Viessmann VITOLIGNO 200-S Installation And Service Instructions Manual Download Page 11

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Removing the doors

M8 x 25

Fig. 4

Remove headless screws.

Unhook the doors.
Keep washers

safe.

Remove the display panel with outside tempera-
ture sensor and boiler water temperature sensor
from the boiler.

Remove transport brackets from inner doors and
the combustion chamber.

Note

Fully insert the thermal insulation plates of the
combustion chamber.

Undo screw and remove air damper guard.

Remove all spring hooks

from the thermal insu-

lation mats so that the retaining rails can be fitted.

Preparing for installation

Preparing for installation

(cont.)

5777 985 GB

Installation

Summary of Contents for VITOLIGNO 200-S

Page 1: ... instructions for contractors VIESMANN Vitoligno 200 S Type VL2A High performance wood gasification boiler for split logs up to 50 cm long For applicability see the last page VITOLIGNO 200 S 5777 985 GB 3 2017 Please keep safe ...

Page 2: ...stem Working on the system Isolate the system from the power supply e g by removing the separate fuse or by means of a mains isolator and check that it is no longer live Safeguard the system against reconnection Danger Hot surfaces can cause burns Before maintenance and service work switch OFF the appliance and let it cool down Never touch hot surfaces on the boiler burner flue system or pipework ...

Page 3: ...fications to the building characteristics are not permissible e g cable pipework routing cladding or partitions Danger Leaking or blocked flue systems or an inade quate supply of combustion air can cause life threatening poisoning from carbon monoxide in the flue gas Ensure the flue system is in good working order Vents for supplying combustion air must be non closable Extractors Operating applian...

Page 4: ...Fitting the covers 21 Connections on the flue gas side 22 Connections on the water side 22 4 Commissioning inspec tion maintenance Steps commissioning inspection and maintenance 24 5 Codes Code 1 46 Calling up code 1 46 Code 2 54 Calling up code 2 54 6 Service checks Service menu 58 Calling up the service menu 58 Leaving the service menu 58 Calling up operating conditions and sensors 58 Diagnosis ...

Page 5: ...nlet outlet assembly 40 and 50 kW 86 Miscellaneous assembly 88 10 Function description Display and operating elements 90 Programming unit 90 Heating circuit control unit 90 Control functions 90 DHW temperature control 91 Screed drying 91 11 Connection and wiring dia gram Connection and wiring diagram 93 Position of the PCB 93 Overview of PCB 94 230 V connections 95 LV connections 96 Heating circui...

Page 6: ...a Pay particular attention Component must audibly click into place or Acoustic signal Fit new component or In conjunction with a tool Clean the sur face Dispose of component correctly Dispose of component at a suitable collec tion point Do not dispose of component in domestic waste The steps in connection with commissioning inspec tion and maintenance are found in the Commission ing inspection and...

Page 7: ...result in an exclusion of lia bility Incorrect usage also occurs if the components in the heating system are modified from their intended use e g if the flue gas and ventilation air paths are sealed or if other fuels than those intended for this appliance are used Maintenance and cleaning Please note During maintenance and cleaning work and when manipulating the ash box there is a risk of fire and...

Page 8: ...ion requirements The installation room must be dry and free from the risk of frost Avoid high humidity levels e g from continuous dry ing of washing Ambient temperatures between 0 and 35 C Ensure a supply of fresh air Danger Suffocation hazard due to carbon monoxide produced during incomplete combustion due to lack of combustion air Ensure an adequate supply of fresh air Never cover or close vents...

Page 9: ...per door and ignition door Remove the lower door inspection door or ash door from the boiler for transportation with a pallet truck Aligning the boiler Please note Do not damage or lose the foot caps on the adjustable feet Pay attention to the foot caps when lifting the boiler and removing the pallet 10 20 Fig 2 Align the boiler on the adjustable feet with an inclina tion towards the front This al...

Page 10: ...ess apply chalk to the sealing contour of the boiler body Close the doors open them again and examine the packing cord Leaks are evident where the chalk has left no mark on the packing cord 2 If necessary adjust the door in question Note If required either the hinges or the lock plates or both can be adjusted Observe the following sequence Undo nuts A Shift the hinge or lock plate To do this with ...

Page 11: ...erature sensor from the boiler 4 Remove transport brackets from inner doors and the combustion chamber Note Fully insert the thermal insulation plates of the combustion chamber 5 Undo screw and remove air damper guard 6 Remove all spring hooks B from the thermal insu lation mats so that the retaining rails can be fitted Preparing for installation Preparing for installation cont 5777 985 GB Install...

Page 12: ...tie bars have been fitted and the base protection plate is installed see page 15 When fitting the front left rail pay attention to the cables of the door contact switch If any edges of the thermal insulation jacket protrude at the sides push them behind the retaining rails Installation sequence Fitting the thermal insulation 5777 985 GB Installation ...

