “w.c.

ºF/ºC ºF/ºC

ºF/ºC

Ømm Ømm

55-172

16-50

49-153

14-44

55-155

16-45

49-138

14-40

14 14

95/35 91/33

149/65

172

4.87

1.75

(E44) 8.40 (P44) 6.10

80-230

23-67

71-205

21-60

37-112

11-33

33-101

10-30

14 14

104/40

95/35

158/70

230

6.51

85.6

2.42

(E60) 9.00 (P60) 6.70

5285 961 v1.3

Page 47

Burner Control Unit LGM 29.XX

Program sequence

Standby

Initial boiler run

time with

internal tests Call for heat Ionization Safety chain (FHL)

Gas combi valve

Ignition transformer Combustion air modulation

Speed

Time in sec. <71 2 0.2 <5 5 Heating mode

signal required signal invalid

signal required for transition to next phase

Pre-purge time

Pre-ignition time

Safety time

Flame

recognition

Operation

Modulation range

Shutdown and

auto reset with

max. 51

Additional Information

internal tests

Standby

Waiting time until next call for heat start. Differential air pressure sensor must be reset and the speed feedback signal (HALL) must record that fan is stationary.

Start-up and initial boiler run time

Start takes place when a call f or heat is received f rom the temperature controller, provided no air pressure is detected. The fan motor receives voltage. The speed signal (HALL) and the differential air pressure voltage signal must be received by the burner control unit LGM 29.XX within approx. 70 seconds, otherwise a fault message is transmitted. During the initial boiler run time, self-tests take place within the burner control unit LGM 29.XX.

Pre-purge time

The combustion chamber is flushed out by the fan.

Pre-ignition time

Ignition spark is initiated.

Safety time

The gas combination valve coils receive voltage (energized), flame monitoring is activated. Ignition is switched off after approx. 4 seconds. If the flame is not recognized during ignition after three trials, automatic lockout takes place.

5285 961 v1.3

Burner operation (green LED is lit)

Burner operation begins after the safety time has e lapsed, and flame recognition has taken place successfully. The burner control unit modulates from its ignition load according to the currently selected setpoint value. After controlled shutdown (heat demand is satisfied), a uto reset to the standby mode takes place.

Shutdown

The gas valve is de-energized. Internal tests are performed.

Test time

Auto reset is the end of the shutdown phase after controlled switch-off. Auto reset also takes place after resetting, failure of the flame during operation or after a call for heat is terminated before the start of the safety time.

Safety chain (FHL)

The fixed high limits must be closed at all times during the entire period of operation, otherwise automatic lockout takes place immediately.

Burner control unit LGM 29.XX The burner control unit LGM 29.XX performs self-tests in the following instances: H when the burner has been in

continuous operation for more than 24 hours,

H before each time the burner is

switched on,

H after each time the burner is

switched off.

Behavior in the event of malfunctions

If faults are detected, e ither no start-up takes place or automatic lockout is triggered. In case of all safetyrelevant malfunctions, the gas supply is cut off. Automatic lockout takes place H when flame establishment fails

before the end of the flame recognition time,

H in the event of an uninterrupted delay

of the flame signal for more than 3 seconds,

H in the event of an incorrect differential

air pressure sensor signal longer than 70 seconds,

H in the event of internal faults.

In the event of a line voltage drop, the burner control unit either operates without a fault indication function or goes into reset position (gas valve closed). When the line voltage reaches its normal level again, burner c ontrol is ready for another start-up.

Page 48

Additional Information

Control Unit for Weather-Responsive Operation with programming unit

Functional description

Space heating mode

The control unit calculates a boiler water setpoint temperature based on the outdoor or room temperature (where a room temperature dependent remote control is connected) and on the slope/shift of the heating curve. The computed boiler water setpoint temperature is transmitted to t he burner control unit. From the boiler water setpoint and the actual temperature the burner control calculates the degree of modulation required, and regulates the burner accordingly. The maximum operating boiler water temperature is limited in the burner control unit to 167ºF / 75ºC by the electronic temperature control. The maximum adjustable high limit of the boiler is 180ºF / 82ºC. The fixed high limits of the safety chain interlock the burner control unit at 210 ºF/99 ºC boiler water temperature.

Programming Unit (removable)

Domestic hot water supply with gas-fired space heating boiler

Domestic hot water heating is activated when the tank temperature is

4.5 ºF/2.5 ºC below the tank temperature setpoint value. The burner and the tank DHW pump are switched on. In the f actory default setting, the desired boiler water temperature is set at 36 ºF/20 ºC above the tank temperature setpoint value. When the actual tank temperature rises 4.5 ºF/2.5 ºC above the tank temperature setpoint value, the burner is switched off and the time delay function of the tank DHW pump is activated.

