Viessmann Vitogas 200-F GS2 Service Instructions Manual Download

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Service instructions

for contractors

VIESMANN

Vitogas 200-F
Type GS2

Rated heating output 72 to 144 kW
Gas boilers
Natural gas and LPG version

For applicability, see the last page

VITOGAS 200-F

5692 704 GB

2/2013

Please keep safe.

Summary of Contents for Vitogas 200-F GS2

Page 1: ...uctions for contractors VIESMANN Vitogas 200 F Type GS2 Rated heating output 72 to 144 kW Gas boilers Natural gas and LPG version For applicability see the last page VITOGAS 200 F 5692 704 GB 2 2013 Please keep safe ...

Page 2: ...llowing when working on this system Statutory regulations regarding the prevention of accidents Statutory regulations regarding envi ronmental protection Codes of practice of the relevant trade associations All current safety regulations as defined by DIN EN DVGW TRGI TRF VDE and all locally applicable standards a ÖNORM EN ÖVGW TR Gas ÖVGW TRF and ÖVE c SEV SUVA SVGW SVTI SWKI VKF and EKAS guideli...

Page 3: ... can create neg ative pressure If the boiler is operated at the same time this can lead to reverse flow of the flue gas Danger The simultaneous operation of the boiler and appliances that extract air to the outside can result in life threatening poison ing due to reverse flow of the flue gas Fit an interlock circuit or take suit able steps to ensure a sufficient supply of combustion air Working on...

Page 4: ... the system can compromise its function Installing non author ised components and making non approved modifications or conversions can compromise safety and may invalidate our warranty For replacements use only orig inal spare parts supplied or approved by Viessmann Safety instructions Safety instructions cont 5692 704 GB ...

Page 5: ...g the individual steps 8 Troubleshooting Diagnosis 25 Ignition system Time chart and function 26 Designs Burner connection diagram 28 Parts lists 30 Commissioning service reports 35 Specification 36 Certificates Declaration of conformity 37 Manufacturer s certificate according to the 1st BImSchV Germany 37 Keyword index 39 Index Index 5692 704 GB ...

Page 6: ...omponents has been carried out Commercial or industrial usage for a pur pose other than heating the building or DHW does not comply with regulations Any usage beyond this must be approved by the manufacturer for the individual case Incorrect usage or operation of the appli ance e g the appliance being opened by the system user is prohibited and results in an exclusion of liability Incor rect usage...

Page 7: ...19 10 Checking the burner tubes 19 11 Checking the pilot burner 20 12 Cleaning the heating surfaces if required 21 13 Fitting the burner 22 14 Checking connections on the water side for tightness 15 Checking the safety equipment 16 Checking firm seating of electrical connections 17 Checking all gas equipment for tightness at operating pressure 22 18 Checking the external LPG safety valve if instal...

Page 8: ...ftened e g with a small soft ening system for heating water Total permissible hardness of the fill and top up water Total heating output Specific system volume Conversion rate 1 mol m3 100 ppm kW 20 l kW 20 l kW to 50 l kW 50 l kW 50 3 0 mol m3 2 0 mol m3 0 02 mol m3 50 to 200 2 0 mol m3 1 5 mol m3 0 02 mol m3 200 to 600 1 5 mol m3 0 02 mol m3 0 02 mol m3 600 0 02 mol m3 0 02 mol m3 0 02 mol m3 On...

Page 9: ...il the charge pressure at the pressure gauge is higher than the pre charge pressure of the expan sion vessel 0 1 to 0 2 bar 10 to 20 kPa Minimum system pressure 0 8 bar 8 kPa permiss operating pressure 3 bar 0 3 MPa 5 Return the check valves to their oper ating position Checking the gas type The boiler is factory set for natural gas E Note The boiler can be operated in the Wobbe index range 12 0 t...

Page 10: ...5 MJ m3 43 2 to 58 0 36 0 to 47 2 76 9 to 81 0 Changing the gas type if required Conversion kit installation instructions Checking the static and supply pressure Danger CO build up as a result of incor rect burner adjustment can have serious health implications Carry out a CO test before and after work on gas appliances Operation with LPG Flush the LPG tank twice during com missioning or replaceme...

Page 11: ...unit ON OFF switch OFF and ON again The ignition process will then be repeated 06 Check the supply pressure flow pressure Natural gas 17 4 to 25 mbar 1 74 to 2 5 kPa LPG 42 5 to 57 5 mbar 4 25 to 5 75 kPa at 50 mbar 5 kPa pre charge pressure Record the actual value in the serv ice report Note Use a suitable measuring device with a resolution of at least 0 1 mbar 10 Pa to check the supply pressure ...

