Vaillant VCW 2O Instructions For Installation And Servicing
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Vaillant VCW 2O Instructions For Installation And Servicing

Vaillant VCW 2O Instructions For Installation And Servicing

Combined appliances for heating and domestic hot water
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Instructions for Installation and Servicing
Vaillant
Combined appliances
for heating
and
domestic hot water
VCW 2Ol1 T3 W
GC-No. 47 04403
VCW 2511 T3 W
GC-No. 47 04405
VCW-sine 18 T3 W
GC-No. 47 O44 01
Central heating
Domestic hot water
This aooliance shall be installed in accordance with the relevant
Codes of Practice by British Gas or by an authorized installer
C O R G I m e m b e r )
These instructions should be left near the gas meter when
the installation is completed.

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  • Page 1 Instructions for Installation and Servicing Vaillant Combined appliances for heating domestic hot water VCW 2Ol1 T3 W GC-No. 47 04403 VCW 2511 T3 W GC-No. 47 04405 VCW-sine 18 T3 W GC-No. 47 O44 01 Central heating Domestic hot water...
  • Page 2 1 lntrcduction Contents The Vaillant csnbi boiler is a wall-rnqrrH natural draught open-flued (or in the case d lntroduction VCW-sine, room-sealed) boiler with buifr it Construction of aPPliance instantaneous domestic hot water heater, General reouirements "Technical Dda-. lnstallation of boiler...
  • Page 3 Fkrcorinection Terminal box 2 Down draught diverter Switch board (main switch, heating 3 Sensorof overheat cut-off device switch, domestic hot water switch) 4 Mainheatexchanger Domestic heat exchanger 4a Combustion chamber Flowthermostat ' 1 8 5 Main hrmer Pressure relief valve 6 Gasgovernor Service cock 7 Flowswitch...
  • Page 4 Centralized hot water suPPlY cP 342 3 General requirements Part 1 Individual dwellings, Part 2 Buildings other than 3.1 Related documents dwellings. The installation of the combi boiler must be in accordance with the relevant requirements of BS 5440 Flues and air suPPlY for the Gas Safety Begulations.), building regula- appliances of rated input not tions, l.E.E.
  • Page 5 3.3.2 Meters 3.3.3 lnstallation pipes A gas meter is connected to the service pipe by Installation pipes should be fitted in accordance the local gas region or a local gas region with CP 331 :3. contractor. Pipework from the meter to the combi boiler An existing meter should be checked to ensure must be of a adequate size.
  • Page 6 minimum effective area of permanent air 3.5 Air supPlY vent(s) is specified below and is related to the Detailed recommendations for air supply are maximum rated heat input of the unit. given in BS 5440 : 2. The following notes are intended to give general guidance.
  • Page 7 50 Hz. Fuse rating is 3 A. 3.7 Electrical supply The combi boiler has to be connected direct to Wiring external to the combi boiler must the mains electricity supply using the internal be installed in accordance with the l.E.E. terminal box.
  • Page 8 All dimensions in mm F i g . 4 4.2 Fluing 1. Compression union (flow of heating For the installation of the flue set (wall case) ot a room sealed combi boiler, we reter-to rne svstem) -in.t"llation z. S-ervice cock (flow of heating system) i nstructions No' 806901 .!-o"t"i"...
  • Page 10 4.3.1 lnstallation aids 4.3.1.1 Open flued combi boiler After fixing the connecting group to thewall put the template in position ancl mark posltlons oI fixing holes. The type of fixing used will depend on the type of wall. **!**o 4.3.1.2 Room sealed combi boiler After installinq the terminal/duct assembly, hano the tempi-ate on the fixing bolts (1 ) and drill the 5 holes with 8 mm (5/16 inches) diameterto...
  • Page 11 {33 Gonnection of heating system Fledirtg syslem flow and return should be in 2. rrtn copper pipe and connected to the cqrtecting group as shown in fig. 9. Ftl lhe heating system and test for soundness. 4.3.4 Pressure relief valve and overflow The pressure relief valve, required for a sealed system, is included into the connecting group.
  • Page 12 4.4.1 Open flued aPPliance Unpack boiler from carton and remove side oarieis las in 8.1'1.), lint arrestor (as in 8'2'2) inO pait ing aids as well as plastic caps.from the ionneciions. Insert the appliance wltn tne connection tubes downwards into the com- oiession unions of the service cocks and hang it on to the bolts(1) and fasten screws (10)' Fasten compression unions (6) and union nuts...
