VIESMANN. Service instructions VITODENS 200-W. for contractors

Transcription

1 Service instructions for contractors VIESMANN Vitodens 200-W Type WB2B, 4.8 to 35.0 kw Wall mounted gas fired condensing boiler Natural gas and LPG version For applicability, see the last page VITODENS 200-W 5/2008 Please keep safe.

2 Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained! Danger This symbol warns against the risk of injury. Please note This symbol warns against the risk of material losses and environmental pollution. Note Details identified by the word "Note" contain additional information. Target group These instructions are exclusively designed for qualified personnel. & Work on gas equipment must only be carried out by a qualified gas fitter. & Work on electrical equipment must only be carried out by a qualified electrician. & The system must be commissioned by the system installer or a qualified person authorised by the installer. Regulations Observe the following when working on this system & all legal instructions regarding the prevention of accidents, & all legal instructions regarding environmental protection, & the Code of Practice of relevant trade associations, & all current safety regulations as defined by DIN, EN, DVGW, TRGI, TRF, VDE and all locally applicable standards. If you smell gas Danger Escaping gas can lead to explosions which may result in serious injury. & Never smoke. Prevent naked flames and sparks. Never switch lights or electrical appliances ON or OFF. & Close the gas shut-off valve. & Open windows and doors. & Remove all people from the danger zone. & Notify your gas or electricity supplier from outside the building. & Shut off the electricity supply to the building from a safe place (outside the building). If you smell flue gas Danger Flue gas can lead to life-threatening poisoning. & Shut down the heating system. & Ventilate the boiler room. & Close all doors leading to the living space. 2

3 Safety instructions Safety instructions (cont.) Working on the system & When using gas as fuel, also close the main gas shut-off valve and safeguard against unauthorised reopening. & Isolate the system from the power supply and check that it is no longer 'live', e.g. by removing a separate fuse or by means of a main isolator. & Safeguard the system against unauthorised reconnection.! Please note Electronic modules can be damaged by electro-static discharges. Touch earthed objects, such as heating or water pipes, to discharge static loads. Repair work! Please note Repairing components which fulfil a safety function can compromise the safe operation of your heating system. Replace faulty components only with original Viessmann spare parts. Ancillary components, spare and wearing parts! Please note Spare and wearing parts which have not been tested together with the heating system can compromise its function. Installing non-authorised components and non-approved modifications/conversion can compromise safety and may invalidate our warranty. For replacements, use only original spare parts from Viessmann or those which are approved by Viessmann. 3

4 Index Index Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance... 5 Further details regarding the individual steps... 7 Coding Code Code Resetting codes to their delivered condition Service scans Service level overview Temperatures, boiler coding card and brief scans Checking outputs (relay test) Scanning operating conditions and sensors Troubleshooting Fault display Fault codes Repairs Function description Constant temperature control unit Weather-compensated control unit Extensions for external connections (accessories) Control functions Remote control DIP switches Electronic combustion control unit Designs Connection and wiring diagram internal connections Connection and wiring diagram external connections Parts lists Commissioning/service reports Specification Certificates Declaration of conformity Manufacturer's certificate according to the 1st BImSchV [Germany] Keyword index

5 Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated!!! Commissioning steps Inspection steps Maintenance steps Page 01. Filling the heating system Venting the boiler Venting the heating system Filling the siphon with water Checking the power supply connection 06. Setting the time and date (if required) only for weather-compensated control units Selecting the language (if required) only for weather-compensated control units Checking the gas type Gas type conversion (only for operation with LPG) Function sequence and possible faults Checking the static and supply pressure Setting the maximum output Checking all connections on the heating water side and DHW side for leaks 14. Checking the balanced flue system for tightness (annular gap check) Burner removal Checking the burner gasket and the burner gauze assembly Checking and adjusting the ignition and ionisation electrodes Cleaning the heating surfaces and installing the burner Checking the condensate drain and cleaning the siphon Checking the neutralising system (if installed) 5

6 Commissioning, inspection, maintenance Steps - commissioning, inspection and... (cont.)!!! Commissioning steps Inspection steps Maintenance steps Page 21. Flow limiter (only for gas combi boilers) Checking the diaphragm expansion vessel and system pressure Checking the function of all safety valves 24. Checking the tightness of electrical connections 25. Checking all gas equipment for tightness at operating pressure Flue gas emissions test Checking the external LPG safety valve (if installed) 28. Matching the control unit to the heating system Adjusting the heating curves (only for weathercompensated control units) Connecting the control unit to the LON system (only for weather-compensated control units) Instructing the system user Scanning and resetting the "Service" display

7 Commissioning, inspection, maintenance Further details regarding the individual steps Filling the heating system! Please note Unsuitable fill water increases the level of deposits and corrosion and may lead to boiler damage. & Thoroughly flush the entire heating system prior to filling it with water. & Only use fill water of potable quality. & Soften fill water with hardness exceeding 3.0 mol/m 3, e.g. using a small softening system for heating water (see Viessmann Vitoset price list). & An antifreeze additive suitable for heating systems can be mixed with the fill water. The antifreeze manufacturer must verify its suitability. 1. Check the inlet pressure of the diaphragm expansion vessel. 2. Close the gas shut-off valve. 3. Fill the heating system via the boiler fill & drain valve A in the heating return (at the connection set or on site). (Minimum system pressure > 1.0 bar). 4. If the control unit had already been switched ON before filling began: Switch ON the control unit and activate the fill program via coding address "2F:2". 5. Close boiler fill & drain valve A. 6. Close the shut-off valves on the heating water side. Note If the control unit has not been switched ON prior to filling the system, then the servomotor of the diverter valve will still be in its central position, and the system will be completely filled. 7

8 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Venting the boiler 1. Close the shut-off valves on the heating water side. 2. Connect the drain hose between top valve B and a drain outlet. 3. Open valves A and B and vent using mains pressure until no more air noise is audible. If required, move the 3-way valve into its central position to achieve complete venting. For this, set code "2F:2". 4. Close valves A and B and open the heating water shut-off valves. Venting the heating system 1. Close the gas shut-off valve and switch ON the control unit. 8

9 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Activate the venting program via coding address "2F:1" in code Check the system pressure. Note To call up code 1 and for setting the coding address, see page 36. For function and sequence of the venting program, see page 99. Whilst the venting program runs, the display shows "EL" (constant temperature control unit) or "Entlüftung" (Venting) (weathercompensated control unit). Filling the siphon with water 1. Remove retaining clip A and siphon B. 2. Fill siphon B with water. 3. Fit siphon B and secure with retaining clip A. 9

10 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Setting the time and date (if required) only for weathercompensated control units Note & During commissioning, or after a prolonged time out of use, it may be necessary to reset the time and date, if the time flashes in the display. & When the unit is first taken into operation the display is in German (default language setting): Time (see step 1) Date (see step 2) Press the following keys: 1. a/b for the current time. 2. d to confirm; "Datum" is displayed. 3. a/b for the current date. 4. d to confirm. Selecting the language (if required) only for weather-compensated control units Note When the unit is first taken into operation the display is in German (default language setting): Outside temperature (see step 3.) Select heating circuit (see step 1.) Press the following keys: 1. c "Heizkreis wählen" (select heating circuit) is displayed. 2. d to confirm; wait approx. 4 s. 10

11 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. c press this button again, "Außentemperatur" (outside temperature) is displayed. 4. b for the required language. 5. d to confirm. Checking the gas type The boiler is equipped with an electronic combustion control unit that adjusts the burner for optimum combustion in accordance with the prevailing gas quality. & The boiler can be operated with natural gas in the Wobbe index range 10.0 to 16.1 kwh/m 3 (36.0 to 58.0 MJ/m 3 ) without conversion. & Convert the burner for operation with LPG (see "Gas type conversion" on page 12). 1. Determine the gas type and Wobbe index by asking your local gas supply utility or LPG supplier. 2. Convert the burner for operation with LPG (see page 12). 3. Record the gas type in the service report on page 117. Wobbe index ranges Gas type Wobbe index range kwh/m 3 MJ/m 3 Delivered condition Natural gas E 12.0 to to 58.0 or Natural gas LL 10.0 to to 47.2 After conversion LPG P 20.3 to to

12 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Gas type conversion (only for operation with LPG) 1. Set adjusting screw A at the gas train to "2". 2. Switch ON system ON/OFF switch "8". 3. Adjust the gas type (see page 82): & Call up code 2 & In coding address "11", select value "9" & In coding address "82", select value "1" (operation with LPG) & Set code "11" "9". & Terminate code Open the gas shut-off valve. Function sequence and possible faults Control unit issues heat demand Yes Display screen No Measures Increase set value and ensure heat is drawn off 12 Fan starts No after approx. 51 s fault F9 Check the fan, fan connecting cables, power at the fan and fan control

13 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Yes Ignition No Fault F4 Check the ignition module (control voltage 230 V across plugs "X2.1" and "X2.2") Yes Gas train opens No Fault F4 Check the gas train (control voltage 230 V); check the gas supply pressure Yes Ionisation current builds Symbol A No Fault F4 Check the ionisation electrode adjustment and the gas pipe for airlocks Yes Burner in operation No Stops below the set boiler water temperature and restarts immediately Check the flue gas system for soundness (flue gas recirculation), check the gas flow pressure Yes Automatic calibration of the combustion control unit No Fault Eb Check the connecting cable and the ionisation electrode, check the flue gas system (flue gas recirculation) 13

14 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) For further details regarding faults, see page 69. Checking the static and supply pressure Danger CO build-up as a result of an incorrect burner setup can have serious health implications. Carry out a CO test prior to and after work on gas equipment. Operation with LPG Flush the LPG tank twice during commissioning/replacement. Thoroughly vent the tank and gas supply lines after flushing. 1. Close the gas shut-off valve. 2. Undo the screw inside test connector "IN" A on the gas train, but do not remove, then connect the pressure gauge. 3. Open the gas shut-off valve. 4. Measure the static pressure and record it in the service report. Set value: max mbar. 5. Start the boiler. Note During commissioning, the boiler can enter a fault state because of airlocks in the gas pipe. After approx. 5 s, press "E RESET" to reset the burner. 14

15 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Check the supply (flow) pressure. Set values: & Natural gas 20 mbar. & LPG 50 mbar. Note Use suitable test equipment with a resolution of at least 0.1 mbar to measure the supply pressure. 7. Record the actual value in the service report. Take the action shown in the following table. 8. Shut down the boiler, close the gas shut-off valve, remove the pressure gauge and close test nipple A with the screw. 9. Danger Gas escaping from the test nipple leads to a risk of explosions. Check for tightness. Open the gas shut-off valve, start the boiler and check for tightness at test nipple A. Supply (flow) pressure for natural gas Supply (flow) pressure for LPG Measures below 17.4 mbar below 42.5 mbar Do not start the boiler. Notify your mains gas or LPG supplier to 25 mbar 42.5 to 57.5 mbar Start the boiler. in excess of 25 mbar in excess of 57.5 mbar Install a separate gas pressure governor upstream of the system and regulate the inlet pressure to 20 mbar for natural gas or 50 mbar for LPG. Notify your mains gas or LPG supplier. 15

16 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Setting the maximum output Note You can limit the maximum output for heating operation. The limit is set via the modulation range. The max. adjustable heating output is limited upwards by the boiler coding card. 1. Start the boiler. 2. Press K and F simultaneously until a value flashes (e.g. "85") and "A" appears. In the delivered condition, this value represents 100 % of rated output. On weather-compensated control units, the display additionally shows "Max. output". 3. With a/b select the required value in % of rated output as maximum output. 4. Confirm the set value with d. 5. Record the settings for maximum output on the additional type plate included with the "technical documentation". Affix the type plate next to the original type plate on top of the boiler. Note The output can also be limited for DHW heating. For this, change coding address "6F" in code 2. Checking the balanced flue system for tightness (annular gap check) A Combustion air port 16