Additional heating function (anti legionnaire-function) for domestic hot water production

The additional heating function is activated when an activation period of 10 minutes is selected (e.g. 22.10 to

22.20 hrs). This period must lie outside the switching times for normal domestic hot water heating so that the signal is recognized by t he control unit.

The temperature setpoint value for additional heating is set in coding address ”0A7”.

Pressure gage

Display window

Heating program selector switch

Burner fault reset button

Emission test switch (override switch)

Selector knob for ”normal room temperature”

Burner operating status indicator

Burner fault indicator

Boiler on/off switch

Party button

Energy savings button

Selector knob for ”reduced room temperature”

Information button

”Factory default settings” button

Selector knob

Flip-down cover

Selector buttons

DHW comfort function switch (only available on Combi heating boiler)

5285 961 v1.3

Page 49

Additional Information

Control Unit for Weather-Responsive Operation

with programming unit (continued)

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”.

H The coding is set automatically when a tank temperature sensor is connected (for operation with a DHW tank). H The control unit must be r e-coded m anually if a heating circuit with mixing valve is connected:

For this purpose the corresponding heating system type is coded in the coding address ”000”. For other settings please note numbers of system types.

See page 50 for information of how to access t he required coding level.

Please note:

If only heating circuit B with mixing valve is connected (i.e. there is no direct-connected heating circuit), coding address ”008” must be set to value ”001”.

Refer to the Vitodens 200 Installation Instructions for piping layout details.

System type ”000:000”

Heating system with one heating circuit without mixing valve, without DHW heating

Circulating pump and check valve are external to the boiler and not internal as illustrated.

5285 961 v1.3

or Heating system with low-loss header and heating circuits connected downstream with separate heating circuit control unit (Dekamatik-HK), without DHW heating.

System type ”000:001”

Heating system with one heating circuit without mixing valve, with DHW heating or Heating system with low-loss header and heating circuits connected downstream with separate heating circuit control unit (Dekamatik-HK), with DHW heating.

System type ”000:002”

Heating system with one heating circuit with mixing valve, without DHW heating (with or without low-loss header) or Heating system with one heating circuit with mixing valve and one heating circuit without mixing valve, without DHW heating (with or without low-loss header).

System type ”000:003”

Heating system with one heating circuit with mixing valve, with DHW heating (with or without lowloss header) or Heating system with one heating circuit with mixing valve and one heating circuit without mixing valve, with DHW heating (with or without low-loss header).

Page 50

Additional Information

Control Unit for Weather-Responsive Operation

Accessing coding addresses

The coding of the programming unit is performed by using the ”A”, ”B”, ”C” and ”D” buttons and t he ”G” selector knob.

Open cover: Menu option Button

→ SYSTEM ”D” → INSTALLER SETUP ”C”

→ CODE PLEASE: ”B-C-C-B” → CODING 1 ”B”

or CODING 2 ”C”

The desired coding address is selected by pressing button ”A” (CONTINUE) or ”B”(BACK). The respective coding address is changed with the ”G” selector knob (CHANGE). The change is confirmed with button ”D” (change is stored).

with programming unit (continued)

Please note:

All the settings are performed in the ”Installer Setup” menu which contains ”Coding 1” (main coding addresses in plain language) and ”Coding 2” (all coding addresses).

Changes made and confirmed in Coding Level 1 are automatically adopted in Coding Level 2 and vice versa.

5285 961 v1.3

Page 51

Additional Information

Control Unit for Weather-Responsive Operation

Heating curve

Slope

Boiler water temperature or

230

212

194

176

158

140

122

supply temperature in ºF/ºC

104

ºF ºC

110

100

3.2

3.4

10 5 0 -5 -10

50 41 32 23

Outdoor temperature

3.0

2.8

-15

2.4

2.6

2.2

2.0

1.8

1.6

1.4

1.2

1.0

0.8

0.6

0.4

0.2

ºC

-20

-4

ºF

with programming unit (continued)

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. In turn, the room temperature is dependent on the boiler water or supply temperature. If a different room temperature is set, the curves are shifted parallel to the desired room temperature axis.

Factory settings:

H slope ”n”=1.4 H shift ”N”=0

230/ 110

Boiler water temperature or

supply temperature in ºF/ºC

+68/20 -4/20

Outdoor temperature in ºF/ºC

230/ 110

Boiler water temperature or

supply temperature in ºF/ºC

+68/20 -4/20

5285 961 v1.3

Outdoor temperature in ºF/ºC

3.5

-13

+40

1.4

0.2

1.4

1. To change the slope

Open cover on programming unit a nd go through menu as follows: Menu option Button → HEATING CIRCUIT A ”A”

or HEATING CIRCUIT B ”B”

→ HEATING CURVE ”B” → CHANGE ”A”

2. To change the shift

Open cover on programming unit a nd go through the menu as follows: → HEATING CIRCUIT A ”A”

or HEATING CIRCUIT B ”B”

→ HEATING CURVE ”B” → CHANGE 2 × ”A”

Page 52

Additional Information

Control Unit for Weather-Responsive Operation

Overview of coding addresses

Coding addresses not discussed in this section must not be changed. See page 50 for information of how to access coding addresses.

