Viessmann VITODENS 200 WB2A Installation & Servicing Instructions Manual Download Page 74

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1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Information

1.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appliance description

1.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Certification details

2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Specifications

2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Performance data

2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General specifications

2.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overall appliance dimensions

2.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimum installation clearances

2.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flue system specifications

2.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic circuit

2.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sectional diagram

3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Requirements

3.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Statutory requirements

3.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boiler position

3.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flue terminal location

3.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation requirements

3.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Central heating system

3.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Domestic hot water system

3.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas supply

3.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electricity supply

3.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External controls

4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Procedure

4.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Unpacking the appliance

4.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparing the wall for installation

4.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the boiler

4.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Making the water connections

4.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting the gas supply

4.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure relief valve connection

4.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flue system preparation

4.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting the flue system

4.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring instructions

4.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

External controls

4.11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Condensate drain

5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning and Testing

5.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling the central heating (CH) water circuit

5.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Venting the boiler

5.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Venting the heating system

5.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling the domestic hot water (DHW) circuit

5.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filling the siphon with water

5.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning the boiler

5.7 . . . . . . . . . . . . . . . . . . . . . . . . . . .

Domestic hot water (DHW) flow rate and temperature

5.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the boiler water temperature

5.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final checks

5.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

User’s instructions

11 Index

Summary of Contents for VITODENS 200 WB2A

Page 1: ...VITODENS 200 WB2A INSTALLATION SERVICING INSTRUCTIONS Fully automatic fan assisted balanced flue condensing Combination System boiler for use with Natural Gas or Propane ...

Page 2: ...stallation Procedure 21 35 Section 5 Commissioning and Testing 36 43 Section 6 Routine Servicing Instructions 44 49 Section 7 Internal Wiring 50 Section 8 Fault Finding 51 52 Section 9 Replacement of Parts 53 69 Section 10 Replacement Parts 70 73 Section 11 Index 74 75 Benchmark Booklet Service Interval Record 76 79 Contents 2 ...

Page 3: ...re supplied for the heating service connections a filling loop is included and an automatic heating bypass is fitted to maintain an adequate flow rate through the boiler Note that if thermostatic radiator valves are installed we recommend that one radiator is fitted with lockshield valves normally in the bathroom If desired the mounting bracket may be fitted and the system pipework and flue system...

Page 4: ...P G31 with a supply pressure of 37mb 14 5in wg The appliance classification is either C13 or C33 depending upon whether a horizontal or vertical flue terminal is used 1 General Information 2 Technical Specifications 1 2 Certification Details 2 1 Performance Data Combi only 4 Boiler Model Maximum gas rate after 10mins operation i e hot DHW Domestic hot water flow rate Design domestic hot water perf...

Page 5: ...um CH system pressure static head Cold 0 8 bar 11 6psi 0 8 bar 11 6psi Maximum CH system pressure static head Hot 3 bar 43psi 3 bar 43psi Empty weight 54kg 52kg Electrical supply 230V 50Hz 230V 50Hz Internal fuses 6 3A 6 3A Maximum power consumption 165w 165w Maximum CH flow temperature 74 C 74 C Integral expansion vessel capacity 10 Litres 10 Litres Integral expansion vessel pre charge pressure 0...

Page 6: ...by 1m 40 in An extra 45 elbow can be used but this reduces the maximum permissible length by 0 5 m 20 in Right hand side 10mm 3 8in 10mm 3 8in Left hand side 10mm 3 8in 10mm 3 8in Top above casing 350mm 14in 350mm 14in Front 450mm 18in 450mm 18in The following minimum clearances must be maintained for installing and servicing the appliance Connection Sizes Combi System Gas Rc 1 2 Female Rc 1 2 Fem...

Page 7: ...ra 45 elbow can be used but this reduces the maximum permissible length by 0 5 m 20 in Refer to figure 2 A to determine which option kits are required before commencing the installation Installation instructions for installing the appliance with a standard flue and straight extension ducts are included in the main text of these instructions Figure 2 A shows the optional flue systems available for ...