17 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) For balanced flue systems tested together with the wall mounted gas fired boiler, the requirement for a tightness test during commissioning by the flue gas inspector is not applicable. We recommend that your heating engineer carries out a simple leak/ tightness test during the commissioning of your system. For this, it would be sufficient to check the CO2 or O2 concentration in the combustion air at the annular gap of the balanced flue pipe. The flue pipe is deemed to be gastight if the CO2 concentration in the combustion air is no higher than 0.2 % or the O2 concentration is at least 20.6 %. If actual CO2 values are higher or O2 values are lower, then pressure test the flue pipe with a static pressure of 200 Pa. Burner removal 17

18 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Switch OFF the main power supply and the ON/OFF switch at the control unit. 2. Close the gas shut-off valve and safeguard against reopening. 3. Pull cables from fan motor A, gas train B, ionisation electrode C, ignition unit D and earth tab E. 4. Release gas supply pipe F fitting. 5. Undo four screws G and remove the burner.! Please note To prevent damage, never rest the burner on the gauze assembly. 18

19 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the burner gasket and the burner gauze assembly Check burner gasket A and burner gauze assembly E for damage and replace, if required. Generally replace the burner gasket every 2 years. 1. Remove electrodes B. 2. Undo three retaining clips C at thermal insulation ring D and remove thermal insulation ring D. 3. Undo four Torx screws and remove burner gauze assembly E with its gasket F. 4. Insert and secure a new burner gauze assembly E with a new gasket F. Torque: 3.5 Nm. 5. Refit thermal insulation ring D. 6. Refit electrodes B. Torque: 2.5 Nm. 19

20 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking and adjusting the ignition and ionisation electrodes A Ignition electrodes 1. Check the electrodes for wear and contamination. 2. Clean the electrodes with a small brush (not with a wire brush) or emery paper. B Ionisation electrode 3. Check the electrode gaps. If the gaps are not as specified or the electrodes are damaged, replace and align the electrodes together with new gaskets. Tighten the electrode fixing screws with 2.5 Nm. Cleaning the heating surfaces and installing the burner! Please note Scratches on parts that are in contact with flue gas can lead to corrosion. Never use brushes to clean the heat exchanger. 20

21 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Use a vacuum cleaner to remove residues from the heat exchanger A inside the combustion chamber. 2. If required, spray slightly acidic, chloride-free cleaning agents based on phosphoric acid (e.g. Antox 75 E) onto the heat exchanger A and let the solution soak in for approx. 20 min. 3. Thoroughly flush the heat exchanger A with water. 4. Install the burner and torque the screws diagonally with 4 Nm. 5. Fit the gas supply pipe with a new gasket. 6. Check the gas connections for tightness. Danger Escaping gas leads to a risk of explosion. Check all fittings for gastightness. 7. Connect the electrical cables/leads to each corresponding component. 21

22 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the condensate drain and cleaning the siphon 1. Check that the condensate can drain freely at the siphon. 2. Remove retaining clip A and siphon B. 3. Clean siphon B. 4. Fill siphon B with water, fit it and secure with retaining clip A. Flow limiter (only for gas combi boilers) 1. Switch OFF the control unit, shut off the cold water line and drain the DHW side of the boiler. 2. Undo Allen screws A. Note Residual water may escape during dismantling. 3. Remove flow switch B and remove flow limiter C downwards. 4. Check flow limiter C; replace in case of excessive scaling or damage. Secure flow switch B. 22

23 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the diaphragm expansion vessel and system pressure Note Carry out this test on a cold system. 1. Drain the system, or close the cap valve on the diaphragm expansion vessel and reduce the pressure, until the pressure gauge indicates "0". 2. If the inlet pressure of the diaphragm expansion vessel is lower than the static system pressure, top up with nitrogen until the inlet pressure is raised by 0.1 to 0.2 bar. 3. Top up your heating system with water and vent until the filling pressure of a cooled system is 0.1 to 0.2 bar higher than the inlet pressure of the diaphragm expansion vessel. Permiss. operating pressure: 3 bar Checking all gas equipment for tightness at operating pressure Danger Escaping gas leads to a risk of explosion. Check gas equipment for tightness. Flue gas emissions test The electronic combustion control unit automatically ensures an optimum combustion quality. Only the combustion values need to be checked during commissioning and maintenance. For this, check the CO2 or O2 content. For a function description of the electronic combustion control unit, see page 105. CO2 or O2 content The CO2 content must be within the following ranges (upper and lower output): & 7.7 to 9.2% for natural gas E and LL & 9.3 to 10.9% for LPG P For all gas types, the O2 content must be between 4.4% and 6.9%. If the actual CO2 or O2 values lie outside their respective ranges, check the balanced flue system for tightness. 23

24 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Note During commissioning, the combustion control unit carries out an automatic calibration. Only test the emissions approx. 30 s after the burner has started. 4. Check the CO2 content. Should the actual value deviate from the above ranges by more than 1 %, implement steps from page Enter actual values into the service report. 6. Adjust the upper output. 1. Connect a flue gas analyser at test port A (on the boiler flue outlet). 2. Open the gas shut-off valve, start the boiler and create a heat demand. 3. Adjust the lower output. Constant temperature control unit: K + d press simultaneously: "1" is shown. Weather-compensated control unit: K + d press simultaneously: "Relay test" and then "Base load" is shown. Constant temperature control unit: a press: "2" is shown. Weather-compensated control unit: a press: "Full load" is shown. 7. Check the CO2 content. Should the actual value deviate from the above ranges by more than 1 %, implement steps from page After testing, press d. 9. Enter actual values into the service report. 24

25 Matching the control unit to the heating system Note Subject to the equipment level, the control unit must be matched to the system. Various system components are recognised automatically by the control unit and the relevant codes are adjusted automatically. In the following system designs, DHW heating is illustrated with a separate DHW cylinder. The designs also apply to systems where DHW is heated by an integral instantaneous water heater. & For the selection of an appropriate design, see the following diagrams. & For coding steps, see page 36. System version 1 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) One heating circuit without mixer A1 (with/without DHW heating) 1 Vitodens 200-W 2 Outside temperature sensor (only for weather-compensated control units) 3 Vitotrol 100 (only for constant temperature control units) 4 DHW cylinder 5 Cylinder temperature sensor 6 Heating circuit without mixer A1 Required coding Address Operation with LPG 82:1 25

26 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) System version 2 One heating circuit without mixer A1 and one heating circuit with mixer M2 (with/without DHW heating) Note The volume flow of the heating circuit without mixer must be at least 30% greater than the volume flow of the heating circuit with mixer. 1 Vitodens 200-W 2 Outside temperature sensor 3 DHW cylinder 4 Cylinder temperature sensor 5 Heating circuit without mixer A1 6 Heating circuit with mixer M2 7 Temperature limiter for limiting the max. temp. of underfloor heating systems 8 Flow temperature sensor M2 9 Heating circuit pump M2 qp Extension kit for one heating circuit with mixer M2 Required coding Address Operation with LPG 82:1 System with only one heating circuit with mixer & with DHW heating 00:4 & without DHW heating 00:3 26

27 System version 3 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) One heating circuit without mixer A1 and one heating circuit with mixer M2 with system separation (with/without DHW heating) 1 Vitodens 200-W 2 Outside temperature sensor 3 DHW cylinder 4 Cylinder temperature sensor 5 Heating circuit without mixer A1 6 Heating circuit with mixer M2 7 Temperature limiter for limiting the max. temp. of underfloor heating systems 8 Flow temperature sensor M2 9 Heating circuit pump M2 qp Extension kit for one heating circuit with mixer M2 qq Heat exchanger for system separation Required coding Address Operation with LPG 82:1 27

28 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) System version 4 One heating circuit with mixer M1 (with Vitotronic 200-H), one heating circuit with mixer M2 (with extension kit) and low loss header (with/without DHW heating) 1 Vitodens 200-W 2 Outside temperature sensor 3 DHW cylinder 4 Cylinder temperature sensor 5 Heating circuit with mixer M1 6 Flow temperature sensor M1 7 Heating circuit pump M1 8 Vitotronic 200-H 9 Heating circuit with mixer M2 qp Temperature limiter for limiting the max. temp. of underfloor heating systems qq Flow temperature sensor M2 qw Heating circuit pump M2 qe Extension kit for one heating circuit with mixer M2 qr Low loss header qt Flow temperature sensor, low loss header Required coding Address Operation with LPG 82:1 One heating circuit with mixer with extension kit for mixer and one heating circuit with mixer with Vitotronic 200-H & with DHW heating 00:4 & without DHW heating 00:3 28

29 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Adjusting the heating curves (only for weather-compensated control units) The heating curves illustrate the relationship between the outside temperature and the boiler water or flow temperature. To put it simply: The lower the outside temperature, the higher the boiler water or flow temperature. The room temperature, again, depends on the boiler water or the flow temperature. Settings in the delivered condition: & Slope = 1.4 & Level = 0 A Heating curve slope for underfloor heating systems B Heating curve slope for low temperature heating systems (according to the Energy Savings Order [Germany]) 29

30 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Changing the slope and level 1. Slope: Change with coding address "d3" in code 1. Setting range 2 to 35 (equals slope 0.2 to 3.5). 2. Level: Change with coding address "d4" in code 1. Setting range -13 to +40 K. A Changing the slope B Changing the level (vertical parallel offset of the heating curve) 30

31 Adjusting the set room temperature Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Standard room temperature 5. Adjust the set day temperature with rotary selector "ts". The value will be automatically accepted after approx. 2 s. Accordingly, the heating curve is adjusted along set room temperature axis C, which results in modified start/stop characteristics of the heating circuit pumps if heating circuit pump logic function is active. Reduced room temperature Example 1: Adjustment of standard room temperature from 20 to 26 C A Boiler water temperature or flow temperature in C B Outside temperature in C C Set room temperature in C D Heating circuit pump "OFF" E Heating circuit pump "ON" Press the following keys: 1. a "1r" flashes. 2. d to select heating circuit A1 (heating circuit without mixer) or 3. a "2r" flashes. 4. d to select heating circuit with mixer M2. Example 2: Adjustment of reduced room temperature from 5 C to 14 C A Boiler water temperature or flow temperature in C B Outside temperature in C C Set room temperature in C D Heating circuit pump "OFF" E Heating circuit pump "ON" Press the following keys: 1. a "1r" flashes. 31

32 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. d to select heating circuit A1 (heating circuit without mixer) or 3. a "2r" flashes. 5. E Call up the set night temperature. 6. a/b Change the value. 7. d Confirm the value. 4. d to select heating circuit with mixer M2. Connecting the control unit to the LON system (only for weather-compensated control units) The LON communication module (accessories) must be plugged in. Installation instructions LON communication module Note The data transfer via LON can take several minutes. Single boiler system with Vitotronic 200-H and Vitocom 300 Set up the LON subscriber numbers and further functions via code 2 (see the following table). Note In the same LON system, the same number cannot be allocated twice. Only one Vitotronic may be programmed as fault manager. Boiler control unit Vitotronic 200-H Vitotronic 200-H Vitocom Subscriber no. 1 Code "77:1" Control unit is fault manager Code "79:1" Control unit transmits the time Code "7b:1" Subscriber no. 10 Code "77:10" Control unit is not fault manager Code "79:0" Control unit receives the time Set code "81:3" Subscriber no. 11 Set code "77:11" Control unit is not fault manager Code "79:0" Control unit receives the time Set code "81:3" Subscriber no. 99 Device is fault manager Device receives the time 32

33 Boiler control unit Vitotronic 200-H Vitotronic 200-H Vitocom Control unit transmits outside temperature Set code "97:2" Control unit receives outside temperature Set code "97:1" Control unit receives outside temperature Set code "97:1" LON subscriber fault monitoring Code "9C:20" LON subscriber fault monitoring Code "9C:20" Updating the LON subscriber list Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) LON subscriber fault monitoring Code "9C:20" Only possible if all subscribers are connected and the control unit is programmed to be fault manager (code "79:1"). Press the following keys: 2. e The subscriber list is updated after approx. 2 min. The subscriber check is completed. 1. L + d simultaneously for approx. 2 s. Subscriber check initiated (see page 33). Carrying out a subscriber check Communication with the system devices connected to the fault manager is tested with a subscriber check. Precondition: & The control unit must be programmed as fault manager (code "79:1") & The LON subscriber number must be programmed in all control units (see page 32) & The LON subscriber list in the fault manager must be up to date (see page 32) A Consecutive number in the subscriber list B Subscriber number 33

34 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Press the following keys: 1. L + d simultaneously for approx. 2 s. The subscriber check has been initiated. 2. a/b for the required subscriber. 3. d Check is enabled "Check" flashes until its completion. The display and all key illuminations for the selected subscriber flash for approx. 60 s. 4. "Check OK" is displayed during communication between both devices. or "Check not OK" is displayed if there is no communication between both devices. Check the LON connection. 5. Repeat points 2 and 3 to check further subscribers. 6. L + d simultaneously for approx. 1 s. The subscriber check is completed. Instructing the system user The system installer must hand the operating instructions to the system user and instruct him/her in the operation of the system. Scanning and resetting the "Service" display The red fault indicator flashes when the limits set via coding address "21" and "23" have been reached. The programming unit display flashes: & On a constant temperature control unit: & The defaulted hours run or the defaulted interval with clock symbol "u" (subject to setting) & On a weather-compensated control unit: & "Service" Note Set code "24:1" and then code "24:0" if a service is carried out before the service display is shown; the set service parameters for hours run and interval are then reset to 0. Press the following keys: 1. c The service scan is active a/b Scan service messages.