  • Page 13 22.aCollar otthe draught diverter 24. Adapter 25. Splitsocketconnector 4.7 Electrical connections Vaillant combi boilers are completelywired. lt is only necessary to connect the electrical mains and the room thermostat. Connectto220/240v 50 Hz. electrical sgpply fused 3 A. Warning!This appliance must be earthed.
  • Page 14 (no' 394) Connection of room thermostat is made to the terminiri g anO 4. lt is recommended to install a Vaillant room thermostat (RT) with accelerating resistance. The room thermostat must De inJiiiteo on an inner wall which is influenced neiiner Ov current of air nor by the sun, in the livinq rooin.
  • Page 15 3 and 4. Setthe pump control to position ll. VCW-Terminal RANDALL TimeSwitch 103 Do not link terminal3 & 6 VAILLANT Roomthermostat N Mains VBT378 L Supply 24OV/5OHz F i g . 2 1 VCW-Terminal...
  • Page 16 L a n d 5 ! V A I L L A N T t . i n " Foomlhetmostat v R T 3 7 8 SuPPIY l':- 2r0v/50H2 F i g . 2 3 VAILLANT Roomthermostat N Mains VRT 378 L SUPPIY + 24ovl5oHz...
  • Page 17 - 9 - 6 = O E ; E 9 p 5 " 9 = i E $ s l t ^ 9 8 8 - x * ' t : o o o ( g ; ", .st,...
  • Page 18 / - f f i 0t[|il[[|ll F i g . 2 6 1 6 sensor of overheat cut-off device 1 service cock 17 main heat excnanger 3 flow switch 18 air venting screw 4 thermostatic element 19 expansionvesset 5 gas inlet 20 main burner 6 automatic valve 21 gas governor ..
  • Page 19 -'_-43 N--.a.-:.*. 58 micro-switch hot water 59 water sedlon . 3? :li"#3[?t!l3ll o"'"""'ic water 60 cold water inlel 61 water governor. 32 heating circutr 63 hot water outlel 39 main switch switch 41 terminal 3e !3il'J3-:Y':ilvarcr tlo"o"* rn"rto""' 70 electronic control 71 NTC resistor *"*"' $i[#s$:rrtt:"'...
  • Page 20 5 Water circulating system 5.1 General are unavoidable the pipes should rise upwards The combi boiler is suitable for use on most towards a vent point. minibore and microbore systems. For qeneral quidance reference should It is recommended to use copper tubing to BS be mide to ihe British Gas publication 2871 :1for water carrying PiPework.
  • Page 21 S2Gontols Vdilt cofiti bcilers are ready for connecting oleebcLft:d mains. W$Gn conhds (24OV) may be connected as sfwn h figures 21 to 24. 53 lrolating valves The +dianoe shall be installed with isolatinq (service cocks) as described unde-r 4-3_3. 5.'tGirculating pump The cirolating pump is included into the combi boiler.
  • Page 22 5.7 Sealed systems Sealed systems do not require leed and exDansion cisterns, open vents etc' only gooo ouitiW raOiator valve's and fittings should be Jsed in order to prevent excessive detrlmenlal topping-uP. 5.7.1 Pressure lelief valve This is required on all sealed systems and is connected'as shown in 4'3.4' 5.7.2 Pressure gauge This is factory fitted to the boiler and shows the...
  • Page 23 6 Cornmissioning and testing 6, 1 El€ctrical installation r-e,'rinary electrical sysiem checks to ensure +€sflcal safety shall be carried out by a :r,mpetent person. Those checks are outliired r tne INSTRUCTIONS FOR BR|T|SH GAS IiIULTIMETER. 6.2 Gas installation Tne whole of the gas installation, includinq the reter.
  • Page 24 6.4.2.1 Nominal heating inPut The pressure must be as follows: mbar (8.08 in' WG) intetbressure:20 main burner pressure (cold and hot): 9.0 mbar (3.61 in. WG) vcw 2011 9.0 mbar (3.61 in. WG) vcw 2511 10.6 mbar (4.26 in. wG) VCW-sine 18 The apoliance is regulated at factory to the .b'ti"5i neating influt.