Page 8: ...2 6 Hydraulic Circuit Figure 2 B Hydraulic Circuit 2 Technical Specifications 8 ...

Page 9: ...Figure 2 C Sectional Diagram Combi Boiler Illustrated 2 7 Sectional Diagram 2 Technical Specifications 9 ...

Page 10: ... 2 BS 6798 BS 7593 BS 6891 and IGE UP 7 IMPORTANT NOTES Please be advised that NO asbestos mercury or CFC s have been nor will be used in this product Manufacturers instructions must not be taken in any way as overriding statutory obligations 3 Installation Requirements 3 1 Statutory Requirements a The boiler is not suitable for external installation The position selected for installation should b...

Page 11: ...UST be designed and constructed specifically for this purpose An existing cupboard or compartment may be used provided it is modified accordingly BS 5376 2 gives details of the essential features of cupboard compartment design including airing cupboards g Where installation will be in an unusual location special procedures may be necessary BS 6798 gives detailed guidance on this aspect 3 2 Boiler ...

Page 12: ...on L M N O P Q R 300mm 300mm 200mm 300mm 1000mm 600mm 300mm 12in 12in 8in 12in 40in 24in 12in Horizontally from a terminal on same wall Adjacent to opening Below carport From adjacent wall From adjacent opening window From another terminal Minimum height Minimum Spacing 12 ...

Page 13: ...nings are specified in Figure 3 A BS 5440 Part 1 e If the terminal discharges into a pathway or passageway check that combustion products will not cause nuisance and that the terminal will not obstruct the passageway f Where the lowest part of the terminal is fitted less than 2m 78in above ground above a balcony or above a flat roof to which people have access the terminal MUST be protected by a p...

Page 14: ...ible UTD Compatible The Boiler will require a permanent live feed via plug 40 see section 4 Detailed recommendations for air supply are given in BS 5440 2 The following notes are for general guidance a It is not necessary to have a purpose provided air vent in the room or internal space in which the appliance is installed b If the boiler is to be installed in a cupboard or compartment no permanent...

Page 15: ...rature Compatible Timed Control of DHW not Available Timer with Constant temperature Compatible Weather Compensated controls Compatible UTD Compatible The boiler will require a permanent live feed via plug 40 See section 4 10 The Viessmann DHW sensor MUST BE ATTACHED to the cylinder by secure means to ensure good contact is made with the cylinder itself as shown The DHW will always take priority o...

Page 16: ... as a fully pumped system for heating and hot water using only 2 pipes from boiler the boiler will require the hot water pipes capping off and a permanent live feed via plug 40 with the system demand being connected to the boiler via plug 96 The Viessmann DHW sensor MUST NOT BE FITTED The following Viessmann control configurations are possible Constant temperature Compatible Timer with Constant te...

Page 17: ... the system Instructions for filling the system using the filling loop are supplied in Section 5 c The available pump head is given in Figure 3 F a An automatic heating bypass is fitted within the appliance b The following paragraphs outline the specifications of the items fitted to the boiler 3 Installation Requirements 3 5 Central Heating System Figure 3 F Available Pump Head Figure 3 E Typical ...

Page 18: ... 5 bar or greater when the appliance is at maximum temperature with all radiators in circulation an extra expansion vessel is required PRESSURE GAUGE A pressure gauge is situated on the appliance control panel This can be viewed by lowering the plastic panel cover PRESSURE RELIEF VALVE A pressure relief valve set at 3 bar 43 5 psi is supplied with the appliance bar 0 5 1 0 1 5 psi 7 3 14 5 21 5 li...

Page 19: ...al Water Authority regulations is suitable a Check that the mains water pressure is sufficient to produce the required DHW flow rate but does not exceed the maximum DHW pressure 10 bar If necessary a pressure reducing valve must be fitted to the mains supply before the DHW inlet connection b The final 600 mm 24 in of the mains supply pipe to the boiler must be copper c A regulator is fitted to con...

