Viessmann VITORONDENS 200-T Operating instructions

Service instructions
for contractors
VIESMANN
Vitorondens 200-T
Type BR2A, 20.2 to 53.7 kW
Oil Unit condensing boiler
VITORONDENS 200-T
5624309 GB 7/2019 Please keep safe.

2
Please follow these safety instruc-
tions closely to prevent accidents
and material losses.
Safety instructions explained
Danger
This symbol warns against the risk
of injury.
!Please note
This symbol warns against the risk
of material losses and environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■Work on gas installations may only be
carried out by a registered gas fitter.
■Work on electrical equipment may only
be carried out by a qualified electrician.
■The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention
of accidents
■Statutory regulations for environmental
protection
■Codes of practice of the relevant trade
associations
■Relevant country-specific safety regu-
lations
Safety instructions for working on the system
Working on the system
■Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■Isolate the system from the power sup-
ply, e.g. by removing the separate fuse
or by means of a mains isolator, and
check that it is no longer live.
■Safeguard the system against recon-
nection.
■Wear suitable personal protective
equipment when carrying out any work.
Safety instructions
Safety instructions
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Danger
Hot surfaces and fluids can lead to
burns or scalding.
■Before maintenance and service
work, switch OFF the appliance
and let it cool down.
■Never touch hot surfaces on the
boiler, burner, flue system or pipe-
work.
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing work, touch
earthed objects such as heating or
water pipes to discharge static
loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise the
safe operation of the system.
Replace faulty components only
with genuine Viessmann spare
parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that have
not been tested together with the
system can compromise its func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate our warranty.
For replacements, use only original
spare parts supplied or approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
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Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■Do not smoke. Prevent naked
flames and sparks. Never switch
lights or electrical appliances on
or off.
■Close the gas shut-off valve.
■Open windows and doors.
■Evacuate any people from the
danger zone.
■Notify your gas or electricity sup-
ply utility from outside the building.
■Have the power supply to the
building shut off from a safe place
(outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening
poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to
prevent flue gases from spread-
ing.
What to do if water escapes from the
appliance
Danger
If water escapes from the appliance
there is a risk of electrocution.
Switch OFF the heating system at
the external isolator (e.g. fuse box,
domestic distribution board).
Danger
If water escapes from the appliance
there is a risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be
harmful to health.
Never let condensate touch your
skin or eyes and do not swallow it.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
external causes.
Ensure an adequate supply of combus-
tion air.
Inform system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or
an inadequate supply of combus-
tion air can cause life threatening
poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good
working order. Vents for supplying
combustion air must be non-seala-
ble.
Extractors
Operating appliances that exhaust air to
the outside (extractor hoods, extractors,
air conditioning units, etc.) can create
negative pressure. If the boiler is oper-
ated at the same time, this can lead to a
reverse flow of flue gas.
Safety instructions
Safety instructions (cont.)
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Danger
The simultaneous operation of the
boiler and appliances that exhausts
air to the outside can result in life
threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suita-
ble steps to ensure an adequate
supply of combustion air.
Safety instructions
Safety instructions (cont.)
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1. Information Symbols ................................................................................................. 7
Intended use .......................................................................................... 7
Spare parts lists ..................................................................................... 8
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 9
3. Commissioning/service
reports
................................................................................................................ 19
4. Specification ................................................................................................................ 20
5. Shutdown and disposal Final decommissioning and disposal ..................................................... 21
6. Certificates Declaration of conformity ....................................................................... 22
Manufacturer's certificate according to the 1st BImSchV [Germany] .... 22
7. Keyword index ................................................................................................................ 23
Index
Index
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Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is intended solely for installation and
operation in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions. It is only designed for heating up heating water
that is of potable water quality.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than heating the building or DHW shall be deemed
inappropriate.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended use (e.g. if the
flue gas and ventilation air paths are sealed).
Information
Symbols
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Information

8
Information about spare parts can be found on the
Viessmann spare parts app.
Information
Spare parts lists
5624309
Information