35 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. d The service display will be cleared (for a weathercompensated control unit: "Acknowledge: Yes", reconfirm with d). The red fault display continues to flash. Note An acknowledged service message can be redisplayed by pressing d (approx. 3 s). After a service has been carried out 1. Reset code "24:1" to "24:0". The red fault indicator extinguishes. Note If coding address "24" is not reset, the "Service" message reappears: & On a constant temperature control unit: & After 24 hours & On a weather-compensated control unit: & At 07:00 h on Monday 2. Reset the burner hours run, burner starts and consumption, if required. Press the following keys: c Scanning is active. a/b for the selected value. e The selected value will be set to "0". a/b for further scans. d Scanning is completed. 35

36 Coding Code 1 Calling up code 1 Note & On weather-compensated control units, codes are displayed as plain text. & Codes that are irrelevant due to the system equipment level or the setting of other codes will not be displayed. & Heating systems with one heating circuit without mixer and one heating circuit with mixer: & Initially, the possible coding addresses "A0" to "d4" for the heating circuit without mixer A1 are scanned; then the coding addresses for the heating circuit with mixer M2 are scanned. Press the following keys: 1. K + L simultaneously for approx. 2 s. 2. a/b for the required coding address; the address flashes. 3. d to confirm. 4. a/b for the selected value. 5. d to confirm; the display briefly shows "accepted" (weather-compensated control unit); the address flashes again. 6. a/b for the selection of further addresses. 7. K + L press simultaneously for approx. 1 s; code 1 is terminated. 36

37 Coding Code 1 (cont.) Overview Coding Coding in the delivered condition System design 00 :1 System version 1: 1 heating circuit without mixer A1, without DHW heating Max. boiler water temp. 06:... Maximum limit of the boiler water temperature, defaulted by the boiler coding card Venting/filling 2F:0 Venting program/fill program disabled Possible change 00 :2 System version 1: 1 heating circuit without mixer A1, with DHW heating 00 :3 System version 4: 1 heating circuit with mixer M2, without DHW heating 00 :4 System version 4: 1 heating circuit with mixer M2, with DHW heating 00 :5 System version 2, 3: 1 heating circuit without mixer A1 and 1 heating circuit with mixer M2, without DHW heating 00 :6 System version 2, 3: 1 heating circuit without mixer A1; 1 heating circuit with mixer M2, with DHW heating 06:20 to 06:127 Maximum limit of the boiler water temperature within the ranges defaulted by the boiler 2F:1 Venting program enabled 2F:2 Fill program enabled 37

38 Coding Code 1 (cont.) Coding in the delivered condition Possible change Subscriber no. 77:1 LON subscriber number 77:2 to 77:99 LON subscriber number, adjustable from 1 to 99: 1-4 = Boiler 5 = Cascade = Vitotronic 200-H 99 = Vitocom Note Allocate each number only once. Summer econ. A1/M2 A5:5 With heating circuit pump logic function (only for weather-compensated control units) Min. flow temp. A1/M2 C5:20 Electronic minimum flow temperature limit 20 C (only for weathercompensated control units) Max. flow temp. A1/M2 C6:75 Electronic maximum flow temperature limit 75 C (only for weathercompensated control units) Slope A1/M2 d3:14 Heating curve slope = 1.4 (only for weathercompensated control units) Level A1/M2 d4:0 Heating curve level = 0 (only for weather-compensated control units) A5:0 Without heating circuit pump logic function C5:1 to C5:127 C6:10 to C6:127 d3:2 to d3:35 d4: 13 to d4:40 Minimum limit adjustable from 1 to 127 C (limited by the boiler coding card) Maximum limit adjustable from 10 to 127 C Heating curve slope adjustable from 0.2 to 3.5 (see page 29) Heating curve level adjustable from 13 to 40 (see page 29) 38

39 Coding Code 2 Calling up code 2 Note & On weather-compensated control units, codes are displayed as plain text. & Codes that are irrelevant due to the system equipment level or the setting of other codes will not be displayed. Press the following keys: 1. L + G simultaneously for approx. 2 s. 2. d to confirm. 3. a/b for the required coding address; the address flashes. 4. d to confirm; the value flashes. 5. a/b for the selected value. 6. d to confirm; the display briefly shows "accepted" (for weather-compensated control units); the address flashes again. 7. a/b for the selection of further addresses. 8. L + G press simultaneously for approx. 1 s; code 2 is terminated. The coding addresses are grouped according to the following function areas. The respective function area is shown on the display. 39

40 Coding Code 2 (cont.) The areas are scanned in the following sequence with a/b: Function area Coding addresses System design 00 Boiler/burner 06 to 54 DHW 56 to 73 General 76 to 9F Heating circuit A1 (heating circuit without A0 to Fb mixer) Heating circuit with mixer M2 A0 to Fb Note Heating systems with one heating circuit without mixer and one heating circuit with mixer: Initially, the possible coding addresses "A0" to "Fb" for the heating circuit without mixer A1 are scanned; then the coding addresses for the heating circuit with mixer M2 are scanned. 40

41 Coding Code 2 (cont.) Coding Coding Coding in the delivered condition System design 00 :1 System version 1: 1 heating circuit without mixer A1, without DHW heating Boiler/burner 06:... Maximum limit of the boiler water temperature, defaulted by the boiler coding card 11: 9 No access to the coding addresses for the parameters of the combustion controller 21:0 No maintenance interval (operating hours) selected Possible change 00 :2 System version 1: 1 heating circuit without mixer A1, with DHW heating 00 :3 System version 4: 1 heating circuit with mixer M2, without DHW heating 00 :4 System version 4: 1 heating circuit with mixer M2, with DHW heating 00 :5 System version 2, 3: 1 heating circuit without mixer A1; 1 heating circuit with mixer M2, without DHW heating 00 :6 System version 2, 3: 1 heating circuit without mixer A1; 1 heating circuit with mixer M2, with DHW heating 06:20 to 06:127 Maximum limit of the boiler water temperature within the ranges defaulted by the boiler 11:9 Access open to the coding addresses for the parameters of the combustion controller 21:1 to 21:9999 The number of hours run before the burner should be serviced is adjustable from 1 to 9999 h 41

42 Coding Code 2 (cont.) Coding in the delivered condition 23:0 No time interval for burner service selected 24:0 The service display is reset 25:0 With outside temperature sensor for constant temperature control units: No recognition of outside temperature sensor or fault monitoring 28:0 No burner interval ignition 2E:0 Without external extension 2F:0 Venting program/fill program disabled 30:0 Internal fixed speed circulation pump (automatic adjustment, do not modify) 32:0 Influence of the signal "External blocking" on circulation pumps: All pumps in control function Possible change 23:1 Interval adjustable from 1 to to 24 months 23:24 24:1 "Service" display (the value is automatically set and must be manually reset after a service has been carried out) 25:1 Outside temperature sensor and fault monitoring recognised 28:1 to 28:24 Time interval adjustable from 1 to 24 h. The burner is force-started once every 30 s (only when operating with LPG). 2E:1 With external extension (automatic setting on connection) 2F:1 Venting program enabled 2F:2 Fill program enabled 32:1 to 32:15 Influence of the signal "External blocking" on circulation pumps: see the following table Note Generally, the burner will be blocked when signal "External blocking" is enabled. 42

43 Coding Code 2 (cont.) Value address 32:... Internal circulation pump Heating circuit pump Heating circuit without mixer Heating circuit pump Heating circuit with mixer Circulation pump for cylinder heating 0 Control funct. Control funct. Control funct. Control funct. 1 Control funct. Control funct. Control funct. OFF 2 Control funct. Control funct. OFF Control funct. 3 Control funct. Control funct. OFF OFF 4 Control funct. OFF Control funct. Control funct. 5 Control funct. OFF Control funct. OFF 6 Control funct. OFF OFF Control funct. 7 Control funct. OFF OFF OFF 8 OFF Control funct. Control funct. Control funct. 9 OFF Control funct. Control funct. OFF 10 OFF Control funct. OFF Control funct. 11 OFF Control funct. OFF OFF 12 OFF OFF Control funct. Control funct. 13 OFF OFF Control funct. OFF 14 OFF OFF OFF Control funct. 15 OFF OFF OFF OFF Coding in the delivered condition Boiler/burner 34:0 Influence of the signal "External demand" on the circulation pumps: All pumps in control function Possible change 34:1 to 34:23 Influence of the signal "External demand" on the circulation pumps: see the following table Value address 34:... Internal circulation pump 0 Control funct. 1 Control funct. 2 Control funct. Heating circuit pump Heating circuit without mixer Control funct. Control funct. Control funct. Heating circuit pump Heating circuit with mixer Control funct. Control funct. OFF Circulation pump for cylinder heating Control funct. OFF Control funct. 43

44 Coding Code 2 (cont.) Value address 34:... Internal circulation pump Heating circuit pump Heating circuit without mixer Control funct. Heating circuit pump Heating circuit with mixer OFF Circulation pump for cylinder heating 3 Control funct. OFF 4 Control OFF Control funct. Control funct. funct. 5 Control OFF Control funct. OFF funct. 6 Control OFF OFF Control funct. funct. 7 Control OFF OFF OFF funct. 8 OFF Control Control funct. Control funct. funct. 9 OFF Control Control funct. OFF funct. 10 OFF Control OFF Control funct. funct. 11 OFF Control OFF OFF funct. 12 OFF OFF Control funct. Control funct. 13 OFF OFF Control funct. OFF 14 OFF OFF OFF Control funct. 15 OFF OFF OFF OFF 16 ON Control Control funct. Control funct. funct. 17 ON Control Control funct. OFF funct. 18 ON Control OFF Control funct. funct. 19 ON Control OFF OFF funct. 20 ON OFF Control funct. Control funct. 21 ON OFF Control funct. OFF 22 ON OFF OFF Control funct. 23 ON OFF OFF OFF 44

45 Coding Code 2 (cont.) Coding in the delivered condition Boiler/burner 38:0 Status burner control unit: Operational (no fault) 51:0 Internal circulation pump is always started when there is a heat demand 52:0 Without flow temperature sensor for low loss header 53:1 Function connection sk of the internal extension: DHW circulation pump 54:0 Without solar control unit DHW 56:0 Set DHW temperature adjustable from 10 to 60 C Possible change 38: 0 Fault burner control unit 51:1 When there is a heat demand, the internal circulation pump will only be started when the burner is operational. System with heating water buffer cylinder. 52:1 With flow temperature sensor for low loss header (automatic adjustment on connection) 53:0 Function connection sk: Central fault 53:2 Function connection sk: External heating circuit pump (heating circuit A1) 53:3 Function connection sk: External circulation pump for cylinder heating 54:1 With Vitosolic 100 (automatic adjustment on connection) 54:2 With Vitosolic 200 (automatic adjustment on connection) 56:1 Set DHW temperature adjustable from 10 to above 60 C Note Maximum value subject to boiler coding card. Observe the max. permissible DHW temperature. 45