Page 13: ...13 Fitting the tie bars 4 8 x 9 5 Fig 6 Installation sequence Fitting the thermal insulation cont 5777 985 GB Installation ...

Page 14: ...ection plate downwards 2 Insert the thermal insulation mat with the black side facing down 3 Turn the tabs on the plinth trim inwards 4 Insert the base protection plate 5 Slide the base protection plate with the recess onto the tab bolt Installation sequence Fitting the thermal insulation cont 5777 985 GB Installation ...

Page 15: ...nto the front panel 4 Position the front panel on the location studs and press together firmly first at the bottom then at the top Note For easier handling first place the front panel on cleaning gate A Fitting the display panel and sensors Please note Damaged capillary tubes will result in faulty sen sor function Never kink the capillary tubes Note The ribbon cable of the programming unit must no...

Page 16: ... 5 Insert the thermally activated safety valve sensor not included in standard delivery as far as it will go 6 Push the supplied corrugated hose completely over the high limit safety cut out sensor capillaries Note The corrugated hose protects the capillaries from damage and kinking 7 Pull the thermal insulation forwards by hand Thread the sensors through the holes in the ther mal insulation mat 8...

Page 17: ...ables together and secure them to the wiring rail and retaining rail Please note Contact with hot components causes damage to cables After installation cables must not come into con tact with hot components Electric ignition system if available If an electric ignition system accessories has been ordered install this now Electric ignition system installation instructions Installation sequence Fitti...

Page 18: ...18 Fitting the doors 3x A 2 3 1 Fig 11 A Washer 1 per door Installation sequence Fitting the thermal insulation cont 5777 985 GB Installation ...

Page 19: ...ty requirements of protection class II must be observed This means 8 0 mm air and creep paths or 2 0 mm insulation thickness against live components Ensure the safe electrical separation of all on site com ponents incl PCs laptops in accordance with EN 60 335 and IEC 65 Please note Electronic assemblies can be damaged by elec trostatic discharge Prior to commencing any work touch earthed objects s...

Page 20: ...o ensure it will not be pulled off under ten sion Mains isolator requirements if necessary For combustion equipment to DIN VDE 0116 the mains isolator installed on site must comply with the requirements of DIN VDE 0116 section 6 or local regulations Fit the mains isolator outside the installa tion room it must be able to isolate all non earthed conductors simultaneously with at least 3 mm contact ...

Page 21: ...21 1 4 8 x 9 5 4 8 x 9 5 2 Fig 14 1 Close the control unit enclosure 2 Fit the top panel Installation sequence Fitting the covers 5777 985 GB Installation ...

Page 22: ...e pipe length to the chimney 3000 mm Note Let the flue pipe connector project about 1 cm into the chimney This prevents condensate or rainwa ter from the chimney running into the flue pipe 2 The entire flue pipe with cleaning aperture must be gas tight 3 Thermally insulate the flue pipe with at least 30 mm of insulation 4 Install a draught limiter accessories in the chim ney Separate installation ...

Page 23: ...te Only connect controlled heating circuits with mixer Always install a return temperature raising facility minimum return temperature 65 C Safety equipment block installation instructions Install the safety lines Permiss operating pressure 3 bar 0 3 MPa Test pressure 4 bar 0 4 MPa Note Equip boilers with a safety valve that is type tested to TRD 721 or local regulations and is marked accord ing t...

Page 24: ...puts and actuators 29 18 Calibrating the O2 probe 30 19 Ending commissioning 30 20 Displaying the menu structure 31 21 Matching the control unit to the heating system 31 22 Adjusting the heating curves 31 23 Heat up 33 24 Shutting down the system 33 25 Hopper cleaning if required 35 26 Cleaning the secondary heating surfaces 36 27 Cleaning the ash chamber and combustion chamber 37 28 Checking the ...

Page 25: ...mmissioning steps Inspection steps Maintenance steps Page 40 Checking the draught 45 41 Instructing the system user 45 Commissioning inspection maintenance Steps commissioning inspection and cont 5777 985 GB ...

Page 26: ...g output Specific system volume kW 20 l kW 20 l kW to 50 l kW 50 l kW 50 3 0 mol m3 16 8 dH 2 0 mol m3 11 2 dH 0 02 mol m3 0 11 dH 50 to 200 2 0 mol m3 11 2 dH 1 5 mol m3 8 4 dH 0 02 mol m3 0 11 dH 200 to 600 1 5 mol m3 8 4 dH 0 02 mol m3 0 11 dH 0 02 mol m3 0 11 dH 600 0 02 mol m3 0 11 dH 0 02 mol m3 0 11 dH 0 02 mol m3 0 11 dH Fig 17 1 Check the pre charge pressure of the expansion vessel If the...

Page 27: ...irm The display shows Date setting Setting the date Press the following keys 1 for the required date 2 d to confirm The display shows Time setting Setting the time Press the following keys 1 for the required time 2 d to confirm Selecting the number of buffer temperature sensors Press the following keys 1 for buffer temperature sensor 3 4 or 5 2 d to confirm Selecting the type of heating water buff...