Page 20: ...g The complete installation must be tested for gas soundness a Wiring external to the appliance must be in accordance with BS 7671 the current I E E Wiring Regulations for electrical installation and any local regulations which apply b The mains cable must be at least 0 75 mm 24 0 2 mm PVC insulated to BS 6500 table 16 c WARNING THIS APPLIANCE MUST BE EARTHED Failure to provide a satisfactory eart...

Page 21: ...able section 3 2 adequate installation clearances are available section 2 4 and that the requirements for flue terminal position section 3 3 are satisfied The appliance is supplied as standard in 2 separate packages Any optional extras are supplied individually Check the availability and contents of each package before commencing the installation Boiler package Boiler assembled Wall mounted templa...

Page 22: ...Figure 4 A Determining the position of the flue duct hole Figure 4 B Wall template connections detail 4 Installation Procedure 239mm position of side flue corner of wall corner of wall wall template 22 ...

Page 23: ...Figure 4 B Full Wall template 4 Installation Procedure 23 ...

Page 24: ...he outer casing by removing the two lower fixing screws pulling forward and lifting clear of the appliance Place the outer casing in a safe place until after installation Figure 4 D stand the appliance in a vertical position 4 2 2 Fitting the Flue Support Bracket a Fix the flue support bracket to the wall using the screws provided as shown in Figure 4 C 4 2 3 Fitting the Connection Adapters a Assu...

Page 25: ...ir olives aligned c Lift the boiler in a vertical attitude two persons will be needed for this task and offer the boiler against the wall mounting frame entering the two 22 mm vertical flow and return pipes into the compression couplings on the piping frame before lowering the boiler onto the two supporting lugs at the top of the wall support frame 25 ...

Page 26: ...e of the control pod and hinge the pod forwards e Tighten the CH compression couplings f Connect the DHW inlet and outlet couplings by inserting a sealing washer supplied and lifting the nut to engage with the thread tighten both nuts to make a watertight seal g Pass the gas cock assembly through the central hole in the piping frame ensuring that it is the correct way round Insert a sealing washer...

Page 27: ...uitable discharge pipe to the pressure relief valve outlet using a tundish and pipework as required by the Building Regulations The pipe between the appliance and the tundish must be a minimum of 15 mm copper and run continually downwards NOTE There is a safety device incorporated within the gas service cock which when exposed to heat 100 C will shut off the gas supply Care should be taken whilst ...

Page 28: ...ut from the extension s to achieve length L 620 mm Note that a 40 mm overlap is necessary at each joint f Cut the excess length from the plain end of one of the extension ducts Cut both ducts flush and square Remove any burrs or sharp edges Figure 4 F Measuring the flue length from outside wall face to flue centre line NOTE Side flue shown but procedure applies equally to rear flue installations 4...

Page 29: ...ece to the correct length the distance from the socket end to the cut can the calculated the same as before b H 20 40 Note Cut both inner and outer ducts flush and square remove any burrs or sharp edges Cut only the opposite end to the socket 4 7 2 Vertical Flue Systems Figure 4 G Measuring the flue length from the terminal to the top of the outer casing Overall Height H T 1187mm overlap 40mm cut ...

Page 30: ...ssembly through the hole in the wall from outside the building Alternatively this can be done from inside the room if no external access is available in which case the outer seal is not used Step 5 Loosely push the inner sealing ring over the terminal assembly Step 6 Push the terminal assembly into the extension ducts or elbow and ensure that the outer sealing ring if fitted is flush against the o...

Page 31: ...aptor into the top half of the spigot at the top of the boiler as shown Step 2 If applicable push any extension ducts into the elbow Step 3 Push the roof sealing assembly over the flue terminal and slide the flue terminal assembly through the roof from outside the building Push the terminal into the adaptor or extension duct Step 4 Make good the roof seal from outside the building 4 8 2 Vertical F...

Page 32: ...d and lift off the lid a If the flue system incorporates additional 90 or 45 elbows the procedure for adding the elbows into the system is exactly the same as for extension ducts Measurements to be used for such purposes are given in Figure 4 J Figure 4 J Dimensions of Additional elbows for use in Flue Systems 4 Installation Procedure 4 8 3 Flue Systems with Additional Elbows 4 9 Wiring Instructio...