46 Coding Code 2 (cont.) Coding in the delivered condition 58:0 Without auxiliary function for DHW heating 59:0 Cylinder heating: Starting point -2.5 K Stopping point +2.5 K 5b:0 DHW cylinder directly connected to the boiler 60:20 During DHW heating, the boiler water temperature is max. 20 K higher than the set DHW temperature 62:2 Circulation pump with 2 min run-on time after cylinder heating 63:0 Without auxiliary function for DHW heating (only for constant temperature control units) 65:... Information regarding the type of diverter valve (not adjustable) 67:40 With the Vitosolic: Third set DHW temperature = 40 C Possible change 58:10 Input of a second set to DHW temperature, adjustable from 10 to 60 C 58:60 (observe coding addresses "56" and "63") 59:1 to 59:10 Starting point adjustable from 1 to 10 K below the set value 5b:1 DHW cylinder connected downstream of the low loss header 60:5 to 60:25 The difference between the boiler water temperature and the set DHW temperature is adjustable from 5 to 25 K 62:0 Circulation pump without run-on 62:1 Run-on time adjustable to from 1 to 15 min 62:15 63:1 Auxiliary function: 1 x daily 63:2 to 63:14 Every 2 days to every 14 days 63:15 2 x daily 65:0 Without diverter valve 65:1 Diverter valve by Viessmann 65:2 Diverter valve by Wilo 65:3 Diverter valve by Grundfos 67:0 Without third set DHW temperature 67:1 Third set DHW temperature to adjustable from 1 to 67:60 60 C (subject to the setting of coding address "56") 46

47 Coding Code 2 (cont.) Coding in the delivered condition 6F:... Maximum output for DHW heating in %; defaulted by the boiler coding card 71:0 DHW circulation pump: "ON" in accordance with the time program (only for weather-compensated control units) 72:0 DHW circulation pump: "ON" in accordance with the time program (only for weather-compensated control units) 73:0 DHW circulation pump: "ON" in accordance with the time program (only for weather-compensated control units) General 76:0 Without LON communication module (only for weather-compensated control units) 77 :1 LON subscriber number (only for weather-compensated control units) Possible change 6F:0 Max. output during DHW to heating adjustable from 0 6F:100 to 100 % 71:1 "OFF" during DHW heating to the first set value 71:2 "ON" during DHW heating to the first set value 72:1 "OFF" during DHW heating to the second set value 72:2 "ON" during DHW heating to the second set value 73:1 to 73:6 during the time program "ON" 1x/h for 5 min "ON" up to 6x/h for 5 min 73:7 permanently "ON" 76:1 With LON communication module; automatic recognition 77 :2 to 77 :99 LON subscriber number, adjustable from 1 to 99: 1-4 = Boiler 5 = Cascade = Vitotronic 200-H 99 = Vitocom Note Allocate each number only once. 79:1 With LON communication module: Control unit is fault manager (only for weather-compensated control units) 79:0 Control unit is not fault manager 47

48 Coding Code 2 (cont.) Coding in the delivered condition Possible change 7b:1 With LON communication 7b:0 Do not transmit time module: The control unit transmits the time (only for weather-compensated control units) 7F:1 Detached house (only for weather-compensated control units) 7F:0 Apartment block Separate adjustment of holiday program and time program for DHW heating, as option 80:1 A fault message is displayed, providing a fault is active for at least 5 s 80:0 Immediate fault message 81:1 Automatic summer/winter time changeover 82:0 Operation with natural gas 80:2 to 80:199 The fault message is issued after a delay that is adjustable from 10 s to 995 s; 1 step 5 s 81:0 Manual summer/winter time changeover 81:2 Radio clock module is automatically detected 81:3 With LON communication module: The control unit receives the time 82:1 Operation with LPG (only adjustable if coding address 11:9 has been set) 48

49 Coding Code 2 (cont.) Coding in the delivered condition Possible change 85:0 Standard mode 85:1 Manual calibration of the combustion controller (only adjustable if coding address 11:9 has been set). The red fault indicator also flashes during calibration. The process has terminated when the red fault indicator no longer flashes (after approx. 1 min). Note Heat must be drawn off during manual calibration. 88:0 Temperature displayed in C (Celsius) 8A:175 Never adjust 90:128 Time constant for calculating the adjusted outside temperature 21.3 hours 91:0 No external heating program changeover via external extension (only for weather-compensated control units) 88:1 Temperature displayed in F (Fahrenheit) 90:0 to 90:199 Fast (low values) or slow (high values) matching of the flow temperature, subject to the set value when the outside temperature changes; 1 step 10 min. 91:1 The external heating program changeover affects the heating circuit without mixer 91:2 The external heating program changeover affects the heating circuit with mixer 91:3 The external heating program changeover affects the heating circuit without mixer and the heating circuit with mixer 49

50 Coding Code 2 (cont.) Coding in the delivered condition Possible change 95:0 Without Vitocom 100 communication interface 95:1 With the Vitocom 100 communication interface; automatic recognition 97:0 With LON communication module: The outside 97:1 The control unit receives the outside temperature temperature of the sensor connected to the control unit is utilised 97:2 The control unit sends the outside temperature to the Vitotronic 200-H internally (only for weather-compensated control units) 98:1 Viessmann system number (in conjunction 98:1 to System number adjustable from 1 to 5 with monitoring several systems via Vitocom 300) 98:5 9b:0 No minimum set boiler water temperature for external demand 9b:1 to 9b:127 Minimum set boiler water temperature adjustable from 1 to 127 C (limited by the boiler-specific parameters) 9C:20 Monitoring LON subscribers 9C:0 No monitoring When there is no response from a subscriber, values defaulted by the control unit are used after 20 min and a fault message is issued (only for weather-compensated control units) 9C:5 to 9C:60 Time adjustable from 5 to 60 min 9F:8 Differential temperature 8 K; only in conjunction with the mixer circuit (only for weather-compensated control units) Boiler circuit, mixer circuit A0:0 Without remote control (only for weather-compensated control units) 50 9F:0 to 9F:40 Differential temperature adjustable from 0 to 40 K A0:1 With Vitotrol 200 (automatic recognition) A0:2 With Vitotrol 300 (automatic recognition)

51 Coding Code 2 (cont.) Coding in the delivered condition A3:2 Outside temperature below 1 C: Heating circuit pump "ON" Outside temperature above 3 C: Heating circuit pump "OFF"! Possible change A3:-9 Heating circuit pump to "ON/OFF" (see the following A3:15 table) Please note When selecting a value below 1 C, there is a risk of pipes outside the thermal envelope of the building being damaged by frost. The standby mode, in particular, should be taken into consideration, e.g. during holidays. Parameter Heating circuit pump Address A3:... "ON" at "OFF" at C -8 C -8-9 C -7 C -7-8 C -6 C -6-7 C -5 C -5-6 C -4 C -4-5 C -3 C -3-4 C -2 C -2-3 C -1 C -1-2 C 0 C 0-1 C 1 C 1 0 C 2 C 2 1 C 3 C to to C 16 C 51

52 Coding Code 2 (cont.) Coding in the delivered condition Boiler circuit, mixer circuit A4:0 With frost protection (only for weather-compensated control units) Possible change A4:1 No frost protection, adjustment only possible if coding address "A3: -9" has been selected. A5:5 With heating circuit pump logic function (economy circuit): Heating circuit pump "OFF" when the outside temperature (AT) is 1 K higher than set room temperature (RTset) AT > RTset + 1 K (only for weather-compensated control units) Note Observe the note for code "A3" A5:0 Without heating circuit pump logic function A5:1 With heating circuit pump to logic function: Heating A5:15 circuit pump "OFF", if (see the following table) Parameter address With heating circuit pump logic function: Heating A5:... circuit pump OFF, if 1 AT > RTset + 5 K 2 AT > RTset + 4 K 3 AT > RTset + 3 K 4 AT > RTset + 2 K 5 AT > RTset + 1 K 6 AT > RTset 7 AT > RTset - 1 K to 15 AT > RTset - 9 K 52

53 Coding Code 2 (cont.) Coding in the delivered condition Boiler circuit, mixer circuit A6:36 Extended economy function disabled (only for weather-compensated control units) A7:0 Without mixer economy function (only for weather-compensated control units) A8:1 Heating circuit with mixer M2 creates a demand for the internal circulation pump (only for weather-compensated control units) Possible change A6:5 to A6:35 Extended economy mode is enabled, i.e. the burner and heating circuit pump are switched OFF and the mixer will be closed at a variable value that is adjustable between 5 and 35 C plus 1 C. This value is based on the adjusted outside temperature, comprising the actual outside temperature and a time constant that takes the cooling down of an average building into consideration. A7:1 With mixer economy function (extended heating circuit pump logic): Heating circuit pump also "OFF" if the mixer was closed longer than 20 min. Heating pump "ON": & If the mixer changes to control function & or & If there is a risk of frost A8:0 Heating circuit with mixer M2 creates no demand for the internal circulation pump 53

54 Coding Code 2 (cont.) Coding in the delivered condition A9:7 With pump idle time: Heating circuit pump "OFF" if the set value changes through a change in operating mode or through a change in the set room temperature (only for weather-compensated control units) b0:0 With remote control: Heating mode/reduced mode: weather-compensated (only for weather-compensated control units; change the coding only for the heating circuit with mixer M2) b2:8 Heating with room temperature hook-up must be programmed for remote control and for the heating circuit: Room influence factor 8 (only for weather-compensated control units; change the coding only for the heating circuit with mixer M2) b5:0 With remote control: No room temperature-compensated heating circuit pump logic function (only for weather-compensated control units; change the coding only for the heating circuit with mixer M2) Possible change A9:0 Without pump idle time A9:1 With pump idle time; adjustable from 1 to 15 to A9:15 b0:1 Heating mode: weathercompensated Reduced mode: with room temperature hookup b0:2 Heating mode: with room temperature hook-up Reduced mode: weathercompensated b0:3 Heating mode/reduced mode: with room temperature hook-up b2:0 Without room influence b2:1 to b2:64 b5:1 to b5:8 Room influence factor adjustable from 1 to 64 Heating circuit pump logic function; see the following table 54

55 Coding Code 2 (cont.) Parameter address With heating circuit pump logic function: Heating cir- b5:... cuit pump OFF, if 1: enabled RTactual > RTset + 5 K; disabled RTactual < RTset + 4 K 2: enabled RTactual > RTset + 4 K; disabled RTactual < RTset + 3 K 3: enabled RTactual > RTset + 3 K; disabled RTactual < RTset + 2 K 4: enabled RTactual > RTset + 2 K; disabled RTactual < RTset + 1 K 5: enabled RTactual > RTset + 1 K; disabled RTactual < RTset 6: enabled RTactual > RTset; disabled RTactual < RTset - 1 K 7: enabled RTactual > RTset - 1 K; disabled RTactual < RTset - 2 K 8: enabled RTactual > RTset - 2 K; disabled RTactual < RTset - 3 K Coding in the delivered condition Boiler circuit, mixer circuit C5:20 Electronic minimum flow temperature limit 20 C (only for weathercompensated control units) C6:74 Electronic maximum flow temperature limit 74 C (only for weathercompensated control units) d3:14 Heating curve slope = 1.4 (only for weathercompensated control units) d4:0 Heating curve level = 0 (only for weather-compensated control units) d5:0 The external heating program changeover alters the heating program to "Constant operation with reduced room temperature" (only for weather-compensated control units) Possible change C5:1 to C5:127 C6:10 to C6:127 d3:2 to d3:35 d4: 13 to d4:40 Minimum temperature limit adjustable from 1 to 127 C (limited by boilerspecific parameters) Maximum temperature limit adjustable from 10 to 127 C (limited by boilerspecific parameters) Heating curve slope adjustable from 0.2 to 3.5 (see page 29) Heating curve level adjustable from 13 to 40 (see page 29) d5:1 The external heating program changeover changes the heating program to "Constant central heating with standard room temperature" 55

