Viessmann VITODENS 200 WB2A Release note

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

Section 1
General Information
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Section 2
Technical Specifications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Section 3
Installation Requirements
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Section 4
Installation 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

Appliance gas council numbers: 47-819-06 Vitodens 200 WB2A 26kW Combi
41-819-11 Vitodens 200 WB2A 26kW System
The Vitodens 200 is a fully automatic, wall hung, fan assisted balanced flue condensing system and
combination boiler for use with Natural Gas (G20) or Propane (G31). The appliance incorporates a
microprocessor based fully modulating gas control system with direct burner ignition.
The appliance features an attractive white enamelled casing with an inset control panel behind a drop
down door.
The Vitodens 200 provides central heating output between 8.0 kW (27,300Btu/h) and 24.7 kW
(84,300Btu/h) and instantaneous hot water at outputs between 8.0 kW (27,300 Btu/h) and 27.4 kW
(93,550 Btu/h). If required, the heat output can be range rated to suit the system requirements.
Heat output is controlled according to demand (in both domestic hot water and central heating mode)
by the modulating gas control. The appliance always gives priority to domestic hot water supply.
The appliance is designed for use with sealed primary water systems (only) and incorporates a
circulation pump, diverter valve assembly, pressure gauge, flow switch, DHW plate heat exchanger,
safety valve and CH expansion vessel. A separate DHW expansion vessel is not required.
Isolation valves are 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 completed
and pre-filled prior to the boiler being fitted.
Internal frost protection and an electronic control unit is fitted as standard equipment and the boiler
may be used with any suitable room thermostat and/or time clock in addition to the optional controls
available from Viessmann.
The boiler is supplied with a standard concentric air and flue duct system 125mm diameter (5 in),
which is suitable for a wall thickness of up to 360 mm (14 in) for a rear flue or 345 mm (13 3/5 in) for
a side flue with minimum clearances. The duct assembly is connected to the boiler by a
multidirectional turret, which can exit the boiler in any horizontal direction. Extension ducts may be
fitted up to a total length of 10 m (393 in).
A vertical outlet kit is also available for installation where an outside wall is not accessible and it is
necessary to fit the duct through the roof.
The appliance incorporates an electronic fault diagnosis system and display to facilitate rapid
identification of any fault conditions.
1 General Information
1.1 Appliance Description
3

Mode Rate Output Input
KW Btu/h Net Gross
Central Heating Max 24.7 84,300 25.7 87,700 28.5 97,100
Min 8.0 27,300 8.4 28,660 9.3 31,800
Domestic Hot Water Max 27.4 93,550 29.5 100,650 32.74 111,700
Min 8.0 27,300 8.4 28,660 9.3 31,800
2.1.1 Thermal Performance Details
2.1.2 General Performance Details
The Vitodens 200 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) or 3P (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 performance (specific rate)
Domestic hot water temperature range
Maximum mains water inlet pressure
Minimum mains water inlet pressure for operation
Minimum mains water inlet pressure for max output
Combi
3.1m_/h (110 ft_/h)
4-14l/min (0.88 – 3.1 gpm)
13.1l/min
38 – 57°C
10 bar (145psi)
1.0 bar (14.5psi)
2.0 bar (29psi)
System
2.7m3/h (96ft3/h)
-
-
-
-
-
-

2.2 General Specifications
2 Technical Specifications
5
2.3 Overall Appliance Dimensions
Boiler Model Combi System
Main burner gas restrictor 6.2mm 6.2mm
Total water capacity (Including expansion Vessel) 11litres 10.5litres
Minimum 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 0.75 bar (11psi) 0.75 bar (11psi)

2.5.1 Concentric Horizontal Flue Systems
Standard horizontal flue kit: The appliance is supplied complete with a standard concentric
horizontal balanced flue terminal assembly suitable for flue lengths of up to 620 mm (24.4 in)
from the centre of the flue outlet which equates to wall thicknesses of up to 380 mm (15 in) for
rear flues or 370 mm (14.6 in) for side flues with minimum clearances.
Extension ducts can be used to increase the straight flue length up to 10 m (393 in) and include
two 87° elbows or three 45°elbows. An extra 87° elbow can be used but this reduces the
maximum permissible length 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 (Female
Central heating flow Rc 3/4 (Female) Rc 3/4 (Female)
Central heating return Rc 3/4 (Female) Rc 3/4 (Female)
Domestic water inlet Rc 1/2 (Female) _
Domestic water outlet Rc 1/2 (Female) _
Pressure relief valve outlet Rc 3/4 (Female) Rc 3/4 (Female)
Condensate connection 19mm (Female) Flexible 19mm (Female) Flexible
2 Technical Specifications
2.4 Minimum Installation Clearances
2.5 Flue System Specifications
6