Page 33: ...ut off switch with a contact separation of at least 3 mm MUST be fitted in the mains supply to the boiler with a maximum fuse value of 3A Route the main cable through one of the cable glands at the rear of the controls pod to the mains connection terminal 40 the brown wire being connected to terminal L the blue wire to N and the green yellow to E ensuring that the earth green yellow is longer that...

Page 34: ...train relief retaining clamp Note that the line brown wire must be connected to the terminal marked L the blue wire to the terminal marked N and the green yellow wire to earth Room Thermostat With Anticipator Fitted If a room thermostat with anticipator fitted is to be used connect the switching contacts across terminals L and 1 and return the neutral anticipator wire to the neutral connection in ...

Page 35: ... an internal waste system A O22mm plastic condensate pipe B External length of pipe 3m max C Open end direct into gully below ground but above water level Terminating into an external waste system A O22mm plastic condensate pipe B External length of pipe 3m max C Open end direct into gully below ground but above water level Terminating into an external purpose made soakaway A O22mm plastic condens...

Page 36: ...essure System design pressure should be between 1 0 and 1 5 bar The following procedure is recommended when the boiler has been fitted Before commissioning the appliance the whole gas installation including the meter MUST be purged and tested for gas soundness in accordance with BS 6891 1988 IMPORTANT Open all doors and windows extinguish naked lights and DO NOT SMOKE whilst purging the gas line B...

Page 37: ...the heating system Adjusting Max boiler output Range Rating 5 2 Venting the Boiler a Start the control unit and select code 1 by simultaneously pressing and for approximately 2 seconds See fig 5 A b Using select coding 2F 2 when the diverter valve will be in the central position and display shows bF in Constant temperature mode Weather compensated mode will show VENTING c Close the isolation flow ...

Page 38: ...ning and Testing Fig 5 B 5 2 Venting the Boiler e Open valves A and B and vent at mains pressure until the sound of escaping air cannot be heard f Close valves A and B and open the primary isolation flow valve 38 ...

Page 39: ...on the display rated output and appears On weather compensated controls the display additionally shows Max output c With buttons select the required value in of rated output as max output d Confirm the set value with e Record the setting of max output on the additional data plate included with the technical documentation Affix this data plate next to the original data plate on top of the boiler f ...

Page 40: ...two plastic clips at each end of the control and rotating the control box forwards see section 4 9 NOTE The boiler is supplied for use on Natural Gas G20 If the boiler is to be used on LPG Propane G31 follow the instructions supplied with the relevant conversion kit before commissioning the boiler c Refer to Figure 5 D Loosen the screw A and connect a pressure gauge to the inlet pressure test poin...

Page 41: ...after maintenance the CO2 level can be checked at the boiler flue adaptor position A as illustrated in Figure 5 E Subject to Wobbe index the CO2 content fluctuates between 7 4 to 10 5 for natural gas 8 5 to 11 0 for LPG Propane Compare the actual CO2 value measured at position A with the above CO2 value ranges for the individual gas groups If the actual CO2 value deviates by more than 1 for natura...

Page 42: ... The boiler water temperature must be set at an adequate level to satisfy the requirements of the heating system The level is factory set at 74 C but may be adjusted as follows Press and the currently set temperature will flash Use to adjust the set temperature to that required Press to confirm and save the new setting 5 7 Domestic Hot Water Flow Rate and Temperature Combi Boiler Only 5 8 Adjustin...

Page 43: ...o the system and to the building in the event of the system remaining inoperative during frost conditions e Explain the function of the boiler safety controls and how to reset them Emphasise that if cut out persists the boiler should be turned off and the installer or service engineer consulted f Stress the importance of an annual service by a registered heating engineer NOTE Should the timer firs...

