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Viessmann VITODENS 200-W WB2B 80 User Manual

Viessmann VITODENS 200-W WB2B 80
80 pages
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Start-up/Service Instructions
for use by heating contractor
Vitodens 200-W, WB2B Series
Models WB2B 80, 105
Wall-mounted, natural gas-fired condensing boiler
For operation with natural gas and liquid propane gas
Heating input 104 to 370 MBH
30 to 108 kW
VITODENS 200-W
Read and save these instructions
for future reference.
IMPORTANT
This trademark is registered with the U.S. Patent and Trademark Office.
5443 207 v1.5 11/2012
Please file in Service Binder
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Viessmann VITODENS 200-W WB2B 80 Specifications

General IconGeneral
ModelVITODENS 200-W WB2B 80
CategoryBoiler
EfficiencyUp to 98% (Hs) / 109% (Hi)
Fuel TypeNatural gas or LPG
InstallationWall-mounted
Modulation Range1:6
Water Pressure (max)3 bar
TypeCondensing Boiler
ControlVitotronic control system
Water Temperature Range30 to 85 °C
Noise Level45 dB(A)

Summary

Safety, Installation, and Warranty Requirements

Licensed Professional Heating Contractor

Installation, service, and maintenance must be performed by a licensed professional.

Product Documentation Importance

Read all applicable documentation before installation and store it accessibly.

Carbon Monoxide Hazards

Improper installation can cause flue products with carbon monoxide to enter living space.

Equipment Venting Requirements

Never operate the boiler without a properly installed venting system.

Warranty Information

Failure to follow documentation renders warranty null and void.

Advice to Owner

Familiarize the owner with operation, safety, and shutdown procedures.

Important Regulatory and Installation Requirements

Applicable Codes and Standards

Installation must comply with local codes and national standards like NFPA 70.

System User Instruction

Ensure the system operator is familiar with operation, activation, and shutdown.

Initial Start-up Procedure

Start-up must be performed by a qualified heating contractor.

Working on Equipment

Installation, service, and maintenance must be done by a licensed professional.

Massachusetts Regulations and CO Detectors

Fixed High Limit Fault Simulation Method #1

Simulate fault by closing boiler valve and jumping flow switch.

Fixed High Limit Fault Simulation Method #2

Throttle boiler valve to minimum flow, run at high fire.

Fixed High Limit Fault Simulation Method #3

Remove wire from limit switch to create fault.

General Information and Instructions

Understanding Symbols and Notations

Note symbols like WARNING, CAUTION, and IMPORTANT for hazards and product info.

Necessary Tools and Equipment

Lists special items, testing equipment, and cleaning supplies required.

Boiler Applicability and Identification

Boiler Serial Number

Provide the boiler serial number when ordering replacement parts.

Model Identification

Details for models WB2B 80 and WB2B 105 for NG/LPG and NG only.

Product Information Overview

Mechanical Room Requirements

Installation Area Conditions

Ensure proper ambient temperatures and avoid contaminated combustion air.

Contaminant Sources

Lists areas and products that can contaminate combustion air.

Marine Environment Operation

Considerations for boilers installed in damp, salty coastal areas.

Removing the Front Enclosure Panel

Initial Start-up and Service Steps

Bleeding Air from Heat Exchanger

Procedure to remove air from the boiler heat exchanger.

Filling the Siphon with Water

Steps to fill and reassemble the condensate siphon.

Initial Start-up and Service Steps (continued)

Filling the Heating System with Water

Procedure to fill the heating system with water and check pressure.

Initial Start-up and Service Steps (continued)

Checking Power Supply Connection

Verify voltage range and neutral conductor for boiler control.

Setting Time and Date

Instructions for setting the current time and date on the control unit.

Initial Start-up and Service Steps (continued)

Selecting the Display Language

How to change the language displayed on the control unit.

Selecting the Gas Type

Ensure the correct gas type (natural gas or LPG) is selected for operation.

Initial Start-up and Service Steps (continued)

Converting Fuel Type to Liquid Propane

Procedure to convert the boiler for operation with liquid propane gas.

Converting for High Altitude Operation

Instructions for replacing coding cards for higher altitudes.

Initial Start-up and Service Steps (continued)

Measuring Gas Pressures

Procedures for measuring static and running gas supply pressures.

Initial Start-up and Service Steps (continued)

Start-up Sequence and Potential Faults

Flowchart of normal start-up and common fault codes encountered.

Initial Start-up and Service Steps (continued)

Setting Maximum Input

How to limit the maximum heating output via the modulation range.

Checking for Circuit Leaks

Ensure all primary and secondary circuit connections are pressure tight.

Performing Combustion Analysis

Importance of CO measurement before and after gas appliance work.

Initial Start-up and Service Steps (continued)

Checking Coaxial Venting System Leaks

Performing a simplified leak test on the venting system.