56 Coding Code 2 (cont.) Coding in the delivered condition E1:1 With remote control: The set day temperature is adjustable at the remote control unit from 10 to 30 C (only for weather-compensated control units) E2:50 With remote control: No display correction for the actual room temperature (only for weather-compensated control units) F1:0 Screed drying function disabled (only for weather-compensated control units). F2:8 Time limit for party mode or external heating program changeover via key: 8 hours (only for weather-compensated control units) * 1 F5:12 Run-on time of the internal circulation pump in heating mode 12 min (only for constant temperature control units) Possible change E1:0 Set day temperature adjustable from 3 to 23 C E1:2 Set day temperature adjustable from 17 to 37 C E2:0 to E2:49 E2:51 to E2:99 F1:1 to F1:6 Display correction -5 K to Display correction -0.1 K Display correction +0.1 K to Display correction +4.9 K Screed drying function adjustable in accordance with 6 optional temperature/time profiles (see page 100) F1:15 Constant flow temperature 20 C F2:0 No time limit for party mode F2:1 Time limit adjustable from to 1 to 12 hours * 1 F2:12 F5:0 No run-on time for the internal circulation pump F5:1 Run-on time of the internal circulation pump ad- to F5:20 justable from 1 to 20 min *1 Party mode ends automatically in the "Heating and DHW" program, when the system changes over to operation with standard room temperature. 56

57 Coding Code 2 (cont.) Coding in the delivered condition F6:25 In the "DHW only" operating mode, the internal circulation pump is permanently ON (only for constant temperature control units) F7:25 In "Standby mode", the internal circulation pump is permanently ON (only for constant temperature control units) F8:-5 F9:-14 Temperature limit for terminating the reduced mode -5 ºC, see example on page 102. Observe the setting of coding address "A3". (only for weather-compensated control units) Temperature limit for raising the reduced set room temp. -14 ºC, see example on page 102. (only for weather-compensated control units) Possible change F6:0 In the "DHW only" operating mode, the internal circulation pump is permanently OFF F6:1 In the "DHW only" operating mode, the internal cir- to F6:24 culation pump will be started for 10 min respectively 1 to 24 times per day. F7:0 In "Standby mode", the internal circulation pump is permanently OFF F7:1 to F7:24 F8:+10 to F8:-60 F8:-61 F9:+10 to F9:-60 In "Standby mode", the internal circulation pump in operating mode will be started for 10 min respectively 1 to 24 times per day. Temperature limit adjustable from +10 to -60 C Function disabled Temperature limit for raising the set room temperature to the value selected for standard mode adjustable from +10 to -60 C 57

58 Coding Code 2 (cont.) Coding in the delivered condition Possible change FA:20 Raising the set boiler water temperature or the set flow temperature when changing from operation with reduced room temperature to operation with standard room temperature, by 20 %. See example on page 103 (only for weather-compensated control units). FA:0 to FA:50 Fb:30 Duration for raising the Fb:0 set boiler water temperature to or the set flow Fb:150 temperature (see coding address "FA") 60 min. See example on page 103 (only for weather-compensated control units). Temperature rise adjustable from 0 to 50 % Duration adjustable from 0 to 300 min; 1 step 2 min Resetting codes to their delivered condition Constant temperature control unit: 1. L + G simultaneously for approx. 2 s. 2. e press. Weather-compensated control unit: 2. e "Factory set? Yes" appears. 3. d to confirm or a/b to select "Factory set? No". 1. L + G simultaneously for approx. 2 s. 58

59 Service scans Service level overview Function Key combination Exit Page Temperatures, boiler coding Press K and G simulta- Press d 60 card and brief scans neously for approx. 2 s Relay test Press K and d simultaneously Press d 63 for approx. 2 s Max. output (heating Press K and F simultaneously Press d 16 mode) for approx. 2 s Operating conditions and Press c Press d 65 sensors Service scan c (if "Service" flashes) Press d 34 Adjusting the display contrasmultaneously; Press d and asimulta- the display darkens Press d and b simultaneously; the display be- comes lighter Calling up acknowledged Press d for approx. 3 s 68 fault messages Fault history Press G and d simultaneously for approx. 2 s Press d 69 Subscriber check (in conjunction with LON) Emissions test function "S" Coding level 1 Plain text display Coding level 2 Numerical display Press L and d simultaneously for approx. 2 s Weather-compensated control unit: Press F and E for approx. 2 s simultaneously Constant temperature control unit: Press O and F for approx. 2 s simultaneously Press K and L simultaneously for approx. 2 s Press L and G simultaneously for approx. 2 s Press L and d simultaneously F and E or O and F simultaneously for approx. 1 s, alternatively automatic after 30 min Press K and L simultaneously for approx. 1 s Press L and G simultaneously for approx. 1 s

60 Service scans Service level overview (cont.) Function Key combination Exit Page Resetting codes to their delivered condition Press L and G simultaneously for approx. 2 s; then e 58 Temperatures, boiler coding card and brief scans Weather-compensated control unit Press the following keys: 1. K + G simultaneously for approx. 2 s. 2. a/b for the required scan. 3. d Scanning is completed. The following values can be scanned, subject to the actual system equipment level: Display screen Explanation Slope A1 level A1 Slope M2 level M2 Outside temp. adj. The adjusted outside temperature can be reset Outside temp. actual to the actual outside temperature with e. Boiler temp. set Boiler temp. actual DHW temp. set DHW temp. actual DHW outlet temp. actual Only for combi boilers DHW outlet temp. set Only for combi boilers Flow temp. set Heating circuit with mixer Flow temp. actual Mixed flow temp. set Mixed flow temp. actual Boiler coding card Brief scan 1 to 8 Heating circuit with mixer Low loss header Low loss header Brief scan Display screen 1 Software version Control unit Equipment version Burner control unit version 60

61 Service scans Temperatures, boiler coding card and brief... (cont.) Brief scan Display screen 2 System designs 01 to 06 3 Flow switch position Software version Programming unit 4 Software version Burner control unit 5 0: no external 0: no exmand deternal blocking 1: external 1: extermand denal blocking 6 Number of LON subscribers Boiler Number of KM BUS subscribers Software version Mixer extension 0: no mixer extension Type Remote control 0: w/o 1: Vitotrol 200 2: Vitotrol 300 Maximum demand temperature Software version Solar control unit 0: no solar control unit Software version LON module 0: no LON module Equipment type Burner control unit 0 External 0 to 10 V hook-up Display in C 0: no external hook-up Software version External extension 0: no external extension Check digit Max. output Details in % Heating circuit A1 Heating circuit M2 (without mixer) (with mixer) Software Remote Software version control version Remote 0: w/o Remote control 1: Vitotrol control 0: no remote 200 0: no re- 2: Vitotrol mote control control

62 Service scans Temperatures, boiler coding card and brief... (cont.) Brief scan Display screen Internal circulation pump 8 Variable Software speed version pump variable 0: w/o speed 1: Wilo pump 2: Grundfos 0: no variable speed pump Heating circuit pump to connection extension Variable Variable speed speed pump pump 0: w/o 0: w/o 1: Wilo 1: Wilo 2: Grundfos 2: Grundfos Software version variable speed pump 0: no variable speed pump Software version variable speed pump 0: no variable speed pump Constant temperature control unit Press the following keys: 1. K + G simultaneously for approx. 2 s. 2. a/b for the required scan. 3. d Scanning is completed. The following values can be scanned, subject to the actual system equipment level: Brief scan Display screen 0 Flow switch position 1 Software version Solar control unit 0: no solar control unit System designs 1 to 6 Software version Burner control unit Software version Control unit Software version External extension 0: no external extension Software version Programming unit 0 62

63 Service scans Temperatures, boiler coding card and brief... (cont.) Brief scan Display screen E 0: no external demand 1: external demand 0: no external blocking 1: external blocking External 0 to 10 V hook-up Display in C 0: no external hook-up Set boiler water temperature A 0 0 Highest demand temperature 4 0 Burner control unit type Equipment type Set cylinder temperature b 0 0 Max. output in % C 0 Boiler coding card (hexadecimal) c 0 Version Equipment Version Burner control unit d Variable speed pump 0 w/o 1 Wilo 2 Grundfos Software version variable speed pump 0: no variable speed pump Checking outputs (relay test) Weather-compensated control unit Press the following keys: 1. K + d simultaneously for approx. 2 s. 2. a/b for the required relay output. 3. d Relay test is completed. The following relay outputs can be controlled subject to system design: Display screen Explanation Base load Burner modulation base load Full load Burner modulation full load Intern.pump On Int. output 20 63

64 Service scans Checking outputs (relay test) (cont.) Display screen Htg. system valve Valve in middle pos. DHW valve Htg.cir.pump M2 On Mix.valve open Mix.valve closed Intern.output On Htg.cir.pump A1 On DHW pump On Recirc.pump On Centr.fault ind.on Explanation Diverter valve set to heating mode Diverter valve in central position (filling/draining) Diverter valve set to DHW mode Mixer extension Mixer extension Mixer extension Output sk internal extension External extension H1 External extension H1 External extension H1 External extension H1 Constant temperature control unit Press the following keys: 1. K + d simultaneously for approx. 2 s. 2. a/b for the required relay output. 3. d Relay test is completed. The following relay outputs can be controlled subject to system design: Display screen Explanation 1 Burner modulation base load 2 Burner modulation full load 3 Internal pump / output 20 "ON" 4 Diverter valve set to heating mode 5 Diverter valve in central position (filling/draining) 6 Diverter valve set to DHW mode 10 Output sk internal extension 11 Heating circuit pump A1 External extension H1 12 Cylinder primary pump External extension H1 14 Central fault message External extension H1 64

65 Service scans Scanning operating conditions and sensors Weather-compensated control unit Press the following keys: 1. c "Select heating circuit" is displayed. 2. d to confirm; wait approx. 4 s. 3. c press again. 4. a/b for the required operating condition. 5. d Scanning is completed. The following operating conditions can be scanned, subject to the actual system equipment level for heating circuit A1 and heating circuit with mixer M2: Display screen Explanation Participant no. Programmed subscriber no. in the LON system Holiday program If a holiday program has been entered Departure date Date Return date Date Outdoor temp.,... C Actual value Boiler temp.,... C Actual value Supply temp.,... C Actual value (only for mixer circuit M2) Normal Set value room temp.,... C Room temperature,... C Actual value Ext. room t.setpt,... C For external hook-up DHW temp.,... C Actual DHW temperature Solar DHW temp.... C Actual value Collector temp.,... C Actual value Com. supply temp.,... C Burner,...h Burner cycles,... Actual value, only with low loss header Actual hours run Hours run and burner starts (reset after maintenance with e to "0"). Solar energy,... kw/h Time Date Burner OFF/ON Intern. pump OFF/ON Output 20 Intern. output OFF/ON Output 28, if an internal extension is installed Htg. circ. pump OFF/ON If an external extension or extension kit for one heating circuit with mixer is installed DHW pump OFF/ON If an external extension is installed Recirc. pump OFF/ON If an external extension is installed 65

66 Service scans Scanning operating conditions and sensors (cont.) Display screen Centr. fault ind. OFF/ON Mix. valve OPEN/CLOSE Solar pump OFF/ON Solar pump,...h Various languages Explanation If an external extension is installed If an extension kit for one heating circuit with mixer is installed If a Vitosolic is installed Actual hours run The respective languages can be selected as permanent display language with d Constant temperature control unit Press the following keys: 1. c press. 2. a/b for the required operating condition. 3. d Scanning is completed. The following operating conditions can be scanned, subject to the actual system equipment level: Display screen Explanation 1 15 C/ F Actual outside temperature 3 65 C/ F Actual boiler water temperature 5 50 C/ F Actual cylinder temperature (if a cylinder temperature sensor is installed) 5 45 C/ F Solar - actual DHW temperature 6 70 C/ F Actual collector temperature P Burner hours run (after a service, reset with e to "0") h PPP Burner starts (after a service, reset with e to "0") PPPPP Solar circuit pump hours run h PPPPPP Solar energy in kwh

