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

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.

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

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

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

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

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

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

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

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

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

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

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

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.

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

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.

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

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

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

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

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

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

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

+ 50 hidden pages

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

Specifications and Main Features

Frequently Asked Questions

User Manual