Page 28: ...No Not installed for On the boiler if heating circuit exten sion module installed Connected at internal PCB for On the mixer module Connected to extension kit via KM BUS 2 d to confirm Selecting DHW circulation if heating circuit extension module installed To specify whether a DHW circulation pump is connec ted press the following keys 1 for DHW circulation Yes No 2 d to confirm Selecting the sola...

Page 29: ...Heating circuit 3 DHW Solar Checking the outputs and actuators Carrying out an actuator test Note An actuator test can only be carried out when the boiler is cold The actuators are split into several categories based on their application Boiler actuators Actuators for the corresponding mixer modules Press the following keys 1 d å simultaneously for approx 4 s The Service menu appears 2 for Actuato...

Page 30: ...depending on the module rec ommended during commissioning Display Explanation Pump On Valve open Valve close These actuators can also be switched if the heating circuit extension module accessories is used Display Explanation DHW circulation DHW circulation Pump Connected to the boiler at PCB HKK Solar Solar Pump Solar Valve open Solar Valve close Connected to the boiler at PCB HKK Calibrating the...

Page 31: ...the flow temperature The flow temperature in turn affects the room tempera ture Settings in the delivered condition Slope 1 4 Level 0 0 2 Outside temperature in C Flow temperature in C Slope 2 4 2 6 2 8 3 0 3 2 3 4 90 80 70 60 50 40 30 0 10 20 10 2 0 2 2 Set room temperature in C 35 30 25 20 15 10 5 0 4 0 6 0 8 1 0 1 2 1 4 30 1 8 1 6 14 C B A Fig 18 Example for outside temperature 14 C A Underfloo...

Page 32: ...emp 7 d to confirm 8 for the required value 9 d to confirm Reduced room temperature 3 14 20 C 110 3 C A D E B 20 C 14 C Fig 20 Changing the reduced room temperature from 3 to 14 C A 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 in the standard menu 1 å 2 for Heating 3 d to confirm 4 for sel...

Page 33: ...Press ä to return to default display Heat up Operating instructions Shutting down the system Danger Contact with live or hot components can result in serious injuries Before starting cleaning work disconnect from the mains voltage at the fuse or mains isolator Safeguard against unauthorised reconnection Wait until the boiler has cooled down 1 Let the fuel burn out 2 After the boiler has cooled dow...

Page 34: ... X Check all installed position switches X Maintenance of moving parts shafts and bearings X Replace the battery inside the control unit X For periodic testing please note Clean the flue gas routes and chimney 3 to 5 days before testing Run the boiler for at least 24 h between cleaning and testing Heat up the boiler for approx 1 hour before the test Ideally the heating water buffer cylinder temper...

Page 35: ... life of the parts Shiny black deposits on the interior walls of the hopper are normal Deposits need not be removed 2 Check primary air vents A in side elements B for unrestricted flow Clean with a vacuum cleaner if required 3 Clean nozzle slot C in base element D 4 Use a scraper or spatula to remove dry and flaking deposits ash carbon and tar from the hopper walls E door frame F and the inside of...

Page 36: ...t E a little way towards the side panel on both sides Shift until rear bracket F can be removed Remove rear bracket F upwards together with the turbulators 6 Slide both retaining brackets E all the way towards the side panel Remove front bracket G upwards together with the turbulators 7 Clean the interior walls of the flue gas collector and the secondary heating surface with a spatula cleaning bru...

Page 37: ...n chamber If intensive cleaning is not carried out a residual layer of ash can remain in the ash chamber This residual layer acts as thermal insulation 3 If necessary clean combustion chamber and ash chamber 4 Close doors B and A again Checking the packing cords Clean the packing cords on all doors and cleaning cov ers and check for damage Replace any damaged packing cords Commissioning inspection...

Page 38: ...e the packing cord Leaks are evident where the chalk has left no mark on the packing cord 2 If necessary readjust the doors Note Depending on the location of the leak either the hinges or the lock plates or both can be adjusted 3 After this check the function of the door contact switch 4 If a leak still exists replace gasket D on the rele vant door If doors were leaking clean the Lambda probe and ...

Page 39: ...ns from hot components Switch off the boiler and let it cool down Danger Working on a running fan can cause serious injury Turn off the boiler and safeguard against restart ing Note The flue gas fan requires cleaning in the following cases Vibration noises occur due to impeller imbalance deposits on the impeller vanes Output is reduced Commissioning inspection maintenance Checking the doors for ti...

Page 40: ...es damage to cables Mount the flue gas fan in such a way that the wiring does not come into contact with the fan casing Cleaning the Lambda probe and air dampers Danger Risk of burns from hot components Switch off the boiler and let it cool down Danger Mains voltage can be life threatening When performing maintenance work isolate the system from the power supply and safeguard against re connection...