Page 44: ...ish Gas engineer or other CORGI registered personnel The boiler incorporates a flue sampling point in front of the flue outlet see Figure 5 C The service engineer has suitable equipment to analyse the flue gas The push fit cap may be removed and a sample tube fitted The push fit cap must be replaced after use The flue gas sample will enable the service engineer to judge whether any major action is...

Page 45: ...onisation electrode D and ignition unit E d Disconnect the union and release the gas connection pipe taking care not to lose the sealing washer e Remove the four nuts G and remove the burner plate complete with the burner f Check the burner plate gasket for damage and change if necessary Generally this gasket should be changed every two years 6 1 Routine Servicing 6 2 Ignition and Detection Electr...

Page 46: ...ctrodes See Figure 6 B above Figure 6 C below b Release the three Torx screws and remove the thermal insulating ring B c Release the four Torx screws and remove the burner assembly with its gasket d Inspect the burner for blocked ports cracks or slits If sound clean with a soft brush and refit in reverse order e Refit the thermal insulating ring B 46 ...

Page 47: ...th water Important Scratches on parts which are in contact with flue gases can lead to corrosion Only use plastic brushes rather than wire brushes b Replace the burner assembly as a reverse of removal a Check that the pressure switch sensing pipes are not blocked or damaged It is not necessary to remove the air pressure switch this is not adjustable and does not require any servicing 47 ...

Page 48: ...with the retaining clip 6 6 Checking the Condensate Drain and Cleaning the Siphon 6 7 Domestic Hot Water Flow Limiter Combi Boiler only a Shut of the cold water supply b Release the Allen screws A c Remove the flow switch B and remove the flow limiter C downwards d Check the flow limiter C and replace if excessive deposits are evident or if the unit appears damaged Replace and secure flow switch B...

Page 49: ... appliance in both central heating and DHW modes d Check the combustion performance at maximum rate as in section 5 6 a Check the operation of the pressure relief valve as described in section 5 1 b Check the correct operation of the appliance pressure gauge by noting the reading when cold and check that the pressure increases with temperature Replace the gauge if readings are not reliable c Check...

Page 50: ...nsor 30 Step motor Diverter valve Combi only 54 Ignition unit 131 Air Pressure switch 149 Flow switch Combi only 4 DHW outlet sensor Combi only 5 Comfort sensor Combi only 47 Temperature limiter 100 Fan motor 11 Ionisation electrode 15 Flue gas temperature sensor 50 ...

Page 51: ...ign pressure Before attempting any electrical fault finding always conduct the preliminary electrical system checks as described in the Instructions for the British Gas Multimeter or other similar instrument On completion of any service or fault finding operation involving making or breaking electrical connections always check for EARTH CONTINUITY POLARITY and RESISTANCE TO EARTH Detailed procedur...

Page 52: ...tes F2 Burner will not run Flow temperature limiter Check heating system water level has responded Check circulation Check limit thermostat and leads PRESS F3 Burner will not start False flame signal Check ionisation electrodes and leads PRESS F4 Burner will not run No flame signal Check ionisation electrode gas pressure gas valve ignition transformer electrode and condensate drain PRESS F7 Burner...

Page 53: ...ttom and hinge upwards unhooking from the top fixing lugs Place the cover in a safe position d Pull the electrical cable connector from the fan motor A pressure switch B gas valve C ionisation electrode D and ignition unit E e Disconnect the electrical connections from the boiler temperature sensor temperature limiter and flue gas temperature sensor f Disconnect the gas inlet union from the gas va...

Page 54: ... pipe m Support the flue system above the flue connection collar n Remove the screws and clamps retaining the flue connection collar and remove the collar o Unscrew the automatic air vent from its sea behind the flue collar p Slacken the four M6 nuts securing the heat exchanger rear brackets slide the heat exchanger upwards to release it from the keyhole slots and remove in a forward direction q R...

Page 55: ...ure that the outer casing is secured in position and carry out a combustion check as in 5 6 a Gain access by removing the burner assembly as described in section 9 1 steps b to g b Remove the ignition and detection electrodes c Release the three Torx screws and remove the thermal insulating ring B d Release the four Torx screws and remove the burner assembly C with its gasket e Replace the burner ...