Coding (factory default setting) Address: Value

000:000 One heating circuit without mixing valve,

001:000 Do not change 003:001 DHW

004:000 Do not change 005:001 Heating

006:001 Heating

007:000 DHW

Function mode Coding

change Address: Value

000:001 system without domestic hot water heating

000:002

000:003

tank

circuit

With priority switching over heating circuit pump(s)

With heating circuit pump logic function

003:000 Without priority switching over heating circuit

005:000 Without heating circuit pump logic function

pump

circuit pump

tank

Heating circuit pump speed in reduced range as per coding address ”044:...”

Setting range of domestic hot water temperature

006:000 Heating circuit pump speed in reduced range

007:001 Setting range of domestic hot water tempera-

50 to 140 ºF/10 to 60 ºC

*1, 2

with programming unit (continued)

Possible change

One heating circuit without mixing valve, system with domestic hot water heating One heating circuit with mixing valve, system without domestic hot water heating One heating circuit with mixing valve, system with domestic hot water heating

pump(s)

as per coding address ”046:...”

ture 50 to 158 ºF/10 to 70 ºC

IMPORTANT

Note max. tank water temperature.

008:000 Do not change 009:000 Program-

ming unit

Display of boiler water temperature

010:000 Do not change 011:000 External call for heat or external

switching of heating program blocked

012:000 Do not change 013:000 Heating

circuit pump

Heating circuit pump without variable speed operation (e.g. as temporary m easure f or servicing)

014:000

Heating circuit

Party button ”g” effective for heating circuit B

015:001 Do not change

Coding for systems with domestic hot water heating is automatically recognized.

These codings also apply on systems with one heating circuit without mixing valve and one heating circuit with mixing valve.

Only on heating system types ”000:002” and ”000:003” (heating systems with one heating circuit with mixing valve).

IMPORTANT

Do not adjust domestic hot water temperature more than 140 ºF/ 60 ºC.

009:001 Display of outdoor temperature

011:001 External call for heat or external switching of

heating program active at X4.1 - X4.2

013:001 With variable speed heating circuit pump (au-

tomatic recognition)

014:001

Party button ”g” effective for heating circuit A and heating circuit B

5285 961 v1.3

Page 53

Additional Information

Control Unit for Weather-Responsive Operation

with programming unit (continued)

Overview of coding addresses (continued)

Coding (factory default setting) Address: Value

Function mode Coding

change Address: Value

Possible change

016:000 Do not change 017:001 Do not change 018:000 DHW

tank

019:000 Program-

ming unit or remote control

Circulating pump with time delay function

Weather-responsive operation (WS function) for all connected heating circuits

018:001 Circulating pump without time delay function

019:001

H On systems with one heating circuit

without mixing valve or one heating circuit with mixing valve: Operation with room temperature dependent control (RS function)

H On systems with one heating circuit

without mixing valve and one heating circuit with mixing valve: Weather-responsive operation (WS function) for heating circuit with mixing valve and operation with room temperature dependent control (RS function) for heating circuit with mixing valve

H On systems with one heating circuit

019:002

without mixing valve or one heating circuit with mixing valve: Weather-responsive operation (WS function) in normal heating mode and operation with room temperature dependent control (RS function) in reduced operation

H On systems with one heating circuit

without mixing valve and one heating circuit with mixing valve: Weather-responsive operation (WS function) for heating circuit without mixing valve and on weather-responsive basis in normal heating mode and operation with room temperature dependent control in reduced operation (WS/RS function) for heating c ircuit with mixing valve

020:000 Heating

circuits

Without WS or RS remote control unit

020:001 With WS or RS remote control unit

027:000 External switching of heating program 027:001 External call for heat 028:000 Boiler During DHW production, the

boiler water temp. is max. 36 ºF / 20 ºC higher than the

028:001 During domestic hot water production, the

boiler water temperature is limited to 172 ºF/78 ºC by the limit thermostat

desired tank water temp. 029:001 Do not change 033:000 Do not change 034:000 Do not change 036:000 Do not change 038:020 Minimum supply temperature in heating mode 020 to 127 Min. possible supply temperature

68 to 261 ºF / 20 to 127 ºC

Change only feasible if programming unit is mounted on a wall-mount base.

Address set automatically, must be reset manually.