Page 41: ... compressed air 2 Check the Lambda probe for damage and replace if required 3 If the Lambda probe needs to be replaced Pull out spring clip B and remove the Lambda probe from its retainer 4 Remove air dampers C and clean with a wire brush or oil free compressed air 5 Calibrate the Lambda probe See page 67 Commissioning inspection maintenance Cleaning the Lambda probe and air dampers cont 5777 985 ...

Page 42: ...42 A B C Fig 30 1 Remove top panel A and side panels B 2 Fold up thermal insulation mat C Commissioning inspection maintenance Cleaning the air box and secondary air supply 5777 985 GB ...

Page 43: ...or 0 3 MPa The safety valve may also respond and discharge the excess pressure Therefore check the expansion vessel pre charge pressure annually Check whether the installed expansion vessel is ade quate for the system water volume GB only Carry out this test on a cold system 1 Drain the system until the pressure gauge shows 0 Alternatively close the cap valve on the expansion vessel and reduce the...

Page 44: ...ify that the boiler meets the currently applicable emission limits The boiler must be operated correctly in order to stay within these limits Apart from cleaning this includes correct firing and selection of suitable wood fuel The Vitoligno 200 S is a high performance wood gasifi cation boiler and must therefore be operated with a sufficiently large buffer cylinder In low load operation i e with t...

Page 45: ... be approx 10 cm deep Quickly lay 50 cm long logs lengthways close together The emissions test can begin 5 minutes after closing the hopper door The boiler water temperature must not exceed 82 C during the test duration 15 minutes Closely moni tor the temperature display If it looks likely that this temperature will be exceeded ensure that more heat is drawn off Checking the draught 1 Measure the ...

Page 46: ...se same holiday program for all heating groups 7F 0 Apartment building holiday program can be adjusted separately Minimum temperature buffer sensor top 91 0 No minimum temperature 91 0 to 91 95 If a combined heating water buffer cylinder is installed a minimum tem perature can be set for the top of the buffer cylinder captured by PTS 1 Hardware Coding Coding in the delivered condition Possible cha...

Page 47: ...ing circuit 1 instal led Heating circuit 1 On the boiler if heating circuit ex tension module installed Heating circuit is connected to the boiler control unit at the heating cir cuit extension module Heating circuit 1 On the mixer module Heating circuit is connected to the mixer extension kit Heating circuit 2 Heating circuit 2 No There is no heating circuit 2 instal led Heating circuit 2 On the ...

Page 48: ...ted to the boiler has a diverter valve for charg ing the heating water buffer cylinder Heating Coding Coding in the delivered condition Possible change Remote control A0 0 Is available if a remote control is connected Without remote control A0 1 With Vitotrol 200 A Recognised au tomatically A0 2 With Vitotrol 300 A Recognised au tomatically A0 3 With Vitotrol 350 Recognised auto matically Summer e...

Page 49: ...t Heating mode red mode Weath er compensated operation without room temperature hook up B0 1 Heating mode Weather compensa ted operation without room tempera ture hook up Reduced mode Weather compen sated operation with room tempera ture hook up B0 2 Heating mode Weather compensa ted operation with room temperature hook up Reduced mode Weather compen sated operation without room tem perature hook ...

Page 50: ...m flow temperature limit set to 75 C C6 10 to C6 100 Adjustable from 10 to 100 C Room sensor limit C8 31 Is available if code A0 1 or A0 2 and B0 1 B0 2 or B0 3 heating group are set No limit for room influence C8 1 to C8 30 Room influence limit adjustable from 1 to 30 C Party mode time limit F2 8 Party mode time limit is 8 h F2 0 No time limit for party mode Party mode is deactivated when changin...

Page 51: ...he heat ing circuit set in code F3 Heat ing group For this the boiler reg ulates to the max flow tempera ture code C6 Heating group of the heating circuit 44 50 to 44 110 Temperature adjustable from 50 to 110 C Set system temperature 45 1 The min set system temperature can be adjusted in the menu 45 0 The min set system temperature is disabled in the menu and cannot be adjusted O2 control active 5...

Page 52: ...he solar thermal system up to this tempera ture 6F 0 to 6F 100 Setting range in C Differential buffer 70 20 Differential temperature of 20 K between solar and heating water buffer cylinder to start heating wa ter buffer cylinder by the solar ther mal system 70 1 to 70 50 Setting range in C Additional function solar 71 0 Additional function of cylinder heat ing by the solar thermal system disabled ...

Page 53: ...control active Set return tem perature corresponds to DHW tem perature plus value set in C Additional heat generator Is available if code Additional boiler Yes hard ware group is set Coding Coding in the delivered condition Possible change Buffer charging until sensor D0 1 The additional heat generator charges the heating water buffer cylinder up to the first buffer tem perature sensor Note Only u...

Page 54: ...um pause duration of the ad ditional heat generator of 5 min D5 0 to D5 250 Adjustable value in min Start without delay Set system temp D6 20 Start of additional heat generator without delay Condition Actual system temperature set system temperature minus value set here 20 K D6 100 to D6 0 Adjustable value in K Parallel operation D7 1 Parallel operation of both heat generators is possible Note Par...