67 Troubleshooting Fault display Fault display layout A Fault display B Fault symbol The red fault indicator flashes for every fault. C Fault number D Fault code A fault in the burner control unit causes the display to show "E". Constant temperature control unit In case of a fault, the fault code and fault symbol is displayed at the programming unit Weather-compensated control unit The display flashes "Fault" if a fault message is issued Plain text fault displays: & Burner module & Outdoor sensor & Supply sensor & Boiler sensor & Com.supply sens. & DHW sensor & Flue gas sensor & DHW outlet sensor & Room sensor 67

68 Troubleshooting Fault display (cont.) & Collector sensor & Solar DHW sensor & Remote control & Fault participant Checking and acknowledging faults Note If an acknowledged fault is not removed, the fault message will be redisplayed: & With a constant temperature control unit after 24 h & With a weather-compensated control unit at 7:00 h the next day Constant temperature control unit Press the following keys: 1. a/b for further fault codes. 2. d All fault messages are acknowledged simultaneously, the fault display will be deleted and the red fault indicator continues to flash. Weather-compensated control unit Press the following keys: 1. c for the current fault. 2. a/b for further fault messages. 3. d All fault messages are acknowledged simultaneously, the fault display will be deleted and the red fault indicator continues to flash. Calling up acknowledged fault messages Press the following keys: 2. a/b for the acknowledged fault. 1. d for approx. 3 s. 68

69 Troubleshooting Fault display (cont.) Calling up fault codes from the fault memory (fault history) The 10 most recent faults are saved and may be scanned. The faults are ordered by date, thus the most recent fault is fault number 1. Press the following keys: 1. G + d simultaneously for approx. 2 s. 2. a/b for individual fault codes. 3. Note All saved fault codes can be deleted with e. 4. d Scanning is completed. Fault codes Fault code on the display Const. weath.- comp. System characteristics Cause Measures 0F X X Control mode Service Service the equipment. After the service, set coding address "24:0". 10 X Regulates as if the outside temperature was 0 C 18 X Regulates as if the outside temperature was 0 C 20 X Regulates without flow temperature sensor (low loss header) Outside temperature sensor shorted out Outside temperature sensor lead broken System flow temperature sensor shorted out Check the outside temperature sensor (see page 79). Check the outside temperature sensor (see page 79). Check the low loss header sensor (see page 80). 69

70 Troubleshooting Fault codes (cont.) Fault code on the display Const. weath.- comp. System characteristics 28 X Regulates without flow temperature sensor (low loss header) 30 X X Burner blocked 38 X X Burner blocked Cause System flow temperature sensor lead broken Boiler water temperature sensor shorted out Boiler water temperature sensor lead broken 40 X Mixer closes Heating circuit with mixer M2 flow temperature sensor shorted out 48 X Mixer closes Heating circuit M2 flow temperature sensor lead broken 50 X X No DHW heating 51 X X No DHW heating Short circuit in the cylinder temperature sensor or comfort sensor Outlet temperature sensor shorted out Measures Check the low loss header sensor (see page 80). Check the boiler water temperature sensor (see page 80). Check the boiler water temperature sensor (see page 80). Check the flow temperature sensor. Check the flow temperature sensor. Check the cylinder temperature sensor (see page 80). Check the comfort sensor (see page 82). Check the sensor (see page 82). 70

71 Troubleshooting Fault codes (cont.) Fault code on the display Const. weath.- comp. System characteristics 58 X X No DHW heating 59 X X No DHW heating Cause Cylinder temperature sensor or comfort sensor lead broken Outlet temperature sensor lead broken 92 X X Control mode Collector temperature sensor shorted out; connects to the Vitosolic at S1 93 X X Control mode Cylinder temperature sensor shorted out; connects to the Vitosolic at S3 94 X X Control mode Temperature sensor shorted out; connects to the Vitosolic at S2 9A X X Control mode Collector temperature sensor lead broken; connects to the Vitosolic at S1 Measures Check the cylinder temperature sensor (see page 80). Check the comfort sensor (see page 82). Check the sensor (see page 82). Check the sensor at the Vitosolic. Check the sensor at the Vitosolic. Check the sensor at the Vitosolic. Check the sensor at the Vitosolic. 71

72 Troubleshooting Fault codes (cont.) Fault code on the display Const. weath.- comp. System characteristics Cause 9b X X Control mode Cylinder temperature sensor lead broken; connects to the Vitosolic at S3 9C X X Control mode Temperature sensor lead broken; connects to the Vitosolic at S2 9F X X Control mode Solar control unit fault; displayed if a fault without fault code occurs at the solar control unit A7 X Control mode as per delivered condition b0 X X Burner blocked b1 X X Control mode as per delivered condition b4 X X Regulates as if the outside temperature was 0 C 72 Faulty programming unit Flue gas temperature sensor shorted out Communication fault; programming unit (internal) Internal fault Measures Check the sensor at the Vitosolic. Check the sensor at the Vitosolic. Check the solar control unit (see solar control unit service instructions). Replace the programming unit. Check the flue gas temperature sensor (see page 85). Check connections and replace the programming unit if required. Replace the control unit.

73 Troubleshooting Fault codes (cont.) Fault code on the display Const. weath.- comp. System characteristics b5 X X Control mode as per delivered condition b7 X X Burner blocked b8 X X Burner blocked ba X Mixer M2 regulates to a flow temperature of 20 C. bc X Control mode without remote control bd X Control mode without remote control Cause Internal fault Boiler coding card missing, faulty or incorrect boiler coding card Flue gas temperature sensor lead broken Communication fault extension kit for heating circuit M2 Communication fault Vitotrol remote control, heating circuit A1 Communication fault, Vitotrol remote control, heating circuit M2 be X Control mode Vitotrol remote control incorrectly programmed bf X Control mode Incorrect LON communication module Measures Replace the control unit. Plug in boiler coding card or replace it, if faulty. Check the flue gas temperature sensor (see page 85). Check the extension kit connections and coding. Start the extension kit. Check connections, cable, coding address "A0" and remote control DIP switches (see page 104). Check connections, cable, coding address "A0" and remote control DIP switches (see page 104). Check remote control DIP switch settings (see page 104). Replace the LON communication module. 73

74 Troubleshooting Fault codes (cont.) Fault code on the display Const. weath.- comp. System characteristics Cause C2 X X Control mode Communication fault, solar control unit C6 X Control mode, max. pump speed C7 X X Control mode, max. pump speed Communication fault external variable speed heating circuit pump, heating circuit with mixer M2 Communication fault external variable speed heating circuit pump, heating circuit A1 Cd X X Control mode Communication fault Vitocom 100 (KM BUS) CE X X Control mode Communication fault ext. extension CF X Control mode Communication fault, LON communication module da X Control mode without room influence 74 Room temperature sensor, heating circuit A1 shorted out Measures Check connections and coding address "54". Check setting of coding address "E5" Check setting of coding address "E5" Check connections, Vitocom 100 and coding address "95". Check connections and coding address "2E". Replace the LON communication module. Check the room temperature sensor, heating circuit A1.

75 Troubleshooting Fault codes (cont.) Fault code on the display Const. weath.- comp. System characteristics db X Control mode without room influence dd X Control mode without room influence de X Control mode without room influence E4 X X Burner blocked E5 X X Burner blocked E8 X X Burner in a fault state Cause Room temperature sensor, heating circuit with mixer M2 shorted out Room temperature sensor, heating circuit A1 lead broken Room temperature sensor, heating circuit with mixer M2 lead broken Fault, supply voltage 24 V Fault flame amplifier The ionisation current lies outside the permissible range Measures Check the room temperature sensor, heating circuit with mixer M2. Check the room temperature sensor, heating circuit A1 and the remote control DIP switch settings (see page 104). Check the room temperature sensor, heating circuit with mixer M2 and the remote control DIP switch settings (see page 104). Replace the control unit. Replace the control unit. Check the ionisation electrode and cable. Press "E RESET". 75

76 Troubleshooting Fault codes (cont.) Fault code on the display Const. weath.- comp. System characteristics E9 X X Burner in a fault state EA X X Burner in a fault state Eb X X Burner in a fault state EC X X Burner in a fault state Ed X X Burner in a fault state F0 X X Burner blocked F1 X X Burner in a fault state 76 Cause The ionisation current lies outside the permissible range during calibration The ionisation current lies outside the permissible range during calibration Heat drawoff repeatedly too low during calibration The ionisation current lies outside the permissible range during calibration Internal fault Internal fault The flue gas temperature limiter has responded. Measures Check the ionisation electrode and cable. Check the flue gas system for tightness. Press "E RESET". Check the ionisation electrode and cable. Press "E RESET". Initiate a heat draw-off. Switch the boiler OFF and ON again. Press "E RESET". Check the ionisation electrode and cable. Press "E RESET". Replace the control unit. Replace the control unit. Check the heating system fill level. Vent the system. Press "E RESET" after the flue gas system has cooled down.

77 Troubleshooting Fault codes (cont.) Fault code on the display Const. weath.- comp. System characteristics F2 X X Burner in a fault state F3 X X Burner in a fault state F4 X X Burner in a fault state F8 X X Burner in a fault state Cause The temperature limiter has responded. Flame signal is already present at burner start. No flame signal. The fuel valve closes too late Measures Check the heating system fill level. Check the circulation pump. Vent the system. Check the temperature limiter and connecting cables. Press "E RESET". Check the ionisation electrode and connecting cable. Press "E RESET". Check the ionisation electrode and cable, measure the ionisation current, check the gas pressure, check the gas train, ignition, ignition module, ignition electrodes and the condensate drain. Press "E RESET". Check the gas train. Check both control paths. Press "E RESET". 77

78 Troubleshooting Fault codes (cont.) Fault code on the display Const. weath.- comp. System characteristics F9 X X Burner in a fault state FA X X Burner in a fault state FC X X Burner in a fault state Fd X X Burner in a fault state FE X X Burner blocked or in a fault state 78 Cause Fan speed too low during the burner start Fan not at standstill Gas train faulty or faulty modulation valve control; or flue gas path blocked Burner control unit fault Boiler coding card or main PCB faulty Measures Check the fan, check the fan cables and supply; check the fan control. Press "E RESET". Check the fan, fan connecting cables and fan control. Press "E RESET". Check the gas train. Check the flue gas system. Press "E RESET". Check ignition electrodes and connecting cables. Check whether a strong interference (EMC) field exists near the equipment. Press "E RESET". Replace control unit if the fault persists. Press "E RESET". Replace boiler coding card or control unit if the fault persists

79 Troubleshooting Fault codes (cont.) Fault code on the display Const. weath.- comp. System characteristics FF X X Burner blocked or in a fault state Cause Internal fault or "E RESET" key blocked Measures Start the equipment again. Replace the control unit, if the equipment will not restart. Repairs Checking the outside temperature sensor (weather-compensated control unit) 1. Pull plug "X3" from the control unit. 2. Test the resistance of the outside temperature sensor across terminals "X3.1" and "X3.2" on the disconnected plug and compare it with the curve. 79

80 Troubleshooting Repairs (cont.) 3. Where actual values strongly deviate from the curve values, disconnect the wires at the sensor and repeat test immediately at the sensor. 4. Subject to result, replace the lead or the outside temperature sensor. Checking the boiler water temperature sensor, the cylinder temperature sensor or the flow temperature sensor for a low loss header 80

81 Troubleshooting Repairs (cont.) 1. & Boiler water temperature sensor: Pull the leads from boiler water temperature sensor A and check the resistance. & Cylinder temperature sensor: Pull plug % from the cable harness at the control unit and check the resistance. & Flow temperature sensor: Pull plug "X3" from the control unit and check the resistance across terminals "X3.4" and "X3.5". 2. Check the sensor resistance and compare the actual values with the curve. 3. Replace the sensor in case of severe deviation. Danger The boiler water temperature sensor is immersed in the heating water (risk of scalding). Drain the boiler before replacing the sensor. 81

82 Troubleshooting Repairs (cont.) Check the outlet temperature sensor or comfort sensor (gas combi boilers only) 1. Disconnect the leads from outlet temperature sensor A or comfort sensor B. 2. Check the sensor resistance and compare it with the curve. 82

83 Troubleshooting Repairs (cont.) 3. Replace the sensor in case of severe deviation. Note Water can leak when replacing the outlet temperature sensor. Close the cold water shut-off valve. Drain the DHW line and the plate-type heat exchanger (DHW side). 83