5285 961 v1.3

Page 54

Additional Information

Control Unit for Weather-Responsive Operation

with programming unit (continued)

Overview of coding addresses (continued)

Coding (factory default setting) Address: Value

Function mode Coding

change Address: Value

Possible changes

042:070 Boiler water temperature in heating mode 000 to 82 Max. adjustable temperature limit setting

180ºF / 82ºC

044:030 Heating

circuit pump

Minimum rotational speed of heating circuit pump; approx. 1100 rpm

044:001 to 044:100

Lowest value for minimum rotational speed of heating circuit pump; approx. 700 rpm Highest value for minimum rotational speed of heating circuit pump; approx. 2700 rpm

045:065 Heating

circuit pump

Maximum rotational speed of heating circuit pump; approx. 1750 rpm

045:001 to 045:100

Lowest value for maximum rotational speed of heating circuit pump; approx. 700 rpm Highest value for maximum rotational speed of heating circuit pump; approx. 2700 rpm

046:045 Heating

circuit pump

Rotational speed of heating circuit pump in reduced operation; approx. 1200 rpm

046:001 to 046:100

Lowest value for rotational speed of heating circuit pump in reduced operation; approx. 700 rpm Highest value for rotational speed of heating cir-

cuit pump in reduced operation; approx. 2700 rpm 049:___ Hours run (”hundreds”) at 3rd place from left 049:000 Reset hours run 050:___ Hours run (”units”) at 3rd place and

050:000 Reset hours run

”tens” at 2nd place from left 055:040 Do not change 085:032 Do not change 086:032 Do not change 088:007 Do not change 089:008 Do not change 099:000 Possibility for connecting a DHW

recirculating pump (on timer schedule)

099:001 Output signal for domestic hot water

production active (ON), whenever there is a call for DHW only

0A0:020

Differential temperature between desired

boiler water temperature and desired

tank temperature with domestic hot water

0A0:10 to 0A0:50

heating 0A1:000 Do not change 0A2:075 Boiler Desired boiler temperature

with external request 167 ºF/75 ºC

0A2:032 to 0A2:127

Setting range of desired boiler water temperature 90 to 261 ºF/32 to 127 ºC (max. possible boiler water temperature 180 ºF/82 ºC)

0A3:___ Do not change

One increment corresponds to approx. 20 rpm.

Only effective with coding 028:000.

5285 961 v1.3

Page 55

Additional Information

Control Unit for Weather-Responsive Operation

Overview of coding addresses (continued)

Coding (factory default setting) Address: Value

0A4:255 Do not change 0A5:255 Do not change 0A6:255 Do not change 0A7:060 DHW

0A8:000 Boiler See table below for effect of

Function mode Coding

change Address: Value

tank

Setpoint value for ”Additional function for domestic hot water heating” (“Anti-Legionnaire-Function” – domestic hot water heated briefly to 140 ºF/60 ºC)

external disable signal (also see page 59)

A07:061 to A07:070

0A8:001 to 0A8:007

with programming unit (continued)

Possible changes

Setting range between 142 to 158 ºF/ 61 and 70 ºC.

IMPORTANT

Do not adjust domestic hot water temperature more than 158 ºF/ 70 ºC.

See table below for effect of external disable signal

Possible coding changes for coding address 0A8 ”external disable”

Coding

0A8:000 × × × × Blocked 0A8:001 OFF OFF CLOSED OFF Blocked 0A8:002 × × × OFF Blocked 0A8:003 × OFF CLOSED × Blocked 0A8:004 OFF × × × Blocked 0A8:005 OFF × × OFF Blocked 0A8:006 OFF × × × Blocked 0A8:007 OFF OFF CLOSED × Blocked

× = in normal control mode

Heating circuit pump

Heating circuit with mixing valve (extension kit)

Heating circuit pump Mixing valve

Tank (Circulating pump for tank heating)

Burner

5285 961 v1.3

Page 56

Additional Information

pum

fortankheatingtemperature

accordingto

Control Unit for Weather-Responsive Operation

with programming unit (continued)

Overview of coding addresses (continued)

Coding (factory default setting) Address: Value

0A9:098 Circulating

Function mode Coding

change Address: Value

pump

Max. rotational speed of circulating pump for DHW production

0A9:001 to 0A9:100

Possible changes

Lowest value for rotational speed of circulating pump for DHW production Highest value for rotational speed of

circulating pump for DHW production 0B2:___ Fault memory (see page 28) 0B3:___ Fault memory (see page 28) 0B4:___ Do not change 0B8:000 Space heating only - no DHW 0B8:001

0B8:002

With DHW heating

Optimum DHW heating (with anti legionnaire

function) (see page 48).

