Viessmann Vitodens 200-W System User manual

VITODENS 200-W
Installation Instructions
For Corgi Registered Heating Engineers
Vitodens 200-W
Type WB2B, 4.8 to 35.0 kW
Wall mounted gas fired condensing boiler
Natural Gas and LPG version
5350 485 GB 06/2007 Please keep these instructions in a safe place

Index
Product information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Appliance dimensions/connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Sectional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Statutory requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Boiler position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Flue terminal position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Flue system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Plume kit installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ventilation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hydraulic connections (typical system designs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Gas and electric supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electricity supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Integral expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation of boiler
Unpacking the appliance (lifting advice) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Preparing the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Wall mounting bracket installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installing the boiler and making connections (lifting advice) . . . . . . . . . . . . . . . . . . . . . . . . . 38
Safety discharge connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Condensate connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Flue outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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5350 485 GB 06/2007

Index
Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Combination boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
System boiler - Separate heating and DHW circuits (4 pipes) . . . . . . . . . . . . . . . . . . . . . . . 48
System boiler - Calling up code 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
System boiler - Y & S plan systems (2 pipes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
System boiler - Heating only (2 pipes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Routing cables and connecting cylinder sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Filling the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Venting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Venting the heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Checking diaphragm, expansion vessel and system pressure . . . . . . . . . . . . . . 56
Checking the gas type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Gas type conversion (LPG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Checking the static and supply pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Setting maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Checking the balanced flue system for soundness . . . . . . . . . . . . . . . . . . . . . . . . 61
Check the gas installation for soundness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Flue gas emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Heating system start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Function sequence and possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Fitting the outer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
For maintenance and spares information see Service instructions 5692 672
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5350 485 GB 06/2007

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Product information
Vitodens 200-W
Type WB2B, 4.8 to 35.0 kW
Set up for operation with natural gas.
Boiler Type GC number
Vitodens 200-W WB2B System, 19kW 41-819-14
Vitodens 200-W WB2B System, 26kW 41-819-15
Vitodens 200-W WB2B Combi, 26kW 47-819-09
Vitodens 200-W WB2B System, 30kW 47-819-16
Vitodens 200-W WB2B Combi, 30kW 47-819-10
Vitodens 200-W WB2B System, 35kW 47-819-17
Vitodens 200-W WB2B Combi, 35kW 47-819-11
Appliance description
The Vitodens 200-W is a fully automatic,
wall hung, fan assisted balanced flue
condensing boiler for use with natural gas
(G20) and LPG. For gas type
conversions see page 63.
The Vitodens 200-W is fully modulating
and provides central heating outputs
between 4.8kW and 35.0kW and
instantaneous hot water outputs
between 4.8kW and 35.0kW.
The appliance always gives priority to
domestic water supply.
Certification details
The Vitodens 200-W is certified to comply
with the requirements of EN 483 and
EN 625 for use in GB and IE (Great
Britain and Ireland) using gas category
2H (G20 with a governed gas supply at
20 mbar (8 in. wg) inlet pressure).
The appliance is designed for use with
sealed primary water systems (only) and
incorporates a circulation pump, diverter
valve assembly, flow switch (combination
boiler only), DHW plate-type heat
exchanger (combination boiler only),
safety valve and CH expansion vessel.
A separate DHW expansion vessel is not
required. Internal frost protection and
an electronic control unit is fitted as
standard equipment and the boiler may
be used with any suitable room
thermostat, cylinder thermostat
and / or time clock in addition to the
optional controls available from
Viessmann.
Asbestos, mercury or CFCs have not
and will not be used in this product.
The appliance classification is either
C13 or C33 depending upon whether
a horizontal or vertical flue terminal is
used.
5350 485 GB 06/2007

5
Safety instructions
Please follow these safety instructions closely to prevent the risk of
accidents and material damage.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
Please note
This symbol warns against the
risk of material damage and
environmental pollution.
Note
Details identified by the word ‘Note’
contain additional information.
Target
These instructions are exclusively
designed for qualified personnel.
• Work on gas equipment must only
be carried out by a CORGI registered
heating engineer.
• Electrical work must comply with
Part P of the building regulations.
• The system must be commissioned by
a CORGI registered heating engineer.
If you notice a smell of gas
Danger
Escaping gas can cause
explosions which may lead
to serious injury.
• Do not smoke. Prevent
naked flames and sparks.
• Do not operate electrical
switches or equipment.
• Ventilate the area by
opening the windows and
doors.
• Close the gas supply
control valve.
• Remove all personnel from
the danger zone.
• Observe the safety
regulations of your gas
supplier, found on the gas
meter.
• Notify your CORGI
registered heating engineer
or TRANSCO on 0800 111
999.
If you smell flue gas
Danger
Flue gas may lead to
life-threatening poisoning.
• Shut down the boiler and
system
• Ventilate the area.
• Close all doors in
unaffected areas.
• Do not operate electrical
switches or equipment.
5350 485 GB 06/2007

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Safety instructions (cont.)
Working on the system
• Close the main gas shut-off valve
and safeguard against unauthorised
reconnection.
• Isolate the system from the electricity
power supply, check that it is no longer
‘live’ and safeguard the electricity
supply against unauthorised
reconnection.
Please note
Electronic modules can be
damaged by electro-static-
discharges. Touch earthed
objects, such as heating or
water pipes, to discharge
static loads ensuring any
appropriate electrical safety
steps have been taken in
advance.
Repair work
Please note
Repairing components which
fulfil a safety function can
compromise the safe
operation of your heating
system. Replace faulty
components only with original
Viessmann spare parts.
Ancillary components
Please note
Parts which have not been
tested together with the
heating system can
compromise its function.
Installing non-authorised
components and non-
approved modifications/
conversions can compromise
safety and may invalidate the
appliance warranty. For
replacements, use only
original spare parts from
Viessmann or those which
are approved by Viessmann.
5350 485 GB 06/2007