Removing the Burner Assembly

Step-by-step instructions for safely removing the burner assembly.

Initial Start-up and Service Steps (continued)

Checking Burner Refractory and Cylinder Assembly

Inspect and replace burner refractory ring and cylinder assembly if needed.

Adjusting Ignition and Ionization Electrodes

Check and adjust electrode gaps for optimal ignition and flame detection.

Initial Start-up and Service Steps (continued)

Cleaning Combustion Chamber/Heat Exchanger

Procedure for cleaning the internal surfaces of the boiler.

Initial Start-up and Service Steps (continued)

Checking Condensate Drain

Ensure the siphon trap and drain are clear for condensate flow.

Checking Neutralization Unit

Verify pH of condensate and replace granulate if necessary.

Initial Start-up and Service Steps (continued)

Checking Expansion Tank and System Pressure

Verify nitrogen pressure and system fill pressure.

Checking Safety Valve Functionality

Verify operation of low water cut-offs, pressure relief valve, and pumps.

Initial Start-up and Service Steps (continued)

Checking Electrical Connections

Ensure all plug-in connectors are secure and properly seated.

Checking Gas Pipes and Fittings for Leaks

Perform leak tests on gas supply piping before operation.

Initial Start-up and Service Steps (continued)

Checking CO2 Setting

Measure CO2 and O2 content at the vent pipe adaptor for optimal combustion.

Initial Start-up and Service Steps (continued)

Clocking the Natural Gas Meter

Verify boiler input by measuring gas meter performance.

Control Technology

Outdoor Reset Programming Unit (Vitotronic 200, HO1)

Overview of the control unit's features, buttons, and displays.

Controls and Indicators Overview

Identifies buttons, displays, and their functions on the control unit.

Control Technology (continued)

Functional Description

Explains space heating, DHW, and electronic combustion control modes.

Electronic Combustion Control

Details on ionization current, air factor, and combustion quality measurement.

Control Technology (continued)

Heating System Types

Overview of different heating system configurations and corresponding coding addresses.

Control Technology (continued)

Heating Curve Adjustment

How to adjust the heating curve for optimal performance based on outdoor temperature.

Control Technology (continued)

Changing the Heating Curve Slope

Adjusting the slope parameter (d3) of the heating curve.

Changing the Heating Curve Shift

Adjusting the shift parameter (d4) of the heating curve.

Control Technology (continued)

Room Temperature Setpoint Adjustment

Adjusting day temperature setpoints for heating circuits.

Room Temperature Setback

Adjusting night temperature setback values.

Control Technology (continued)

Connecting to a LON System

Instructions for integrating the boiler control into a LON communication system.

Control Technology (continued)

Updating the LON Participant List

Process for updating the list of participants in a LON network.

Control Technology (continued)

Performing Participant Check (LON)

Steps to verify communication and presence of LON participants.

Instructing the System User

Installer's responsibility to train the end-user on system operation.

Control Technology (continued)

Scanning and Resetting Service Display

Procedure for managing maintenance intervals and service messages.

Coding

Coding Level 1

Steps to enter and navigate coding level 1.

Accessing Coding Level 1

Procedure to enter coding level 1 using specific button combinations.

Coding (continued)

Coding Level 1 Overview

Details on system design, temperature limits, participant numbers, and DHW priority.

Coding (continued)

Coding Level 1 Overview (continued)

Settings for summer setback, supply temperatures, slope, and shift.

Coding

Coding Level 2

Steps to enter and navigate coding level 2.

Accessing Coding Level 2

Procedure to enter coding level 2 using specific button combinations.

Coding (continued)

Coding Level 2 Overview

Parameters for system design, boiler/burner functions, and intervals.

Coding (continued)

Coding Level 2 Overview (continued)

Settings for pump control and external signals (demand, blocking).

Coding (continued)

Coding Level 2 Overview (continued)

DHW settings, boiler status, and operational modes.

Coding (continued)

Coding Level 2 Overview (continued)

DHW settings, recirculation pumps, and LON communication.

Coding (continued)

Coding Level 2 Overview (continued)

General settings, fault display options, and calibration.

Coding (continued)

Coding Level 2 Overview (continued)

General settings, mixing valve circuits, and DHW priority.

Coding (continued)

Coding Level 2 Overview (continued)

Mixing valve circuits, economy functions, and frost protection.

Coding (continued)

Coding Level 2 Overview (continued)

Mixing valve circuits, room influence, supply temperatures, slope, and shift.

Coding (continued)

Coding Level 2 Overview (continued)

Mixing valve circuits, heating program changeover, and reduced temperature settings.

Coding (continued)

Resetting Coding Addresses to Factory Defaults

Procedure to restore all coding addresses to their original factory settings.