0B8:005 0B8:006

Combi boiler only

Not assigned. Must be changed to one of the

other coding addresses. 0C1:011 Freeze-up protection threshold

+34/+37ºFor+1/+3ºC

0C1:000 0C1:015

+50/+18ºFor+10/–8ºC

+41/+45ºFor+5/+7ºC 0C2:008 Do not change 0C5:000 Boiler See table below for effect of

external heat demand signal (also see page 59)

0C5:001 to 0C5:011

Possible coding changes for coding address 0C5 ”external heat demand”

Coding Heating circuit

pump

Heating circuit with mixing valve (extension kit)

See table below for effect of external

heat demand signal

Circulating pump for tank heating

Heating circuit pump Mixing valve

0C5:000 ON OFF CLOSED OFF 0C5:001 OFF OFF CLOSED OFF 0C5:002 × OFF CLOSED OFF 0C5:003 OFF × × OFF 0C5:004 ON × × OFF 0C5:005 × × × OFF 0C5:006 OFF OFF CLOSED × 0C5:007 ON OFF CLOSED × 0C5:008 × OFF CLOSED × 0C5:009 OFF × × × 0C5:010 ON × × × 0C5:011 × × × ×

× = in normal control mode

One increment corresponds to approx. 20 rpm.

This is set automatically when a tank temperature sensor is connected; can be reset to ”001” manually if required.

Once this function has ended, the program changes automatically to the ”Space heating and DHW heating” mode.

Boiler water temperature

Maintained at desired value

coding address ”0A2”

5285 961 v1.3

Page 57

Additional Information

Control Unit for Weather-Responsive Operation

Overview of coding addresses (continued)

Coding (factory default setting) Address: Value

0C6:000 Do not change 0C7:003 Resetting

0C8:001 External

0C9:003 Startofsummertime:March 0C9:001

0D0:005 Start of summer time: Last week of

0D1:007 Start of summer time: Last day of week

0D2:010 Startofwintertime: October 0D2:001

0D3:005 Start of winter time: Last week of

0D4:007 Start of winter time: Last day of week

0D5:000 Program-

0D6:000 Program-

0D7:000 Do not change

Function mode Coding

change Address: Value

Automatic 0C7:000

to summer/ winter time

switching of heating program

ming unit

Contact open: Space heating ON/domestic hot water heating ON (accordingtotimeprogram) Contact closed: Central heating OFF/domestic hot water heating OFF.

month

(Sunday)

month

(Sunday)

Normal display format with cover closed

Temperatures displayed in ”ºC” (º Celsius)

0C7:001 0C7:002

0C8:000 Contact open:

to 0C9:012

0D0:001 to 0D0:005

0D1:001 to 0D1:007

to 0D2:012

0D3:001 to 0D3:005

0D4:001 to 0D4:007

0D5:001 Large display format for time and outdoor

0D6:001 Temperatures displayed in ”ºF” (º Fahrenheit)

with programming unit (continued)

Possible change

Manual resetting to s/w / date change blocked Automatic resetting to s/w Manual resetting to s/w / date change released

Central heating ON/domestic hot water heating ON (according to time program) Contact closed: Continuous space heating ON/domestic hot water heating ON (independent of preset time program)

January to December

Week 1 to Week 5 of selected month

Monday to Sunday

January to December

Week 1 to Week 5 of selected month

Monday to Sunday

temperature with cover closed

5285 961 v1.3

Page 58

Additional Information

Control Unit for Weather-Responsive Operation

Accessing temperature settings

The following desired and actual temperature values can be accessed and shown on the display of the programming unit:

H Outdoor temperature H Boiler water temperature H Supply temperature of the extension

kit for the heating circuit with mixing valve

H Room temperature (if programming

unit is mounted on a wall-mount base andusedasaremotecontrol).

Open the cover: Menu option Button → HEATING

CIRCUIT A or ”A” HEATING CIRCUIT B or ”B” SYSTEM ”D”

→ OPERATING STATUS”C”or”B” → CONTINUE ”A”

with programming unit (continued)

Depending on the coding, the boiler water temperature or the outdoor temperature is shown in the first menu on the display.

H Domestic hot water temperature

Open cover: Menu option Button

→ DHW ”C” → DHW TANK ”A” → OPERATING STATUS”C”

5285 961 v1.3

Page 59

Jumper Assignment and Codings

Assignment of plug-in jumper on circuit board VR20

Additional Information

Plug-in jumper ”X6”

Factory default setting without ”External burner disable” function.

With ”External burner disable” function.

Plug-in jumpers ”X2” - ”X 4”

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 r emoved.

External switching of the heating program (telephone contact)

With programming unit

Change coding address ”011:000” to ”011:001”.