Page 55: ... s be fore a fault message is issued 80 0 to 80 199 Adjustable from 0 to 995 s 1 step 5 s Automatic summer wintertime changeover 81 1 Automatic summer wintertime changeover 81 0 Manual summer wintertime change over Outside temperature time constant 90 128 Time constant for calculating the adjusted outside temperature 21 5 h 90 0 to 90 199 Fast low values or slow high val ues matching of the flow t...

Page 56: ...ion On Outside temperature above 3 C Frost protection function Off A3 9 to A3 15 Frost protection function On Off Please note If the frost protection temperature is set to an outside temperature of less than 1 C uninsula ted pipes may freeze There is a particular risk for outdoor pipes and in standby mode e g dur ing holidays Provide pipes with thermal insulation and avoid unsupervised standby mod...

Page 57: ...re 7A 87 Limitation of the max flow temper ature setting range for the user in the main menu The customer can set a max flow temperature of 87 C 7A 88 to 7A 90 Limitation of the max flow tempera ture setting range for the user in the main menu Type O2 probe FF 1 Lambda probe used Type NGK FF 0 Lambda probe used Type LSM11 DHW Coding Coding in the delivered condition Possible change DHW set tempera...

Page 58: ... conditions and check sen sors via the Information menu in the Extended menu and in the Service menu Diagnosis Boiler sub menus Diagnosis Draw off Heating DHW Information Select with Buffer Boiler START STOP Fig 34 Press the following keys 1 d å simultaneously for approx 4 s The Service menu appears 2 for Diagnosis 3 d to confirm 4 for the required group 5 d to confirm 6 for the required parameter...

Page 59: ...n Speed specified in Valve position boiler 3 way valve return temperature raising facility Only available with electric boiler valve Valve position buffer Buffer cylinder control valve Only available with electric boiler valve Stepper motor voltage Test of the air damper stepper motor The stepper mo tor has developed a fault if no voltage is indicated Flue gas controller Modulating set flue gas te...

Page 60: ...Software version DHW circulation sub menu if heating circuit extension module accessory is installed Select the relevant KM BUS subscriber by pressing Ù Ú DHW circulation Pump Solar sub menu if heating circuit extension module accessory is installed Select the relevant KM BUS subscriber by pressing Ù Ú Solar Pump Solar Valve open Solar Valve close Service checks Calling up operating conditions and...

Page 61: ...aults Plain text fault display The following faults are displayed as plain text The fault codes and their meanings are listed in the table on page 62 Excess temperature Repeat heat up Fault O2 probe Boiler flow Boiler return Flue gas sensor Outside t sensor Buffer sensor top Buffer sensor centre Buffer sensor bottom Flow sensor DHW sensor Return sensor KM BUS Calling up fault codes from the fault ...

Page 62: ...ntrol mode Water pressure is too low Notify heating contractor AC Control mode Water pressure is too high Notify heating contractor 20 Control mode Short circuit flow temper ature sensor Check flow temperature sensor 21 Control mode Short circuit boiler return temperature sensor Check boiler return temperature sensor 22 Control mode Short circuit flue gas tem perature sensor Check the flue gas tem...

Page 63: ... group 1 52 Short circuit flow temper ature sensor group 2 Check flow temperature sensor group 2 53 Short circuit flow temper ature sensor group 3 Check flow temperature sensor group 3 54 Short circuit cylinder tem perature sensor Check cylinder temperature sensor 55 Short circuit DHW return temperature sensor Check DHW return temperature sensor 56 No solar yield Short circuit collector temperatur...

Page 64: ...e inaccu rate Logs poorly charged Use suitable dry fuel Recalibrate the Lambda probe see page 67 Acknowledge with d 91 Lambda probe heavily soiled Lambda probe faulty PCB fault Recalibrate the Lambda probe see page 67 Acknowledge with d Troubleshooting Fault display cont 5777 985 GB Diagnosis ...

Page 65: ...ction The high limit safety cut out responds if the boiler water temperature exceeds 95 C Cancelling the function Note The high limit safety cut out can only be reset once the boiler water temperature has dropped to approx 70 C Please note If this function is not reset it inhibits the safety equipment function and can result in system damage Each time the high limit safety cut out is trig gered ch...

Page 66: ...page 70 Connection See chapter Connection and wiring diagram from page 94 Checking the sensors Flue gas temperature sensor Temperature in C 0 100 200 300 0 75 1 25 1 75 2 25 Resistance in kΩ A Fig 37 A Data point shown resistance of 1 1 kΩ at a tem perature of 25 C Further PT1000 sensors Temperature in C Resistance in kΩ 40 30 20 10 0 10 20 30 1 15 1 10 1 05 1 00 0 95 0 90 0 85 1 20 50 Fig 38 1 Pu...