84 Troubleshooting Repairs (cont.) Checking the plate-type heat exchanger 1. Shut off and drain the boiler on its heating water and DHW side. 2. Release the side closures and pivot the control unit forward. 3. Pull the leads from comfort sensor A. 4. Remove the retaining clip and siphon B. 5. Remove thermal insulation C. 6. Undo screws D and remove plate-type heat exchanger E through the front. Note During removal, small amounts of water may trickle out and escape from the removed plate-type heat exchanger. 7. Check the DHW side for scaling and, if required, clean or replace the plate-type heat exchanger. F Heating return G Cold water H Heating flow K DHW 8. Check the heating water side for contamination and, if required, clean or replace the plate-type heat exchanger. 9. Install in reverse order with new gaskets. 10. Danger Escaping gas leads to a risk of explosion. Check gas equipment for tightness. 84

85 Troubleshooting Repairs (cont.) Checking the flue gas temperature sensor The flue gas temperature sensor locks out the boiler when the permissible flue gas temperature is exceeded. Reset the interlock after the flue gas system has cooled down by pressing "E RESET". 1. Pull the leads from flue gas temperature sensor A. 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in case of severe deviation. 85

86 Troubleshooting Repairs (cont.) Checking the temperature limiter If the burner control unit cannot be reset after a fault shutdown, although the boiler water temperature is below approx. 75 C, check the following: 1. Pull the leads from thermocouple A. 3. Remove the faulty thermocouple. 4. Install a new thermocouple. 5. After commissioning, press reset button "E RESET" at the control unit. 2. Check the continuity of the thermocouple with a multimeter. 86

87 Troubleshooting Repairs (cont.) Checking the fuse 1. Switch OFF the power. 2. Release the side closures and pivot the control unit down. 3. Remove cover A. 4. Check fuse F1 (see connection and wiring diagram). Extension kit for heating circuit with mixer Checking the rotational direction of the mixer motor 1. Switch ON/OFF switch A at the extension kit first OFF and then ON again. The device will carry out the following self-test: & Mixer "Close" (150 s) & Pump "ON" (10 s) & Mixer "Open" (10 s) & Mixer "Close" (10 s) 87

88 Troubleshooting Repairs (cont.) Then standard control mode resumes. 2. Note the rotational direction of the mixer motor during its self-test. Then set the mixer manually to "Open" again. Note The flow temperature sensor must now capture a higher temperature. If the temperature drops, either the motor is turning in the wrong direction or the mixer set is incorrectly fitted. Mixer installation instructions Changing the rotational direction of the mixer motor (if required) Danger An electric shock can be life-threatening. Before opening the equipment, switch OFF the ON/OFF switch and mains voltage, for example at the fuse or the main isolator. 1. Remove the lower and upper housing cover of the extension kit. Extension kit installation instructions A ON/OFF switch B Rotational direction switch 88

89 Troubleshooting Repairs (cont.) 2. Change over the rotational direction switch: Switch position I for central heating return from the left (delivered condition). Switch position II for central heating return from the right. Checking the Vitotronic 200-H (accessories) The Vitotronic 200-H is connected to the control unit via the LON cable. To test the connection, carry out a subscriber check at the boiler control unit (see page 33). 89

90 Function description Constant temperature control unit Control and display elements A Pressure gauge B Fault indicator (red) C Optolink interface only in conjunction with the diagnostic adaptor (accessory) and Vitosoft (accessory) D ON indicator (green) E Reset button F User interface G ON/OFF switch Keys at the user interface: O Set boiler water temperature F Set DHW temperature O+F Emissions test function K Standby mode L DHW only G Heating and DHW / Comfort mode b/a Setting values d Confirmation c Information e Standard settings (Reset) Heating operation The selected set boiler water temperature will be maintained when a demand is being raised by the room thermostat and the heating program is set to DHW and central heating "G". The boiler water temperature will be maintained at the default frost protection temperature when there is no demand. The electronic temperature limiter inside the burner control unit limits the boiler water temperature to 82 C. Flow temperature setting range: 40 to 74 C. 90

91 Function description Constant temperature control unit (cont.) DHW heating with gas fired combi boilers If the flow switch detects that hot water is being extracted (> 3 l/min) then the burner, circulation pump and 3-way valve are switched on or changed over. The burner modulates according to the DHW outlet temperature and is limited by the temperature limiter (82 C) on the boiler side. DHW heating with a gas fired boiler The burner, the circulation pump and the three-way valve are started or changed over if the cylinder temperature lies 2.5 K below the set cylinder temperature. In the delivered condition, the set boiler water temperature is 20 K higher than the set DHW temperature (adjustable via coding address "60"). The burner will be switched OFF and the circulation pump run-on time will begin, if the actual cylinder temperature exceeds the set cylinder temperature by 2.5 K. Weather-compensated control unit Control and display elements A Pressure gauge B Fault indicator (red) 91

92 Function description Weather-compensated control unit (cont.) C Optolink interface only in conjunction with the diagnostic adaptor (accessory) and Vitosoft (accessory) D ON indicator (green) E Reset button F User interface G Rotary selector for standard room temperature H ON/OFF switch Keys at the user interface: A B H D E F Central heating time program DHW heating and DHW circulation pump time programs (if connected to the control unit) Holiday program Time/date Reduced room temperature Set DHW temperature O+F Emissions test function K Standby mode L DHW only G Heating and DHW M Party mode N Economy mode b/a Setting values d Confirmation c Information e Standard settings (Reset) Heating operation The control unit determines a set boiler water temperature subject to outside temperature or room temperature (if a room temperature-dependent remote control is connected) and to the slope/level of the heating curve. The determined set boiler water temperature is transferred to the burner control unit. From the set and actual boiler water temperatures, the burner control unit calculates the modulation level and regulates the burner accordingly. The electronic temperature limiter inside the burner control unit limits the boiler water temperature to 82 C. 92

93 Function description Weather-compensated control unit (cont.) DHW heating with gas fired combi boilers If the flow switch detects that hot water is being extracted (> 3 l/min) then the burner, circulation pump and 3-way valve are switched on or changed over. The burner modulates according to the DHW outlet temperature and is limited by the temperature limiter (82 C) on the boiler side. DHW heating with a gas fired boiler The burner, the circulation pump and the three-way valve are started or changed over if the cylinder temperature lies 2.5 K below the set cylinder temperature. In the delivered condition, the set boiler water temperature is 20 K higher than the set DHW temperature (adjustable via coding address "60"). The burner will be switched OFF and the circulation pump run-on time will begin, if the actual cylinder temperature exceeds the set cylinder temperature by 2.5 K. Boosting DHW heating The booster heating function is activated if a switching period is selected for the fourth time phase. The set temperature value for the heating boost is adjustable in coding address "58". 93

94 Function description Extensions for external connections (accessories) Internal extension H1 The internal extension is integrated into the control unit housing. The following alternative functions can be connected to relay output sk. The function is allocated via coding address "53": & Central fault message (coding address "53:0") & DHW circulation pump (coding address "53:1") (only for weathercompensated operation) & Heating circuit pump for a heating circuit without mixer (coding address "53:2") & Cylinder primary pump (coding address "53:3") An external safety valve can be connected to gd. 94

95 Function description Extensions for external connections... (cont.) Internal extension H2 The internal extension is integrated into the control unit housing. The following alternative functions can be connected to relay output sk. The function is allocated via coding address "53": & Central fault message (coding address "53:0") & DHW circulation pump (coding address "53:1") (only for weathercompensated operation) & Heating circuit pump for heating circuit without mixer (coding address "53:2") & Cylinder primary pump (coding address "53:3") An extractor can be switched OFF via connection abj when the burner starts. 95

96 Function description Extensions for external connections... (cont.) External extension H1 The external extension is connected to the boiler control unit via the KM BUS. The following functions can be controlled or processed simultaneously via the extension: A ON/OFF switch (on site) sö Heating circuit pump for the heating circuit without mixer sa Cylinder primary pump sk DHW circulation pump (only for weather-compensated operation) fö Power supply gö Central fault message avd & External blocking & (terminals 2-3) & External demand & (terminals 1-2) & External heating program changeover (terminals 1-2) (only for weather-compensated operation) & The allocation of the function "External heating program changeover" is set via coding address "91". avf External set value 0 to 10 V avg KM BUS 96

97 Function description Extensions for external connections... (cont.) External extension H2 The external extension is connected to the boiler control unit via the KM BUS. The following functions can be controlled or processed simultaneously via the extension: A ON/OFF switch (on site) sk DHW circulation pump (only for weather-compensated operation) fö Power supply avd & External blocking & (terminals 2-3) & External demand & (terminals 1-2) & External heating program changeover (terminals 1-2) (only for weather-compensated operation) & The allocation of the function "External heating program changeover" is set via coding address "91". avg KM BUS 97

98 Function description Control functions External heating program changeover The "External heating program changeover" function is connected via external extension input "avd". You can select which heating circuits the heating program changeover affects in coding address "91": Heating program changeover Coding No changeover 91:0 Heating circuit without mixer A1 91:1 Heating circuit with mixer M2 91:2 Heating circuit without mixer and heating circuit with mixer 91:3 You can select in which direction the heating program changes over in coding address "D5": Heating program changeover Coding Changeover towards "Permanently reduced" or "Permanent d5:0 standby" mode (subject to the selected set value) Changeover towards "Constant heating mode" d5:1 The duration of the heating program changeover can be adjusted in coding address "F2": Heating program changeover Coding No heating program changeover F2:0 Duration of the heating program changeover 1 to 12 hours F2:1 to F2:12 The heating program changeover stays enabled for as long as the contact remains closed, but at least as long as the duration selected in coding address "F2". 98

99 Function description Control functions (cont.) External blocking The "External blocking" function is connected via external extension input "avd". In coding address "32" you can select the influence the "Ext. blocking" signal should have on the connected circulation pumps. External demand The "External demand" function is connected via external extension input "avd". In coding address "34" you can select the influence the "Ext. demand" signal should have on the connected circulation pumps. The minimum set boiler water temperature in case of external demand is selected in coding address "9b". Venting program During the venting program, the circulation pump will be alternately switched ON and OFF for 30 s respectively over a period of 20 min. For a certain period, the diverter valve is alternately set towards heating and DHW heating. The burner is switched OFF during the venting program. The venting program is activated via code "2F:1". The program is automatically disabled after 20 min, and coding address "2F" is set to "0". Fill program In the delivered condition, the diverter valve is set to its central position, enabling the system to be filled completely. After switching ON the control unit, the diverter valve no longer goes into its central position. Afterwards, the diverter valve can be moved via code "2F:2" into the central position. In this position, the control unit can be switched OFF, and the system can be filled completely. 99

100 Function description Control functions (cont.) Filling with the control unit switched ON If the system is to be filled with the control unit switched ON, the diverter valve will be moved to its central position via code "2F:2" and the pump will be started. The burner shuts down if this function is enabled via coding address "2F". The program is automatically disabled after 20 min, and coding address "2F" is set to "0". Screed drying function The screed function enables screeds to be dried. For this, always observe the details specified by the screed manufacturer. When the screed drying function is activated, the heating circuit pump of the mixer circuit is switched ON and the flow temperature will be held at the selected profile. After completion (30 days), the mixer circuit will again be regulated automatically via the set parameters. Observe EN The report to be provided by the heating contractor must contain the following heat-up details: & Heat-up data with respective flow temperatures & Max. flow temperature achieved & Operating condition and outside temperature during handover The various temperature profiles are adjustable via coding address "F1". The function continues after power failure or after the control unit has been switched OFF. "Heating and DHW" will be started after the screed drying function has been terminated or if code "F1:0" is manually adjusted. Temperature profile 1: (EN ) code "F1:1" 100

101 Function description Control functions (cont.) Temperature profile 2: (ZV parquet and flooring technology) code "F1:2" Temperature profile 3: Code "F1:3" Temperature profile 4: Code "F1:4" Temperature profile 5: Code "F1:5" 101