Page 12: ...w 42 5 mbar 4 25 kPa Do not start the boiler Notify your gas supply utility or LPG supplier 17 4 to 25 mbar 1 74 to 2 5 kPa 42 5 to 57 5 mbar 4 25 to 5 75 kPa Start the boiler Above 25 mbar 2 5 kPa Above 57 5 mbar 5 75 kPa Position a separate gas pressure gover nor upstream of the system and regulate the pre charge pressure to 20 mbar 2 kPa for natural gas or 50 mbar 5 kPa for LPG Notify your gas ...

Page 13: ...2 Seal at least the r h half of the gas nozzles H with nozzle caps G sup plied 3 Open the screw at bottom test nipple F of the l h gas train BV1 by one full turn 4 Connect the pressure gauge at bot tom test nipple F of the l h gas train BV1 to check the nozzle pressure 5 Disconnect plug B from the r h gas train BV2 6 Open the gas shut off valve Start the boiler 7 Enable the emissions test function...

Page 14: ...the table on page 16 07 Check the setting values and record them in the report 08 Pull one of the two plugs a Ö E from the modulation coil on the gas train Note The flame of the main burner extin guishes 09 Test the nozzle pressure at partial load In case of deviation from the value in the table on page 16 Counterhold hexagon screw C Adjust the nozzle pressure at Phil lips screw D 10 Check the set...

Page 15: ... bottom test nipple F of the l h gas train BV1 and seal aperture with screw 11 Connect plug B to the r h gas train BV2 12 Remove all nozzle caps from the r h half of the pilot gas nozzles 13 Danger Gas escaping from the test nipple leads to a risk of explosion Check the test nipple for gas tightness Open the gas shut off valve and start the appliance Rated heating output kW 72 84 96 108 120 132 14...

Page 16: ... kPa 13 4 1 34 13 4 1 34 13 4 1 34 13 7 1 37 13 2 1 32 13 1 1 31 13 6 1 36 Nozzle designation 1 90 1 90 1 90 1 90 1 90 1 90 1 90 Air restrictor 7 mm Number of burner tubes 6 7 8 9 10 11 12 Gas nozzles Total number 6 7 8 9 10 11 12 Number covered up 3 4 4 5 5 6 6 Note The values in the nozzle pressure table apply to the following ambient condi tions Air pressure 1013 mbar 101 3 kPa Temperature 15 C...

Page 17: ...sation cable C Push adaptor cable 7 4 6 F onto ionisation electrode E Push measuring device plug A into plug in adaptor B and adap tor cable F 3 Start the boiler 4 Check the ionisation current When the pilot burner is lit Min 1 0 µA When the main burner is lit Min 3 0 µA 5 Record the actual values in the report Commissioning inspection maintenance Further details regarding the individual steps con...

Page 18: ...eport on page 35 Note Required boiler draught 3 Pa 0 03 mbar The chimney draught must not exceed 10 Pa 0 1 mbar It may be necessary to fit a draught stabiliser into the chimney Seek the agreement of your local flue gas inspector where appropriate Commissioning inspection maintenance Further details regarding the individual steps cont 5692 704 GB ...

Page 19: ...supply pipe B 3 Undo the nuts and screws and care fully pull burner A forward and out Checking the burner tubes 1 Check the gas outlets for damage 2 Clean the burner tubes with com pressed air Commissioning inspection maintenance Further details regarding the individual steps cont 5692 704 GB ...

Page 20: ...t burner 3 7 1 Check ionisation electrode A pilot burner B and ignition electrode C for damage 2 Check the electrode gaps Commissioning inspection maintenance Further details regarding the individual steps cont 5692 704 GB ...

Page 21: ... hooks and remove thermal insulation mat C 3 Undo the screw and remove the front panel 4 Bend the locking tab down unhook front top panel F together with con trol unit E and hook in horizontally in the pulled out position Commissioning inspection maintenance Further details regarding the individual steps cont 5692 704 GB ...

Page 22: ... residues from the bottom plate 8 Refit in reverse order Fitting the burner Use new gaskets when fitting the burner Checking all gas equipment for tightness at operating pressure Danger Escaping gas can lead to explo sions Check the tightness of all sealing faces of gas pipes and fittings at operating pressure with a foam ing test agent leak detection spray Commissioning inspection maintenance Fur...

Page 23: ...y out the function test cover the flue outlet at the draught hood with a suitable object 4 Start the boiler 5 The flue gas monitoring device must shut down the burner within 2 min The burner will then be locked out for approx 17 min Commissioning inspection maintenance Further details regarding the individual steps cont 5692 704 GB ...

Page 24: ...roded 7 Shut down the boiler 8 Remove the cover and push the flue pipe on to the draught hood 9 Start the boiler Instructing the system user The system installer should hand the operating instructions to the system user and instruct the user in operating the system This includes all components installed as accessories e g remote control units In addition the system installer must make the user awa...

Page 25: ... check the flue pipe and the chimney If the boiler does not start automatically check the flue gas monitoring device see page 23 Strapping plug CN2 is missing at the burner control unit Retrofit strapping plug CN2 or a flue gas monitoring sensor Burner control unit enters a fault state No gas available air in the gas line Press the reset button at the burner con trol unit The pilot burner will not...