Page 67: ...to grease the threads Do not solder the connecting cable it must be crim ped clamped or secured with screws Connection The Lambda probe is connected with plug a K see chapter Connection and wiring diagram page 96 Calibrating the Lambda probe Note The Lambda probe can only be calibrated manually Requirements Boiler not in operation Flue gas temperature 50 C 1 Disconnect the Lambda probe plug and re...

Page 68: ... 40 35 30 25 20 15 10 5 0 5 10 0 2 4 6 8 10 12 14 16 18 20 22 Fig 39 Test point Plug a K no 3 and 4 see page 96 Probe type OZAS S1 Permiss ambient temperature During storage and transport 40 to 60 C During operation Element tip 350 to 900 C Externally 40 to 100 C Maintenance Lambda probe cont 5777 985 GB Maintenance ...

Page 69: ...plug aJ See pricelist Sensor connections for one heating circuit Flow temperature sensor Sensor connections for DHW heating DHW return temperature sensor extension kit standard delivery aJ Cylinder temperature sensor Required settings 2 3 4 5 6 1 0 9 87 A Fig 41 A Rotary selector S1 extension kit Quantity Settings on the extension kit HC WW 1 2 3 0 1 1 DHW 1 0 1 HC 1 1 1 HC 3 DHW 2 0 1 HC 3 HC 2 1...

Page 70: ...60 529 ensure through design installation Permissible ambient temperature During operation 20 to 90 C During storage and transport 20 to 70 C Curve 0 1 1 10 100 0 20 40 60 80 100 Temperature in C Resistance in kΩ 25 Fig 42 Mixer motor Rated voltage 230 V Rated frequency 50 Hz Rated current 2 A Power consumption 5 5 W Protection class I IP rating IP 32 D to EN 60 529 ensure through design installat...

Page 71: ...at the fuse or mains isolator Remove the casing cover see chapter Overview of electrical connections 2 gS BU Fig 43 Switch cores BK and BK on plug gS 3 Refit the casing cover 4 Check the rotational direction Manual mixer adjustment Lift the motor lever unhook the mixer handle and pull the plug Maintenance Extension kit for heating circuit with mixer cont 5777 985 GB Maintenance ...

Page 72: ...72 Maintenance Extension kit for heating circuit with mixer cont 5777 985 GB Maintenance ...

Page 73: ...rom this parts list Position number of the individual part within the assembly from this parts list B C A D E Fig 44 A Type plate B Thermal insulation assembly C Control unit assembly D Boiler assembly see page 79 E Miscellaneous assembly Parts lists Overview of assemblies 5777 985 GB Components ...

Page 74: ...02 0002 0003 0007 0001 0017 0013 0009 0016 0018 0018 0005 0015 0014 0011 0005 0005 0002 0012 0008 0001 0001 0002 0001 0004 0018 0010 0018 0009 0010 Fig 45 Parts lists Thermal insulation assembly 5777 985 GB Components ...

Page 75: ...te 0009 Viessmann logo 0010 Vitoligno 200 label 0011 Thermal insulation jacket 0012 Lower thermal insulation mat 0013 Thermal insulation mat front 0014 Thermal insulation mat back 0015 Edge protection 0016 Assembly components thermal insulation 0017 Adjustable foot 0018 Location stud M5 Parts lists Thermal insulation assembly cont 5777 985 GB Components ...

Page 76: ...76 0022 0008 0007 0002 0004 0004 0002 0010 0011 0005 0012 0013 0014 0018 0015 0016 0006 0017 0009 0019 0023 0020 0003 0003 Fig 46 Parts lists Control unit assembly 5777 985 GB Components ...

Page 77: ...V 0012 Flow temperature sensor 0013 Connecting cable primary air damper drive 0014 Connecting cable secondary air damper drive 0015 Programming unit 0016 Retainer housing 0017 Outside temperature sensor 0018 Temperature sensor 0019 Slider right 0020 Cable holder panel 0022 High limit safety cut out 0023 Earthing jumper 0024 Mounting panel not shown 0025 Oval diaphragm grommet not shown Parts lists...

Page 78: ...78 Parts lists Control unit assembly cont 5777 985 GB Components ...

Page 79: ...79 A B C Fig 47 A Doors assembly B Fireproof material assembly C Flue gas inlet outlet assembly Parts lists Overview of boiler assemblies 5777 985 GB Components ...

Page 80: ...007 0012 0013 0014 0015 0002 0018 0018 0008 0003 0022 0012 0001 0021 0016 0011 0003 0007 0027 0004 0005 0005 0006 0005 0002 0026 0009 0018 0024 0023 0019 0020 0018 0013 0015 0014 0010 0005 0008 0017 0018 0019 0020 Fig 48 Parts lists Doors assembly 5777 985 GB Components ...

Page 81: ...e 0012 Protective panel complete 0013 Gasket 16 x 12 0014 Casing hopper door 0015 Insulation mat hopper door 0016 Ignition door complete 0017 Protective panel 0018 Gasket 16 x 12 0019 Casing ignition door 0020 Insulation mat ignition door 0021 Inspection door complete 0022 Thermal insulation block 0023 Casing inspection door 0024 Insulation mat inspection door 0025 Firebed cover 0026 Internal door...