  • Page 25 7 Assembling ieotace = () the plug to the NTC (Negative :ernperature Coefficient) resistor before :ssembling. 7.1 Lint arrestor (open flued appliance) To fit the lint arrestor hang it into the front side of the lower retaining frame and clip it against the appilance.
  • Page 26 7.3 Screen Plate Position the left hand edge of the screen plate unOer tne side panel. Press the slide under the eJoe ot tne riqht hand side panel and align with the-slots in the screen plate. Secure the screen otit" *itn 3 screws as indicated in fig 39' ileolace the thermostat knob' 7.4 Front Panel Press the front panel including the grey...
  • Page 27 6 Changing door attachment -r€ roor can also be fitted to open from the -i:--. as described in the following: Changethe -rc,er. and the lower door support from the right -,ar'. to the left hand side panel of the :E€} an@. 7.7 Stickers Stick on - instructions sheet after filling in...
  • Page 28 8.1.1 Removing outer case (fig.44) Remove door by unscrewing hinge pin (b) and oullinq door out and down. Remove upper banei Oy pulling outwards. Remove gauge jlanel bir iemoving boiler thermostat knob' 'screw over rockei switches and loosening screws (c) and sliding right hand panel to the left.
  • Page 29 l,lrcrer the retaining screws (T) and remove Cilean bumers, injectors nozzles and trcs. with a light brush or a vacuum certbly CEE'. Fbsenble in reverse order, replacing the m-r bumer gasket if necessary. F i g . 4 8 82.1.2 Open llued appliance Remove bumers by levering off burner bar with a screwdriver.
  • Page 30 8.2.2 Cleaning of lint arrestor (open flued aPPliances) Remove the lint arrestor by pulling downward the part which is near the connections of the appliance. Clean with the light brush or a vacuum cleaner. Reassemble in reverse order. 8.3 Cleaning of main heat exchanger 8.3.1 Balanced flued aPPliances Remove burner as under 8.2.1 .1 .
  • Page 31 -:_Tove the venturi tube situated in the riqht_ -a-c connection of the heating O"Ov.b'nZci :,:.e and o-ring, clean bore and-repla6" - -gcessary. ;_*;; =;lp9emble ..in reverse oroer, ensurino A:shers .are fitted in heat "".n",ig"i'r;;;X : - J rlue duct engaged in spigot in flr; 6rrn*;;;i 8.4 Descaling of domestic heat exchanger 111:l]r_etcessarytodescatethedomestic-heat...
  • Page 32 Open the water section. Clean the water filter (O) or replace, if necessary' Check diaphragm tpj anO water governor (61), replace, if necessary. Reassemble in reverse order using new washers. Where stuffing gland needs replacing fit new too to water section, incorporating new stuffing box.
  • Page 33 E-7 Eryansion vessel (sealed heating system onlY) lnec* internal pressure of expansion vessel *nir*r should be 0,7 to 0,9 bar' if heating srstem of appliance is without pressure (black :'al of build-in pressure gauge at 0). Refill with ar pump, if necessary. i { : .
  • Page 34 8.10 Change of thermocouple Disconnect the retaining nut (R) and pull the thermocouple out of the thermocouple support. Insert the new thermocouple fully into the support. (ln case of VCW-sine seal the thermolead into the bottom of the chamber plate by a special rubber washer). Connect the retaining nut.
  • Page 35 Change of flow switch or parts |llf t-1f.1 Electrical isolation botde the appliance from the el6ctrical mains. Pr.fl off the plug (S1) by shifting the retaining (S2) top and bottom to the side. Egu6 8.14.1.1 Ghange of flow switch mirco switches Sorinq off the protective cover (SG).
  • Page 36 8.14.2.1 Change of flow switch stuffing box Remove complete flow switch as in 8.14.2. Unscrew retaining screw (S9) and take off the micro switch assembly. Unscrew adiustment nut (S10), remove lever assembly, remove 3 screws securing top cover, unscrew stuffing box, remove both rubber seals and fit new seals, ensuring washer is fitted between the seals.
  • Page 37 Af 5 Change ot piezo igniter (VCW-sine only) Elisconnecl the high voltage lead (pl) from the i.d bolt. Removethe retaining screw (p2) and remove the unit by springing the bracket. Reassemble in reverse onier, ensuring that krcding dimple in the bracket aligns wiih the dd in the piezo unit.