External heat demand field supplied

With programming unit

Change coding address ”011:000” to ”011:001” and ”027:000” to ”027:001”.

Boiler start-up takes place in accordance with the settings of coding address ”0C5”. Boiler water temperature is maintained at the value selected in coding address ”0A2”.

5285 961 v1.3

Page 60

Additional Information

Jumper Assignment and Codings (continued)

External disable field supplied

1. Remove circuit board VR 20 A.

2. Reverse plug-in jumper ”X6” B.

3. Insert circuit board A again.

Boiler shutdown takes place in accordance with the settings selected in coding address ”0A8”.

5285 961 v1.3

Page 61

Additional Information

000:000(withoutDHW;factorydefaultsetting)Setaccordingtosystemla

001(withDHWstoragetank)

indicated

Replacement of Circuit Board VR20

IMPORTANT

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.

Removing circuit board VR20

Coding information

1. Loosen the two screws located

underneath the control carefully fold down t he control.

2. Unscrew and remove cover

3. Slide out circuit board VR20

using supplied handle.

Installing the replacement circuit board

1. Slide circuit board VR20

back into the control. Ensure that circuit board is fully plugged in and makes positive contact.

2. Reinstall front enclosure panel and cosmetic piping cover.

3. Verify that all coding addresses and their values a re programmed t o recorded actual/required values. See table below.

4. Turn on power supply to boiler and start up boiler.

and

Please note! This table does not reflect all necessary coding cha nges required for proper operation of the boiler. See subsection “Overview of coding addresses” in this manual for other coding changes required.

Coding address

000: 000 (without DHW; factory default setting) Set according to system lay-

015: 001(factory default setting) Do not change! 017: 001(factory default setting) Do not change! 0B8: 000 (no DHW storage tank)

5285 961 v1.3

Possible coding values Required action

001 (with DHW storage tank) 002 (with DHW storage tank optimized) 006 not assigned

out. See page 52 for details.

Set to (one of) the value(s) indicated.

Page 62

Additional Information

Replacement of Burner Control Unit LGM 29

Removing the circuit board

1. Unlock hooks

located on both sides of the control unit and remove the control housing

of the control

unit.

2. Remove pressure gage .

3. Loosen the two screws located

underneath the control unit

and

carefully fold down t he control unit.

4. Remove covers , , and .

5. Remove all plug-in connectors and

the grounding wire, including #158 plug.

6. Slide off circuit board VR20

using

the supplied handle.

7. Loosen screws holding installed circuit board LGM 29.22 in place and remove carefully.

Setting the dip switch (applicable only t o replacement boards)

345678

1. Set dip switch

setting of the new circuit board according to the table on the following page.

IMPORTANT

To ensure the boiler is operated in accordance with its certification (see boiler rating plate), the dip switch must be set according to the table on the following page.

Note that in the factory default setting all switches are set to “OFF”.

2. Remove fuse holder from fuse F3 of

the removed circuit board LGM 29.22 and install on fuse F3 on replacement circuit board LGM 29.55.

5285 961 v1.3

Page 63

Replacement of Burner Control Unit LGM 29 (continued)

Setting the dip switch

Additional Information

Boiler model no.

WB2 11-44

WB2 15-60

Installing the replacement circuit board

Dip switch setting

345678

1. Install new circuit board LGM

29.55

IMPORTANT

Do not remove clear covers on the circuit board. These provide protection against static discharge.

2. Connect all plug-in connectors to

circuit board LGM 29.55 including #158 plug.

IMPORTANT

Do not interchange plug-in connectors “X6” and “X7”. None of the other connectors are interchangeable.

3. Install covers

4. Plug in grounding wire.

5. Insert circuit board VR20

6. Install covers

7.Fold up control unit

using screws.

8.Insert pressure gage capillaries).

9. Mount control housing into place with hooks both sides of the control unit.

and .

and secure,

(do not kink

and lock

located on

5285 961 v1.3

Page 64

Additional InformationAdditional Information

Replacement of Burner Control Unit LGM 29 (continued)

Installing the replacement circuit board (continued)

10. Reinstall front enclosure panel.

11. Start up boiler a nd check for proper

functioning of the circuit board and the heating system.

Vitodens 200 Start-up/Service Instructions

IMPORTANT

If “FAULT : FE“ appears in the display of the control unit during the functionality check, check dip switch settings against table on previous page and adjust if required.

Wiring Diagram

See following page.

5285 961 v1.3

Page 65

5285 961 v1.3

Page 66

Additional Information

Parts List

Model No. Serial No.

WB2 11-44 7188578 and WB2 15-60 7188577

Ordering Replacement Parts:

Please provide boiler Model and Serial Number from rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor.