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Technical Specification
General Specifications and Performance Data.
5350 485 GB 06/2007
Vitodens 200-W WB2B
Appliance Combi 26 kW Combi 30 kW Combi 35 kW
Mode Unit
Rated Central heating Output
Tf/Tr 50/30 ºC (condensing) KW 6.5 to 26.0 8.8 to 30.0 8.8 to 35.0
Tf/Tr 80/60 ºC (non condensing) KW 5.9 to 24.1 7.9 to 27.8 7.9 to 32.2
Rated Central Heating Input (net) KW 6.2 to 24.7 8.3 to 28.5 8.3 to 33.0
Rated Central Heating Input (gross) KW 6.9 to 27.4 9.2 to 31.1 9.2 to 36.6
Domestic Hot Water Output range KW 5.9 to 26.0 7.9 to 30.0 7.9 to 35.0
Domestic Hot Water Input (net) KW 6.1 to 27.1 8.2 to 31.3 8.2 to 36.5
Maximum gas rate (CH mode) m3/h 2.61 3.01 3.49
Maximum gas rate (DHW mode) m3/h 2.87 3.31 3.86
Seasonal efficiency (SEDBUK) % 90.0 90.0 90.0
SEDBUK rating A
Noxclassification Class 5
DHW performance @ 35ºC temp rise l/min 10.7 12.3 14.3
DHW temperature range ºC 10 to 57
Maximum mains water inlet pressure bar 10
Minimum mains water inlet pressure
for max DHW flow rate bar 1
Minimum mains water inlet pressure
for operation bar 0.5
Minimum DHW flow rate for operation l/min 3
Minimum CH system pressure - cold bar 1
Maximum CH system pressure - hot bar 2.5
CH flow temperature ºC 30 to 80
Integral expansion vessel capacity ltr 10
Integral expansion vessel pre-charge
pressure bar 0.75
Max CH system water content using
fitted expansion vessel @ 0.75 bar 125
and 80ºC ltr
Total water capacity ltr 7.8 8.2 8.2
Lift weight kg 46 48 48
Total weight (incl packaging) kg 51 53 53
Electricity supply 230v, 50Hz
Internal fuse A 6.3
Maximum power consumption W 95 115 115
Water protection rating IP x4D
Inner flue duct diameter mm 60
Outer flue duct diameter mm 100
Gas council number 47-819-09 47-819-10 47-818-11
Product ID CE-0085 BR 0432

8
5350 485 GB 06/2007
Technical Specification
General Specifications and Performance Data.
Vitodens 200-W WB2B
Appliance System 19 kW System 26 kW System 30 kW System 35 kW
Mode Unit
Rated Central Heating Output
Tf/Tr 50/30 ºC (condensing) KW 4.8 to 19.0 6.5 to 26.0 8.8 to 30.0 8.8 to 35.0
Tf/Tr 80/60 ºC (non condensing) KW 4.3 to 17.5 5.9 to 24.1 7.9 to 27.8 7.9 to 32.2
Rated Central Heating Input (net) KW 4.5 to 17.9 6.2 to 24.7 8.3 to 28.5 8.3 to 33.0
Rated Central Heating Input (gross) kW 5.0 to 19.9 6.9 to 27.4 9.2 to 31.1 9.2 to 36.6
Maximum gas rate m3/h 1.89 2.61 3.01 3.49
Seasonal efficiency (SEDBUK) % 90.1 90.1 90.1 90.1
SEDBUK rating A
Noxclassification Class 5
Minimum CH system pressure - cold bar 1
Maximum CH system pressure - hot bar 2.5
CH flow temperature ºC 30 to 80
Integral expansion vessel capacity ltr 10
Integral expansion vessel pre-charge
pressure bar 0.75
Max CH system water content using
fitted expansion vessel @ 0.75 bar ltr 125
and 80ºC
Total water capacity ltr 7.2 7.8 8.2 8.2
Lift weight kg 43 45 47 47
Total weight (incl packaging) kg 48 50 52 52
Electricity supply 230v, 50Hz
Internal fuse A 6.3
Maximum power consumption W 85 95 115 115
Water protection rating IP x4D
Inner flue duct diameter mm 60
Outer flue duct diameter mm 100
Gas council number 41-819-14 47-819-15 47-819-16 47-819-17
Product ID CE-0085 BR 0432

9
Appliance dimensions/connections
5350 485 GB 06/2007
Heating flow Rp 3/4" to 22mm Cu
A
DHW Rp 1/2" (combi boiler)
to 15mm Cu
Cylinder flow G 3/4" (boiler)
to 15mm Cu
B
Gas Connection 1/2" to 15mm Cu
C
Cold water Rp 1/2" (combi boiler) to
15mm Cu
Cylinder return G 3/4" (boiler) to
|15mm Cu
D
Heating return Rp 3/4" to 22mm Cu
E
Fill & drain valve
F
Condensate discharge pipe
K

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5350 485 GB 06/2007
Installation clearances
The following minimum clearances (mm) must be maintained for installing
and maintaining the appliance.
Behind a cupboard door.
A
Space required for servicing.
B