  • Page 38 8.18 Ghange ot pump 8.18.1 Change of complete pump Drain the appliance as under 8.'l and 8.1.2. lsolate the appliance from the electrical mains. Open the terminal box of the pump. Note the colour code of wiring and disconnect pump connection cable.
  • Page 39 8-18.2 Change of pump head onty Drain the appliance as under 8.1 and g.1.2. lsolatethe appliance from the electrical mains. t-lpen the terminal box of the prmp. fVoie it-e ggroyr code of the wirins ano'oisc[nn6ci .jr,L.',i iii! p:llp,_ connecrion cabie. un.,jr"* L"l:ll,lS screws (p6) ano p.urr otr p-ump.ijE"o] lHrJvJisy*siEb $":F:Ti_{{t,yiHl3lfl...
  • Page 40 8.21 Change of pilot gas filter Remove pilot gas line from the pilot gas filter by disconnecting the union nut (G6). Unscrew the pilot gas filter from the gas section. Reassemble in reverse order, using suitable sealing compound sparingly. Check connections for gas soundness. 8.22 Change of automatic valve stuffing box Disconnect the differential valve as under 8.6.
  • Page 41 3 3? ""0 valve stuffing box 8.24 Change of FFD ffi:t'ru1"1 :g:ti i:Hl""ls 'm#,lx;l*:w',?::#3 and rePrace bY a order' Reassemble in reverse Check - earth continuity - PSlflillset:f,S,l, ,o" BR,''H a"ft'$it'''-+?JU"JF'"- gas soundness' 6nJ"n *nn""'ions for F i g . 8 3 buttons 8.25 Change of FFD Push under 8'23'...
  • Page 42 8.27 Change of thermo-magnet Remove the switch box as outlined under 8.23. Remove micro-switch assembly by unscrewing <G> the 2 retaining screws (88). Skaighten tap washer (B9), unscrew retaining nut (B10), pull out thermo-magnet (B1 1) carefully. Re- assemble in reverse order. Check - earth continuity Polarity - resistance to earth...
  • Page 43 8.30 Change of micro-switches of water section Open control box as in 8.28 and remove switch box as in 8.23. Remove the adjustment screw (C5) and take off the microswitch assembly. Pulloff AMP plugs (C4). Reassemble in reverse order. Check - earth continuity - PolaritY - resistance lo earth according to INSTRUCTIONS FOR BRITISH...
  • Page 44 8.33 Ghange of expansion vessel 8.33.1 Domestic water side Disconnect the tubing nut (W1), unscrew bracket securing screw and remove expansion vessel complete with bracket. Unscrew vessel from bracket. Reassemble with new domestic water expansion vessel in reverse order. 8.33.2 Heating system open flued appliances Disconnect the flue at split collar.
  • Page 45 8.34 Change ol thermometer Pull the temperature sensor (U3) out of the sensor tube. Press the 2 tongues into the thermometer and pull it out to the front side' Reassemble in reverse order. 8.35 Change of manometer ffi\ v Disconnect the tubing nut (U1) ot the control line and remove the fixing nut (U2).
  • Page 46 9 Fault Finding 9.1 Sheet 1: Check of Flame Failure Device and Thermocouple rs gas Push green button pressure Can Pilot be lit? and light Pilot. available? De-aerate Pilot Gas ls Pilot Pipe by unscrewing Gas Pipe Pilot Adlustmdnt de-aerated? Screw.
  • Page 47 Releas€:green button DaesPitot Flame re-main after about 10 seconds. z Adiustment \ Gheck Thermocouple Vohage (min. 15 mV DC). ot Pilot Flame and (Open circuit). Themocouple Voltage satisfactory?
  • Page 48 9.2 Sheet 2: Check Electricity Supply IMPORTANT: The preliminary Electrical System Checks as contained in the B.G.C. multimeter in- struction book are the first electrical checks lo be canied out during a fault finding procedure. On completion of the service/fault finding task which has required the breaking and remakirtg of electrical connections then the checks - A.