Parts

001 Profile gasket 016 Air vent without shut-off, R 3/8” 017 Matrix burner assembly (with Pos.

018, 026, 027, 056, 088, 094, 096, 100 and 120)

018 Matrix burner mesh (with Pos.

096 and 100)

020 Radial fan, RLS154 (without

electrode) 026 Ignition electrode 027 Ionization electrode 028 Flex gas pipe, 90x1½x1½cm 030 Conversion kit, NG 032 Conversion kit, LP

043 Connecting pipe extension (return) 044 Flow sensor 050 Condensate hose 055 Differential pressure sensor 056 Gas valve without orifice 057 Sealing grommet 058 Spring clip (set) 059 P-trap 086 Fixed high limit, 210°F / 99°C 087 Temperature sensor (with Pos.

049)

088 Ignition transformer

093 Heat exchanger assembly ASME 094 Insulation ring 096 Burner gasket (secondary) 100 Burner gasket 120 Burner gasket (primary)

Other Parts (not illustrated)

004 Operating Instructions

and User’s Information Manual 005 Start-up/Service Instructions 006 Parts List 007 Installation Instructions 049 Heat conductive paste

028

055

028

5285 961 v1.3

Page 67

Parts List (continued)

Additional Information

Parts

008 Front panel

(with Pos. 046, 060 and 061) 010 Wall-mount bracket 011 Fuse 6.3 amp (10 pack) 013 Programming unit 015 Ball valve, ½” with handle 019 Electronics box, RLS154 021 Burner control, LGM29.55 022 Circuit board, VR20 025 Hood (internal) for control unit 033 Harness for pump output 035 Circuit board, connection box 037 Vent pipe adaptor 039 Base panel 040 Cover panel 041 Gasket DN110 045 Seal d=150mm 046 Nameplate (set) “Vitodens 200” 047 Seal d=100mm 048 Pressure gage (psi) 060 Cover (flip-down) 060 Cover (flip-down)

061 Accessory pack, front panel hardware 062 Transformer 230V 063 Pressure gage insert 064 Connection module cover 065 Connection module 066 Switch (pair, Reset/Override) 070 Cover (blank) 071 Mounting bracket 072 Cable entry strip 073 Cable entry cover 074 Cover (poti) 075 Circuit board cover for VR20 076 Cable entry plug (pair) 079 Mounting plate 080 Control console (empty) 081 Switch (on/off)

(mechanism only-no switch) 082 Flat cable, 26-pole 084 Circuit board, adaptor 085 Circuit board, Optolink 089 Cap for vent pipe adaptor 200 Fastening bracket (10 pack) 205 Cap G 3/4 SW30

Other Parts (not illustrated)

023 Wiring harness, X 14 024 Wiring harness, X 11 034 Wiring harness, X 13 051 Touch-up paint stick, pure white 052 Touch-up spray paint, pure white 053 Pressure relief valve 054 Lubricating grease (6g) 068 Jumper plug, ionization 077 Counter plug (set) 078 Accessory pack (control unit) 090 Gasket (set) 092 Wiring harness, X 12 095 Accessory pack (burner parts) 097 Accessory pack,

enclosure hardware 10 pack 099 Connection assembly DEV 167 Wiring harness, ION/PE 201 Sensor #1 (outdoor) 202 Power/pump control module 203 Gasket assortment ½”, ¾” 204 Maintenance kit 210 Flow check valve DN25 305 Drain valve kit, ¾” 306 Power conditioner 307 Accessory pack (strain reliefs) 400 Service tool set ”Vitodens 200”

5285 961 v1.3

Page 68

Additional Information

Parts List (continued)

Installation fittings

Parts

110 Gasket, 32 x 44 x 2mm 111 Adaptor (pair with gasket)

1½ - 1¼” 113 Tee, 1¼” x 1¼” x ¾” 114 Nipple, 1¼ NPTM x 2½” 115 Full port ball valve, 1¼” FBV (T) 116 Nipple, ¾” x 3½ 117 Brass tee, ¾” 118 Sediment faucet, ¾” 119 Nipple, ¾ x 2” 120 Pressure relief valve 122 Shut-Off Valve (pair with gasket)

Parts not illustrated

130 Accessory pack

(metal stud mounting k it) 131 Loctite sealant, 6ml Tube 132 Keychain with air bleed key 133 Parts List

Included in DHW Production Kit.

