Viessmann Vitodens 200-W System Guide

Vitodens 200-W & Vitodens 222-F
Heat Exchanger Replacement Instructions
5834 998 - 03 01/2019
For use by heating contractor
For use with: Vitodens 200-W, B2HB 19, 26, 35
Vitodens 222-F, B2TB 19, 35
Vitodens 222-FVitodens 200-W

5834 998 - 03
Ensure that main power to the equipment being serviced is off.
Ensure that the main fuel supply valve to the boiler is closed.
Take precautions to avoid accidental activation of power or fuel during
service work.
Do not perform service work on any component part without ensuring
safe operation of the heating system. When replacing parts, use
original Viessmann or Viessmann approved replacement parts.
Safety and Installation Requirements
Please ensure that these instructions are read and understood before
starting any service work. Failure to comply with these instructions
may cause product/property damage, severe personal injury and/or
loss of life.
Working on the equipment
The installation, adjustment, service and maintenance of this product
must be performed by a licensed professional heating contractor
who is qualified and experienced in the installation, service, and
maintenance of hot water boilers. There are no user serviceable parts
on the boiler, burner or control.
Heat Exchanger Replacement
For more details refer to the Installation and Service
Instructions applicable to this boiler.
Installation Instructions
for use by heating contractor
HViessmann Vitodens Service Tool (PN 9537070)
HAdjustable Wrench (10”)
HSide Cutters
HNeedle Nose Pliers or Linesman Pliers
HFlat Head Screw Driver
HUtility Knife
Cleaning supplies
HRags
Special items
HApproved leak detection fluid for natural gas and liquid propane gas
HFlue Gas Analyzer
Necessary Tools
2

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Removing the Front Covers (B2HB 19, 26 and 35)
For more details refer to the Service
Instructions applicable to this boiler.
Removing the Front Covers (B2TB 19 and 35)
Removing the front panels
1. Remove the front upper panel.
2. Tilt the lower front panel.
3. Loosen the retaining screw.
4. Remove the lower front panel.
5. Slide both sides of the programming unit cover closed.
6. Release the hinged hooks located on both sides of the control unit.
7. To open hinged cover, lift cover and then fold down the control
unit.
8. Remove boiler inner cover.
Removing the front panels
1. Remove the external accessories connection box cover.
2. Loosen the screws at the bottom of the boiler as shown
(do not remove completely).
3. Slide out and remove front enclosure panel.
4. Slide both sides of the programming unit cover closed.
5. Release the hinged hooks located on both sides of the control unit.
6. To open hinged cover, lift cover and then fold down the control
unit.
For more details refer to the Service
Instructions applicable to this boiler.
3
Prior to removing any panels ensure that gas and power is shut off.
IMPORTANT
Prior to removing any panels ensure that gas and power is shut off.
IMPORTANT

5834 998 - 03
Note: For Vitodens 200-W, B2HB and Vitodens 222-F, B2TB,
Drain water from the heat exchanger through the sediment faucet drain valve. For Vitodens 222-F, B2TB
the sediment faucet is located down stream of the boiler pump.
Discontent the wiring from the burner, heat exchanger and fan as indicated below:
Legend
APlug #15 (flue gas temp sensor)
BPlug #47 & spade terminal (fixed high limit)
C Plug #3 has 2x connections (boiler supply temp sensor)
DPlug for ionization electrode
EPlug for spade terminal ground wire
FWhite Plug (without identifying number)
GPlug #54 (ignition transformer)
HPlug #35 (gas valve)
IPlug #190 (gas valve modulation coil)
JPlug #100 (radial fan motor)
KPlug #100A (radial fan motor control)
LWhite Plugs (ignition electrode wires from transformer)
4
E
A
B
C
D
F
GH
I
K
J
L

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Note: For Vitodens 200-W, B2HB and Vitodens 222-F, B2TB,
Disconnect the venting system.
5

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Note: For Vitodens 200-W, B2HB and Vitodens 222-F, B2TB,
Using the T-20 Torx bit or 7 mm nut driver, remove the 4x nuts 1 which secure the vent pipe adaptor 2
to the boiler cabinet. Carefully remove the vent pipe adaptor 2.
Using the T-20 Torx bit, remove the 2x screws (or nuts) holding the flue gas channel 3to the boiler cabinet.
31
2