  • Page 49 Cheek Operaling ol Heating System (Sheet 3) Check Operation ot Domestic Hot Water System (Sheel 6) Check switch lor Domestic Hot Water (She6t 5) Note 1 : Detach the Jollowing parts oithe control box: unscrew the cover of the terminal box unscrew upper part ot control box (2 screws) and press it a little bit upwards unscret/v knob of boiler thermostat...
  • Page 50 9.3. Sheet 3: Check Operation of Heating System (Do not use domestic hot Water, switch for domestic hot water remains in Position Zl) ' ls voltage \ 240 V AC trom Push Heating Switch Can Pilot be Iit? into position l. Switch give .
  • Page 51 ls voltage Flepeat the tollowing Does Main 2ZIO VAC checks: Burner light? trom teminal A. Earth Continuity. C. Polarily. D. Besistance to Earth according to Instructions for British Gas Multimeter. Are external Overheat €*t Go to sheet 4 Thermostats :,t-Otf Device. tested? eef.
  • Page 52 9.4 Sheet 4: Check Electronic and Hydraulic System lsvoltage \ 5 t o l 5 V D C a t D C Check that Multiplug A Check that wire is ls Multiplug A connections are clean, connected to Terminal tested? tight and correctly l , l l o r l l l .
  • Page 53 Repeat the following cnecKS: A. Earth Continuity. Does Maan C. Polarity. Does Burner light? D. Resistance to Earth Pump run? according to Instructtons for British Gas Multimeter. Are Pump Difterentral Setting Valve Terminals tested? tested? 240 V AC lrom termrnal 5 t o l .
  • Page 54 t"- 9.5 Sheet 5: Gheck Switch for Domestic Hot Water (Heating Switch in position "O" do not use domestic hot Water) -Does Pilot Set Switch for lamp in Main Can Pilot be lit? Domestic Hot Water Switch give to position I light? - Go to sheet 2 Device (Ret.
  • Page 55 Repeat the tollowing checks: A. Earth Continuity ls voltage Does Main C. Polarity. 240VAClrom D. Resistance to Earth Bumer light? according to lnstructions lor British Gas Multimeter. Go to sheet 4 ls Overheat Cut-O'tf Device Switch M1 on llow switch tested? check that Multiplug A connstions ile clean, tight and corectly...
  • Page 56 9.6 Sheet 6: Check Operation of Domestic Hot Water System (Heating switch in position 0 switch for domestic hot water in position Zll Heating Set Heatinq Switch lo "o-" lamp in Main Switch to l. Does Can Pilot be lit? Switch give .
  • Page 57 R€peat the tollowing lsvoltage \ checlG: Does 240 V AC from A. Earth Continurty. Main Burnet C. Polarity. D. Resistance to Earth according to Instructions tor British Gas Mullimeter. Swkh off electricRy, lsWater t€move Control Box Slection Cover. Ooen and close tested? hot water iap.
  • Page 58 IUI- VCW-sine 18 TgW vcw20/1 T3w t ( v l ! vcw2s/1 T3w lValllantl OVERHEAT CUT-OFF DEVICE DIFE PRESS SWITCH HEATING (DOM. HOT WATER) SWITCH FLOW SWITCH A1 to A12 = M u l t i p l u g A 81 to 811 = M u l t i p l u g B E1 to E12 =...
  • Page 59 vEffi$iii#* FLOW SWITCH NTC _RESISTOF OVERHEAT CUT-OFF D E V I C E Fig. 99...
  • Page 60 Fig. 100 F i g . 1 0 3 Fig. 105...
  • Page 61 10 Short Part list Description Part Number G. C. Number diaphragm 01-0318 262329 washer 98-0151 262335 diaphragm 02-0220 262356 overheatcut-offdevice 10-1363 262494 flowthermometer 10-1002 263906 pressuregaugq 10-1008 262907 switch board 13-0132 262489 screw 07-0334 support 08-6165 263986 piezo-unit 09-1008 263987 knob 14-3935 262488...
  • Page 62 Fuse 1) For systems having a larger water capacity an additional expansion vessel can be installed easily. Subject to alteration. Northern Region Otfice Headquariers Central Region Office Vaillant Ltd. Vaillant Ltd. Vaillant Ltd. Unit 5 Vaillant Building Vaillant House...

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1 t3 wVcw 25Vcw-sine 18 t3 wVcw 2o/1 t3 wVcw 25/1 t3 w

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