Page 82: ...0004 0013 0004 0013 0002 0002 0003 0004 0013 0001 0008 0006 0009 0007 0009 0006 0005 0007 0006 0009 0013 0010 0012 0004 0010 0011 0012 0012 0012 0012 0012 0012 0012 0005 Fig 49 Parts lists Fireproof material assembly 5777 985 GB Components ...

Page 83: ...eclay panel rear 3 pce 0007 Fireclay panel side 2 pce 0008 Thermal insulation panel lower 2 pce 0009 Thermal insulation panel side 0010 Hook in panel primary air 0011 Hook in panel rear 0012 Hook in panel top 0013 Calofer sealant 0014 Pack GF 10 x 10 3000 mm long not shown Parts lists Fireproof material assembly cont 5777 985 GB Components ...

Page 84: ...0026 0024 0022 0022 0022 0022 0025 0025 0024 0026 0017 0026 0017 0013 0019 0018 0010 0011 0012 0012 0011 0010 0009 0008 0006 0003 0004 0021 0023 0021 0020 0005 0002 0005 0007 0001 0022 0029 0028 Fig 50 Parts lists Flue gas inlet outlet assembly 20 and 30 kW 5777 985 GB Components ...

Page 85: ...ir 0015 Air distribution box rear 0016 Air distribution box side secondary air 0017 Air damper unit 0018 Flue gas temperature sensor 0019 Connecting cable Lambda probe 0020 Sensor well 2x 0021 Dummy cover ignition 0022 Gasket 0023 Side protection tie bar 0024 Sealing flange 0025 Secondary gasket 0026 Stepper motor 0027 Sensor well flue gas temperature sensor 0028 Cable flue gas fan 0029 Socket spa...

Page 86: ...4 0007 0008 0009 0010 0011 0016 0025 0017 0001 0024 0023 0024 0023 0021 0013 0015 0021 0021 0015 0013 0021 0014 0021 0021 0021 0014 0022 0025 0021 0021 0026 0021 0025 0016 0025 0021 0021 0029 0028 Fig 51 Parts lists Flue gas inlet outlet assembly 40 and 50 kW 5777 985 GB Components ...

Page 87: ...14 Air distribution box rear 0015 Air distribution box side secondary air 0016 Air damper unit 0017 Flue gas temperature sensor 0018 Connecting cable Lambda probe 0019 Sensor well 2x 0020 Dummy cover ignition 0021 Gasket 0022 Side protection tie bar 0023 Sealing flange 0024 Secondary gasket 0025 Stepper motor 0026 Sensor well flue gas temperature sensor 0028 Cable flue gas fan 0029 Socket spanner ...

Page 88: ...88 0006 0011 0004 0003 0002 0001 0009 0010 0005 0008 0007 Fig 52 Parts lists Miscellaneous assembly 5777 985 GB Components ...

Page 89: ...h up spray paint Vitosilver 150 ml can 0006 Spray paint black 400 ml can 0007 Spray paint anthracite 0008 Touch up paint stick Vitosilver 0009 Installation and service instructions 0010 Operating instructions 0011 Eye bolt Parts lists Miscellaneous assembly cont 5777 985 GB Components ...

Page 90: ...ordance with the times programmed in the Heating program the control unit time switch regu lates between central heating with standard room tem perature and central heating with reduced room tem perature Every operating mode has its own set level Outside temperature A heating curve must be set up for matching the con trol unit to the building and the heating system see page 31 The heating curve ch...

Page 91: ...y be selected for DHW heating To control DHW heating up to 4 time phases per day can be set in the individual time program via the time switch Operating instructions Vitoligno 200 S Screed drying The screed drying function enables screeds to be dried For this observe the screed manufacturer s instructions When screed drying is activated the heating circuit pump is switched on and the flow temperat...

Page 92: ...20 10 1 5 10 15 20 25 30 Fig 56 Temperature profile 4 code F1 4 Flow temperature C Days 50 40 30 20 10 1 5 10 15 20 25 30 Fig 57 Temperature profile 5 code F1 5 Flow temperature C 1 5 10 15 20 25 30 Days 50 40 30 20 10 Fig 58 Temperature profile 6 code F1 6 Flow temperature C Days 50 40 30 20 10 1 5 10 15 20 25 30 60 Fig 59 Function description Heating circuit control unit cont 5777 985 GB Functio...

Page 93: ...93 Position of the PCB A Fig 60 A PCB in the control unit wiring chamber Connection and wiring diagram Connection and wiring diagram 5777 985 GB Appendix ...

Page 94: ...CB A B C D E Fig 61 A 230 V connections B LV connections C Fuse F10 D Connection for programming unit of the control unit E Battery Connection and wiring diagram Connection and wiring diagram cont 5777 985 GB Appendix ...