Service Level Overview

List of functions accessible via service level and their respective key combinations.

Service Scans

Service Level Overview (continued)

How to view system temperatures, coding card data, and brief scan values.

Temperatures, Boiler Coding Card, and Brief Scans

View system temperatures, coding card data, and brief scan values.

Service Scans (continued)

Checking Outputs (Relay Test)

Procedure to test boiler outputs like pumps, valves, and burner status.

Service Scans (continued)

Scanning Operating Conditions and Sensors

How to view real-time operating data and sensor readings.

Troubleshooting

Diagnostics

Understanding fault messages, indicators, and codes on the control unit.

Fault Display and Symbols

Identify fault indicators, fault codes, and plain text fault displays.

Checking and Acknowledging Faults

Steps to review, acknowledge, and clear fault messages.

Troubleshooting (continued)

Retrieving Fault Messages

How to access acknowledged fault messages and fault history.

Fault Codes List

Comprehensive list of fault codes, their causes, and corrective actions.

Troubleshooting (continued)

Fault Codes List (continued)

Further fault codes, system behaviors, causes, and corrective actions.

Troubleshooting (continued)

Fault Codes List (continued)

More fault codes related to communication, sensors, and control modules.

Troubleshooting (continued)

Fault Codes List (continued)

Fault codes related to ionization current, flame signal, and calibration issues.

Troubleshooting (continued)

Fault Codes List (continued)

Fault codes for high limit switches, fan issues, gas valves, and interference.

Troubleshooting (continued)

Corrective Action

Procedures for diagnosing and fixing common boiler issues.

Checking Outdoor Temperature Sensor

Procedure for testing the resistance of the outdoor temperature sensor.

Checking Boiler/Tank/Supply Sensors

Procedures to test boiler, tank, and supply temperature sensors.

Troubleshooting (continued)

Checking Boiler/Tank/Supply Sensors (continued)

Continued sensor resistance checks and replacement advice.

Checking Flue Gas Temperature Sensor

Procedure for testing the flue gas temperature sensor.

Troubleshooting (continued)

Checking Fixed High Limit Switch

Procedure to test and replace a faulty fixed high limit switch.

Checking Fuses

Locating and checking fuses in the boiler and power/pump module.

Troubleshooting (continued)

Checking Mixing Valve Motor Direction

Verifying the rotational direction of the mixing valve motor.

Changing Mixing Valve Motor Direction

Instructions on how to reverse the mixing valve motor's rotation.

Additional Information

Control Functions

Details on external signals affecting heating programs and pumps.

External Heating Program Changeover

Configuration for external signals to change heating programs.

External Blocking Function

How external blocking signals affect circulation pumps.

External Heat Demand Function

How external heat demand signals affect circulation pumps.

Additional Information (continued)

Control Functions (continued)

Descriptions of air bleed, fill, and temperature raising programs.

Air Bleed Program

Description of the automatic air bleeding sequence.

Fill Program

Description of the system filling program.

Raising Reduced Room Temperature

How reduced room temperature setpoints are automatically raised.

Additional Information (continued)

Control Functions (continued)

Adjusting heat-up time and configuring remote control DIP switches.

Reducing Heat-Up Time

Adjusting parameters to speed up transitions between heating modes.

Remote Control DIP Switch Settings

Configuration of DIP switches for the Vitotrol 300 remote control.

Additional Information (continued)

Burner Program Sequence of Operation

Detailed breakdown of the burner's start-up, operation, and shutdown phases.

Additional Information (continued)

Wiring Diagram

Complete schematic of electrical connections for the boiler system.

Additional Information (continued)

Wiring Diagram (continued)

Explanation of symbols, component labels, and wire colors used in the diagram.

Diagram Legend

Explanation of symbols, component labels, and wire colors used in the wiring diagram.

Additional Information (continued)

Parts Lists

List of components for NG Only and NG/LPG models, with part numbers.

Additional Information (continued)

Parts Lists (continued)

Continued parts list with exploded views and part numbers.

Additional Information (continued)

Parts Lists (continued)

Continued parts list with control console and accessory components.

Additional Information (continued)

Measurements and Maintenance Record

Table for recording service dates, measurements, and setpoint values.

Maintenance Record

Table for recording service dates, measurements, and setpoint values.

Additional Information (continued)

Technical Data

Specifications for Boiler Model WB2B 80 and 105, including gas input, output, and pressures.

Additional Information (continued)

Technical Data (continued)

Continued technical specifications including dimensions, flue gas, and condensate data.

Lighting and Operating Instructions

Safety Warnings Before Operation

Critical safety precautions regarding fire, explosion, and gas leaks.

Operating Instructions

Step-by-step guide for starting and operating the boiler safely.

Turning Off Gas Supply

Procedure for safely shutting off the gas supply to the boiler.

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