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Note: For Vitodens 200-W, B2HB and Vitodens 222-F, B2TB,
For units found with additional sealing ring (adaptor piece);
remove and dispose of them (this rework kit resolves this design).
Dispose of this
adaptor piece

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Note: For Vitodens 200-W, B2HB and Vitodens 222-F, B2TB,
Disconnect from plug #15 and carefully remove the flue gas sensor from the flue gas channel.
(Do not use tools to pull out the sensor as it could damage it)

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Note: For Vitodens 200-W, B2HB and Vitodens 222-F, B2TB,
Using an adjustable wrench, disconnect the gas supply pipe from the gas valve.
Remove and discard the old green gas valve gasket.
9

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Note: For Vitodens 200-W, B2HB and Vitodens 222-F, B2TB,
Using the T-30 Torx bit, loosen and remove the 4x bolts from the burner door assembly.
Carefully remove burner door assembly and store in a safe place.
12
3
4
CAUTION
To avoid damage to the burner, do not lay burner on its cylindrical
burner tube or touch the burner tube mesh.
Failure to heed this caution may cause damage to the burner tube,
which may lead to improper operation.
10

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CAUTION
Residual water may leak out during disassembly
Note: For Vitodens 200-W, B2HB and Vitodens 222-F, B2TB,
Use the foam packaging material from the new heat exchanger to protect the control from leaking water.

5834 998 - 03
Note: For Vitodens 200-W, B2HB and Vitodens 222-F, B2TB,
Using side cutters, remove the tie wrap which secures the rubber condensate hose to the heat exchanger.
Remove the condensate hose from the heat exchanger.
12

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Note: For Vitodens 200-W, B2HB and Vitodens 222-F, B2TB,
Remove the retaining clips on the return pipe 1 and supply pipe 2 by squeezing the end and pulling out.
13
Vitodens 200-W, B2HB 19, 26, 35
Vitodens 222-F, B2TB 19, 35
Vitodens 200-W, B2HB 19, 26, 35 (Only)
Vitodens 222-F, B2TB 19, 35 (No retaining clip)
2Supply Pipe
1Return Pipe

5834 998 - 03
Note: For Vitodens 200-W, B2HB and Vitodens 222-F, B2TB,
Remove the #3 sensor to avoid damaging it during removal of the heat exchanger
Using the T-30 Torx bit, loosen and remove the supply pipe from the heat exchanger nipple.
14
#3 Sensor

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Note: For Vitodens 200-W, B2HB boilers only,
Use an adjustable wrench to disconnect the return pipe connection from the elbow.
(located on the lower right hand side of boiler)

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Note: For Vitodens 222-F, B2TB boilers only,
Remove the boiler control unit to gain access to the heat exchanger for removal.
Removing the boiler control unit
1. Using a flat head screwdriver, release the retaining tabs 1 on
each side of the control unit.
2. Gently lift the control unit upwards to release it.
3. Carefully swing down the control unit such that it hangs from the
wiring harness.
1
16

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Note: For Vitodens 222-F, B2TB boilers only,
Using the screw driver, push the metal tab towards the rear of the boiler. This will release the fastening clip 1
from the plastic pipe clip which supports the return pipe. Be careful not to drop the clip.
Loosen the union nut 2 and disconnect the return pipe from the boiler circulating pump 3.
1
2
3

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Note: For Vitodens 222-F, B2TB Boilers,
Carefully pull the return pipe towards the front left side of the boiler.
This will allow the return pipe to be disconnected from the front plastic pipe clip 1 and the rear plastic pipe clip 2.
2
1
2
Note: The rear plastic pipe clip 2is located behind the DHW
circulation pump and the bottom rear corner of boiler cabinet
Front of boiler Rear of boiler

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Note: For Vitodens 200-W, B2HB and Vitodens 222-F, B2TB,
Disconnect the return pipe from the heat exchanger by pulling down.

5834 998 - 03 20
Note: For Vitodens 200-W, B2HB and Vitodens 222-F, B2TB,
Using the 10 mm nut driver, loosen and remove the 4x nuts while supporting the heat exchanger.
Bend the rating plate out of the way prior to removing the heat exchanger from the cabinet.
CAUTION
Residual water may leak out during disassembly