Viessmann Vitogas 200-F GS2 Betriebsanleitung

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.

Please follow these safety instructions closely to prevent accidents and mate-

rial 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 envi-

ronmental pollution.

Note

Details identified by the word "Note" con-

tain additional information.

Target group

These instructions are exclusively inten-

ded for qualified contractors.

■ Work on gas installations must only be

carried out by a registered gas fitter.

■ Work on electrical equipment must

only be carried out by a qualified elec-

trician.

■ The system must be commissioned by

the system installer or a qualified per-

son authorised by the installer.

Regulations

Observe the following 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

aÖNORM, EN, ÖVGW-TR Gas,

ÖVGW-TRF and ÖVE

cSEV, SUVA, SVGW, SVTI,

SWKI, VKF and EKAS guideline

1942: LPG, part 2

If you smell gas

Danger

Escaping gas can lead to explo-

sions which may result in serious

injury.

■ Do not smoke. Prevent naked

flames and sparks. Do not

switch lights or electrical appli-

ances on or off.

■ Close the gas shut-off valve.

■ Open windows and doors.

■ Evacuate any people from the

danger zone.

■ Notify your gas or electricity

supply utility from outside the

building.

■ Shut off the electricity supply to

the building from a safe place

(outside the building).

Safety instructions

5692 704 GB

If you smell flue gas

Danger

Flue gas can lead to life-threat-

ening poisoning.

■ Shut down the heating system.

■ Ventilate the installation site.

■ Close all doors in the living

space.

Flue systems and combustion air

Ensure that flue systems are clear and

cannot be sealed, for instance due to

accumulation of condensate or other

causes. Ensure a sufficient supply of

combustion air.

Instruct system users that subsequent

modifications to the building characteris-

tics are not permissible (e.g. cable/pipe-

work routing, cladding or partitions).

Danger

Life-threatening poisoning

caused by carbon monoxide in

the flue gas occurs as a result of

leaking or blocked flue systems

or an insufficient supply of com-

bustion air.

Ensure the flue system is in

proper working order. It must not

be possible to close apertures for

interconnected combustion air

supply.

Extractors

Operating appliances that extract air to

the outside (cooker hoods, extractors, air

conditioning units, etc.) 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 the system

■ Where gas is used as the fuel, close

the main gas shut-off valve and safe-

guard it against unintentional reopen-

ing.

■ Isolate the system from the power sup-

ply (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 recon-

nection.

!Please note

Electronic assemblies can be

damaged by electrostatic dis-

charge.

Prior to commencing any work,

touch earthed objects, such as

heating or water pipes to dis-

charge static loads.

Repair work

!Please note

Repairing components that fulfil a

safety function can compromise

the safe operation of your sys-

tem.

Defective components must be

replaced with genuine

Viessmann spare parts.

Safety instructions

Safety instructions (cont.)

5692 704 GB

Auxiliary components, spare and

wearing parts

!Please note

Spare and wearing parts that

have not been tested together

with 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

Product information

Intended use......................................................................................................... 6

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance.......................................... 7

Further details regarding 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

5692 704 GB

The appliance is only intended to be

installed and operated in sealed unven-

ted heating systems that comply with

EN 12828, with due attention paid to the

associated installation, service and

operating instructions. It is only designed

for the heating of water that is of potable

water quality.

Intended usage presupposes that a fixed

installation in conjunction with permissi-

ble, system-specific components 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 also occurs if the components

in the heating system are modified from

their intended function (e.g. if the flue

gas and ventilation air paths are

sealed).

Product information

Intended use

5692 704 GB

For further information regarding the individual steps, see the page indicated

Commissioning steps

Inspection steps

Maintenance steps Page

••• 1. Preparing for commissioning and filling the heating

system............................................................................. 8

••• 2. Checking the gas type.................................................... 9

••• 3. Changing the gas type (if required).............................. 10

••• 4. Checking the static and supply pressure..................... 10

••• 5. Checking the nozzle pressure....................................... 13

••• 6. Determining the flue gas values.................................... 16

••• 7. Checking the ionisation current.................................... 17

••• 8. Checking the draught..................................................... 18

• • 9. Removing the burner...................................................... 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 installed)

••• 19. Commissioning the system

••• 20. Checking the closing function of the valves in the gas

train

••• 21. Checking the flue gas monitoring device..................... 23

•22. Instructing the system user........................................... 24

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5692 704 GB

Preparing for commissioning and filling the heating system

Fill water

!Please note

Unsuitable fill water increases

the level of deposits and corro-

sion and may lead to boiler dam-

age.

■ Flush the heating system thor-

oughly before filling.

■ Only use fill water of potable

quality.

■ An antifreeze additive suitable

for heating systems can be

added to the fill water. The anti-

freeze manufacturer must ver-

ify its suitability.

■ Fill and top-up water with a

water hardness in excess of

the following values must be

softened, 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

Only for commissioning with

Vitotronic 300, type GW2

Check that the high limit safety cut-out of

the control unit is not set higher than

110 °C; adjust to max. 110 °C if

required.

Safety equipment block for 72 to 96 kW

Commissioning, inspection, maintenance

Further details regarding the individual steps

5692 704 GB

Safety equipment block for 108 to

144 kW

APressure gauge

1. Check that the installation room vent

is open.

2. Check the pre-charge pressure of the

expansion vessel.

If the pre-charge pressure of the

expansion vessel is lower than the

static system pressure, top up with

sufficient nitrogen to make the pre-

charge pressure higher than the

static system pressure (0.1 to

0.2 bar/10 to 20 kPa).

3. Open any installed check valves.

4. Fill the heating system with water and

vent it until 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 to 16.1 kWh/m3 (43.2

to 58.0 MJ/m3).

1. Check the gas type and Wobbe index

with your gas supply utility or your

LPG supplier and compare them with

the details on the burner label.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 704 GB

2. If the details do not match, convert

the burner to the available gas type,

in accordance with the information

provided by the gas supply utility or

the LPG supplier.

Conversion kit installation

instructions

3. Record the gas type in the report on

page 35.

Wobbe index range Natural gas E Natural gas

LPG P

G20 G25 G31

kWh/m312.0 to 16.1 10.0 to 13.1 21.4 to 22.5

MJ/m343.2 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 replacement. Vent the tank

and gas connection line thoroughly after

flushing.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 704 GB

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