2.5.2 Concentric Vertical Flue Systems
The vertical flue kit (optional extra) with extensions may be used to provide a straight
length of up to10 m (393 in) and include two 87° elbows or three 45° elbows.
An extra 87° elbow can be used but this reduces the maximum permissible length by 1 m
(40 in). An extra 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 use with the Vitodens 200.
2 Technical Specifications
7
CONCENTRIC HORIZONTAL
CONCENTRIC VERTICAL

2.6 Hydraulic Circuit
Figure 2/B: Hydraulic Circuit
2 Technical Specifications
8

Figure 2/C: Sectional Diagram (Combi Boiler Illustrated)
2.7 Sectional Diagram
2 Technical Specifications
9

GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT ISSUE)
It is the law that all gas appliances are installed by a registered person, in accordance with the
above regulations. Failure to install appliances correctly could lead to prosecution. It is in your
own interest and that of safety, to ensure that the law is complied with.
In addition to the above regulations, this appliance must be installed in accordance with the
current IEE Wiring Regulations for electrical installation (BS 7671), local Building Regulations, the
Building Standards (Scotland) (Consolidation) Regulations, bye laws of the local water
undertaking and Health and Safety Document No. 635 ‘The Electricity at Work regulations 1989’.
It should also be in accordance with the relevant recommendations in the current editions of the
following British Standards and Codes of Practice: BS 5449, BS 5546, BS 5440:1, BS 5440:2, 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 be within the building, unless otherwise protected by a
suitable enclosure and MUST allow adequate space for installation, servicing
and operation of the appliance and for air circulation around it. (Refer to
sections 2.4 and 3.4).
b) This position MUST allow for a suitable flue system and terminal position.
(Refer to sections 2.5 and 3.3). The combination boiler must be installed on
a flat vertical wall capable of supporting the weight of the appliance and any
ancillary equipment when full.
c) Due consideration should be given to the routing of the condensate drain
from the chosen position.
The following limitations MUST be observed when siting the boiler:
3.2 Boiler Position
10

The following limitations MUST be observed when siting the boiler:
d) If the boiler is to be fitted in a timber framed building it should be fitted in
accordance with the institute of gas engineers publication IGE/UP/7 "Gas
installations in Timber Framed Buildings". If in doubt, advice should be sought
from the institute of Gas Engineers directly.
e) If the appliance is to be installed in a room containing a bath or shower, any
electrical switch or control utilising mains electricity must be so situated that
it cannot be touched by a person using the bath or shower. Attention is
drawn to the requirements of BS 7671 (the current I.E.E Wiring Regulations)
and in Scotland the electrical provisions of the Building Regulations
applicable in Scotland.
f) A compartment used to enclose the appliance MUST 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 Position
3 Installation Requirements
Position
A
B
C
D
E
F
G
H
I
J
K
300mm
75mm
200mm
200mm
150mm
300mm
300mm
600mm
1200mm
1200mm
1500mm
12in
3in
8in
8in
6in
12in
12in
24in
48in
48in
60in
Directly below an openable window, air vent or any other ventilation opening
Below gutter drain or soil pipe
Below eaves
Below a balcony
From vertical drain or soil pipes
From internal and external corners
Above adjacent ground or balcony level
From a surface facing the terminal
Facing terminals
From opening door/window in carport into dwelling
Vertically from a terminal on same wall
Minimum Spacing
11

3 Installation Requirements
Figure 3/A: Flue Termination Position
Position
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

3 Installation Requirements
3.3 Flue Terminal Location
Detailed recommendations for flue installation are given in BS 5440:1. The following
notes are for general guidance.
a) The boiler MUST be installed so that the terminal is exposed to external air.
b) It is important that the position of the terminal allows free passage of air
across it at all times.
c) It is ESSENTIAL TO ENSURE that products of combustion discharging from
the terminal cannot re-enter the building or any other adjacent building,
through ventilators, windows, doors, other sources of natural air infiltration
or forced ventilation / air conditioning.
d) The minimum acceptable dimensions from the terminal to obstructions and
ventilation openings 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 purpose designed guard. (Available as
an optional extra).
g) Where the terminal is fitted within 850mm (34in) of a plastic or painted
gutter, or 450mm (18in) of painted eaves, an aluminium shield at least
750mm long must be fitted to the underside of the painted surface.
h) The air inlet / flue outlet duct MUST NOT be closer that 25mm (1in) to
combustible material.
i) In certain weather conditions the terminal may emit a plume of steam. This
is normal but positions where this would cause a nuisance should be
avoided.
13

Figure 3/B: Typical System Design (Combi Boiler)
Note: The boiler incorporates an internal bypass to ensure adequate water flow, however one radiator
(preferably in the bathroom) should be permanently open (fitted with two lockshield valves) to dissipate any
excess heat.
• The following Viessmann control
configurations are available:-
Constant Temperature = Compatible
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)
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
air vents are required for cooling purposes in the cupboard or
compartment, however, it is essential to ensure that the minimum
clearances stated in section 2.4 are maintained.
3 Installation Requirements
3.4 Ventilation Requirements
14