Page 95: ...itional heat source a Ö Flue gas fan aBÖ High limit safety cut out and ON OFF switch aBS Low water indicator aBD Water pressure switch a A Cylinder valve a S Boiler valve Connectors a A and a S a A buffer cylinder control valve Valve connection Plug connection Colour Description N N Blue Neutral conductor Y2 L2 White Actuating signal CLOSE 230 V AC Y1 L1 Black Actuating signal OPEN 230 V AC Connec...

Page 96: ... GND 13V 13V GND AI Fig 63 Outside temperature sensor Flow temperature sensor Buffer temperature sensors aG Flue gas temperature sensor aJ Return temperature sensor lJ Combustion chamber door limit switch 1 lK Combustion chamber door limit switch 2 a ÖA Speed feedback flue gas fan aVG KM BUS a K Lambda probe s D Primary air damper stepper motor s F Secondary air damper stepper motor CAN CAN bus Co...

Page 97: ...Ö Pump heating circuit 2 dXA Valve heating circuit 2 dCÖ Circulation pump for cylinder heating or pump heating circuit 3 or solar circuit pump dCA DHW circulation pump Y2 Note The slot assignment of this PCB may differ subject to the system version System specific assignment Heating circuit extension module installation instructions Connection and wiring diagram Heating circuit extension module ac...

Page 98: ...ircuit 3 d F Not assigned d Ö Default speed for solar circuit pump A Jumper for parameter settings output d Ö fac tory setting closed 0 10V solar circuit pump Note The slot assignment of this PCB may differ subject to the system version System specific assignment Heating circuit extension module installation instructions Connection and wiring diagram Heating circuit extension module accessories co...

Page 99: ...ntenance service Date By Maintenance service Maintenance service Maintenance service Date By Maintenance service Maintenance service Maintenance service Date By Maintenance service Maintenance service Maintenance service Date By Commissioning service reports Commissioning service reports 5777 985 GB Appendix ...

Page 100: ... Minimum return temperature C 65 65 65 65 Permiss operating pressure Boiler bar 3 3 3 3 MPa 0 3 0 3 0 3 0 3 Safety heat exchanger bar 3 6 3 6 3 6 3 6 MPa 0 3 0 6 0 3 0 6 0 3 0 6 0 3 0 6 Thermally activated safety valve Flow rate at min 2 5 bar max 3 5 bar and 15 C fresh water temperature l h 800 800 800 800 CE designation CE Boiler class to EN 303 5 5 5 5 5 Overall dimensions Total length mm 1165 ...

Page 101: ... flue gas 14 14 14 14 Flue outlet 7 mm 150 150 150 150 Required draught at full load Pa 8 8 8 8 mbar 0 08 0 08 0 08 0 08 Max permiss draught 3 Pa 15 15 15 15 mbar 0 15 0 15 0 15 0 15 Recommended min volume heating water buffer cylin der 4 l 1800 1800 2310 2800 1 Values for calculating the size of the flue system according to EN 13384 based on 10 0 CO2 2 Flue gas temperature measured at 20 C combus...

Page 102: ...tem are not part of ordi nary household waste For decommissioning the system isolate the system from the power supply and allow components to cool down where appropriate All components must be disposed of correctly Disposal Final decommissioning and disposal 5777 985 GB Appendix ...

Page 103: ...5 EU Low Voltage Directive 2014 30 EU EMC Directive Applied standards EN 303 5 2012 EN 61000 6 3 2011 EN 61000 6 2 2006 Corrigendum 2011 EN 55011 2011 EN 55014 1 2012 EN 60335 2 102 2006 A1 2010 EN 60335 1 2012 AC 2014 EN 62233 2008 Corrigendum 2008 In accordance with the listed directives this product is designated with Allendorf 16 January 2017 Viessmann Werke GmbH Co KG Authorised signatory Man...

Page 104: ... elements 90 Diverter valve 29 Door contact switch 38 Doors Adjusting 38 Checking 9 38 Fitting 18 Removing 11 Draught checking 45 E Economy mode 90 Electrical connections 20 94 Emissions test 44 Expansion vessel 43 Expansion vessel checking 26 Extended economy mode 90 Extension kit 69 Connections 69 Required settings 69 Setting rotary selector S1 69 F Fault code deletion 62 Fault codes summary 62 ...

Page 105: ...perature 32 Regulations 20 Relay test 29 Room temperature Set value adjustment 31 S Scan 58 Scan temperatures 58 Screed function 91 Secondary heating surfaces cleaning 36 Selecting the DHW connection 28 Selecting the solar connection 28 Sensors calling up 58 Sensors checking 29 Setting the date 27 Setting the time 27 Shutdown 33 Siting Clearance dimensions 8 Handling 9 Specification 100 Boiler 100...

Page 106: ...106 5777 985 GB ...

Page 107: ...107 5777 985 GB ...

Page 108: ...mann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com 5777 985 GB Subject to technical modifications ...

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Viessmann VITOLIGNO 200-S, Installation And Service Instructions Manual

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