Page 26: ...ssure switch D Ignition E Pilot gas valve F Ionisation current G Main gas valve H Modulation valve K Flue gas monitoring device Intervals T1 Waiting period 3 s T2 Pre ignition time 3 s T3 Safety time 1 Max 39 s T4 Pilot burner stabilising time 6 s T5 Safety time 2 Max 3 s T6 Delay 21 s Ignition system Time chart and function 5692 704 GB ...

Page 27: ...n D is switched on The burner control unit receives an ioni sation current F via the ionisation elec trode After the pilot burner T4 has stabilised main gas valves G open and all burner sections ignite Note A reset after a fault shutdown can only be implemented after at least 10 s have elapsed For this switch the control unit ON OFF switch OFF and ON again Ignition system Time chart and function c...

Page 28: ...N M L H K A Burner control unit B Gas pressure switch plug CN3 if installed C Flue gas monitoring sensor plug CN2 or Plug with resistance D Modulation coil to BV1 plug CN6 a Ö Designs Burner connection diagram 5692 704 GB ...

Page 29: ...able G Ionisation cable H External LPG valve BV EXT plug CN4 K Pilot burner L Gas solenoid valve BV2 plug CN10 dH M Gas solenoid valve BV1 plug CN9 dG N Burner cable plug CN1 fA O Burner cable plug CN7 lÖ Designs Burner connection diagram cont 5692 704 GB ...

Page 30: ...on mat front 211 Thermal insulation mat top 212 Logo 213 Diaphragm grommet 214 Edge protector 215 Spring hook 216 Control unit fascia Wearing parts 007 Cleaning brush 105 Pilot burner with pos 106 107 107 Pilot burner nozzle set Parts not shown 300 Side section r h 301 Side section l h 302 Centre section 303 Centre section with R and R 1 304 Connecting taper 305 Threaded rod M12 306 Draught hood a...

Page 31: ...structions Key A Type plate B Boiler control unit Vitotronic 100 type GC1B see separate installa tion and service instructions C Boiler control unit Vitotronic 100 type KC4B or Vitotronic 200 type KO2B see separate installation and service instructions Parts lists Parts lists cont 5692 704 GB ...

Page 32: ...32 201 213 B C 206 205 208 208 207 204 212 007 008 216 108 Parts lists Parts lists cont 5692 704 GB ...

Page 33: ...33 209 203 200 001 211 215 A 214 005 210 004 202 002 003 Parts lists Parts lists cont 5692 704 GB ...

Page 34: ...34 105 111 112 100 109 101 110 109 109 101 106 103 102 006 113 107 109 Parts lists Parts lists cont 5692 704 GB ...

Page 35: ...as LL mbar kPa 17 4 25 1 74 2 5 for LPG at 50 mbar pre charge pressure mbar kPa 42 5 57 5 4 25 5 75 Nozzle pressure mbar Carbon dioxide content CO2 by vol Oxygen content O2 by vol Carbon monoxide con tent CO ppm Flue gas temperature gross C Flue gas loss Ionisation current when the pilot burner is lit µA min 1 5 Draught Max Pa mbar 10 0 1 Min Pa mbar 3 0 03 Commissioning service reports Commission...

Page 36: ...4 268 277 Efficiency η 100 of rated heating output 92 1 92 1 92 3 92 4 92 4 92 4 92 5 30 of rated heat ing output 93 0 93 5 93 4 93 3 93 5 93 4 93 4 Standby loss qB 70 1 0 0 9 0 9 0 9 0 8 0 8 0 8 Power consumption standard parameter at 100 of rated heating output W 351 377 402 426 448 469 489 30 of rated heat ing output W 117 126 134 142 149 156 163 Chimney information Observe the required draught...

Page 37: ...re boilers LT The product characteristics determined as system values for the product Vitogas 200 F 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 4701 10 specified by the EnEV Germany Allendorf 01 September 2012 Viessmann Werke GmbH Co KG Authorised signatory Ma...

Page 38: ...38 Allendorf 01 September 2012 Viessmann Werke GmbH Co KG Authorised signatory Manfred Sommer Certificates Manufacturer s certificate according to the 1st cont 5692 704 GB ...

Page 39: ...ition gas type 9 Diagnosis 25 Draught 18 36 E Efficiency 36 Electrode gaps 20 Expansion vessel 9 F Fault 25 Fill water 8 Flue gas 36 G Gas supply pressure 11 Gas train 11 13 I Ignition system 26 Ionisation current 17 M Manufacturer s certificate 37 Minimum system pressure 9 N Nozzle pressure table 15 P Parts lists 30 Pressure gauge 9 R Removing the burner 19 Report 35 S Static pressure 10 11 Suppl...

Page 40: ...98 7247599 7247600 7247601 Viessmann 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 5692 704 GB Subject to technical modifications ...

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