102 Function description Control functions (cont.) Temperature profile 6: Code "F1:6" Temperature profile 7: Code "F1:15" Raising the reduced room temperature During operation with reduced room temperature, the reduced set room temperature can be automatically raised subject to the outside temperature. The temperature is raised in accordance with the selected heating curve, but no higher than the set standard room temperature. The outside temperature limits for the start and end of the temperature raising can be adjusted via coding addresses "F8" and "F9". 102

103 Function description Control functions (cont.) Example using the settings in the delivered condition A Heating curve for operation with standard room temperature B Heating curve for operation with reduced room temperature Reducing the heat-up time During the transition from operation with reduced room temperature to operation with standard room temperature, the boiler water or flow temperature will be raised in accordance with the selected heating curve. The boiler water or flow temperature can be automatically increased. The value and duration of the additional increase of the set boiler water or flow temperature can be adjusted in coding addresses "FA" and "Fb". 103

104 Function description Control functions (cont.) Example using the settings in the delivered condition A Start of operation with standard room temperature B Set boiler water or flow temperature in accordance with the selected heating curve C Set boiler water or flow temperature in accordance with coding address "FA": 50 C + 20 % = 60 C D Duration of operation with raised set boiler water or flow temperature in accordance with coding address "Fb": 60 min Remote control DIP switches The DIP switches are located on the PCB in the top part of the casing. 104

105 Function description Remote control DIP switches (cont.) Remote control The remote control affects the heating circuit without mixer A1 DIP switch setting The remote control affects the heating circuit with mixer M2 When connecting a separate room temperature sensor, set DIP switch "3" to "ON". Electronic combustion control unit The electronic combustion controller utilises the physical correlation between the level of the ionisation current and the air factor λ. For all gas qualities, the maximum ionisation current results with air factor 1. The ionisation signal is evaluated by the combustion control unit, and the air factor is adjusted to between λ=1.24 and This range provides for an optimum combustion quality. Thereafter, the electronic gas valve regulates the required gas volume subject to the prevailing gas quality. To check the combustion quality, the CO2 content or the O2 content of the flue gas is measured. The actual values enable the prevailing air factor to be determined. The relationship between the CO2 or O2 content and air factor λ is illustrated in the following table. 105

106 Function description Electronic combustion control unit (cont.) Air factor λ CO2 /O2 content Air factor λ O2 content (%) CO2 content (%) for natural gas E CO2 content (%) for natural gas LL CO2 content (%) for LPG P To achieve an optimum combustion control, the system regularly carries out an automatic self-calibration; also after a power failure (shutdown). For this, the combustion is briefly regulated to max. ionisation current (equals air factor λ=1). The automatic calibration is carried out shortly after the burner start and lasts approx. 5 s. During the calibration, higher than normal CO emissions may occur briefly. The combustion control unit can also be calibrated manually. e.g. after maintenance or service work (coding address "85"). 106

107 Designs Connection and wiring diagram internal connections A1 Main PCB X... Electrical interface Boiler water temperature sensor $ Outlet temperature sensor (Gas fired condensing combi boiler) aa Ionisation electrode ag Flue gas temperature sensor 107

108 Designs Connection and wiring diagram internal... (cont.) dö fj gf a-ö Stepper motor for diverter valve Temperature limiter Ignition unit Fan motor a-öa Fan motor control avl Flow switch (Gas fired condensing combi boiler) a:ö Modulation coil 108

109 Designs Connection and wiring diagram external connections A1 Main PCB A2 Power supply unit 109

110 Designs Connection and wiring diagram external... (cont.) A3 Optolink A4 Burner control unit A5 Programming unit A6 Coding card A7 Connection adaptor A8 LON communication module (Vitotronic 200) A9 Internal extension H1 or H2 S1 ON/OFF switch S2 Reset button X... Electrical interface! Outside temperature sensor? Flow temperature sensor, low loss header % Cylinder temperature sensor (gas fired condensing boiler) or Comfort sensor (gas fired condensing combi boiler) (plug on the cable harness) sö Internal circulation pump dg Gas solenoid valve fö Power supply lh Power supply accessories and Vitotrol 100 a-ö Fan motor a-öa Fan motor control aya Gas pressure limiter avg KM BUS 110

111 Parts lists Parts lists Spare parts information Quote the part and serial no. (see type plate) and the item number of the required part (as per this parts list). Obtain standard parts from your local supplier. 001 Quick-acting air vent valve 002 Heating water flow connection pipe 006 Heating water return connection elbow 007 Heating water flow connection elbow 009 Safety spring 010 Pump motor 013 Siphon 014 Heat exchanger 015 Entry grommets (set) 017 Condensate hose 018 Condensate hose 019 Boiler flue connection plug 020 Heat exchanger gasket set* Plate-type heat exchanger* Pressure gauge 023 Flow switch * Flow limiter * Linear stepper motor 026 Boiler flue connection (with items 019 and 036) 027 Drain valve 030 Thermal insulation block 031 Thermal insulation, plate-type heat exchanger* Gas supply pipe 034 Heating water return connection pipe 036 Flue gas gasket 037 Diaphragm expansion vessel 038 Connection line for the diaphragm expansion vessel 052 Burner gauze assembly *1 Only for serial no and Burner gauze assembly gasket 058 Burner door gasket 059 Fan 061 Gas train 062 Burner door 063 Ignition unit 070 Ionisation electrode gasket 071 Ignition electrode gasket 072 Gasket A 17x24x2 074 Venturi extension 080 Vitodens control unit 081 Back cover 082 Locking clips (10 pcs.) 083 Support 084 Flap 085 Pressure gauge retainer 086 Clip 087 Hinge 088 Coding card 089 Fuses (10 pcs.) 090 Programming unit for constant temperature mode 091 Programming unit for weathercompensated mode 092 Internal extension H1 093 LON communication module (accessories) 094 PCB adaptor, LON module (accessories) 095 Fuse holder 106 Access guard 150 Outside temperature sensor 151 Flue gas temperature sensor 152 Temperature limiter 153 Temperature sensor 154 Comfort sensor* Front panel (with item 201) 201 Fixing clip Wearing parts 050 Burner gasket 051 Insulation ring 111

112 Parts lists Parts lists (cont.) 054 Ignition electrode block 055 Ionisation electrode Parts not shown 016 Special grease 028 Plug-in connector retainers (set) 041 Plug-in connector gaskets (set) 042 Fixing parts (set) 073 Gas nozzle 096 Mating plug 097 Cable fixing 100 Cable harness X8/X9 101 Fan connecting cable Gas solenoid valve connecting cable Power cable, stepper motor 104 Ionisation cable 105 Earth/ignition module cable harness 202 Spray paint, Vitowhite 203 Touch-up paint stick, Vitowhite 300 Installation instructions 301 Service instructions 302 Operating instructions for constant temperature mode 303 Operating instructions for weather-compensated mode A Type plate 112

113 Parts lists Parts lists (cont.) 113

114 Parts lists Parts lists (cont.) 114

115 Parts lists Parts lists (cont.) 115

116 Parts lists Parts lists (cont.) 116

117 Commissioning/service reports Commissioning/service reports Set value Date: By: Static pressure mbar max mbar Supply pressure (flow pressure) = for natural gas E mbar mbar = for natural gas LL mbar mbar = for LPG mbar mbar Tick gas type Carbon dioxide content CO2 & at lower output & at upper output Oxygen content O2 & at lower output & at upper output Carbon monoxide content CO & at lower output & at upper output % by vol. % by vol. % by vol. % by vol. ppm ppm Setting and test values Commissioning Service 117

118 Specification Specification Rated voltage: 230 V~ Rated frequency: 50 Hz Rated current: 6 A Safety class: I IP X 4 D to Protection: EN Permissible ambient temperature & during operation: +2 to +45 C & during storage and transport: -20 to +65 C Electronic temperature limiter setting: Temperature limiter setting: Line fuse (mains): 82 C (fixed) 100 C (fixed) max. 16 A Gas fired boiler, category II 2N3P Rated output range kw TV/TR 50/30 C Rated output range for DHW heating kw Gas fired condensing combi boiler Rated thermal load range & Gas fired condensing boiler kw & Gas fired condensing combi boiler kw Connection values in relation to the max. load with Natural gas E m 3 /h Natural gas LL m 3 /h LPG kg/h Product ID _-0085 BR 0432 Note The supply values are only for documentation purposes (e.g. in the gas contract application) or to estimate the supplementary volumetric settings. Because of factory settings, the gas pressure must not be altered from these settings. Reference: 15 C, 1013 mbar. 118

119 Certificates Declaration of conformity Declaration of conformity for the Vitodens 200-W We, Viessmann Werke GmbH & Co KG, D Allendorf, declare as sole responsible body, that the product Vitodens 200-W complies with the following standards: EN 483 EN EN 625 EN EN 677 EN EN EN EN This product is designated _-0085 in accordance with the following directives: 90/396/EEC 92/42/EEC 2004/108/EC 2006/95/EC This product meets the requirements of the Efficiency Directive (92/42/EEC) for condensing boilers. The product characteristics determined as system values for the product Vitodens 200-W as part of EC type testing according to the Efficiency Directive (see specification table), can be utilised to assess the energy consumption of heating and ventilation equipment to DIN V which is specified by the EnEV [Germany]. Allendorf, Viessmann Werke GmbH&Co KG pp. Manfred Sommer 119

120 Certificates Manufacturer's certificate according to the 1st BImSchV [Germany] We, Viessmann Werke GmbH&Co KG, D Allendorf, confirm that the product Vitodens 200-W complies with the NOx limits specified by the 1st BImSchV paragraph 7 (2) [Germany]. Allendorf, Viessmann Werke GmbH&Co KG pp. Manfred Sommer 120

121 Keyword index Keyword index A Acknowledging a fault display B Boiler water temperature sensor Boosting DHW heating Brief scans Burner gasket Burner gauze assembly Burner installation Burner removal C Calling up fault messages Code 1 & calling up Code 2 & calling up Codes, resetting Coding during commissioning Combustion chamber cleaning Combustion controller Comfort sensor Commissioning Commissioning/service report Condensate drain Controls , 91 Cylinder temperature sensor D Date setting Declaration of conformity Delivered condition Diaphragm expansion vessel Display elements , 91 E Electronic combustion controller Extension kit for heating circuit with mixer Extension & external H & external H & internal H & internal H External blocking External demand F Fault codes Fault display layout Fault history Fault manager Fault memory Faults Fill function Fill water Filling the system Flow limiter Flue gas temperature sensor Function descriptions Functions testing Fuse G Gas supply pressure Gas train Gas type Gas type conversion H Heating curve Heating curve level Heating curve slope Heating program changeover Heating surfaces, cleaning Heat-up time Hiding a fault display

122 Keyword index Keyword index (cont.) I Ignition Ignition electrodes Ionisation electrode L Language selection LON LON communication module LON & Fault monitoring & Setting subscriber number & Updating subscriber list M Manufacturer's certificate O Outlet temperature sensor Outside temperature sensor P Parts list Plate-type heat exchanger R Reduced room temperature Reduced room temperature raising Reducing the heat-up output Reducing the heat-up time Relay test Remote control Reports Room temperature adjustment Rotational direction of mixer motor & changing & checking S Scanning Scanning operating conditions Scanning sensors Screed drying Screed drying function Service level overview Service & acknowledge & reset Setting the output Siphon , 22 Small softening system Specifications Standard room temperature Static pressure Supply pressure System designs , 36, 37 System pressure T Temperature limiter Temperature scans Testing outputs Tightness test, balanced flue system Time setting V Venting Venting program Vitocom Vitotronic 200-H , 89 W Wiring diagram

123 123

124 Applicability Printed on environmentally friendly, chlorine-free bleached paper Gas fired condensing boiler Gas fired condensing combi boiler Type WB2B Type WB2B 4.8 to 19.0 kw 6.5 to 26.0 kw from serial no. from serial no to 26.0 kw 8.8 to 35.0 kw from serial no. from serial no to 35.0 kw from serial no Viessmann Werke GmbH&Co KG D Allendorf Telephone: Fax: Viessmann Limited Hortonwood 30, Telford Shropshire, TF1 7YP, GB Telephone: Fax: info-uk@viessmann.com Subject to technical modifications.