Page 56: ...itch are not interchanged g Finally ensure that the outer casing is secured in position and carry out a combustion check as in 5 6 a Gain access by removing the burner assembly as described in section 9 1 steps b to g b Remove the detection electrode by releasing the 5mm socket head screw and withdrawing the electrode c Fit a new electrode assembly using a new gasket and check all clearances If th...

Page 57: ...hanged f Finally ensure that the outer casing is secured in position and carry out a combustion check as in 5 6 a Gain access to the relevant components by following steps b and c in section 9 1 b Pull off the electrical mains leads and HT leads from the spark generator c Release the two 4mm socket head screws securing the spark generator to the burner door casting and remove the spark generator d...

Page 58: ...to the boiler controls e Remove the two screws securing the plastic ventilated cover unclip the four plastic securing clips and remove the cover P C B assembly complete f Deflect the seven clips securing the P C B into the cover and remove the printed circuit board g Replace the P C B and reassemble in reverse order h Check that all original settings have been retained 9 9 P C B 9 10 Limit Thermos...

Page 59: ...ws securing the faulty thermostat to the flow pipe and remove the thermostat d Fit the new thermostat using heat sink compound supplied with the new thermostat and reassemble in reverse order e Finally ensure that the outer casing is secured in position and carry out an ignition check 9 Replacement of Parts 9 11 DHW Thermistor A Combi only 9 10 Limit Thermostat 59 ...

Page 60: ... step 9 1 b b Isolate the DHW circuit closing the DHW inlet valve Drain the DHW circuit by opening any DHW tap below the level of the boiler c The DHW thermistor is situated over the domestic hot water outlet above the piping frame d Disconnect the two electrical connections from the thermistor e Slide out the clip securing the thermistor in position and pull out the thermistor NOTE There may be a...

Page 61: ...sing the drain point situated in the lower part of the flow pipe underneath the heat exchanger at the bottom left hand side d Disconnect the two electrical connections from the thermistor e Slide out the clip securing the thermistor in position and pull out the thermistor NOTE There may be a small discharge of water hence precautions should be taken f Replace the thermistor and reassemble in rever...

Page 62: ...lectrical wiring from the assembly after releasing the securing tab e Replace the internal assembly and reassemble in reverse order f Finally close the drain open the CH isolation valves ensure that the outer casing is secured in position and carry out an ignition and control check a Pull the leads from the flue gas temperature sensor b Pull the sensor together with its mounting bush from its aper...

Page 63: ...ase the gas pipe union above the pipe connection frame and remove the gas connection pipe together with its rubber bulkhead seal g Pull forward and remove the thermal insulation from the plate heat exchanger h Release the four screws G and pull the plate heat exchanger H forward NOTE There may be a small discharge of water hence precautions should be taken i Replace the DHW heat exchanger using ne...

Page 64: ... slightly and remove the section of pipe between the flow switch and the isolation valve e Remove the flow regulator from the inlet of the flow switch f Replace or clean the water flow regulator g Reassemble in reverse order Check for water soundness h Replace the DHW heat exchanger using new gaskets with lubricant and reassemble in reverse order 9 Replacement of Parts 9 17 DHW Flow Regulator to r...

Page 65: ...any DHW tap below the level of the boiler c Remove the four 4mm socket head screws securing the cover of the flow switch d Remove the cover and switch mechanism and disconnect the electrical wiring from the switch e Electrically connect the new switch mechanism and replace in the switch body securing with the four socket head screws f Open the DHW inlet valve and check for water soundness g Finall...

Page 66: ...ions for soundness and then disconnect the filling loop f Finally ensure that the outer casing is secured in position warm up the system and check for water leaks c Unscrew the four recessed hexagon screws and withdraw the pump head d Remove the single screw securing the electrical connection cover Remove and transfer electrical connections to the new pump and reassemble in reverse order ensuring ...