Figure 3/C: Typical System Design (System Boiler - 4 Pipes)
Note: The boiler incorporates an internal bypass to ensure adequate water flow, however one radiator
(preferably in the bathroom) should be permanently open (fitted with two lockshield valves) to dissipate any
excess heat. The System boiler system is illustrated below.
• As shown above the system boiler utilises the DHW flow and return connections making the
DHW fully controllable.
• The following Viessmann control configurations are available:-
Constant temperature = 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 over the Central Heating when timed demand is selected.
• Where an unvented hot water cylinder is used the safety thermostat connected to the
cylinder which controls the 2-port valve can be operated by a remote timer or via an internal
H1 or H2, or external H1 Viessmann accessory.
3 Installation Requirements
15

3 Installation Requirements
Figure 3/D: Typical System Design (System Boiler - 2 Pipes)
Note
• Where Y plan and S plan systems connected to traditional open vented or unvented hot water systems are
used a remote timer, cylinder thermostat and room thermostat are generally required.
•As shown above 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 temperature = Not Compatible
Weather Compensated controls = Not Compatible
UTD = Not Compatible
16

a) These appliances are designed for connection to sealed central heating water
systems. Refer to Figure 3/B - 3/E for typical system designs.
b) A sealed system must only be filled by a competent person. A filling loop is
supplied as part of the installation kit, therefore no special connections are
needed within 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 System Design (System Boiler - CH Only)
A Stage 1
B Stage 2
Volume flow in litres/hour
Residual height in mbar
17

PUMP
The available head shown in figure 3/F is that in excess of the appliance hydraulic resistance,
i.e that available for the system.
EXPANSION VESSEL
The table below shows the maximum system volume that the integral expansion vessel can
sustain under different charge pressure conditions. If the system volume exceeds that
shown, an additional expansion vessel must be fitted and connected to the heating system
primary return pipe as close as possible to the appliance. If an extra vessel is required,
ensure that the total capacity of both vessels is adequate. Further details are available in the
current issues of BS 5449 and BS 6798.
Note: If the pressure gauge indicates 2.5 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
litres 106 75 42
gallons 23 16.5 9
0.0833 0.11 0.16
Vessel charge and initial system pressure
Total water content of system using
10 litre (2.2 gal) capacity expansion vessel
supplied with appliance
For systems having larger capacity, multiply
the total system capacity in litres (Gallons)
by the factor to obtain the total minimum
expansion vessel capacity required
Expansion Vessel Requirements (In accordance with BS 5449)
3 Installation Requirements
3.5 Central Heating System
18

a) The Gas Supplier should be consulted at the installation planning stage in order
to establish the availability of an adequate supply of gas.
b) An existing service pipe MUST NOT be used without prior consultation with
the gas supplier.
c) A gas meter can only be connected by the gas supplier or by their contractor.
d) An existing meter and / or pipework should be of sufficient size to carry the
maximum boiler input plus the demand of any other installed appliance.
(BS 6891: 1988). A minimum of 22 mm dia. pipework is required to within
1 metre of the appliance gas cock.
DOMESTIC HOT / COLD WATER SUPPLY TAPS AND MIXING TAPS. All equipment designed for
use at mains water pressure is suitable.
SHOWERS AND BIDETS. Any mains pressure shower or bidet complying with the Local 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 control the maximum water flow rate.
d) If the appliance is installed in an area where the temporary hardness of the
water supply is high (over 150 ppm) the fitting of an in line scale inhibitor
may be an advantage. Consult the Local Water Authority if in doubt.
e) For specific information relating to fittings (eg. Showers, washing machines
etc) suitable for connection in the DHW circuit, consult the Local Water
Authority. However, the following information is given for guidance.
3 Installation Requirements
3.6 Domestic Hot Water System (Combi Boiler Only)
3.7 Gas Supply
19

To ensure optimum performance, Viessmann offer a range of external controls however the
appliance may be used with any Certificated room thermostat or time clock room thermostat as
described in Section 4.
3 Installation Requirements
3.7 Gas Supply
3.8 Electricity Supply
3.9 External Controls
e) The governor at the meter must give a constant outlet pressure of 20 mbar
(8 in.wg) when the appliance is running. Alternatively for LPG appliances the
supply pressure should maintain 37 mb (14in wg)
f) The gas supply line should be purged. WARNING: Before purging open all doors
and windows, also extinguish any cigarettes, pipes and any other naked lights.
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 earth connection would be a safety hazard and may also result in
appliance malfunction).
d) The method of connection to the mains supply must facilitate complete
electrical isolation of the appliance. Either a 3A fused three pin plug and
unswitched shuttered socket outlet, both complying with BS 1363, or a 3A
fused double pole switch having a 3 mm contact separation in both poles and
serving only the boiler (and its external controls) may be used.
2
20