120

110

119

113

118

117

116

114

122

111

110

111

115

5285 961 v1.3

Page 69

Alphabetical Index

Additional Information

Accessing coding addresses (with

programming unit), 50

Accessing temperature settings

with programming unit, 58

Accessing the boiler water

temperature, 58 Accessing the outdoor temperature, 58 Accessing the tank water temperature,

58 Additional information, 45 Adjusting the CO Assembly of burner, 21

Boiler temperature sensor, 40 Burner control unit LGM 29, 47 Burner mesh assembly, 19

Checking the Dekamatik-HK, 26 Circuit board VR20, 59, Cleaning agents, 21 Cleaning the combustion chamber, 21 Cleaning the heat exchanger surfaces,

21 Coding addresses (general), 24 Condensate drain, 20

Diagnosis with the control unit, 27 Diaphragm expansion tank, 22 Differential pressure sensor, 41 Disassembly of burner, 19

Electrode block, 20 Expansion tank, 22 Extension kit for a heating circuit with

mixing valve, 25 External burner disable, 60 External switching of the heating

program, 59 External call for heat, 59

Fault memory, 28 Fault message, 27 Fixed high limit, 43 Fuse, 43

value, 16

Gas combination valve, 13 Gas orifices, 46 Gas manifold pressure, 13 Gas type, 13

Heating contractor address input, Heating curve H with programming unit, 51 Heating system types H with programming unit, 49

Ignition, 20 Important Regulatory and Installation

Requirements, 4 Initial start-up, 9 Ionization current, 24

Low-loss header, 49

Maintenance Record, 70

Neutralization unit, 21

Operating sequence of burner control

unit LGM 29, 47 Outdoor temperature sensor, 40 Overview of coding addresses, 52

Parts list, 66 Power supply connection, 11 Program sequence, 47

Relay test, 42 RS remote control unit, 44 Running pressure, 13

Selecting the language, 12 Static pressure, 13

Tank temperature sensor, 41 Technical data, 46 Thermostatic radiator valves, 43 Troubleshooting, 27

Viessmann 2-wire BUS expansion

module, 25, 59

H with programming unit, 26

Weather-responsive operation, 48 Wiring diagram, 64 WS remote control unit, 44

5285 961 v1.3

Safety instructions, 2 Safety valves, 22

Page 70

Additional Information

Maintenance Record

Setpoint value

Service

date:

Service

date:

Service

date:

erv

date:

by:

max.

14 ”w.c.

4-14 ”w.c.17-10 ”w.c.211-14 “w.c.

Never exceed

50 ppm air-free

min. 5 μA

Setpoint value running pressure WB2-44

Setpoint value running pressure WB2-60

Service

date:

by:

Service

date:

by:

“w.c.

Measurements

Static pressure

unning pressure (supply pressure)

“w.c.

j Natural gas

“w.c.

j LP

ppm

at lower end of rated input range

ppm

at upper end of rated input range

vol.-%

j Check gas type

Carbon dioxide content CO

H at lower end of rated input range

H at upper end of rated input range

Oxygen content O

vol.-%

at lower end of rated input range

vol.-%

at upper end of rated input range

Carbon monoxide content CO

μA

Ionization current

5285 961 v1.3

Page 71

Lighting and Operating Instructions

FOR YOUR SAFETY READ BEFORE OPERATING

WARNING:Ifyoudonotfollowtheseinstructionsexactly, a fire or explosion may result causing property damage, personal injury or loss of life.

A. This appliance does not have a pilot. It is equipped

with an ignition device which automatically lights the burner. Do not

B. BEFORE OPERATING smell all around the

appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any

phone in your building.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

try to light the burner by hand.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on this label.

2. Set thermostat or other operating control to lowest setting.

3. Turn off all electric power to the appliance.

4. This device is equipped with an ignition device which automatically lights the burner. Do not light the burner by hand.

try to

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob will not push in or turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. Do not use this appliance if any part has been

under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

5. Close main gas shutoff valve.

6. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow ”B” in the safety information above on this label. If you don’t smell gas, go to the next step.

7. Open main gas shutoff valve.

8. Turn on all electric power to the appliance.

Manual gas shutoff

Open

Closed

1. Set thermostat or other operating control to lowest setting.

2. Turn off all electric power to the appliance if service is to be performed.

3. Close main gas shutoff valve.

5285 961 v1.3

9. Set thermostat or other operating control to desired setting.

10. If the appliance will not operate, follow the instructions ”To Turn Off Gas To Appliance” and call your service technician or gas supplier.

TO TURN OFF GAS TO BOILER

Page 72

Printed on environmentally friendly

(recycled and recyclable) paper.

Viessmann Manufacturing Company (U.S.) Inc. 45 Access Road Warwick, Rhode Island • 02886 • USA Tel. (401) 732-0667 • Fax (401) 732-0590 www.viessmann-us.com • info@viessmann-us.com

Viessmann Manufacturing Company Inc. 750 McMurray Road Waterloo, Ontario • N2V 2G5 • Canada Tel. (519) 885-6300 • Fax (519) 885-0887 www.viessmann.ca • info@viessmann.ca

Technical information subject to change without notice.

5285 961 v1.3