Page 67: ... in an anticlockwise direction the plastic clip securing the back of the pressure gauge head and lift out the head f Carefully cut the cable ties securing the pressure gauge connecting tube to the wire bundles and remove the gauge completely g Replace the pressure gauge and reassemble in reverse order re attaching the pressure tube to the wire bundles using suitable cable ties h Connect the fillin...

Page 68: ...ity external to the appliance but as close as possible to the central heating return connection If replacement is desired or necessary due to a leaking vessel proceed as follows a Isolate the central circuit by closing the flow and return valves Drain the appliance using the drain point situated underneath the appliance at the bottom right hand side b Unscrew the automatic air vent situated at the...

Page 69: ...h Lift out the expansion vessel Replace and reassemble in reverse order Check the expansion vessel pre charge pressure i Connect the filling loop open the CH flow and return valves and re pressurise the system to design pressure using the filling loop valves and venting as necessary Check all connections for soundness and then disconnect the filling loop j Finally ensure that the outer casing is s...

Page 70: ...ly pipe 060 Venturi Top 050 Burner Plate Gasket 061 Gas Combination Valve 051 Insulating Ring 062 Burner Door 052 Burner Gauze Assembly 063 Ignition Unit 053 Burner Gauze Assembly Gasket 064 Conversion Kit 054 Ignition Electrode with Gasket 066 Conversion Kit 055 Ionisation Electrode with Gasket Indicates Short Parts List Items 10 Replacement Parts 70 ...

Page 71: ...erature Sensor 028 Pipe Retaining Clip 005 Boiler Adaptor Grommets 031 Hook in Lock 009 Securing Clip 034 Return Pipe with gasket 041 012 Flue Gas Temperature Sensor 035 Combustion Air Gasket 013 Siphon 036 Flue Gas Gasket 014 Heat Exchanger 039 Rear Panel Lid 015 Heat Exchanger Siphon Connection 040 Clip Nut 017 O Ring 28 x 2 5mm 041 Plug in connection gasket set Indicates Short Parts List Items ...

Page 72: ... Coding card 082 Support 091 Fuses 10 off 083 Door 092 User interface Constant temp operation 084 Pressure gauge Retainer 093 User Interface Compensated operation 085 Clip 095 Locking clips 10 off 086 Hinge 096 Outside Temperature Sensor 087 Internal Extension Indicates Short Parts List Items 10 Replacement Parts 72 ...

Page 73: ...mfort Sensor 023 Flow Switch 008 Thermal Insulation 024 Water Flow Limiter 009 Fixing Clip 025 Linear Step Motor 010 Pump Motor 037 Expansion Vessel 011 DHW Valve 038 Connection Line 020 Heat Exchanger Gasket Set Indicates Short Parts List items Indicates Combi boiler only 73 ...

Page 74: ...trols 4 Installation Procedure 4 1 Unpacking the appliance 4 2 Preparing the wall for installation 4 3 Fitting the boiler 4 4 Making the water connections 4 5 Connecting the gas supply 4 6 Pressure relief valve connection 4 7 Flue system preparation 4 8 Fitting the flue system 4 9 Wiring instructions 4 10 External controls 4 11 Condensate drain 5 Commissioning and Testing 5 1 Filling the central h...

Page 75: ...s 9 Replacement of Parts 9 1 Heat exchanger 9 2 Fan Assembly 9 3 Burner 9 4 Ignition electrodes 9 5 Detection electrodes 9 6 Gas control 9 7 Air pressure switch 9 8 Spark generator 9 9 P C B 9 10 Limit thermostat 9 11 DHW thermistor 9 12 DHW Comfort sensor 9 13 CH thermistor 9 14 Flue gas temperature sensor 9 15 Diverter valve mechanism 9 16 DHW heat exchanger 9 17 DHW flow regulator 9 18 DHW flow...

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Page 80: ...Hortonwood 30 Telford Shropshire TF1 7YP United Kingdom Tel 44 0 1952 675060 Fax 44 0 1952 675040 www viessmann co uk 534 3017 GB 08 2005 ...

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Viessmann VITODENS 200 WB2A, Installation & Servicing Instructions Manual

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