9
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system................................................................................................. 10
•2. Venting the boiler at the safety equipment block (accessories).................................... 11
•3. Venting the heating system
• • 4. Shutting down the system
• • 5. Draining the heating system (if required)........................................................................ 12
• • 6. Opening the boiler door..................................................................................................... 12
• • 7. Cleaning the heating surfaces.......................................................................................... 13
• • 8. Checking the gaskets and thermal insulation sections................................................. 14
•9. Fitting the boiler door........................................................................................................ 14
• • 10. Separating the neutralising system or active charcoal filter (if installed) from the
boiler and connecting the drain hose.............................................................................. 15
• • 11. Checking the neutralising system (if installed)............................................................... 15
• • 12. Checking the active charcoal filter (if installed).............................................................. 15
• • 13. Checking the connection on the flue gas side for leaks................................................ 16
• • 14. Cleaning the condensate drain pipe and trap and reconnecting to the drainage
system................................................................................................................................. 16
•15. Filling the trap and neutralising system (accessories) with water................................ 16
••• 16. Checking connections on the heating water and DHW sides and the sensor well for
leaks
••• 17. Checking the function of the safety equipment
• • 18. Checking the expansion vessel and system pressure................................................... 17
••• 19. Checking the thermal insulation for firm seating
• • 20. Checking the mixer for ease of operation and leaks...................................................... 17
••• 21. Checking the ventilation air connection to the burner (if installed).............................. 18
••• 22. Adjusting the burner.......................................................................................................... 18
•23. Instructing the system user.............................................................................................. 18
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Fill water
According to EN 1717 with DIN 1988-100, as a heat
transfer medium for DHW heating, the heating water
must meet fluid category ≤ 3. This requirement is met if
water of potable quality is used as heating water. For
example, if additives are used, the additive manufac-
turer must specify which category the treated heating
water comes under.
!Please note
Unsuitable fill water increases the level of
deposits and corrosion and may lead to appli-
ance damage.
■Flush the heating system thoroughly before
filling.
■Only use fill water of potable water quality.
■Special antifreeze suitable for heating systems
can be added to the fill water. The antifreeze
manufacturer must verify its suitability.
■Fill and top-up water with a water hardness in
excess of the following values must be soft-
ened, e.g. with a small softening system for
heating water.
Total permissible hardness of the fill and top-up water
Total heating output Specific system volume
kW < 20 l/kW ≥ 20 l/kW to < 50 l/kW ≥ 50 l/kW
≤ 50 ≤ 3.0 mol/m3 (16.8 °dH) ≤ 2.0 mol/m3 (11.2 °dH) < 0.02 mol/m3 (0.11 °dH)
> 50 to ≤ 200 ≤ 2.0 mol/m3 (11.2 °dH) ≤ 1.5 mol/m3 (8.4 °dH) < 0.02 mol/m3 (0.11 °dH)
> 200 to ≤ 600 ≤ 1.5 mol/m3 (8.4 °dH) ≤ 0.02 mol/m3 (0.11 °dH) < 0.02 mol/m3 (0.11 °dH)
> 600 < 0.02 mol/m3 (0.11 °dH) < 0.02 mol/m3 (0.11 °dH) < 0.02 mol/m3 (0.11 °dH)
With on-site boiler fill valve in the heating water return
A B
Fig. 1
ABypass valve "OPEN"
BBypass valve "CLOSED"
1. Check the pre-charge pressure of the expansion
vessel.
2. Close the bypass valve on the boiler flow/return
distributor.
3. If using a top-mounted Divicon heating circuit dis-
tributor (accessories):
Set the mixer lever to "OPEN" (red).
4. Fill the system via the boiler fill valve in the heating
water return, until it is fully vented.
5. Open the bypass valve on the boiler flow/return
distributor again.
Commissioning, inspection, maintenance
Filling the heating system
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With safety equipment block (accessories)
Fig. 2
1. Check the pre-charge pressure of the expansion
vessel.
2. Close the bypass valve on the boiler flow/return
distributor.
3. Remove front insulation shell A.
4. Open air vent valve B.
5. Fill the system via boiler fill valve C in the heating
return. Minimum system pressure 0.8 bar
(0.08 MPa).
6. Close air vent valve B when no more air escapes.
7. Close boiler fill valve C.
8. Open the bypass valve on the boiler flow/return
distributor again.
Venting the boiler at the safety equipment block (accessories)
Fig. 3
1. Close the shut-off valves on the heating water side.
2. Remove front insulation shell A (if already fitted).
3. Connect the drain hose on air vent valve B to a
drain.
4. Open valves B and C and vent at mains pres-
sure until no sound of escaping air can be heard.
5. Close valves B and C; open the shut-off valves
on the heating water side.
Venting the heating system
Shutting down the system
Commissioning, inspection, maintenance
Filling the heating system (cont.)
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A
Fig. 4
ADrain
Opening the boiler door
41
Fig. 5
For room sealed operation: Remove the ventilation air
pipe before opening the boiler door.
Commissioning, inspection, maintenance
Draining the heating system (if required)
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Boiler heating surface
A
Fig. 6
ACleaning brush (accessories)
1. Clean the combustion chamber and the boiler
heating surfaces with a cleaning brush and vac-
uum cleaner.
2. Remove soot deposits with alkaline agents con-
taining surfactant additives (e.g. Fauch 400/410*1).
Note
Ensure that no cleaning agent gets between the
boiler body and the thermal insulation.
Cleaning agent manufacturer's instructions
Heating surface of the heat exchanger
Note
If the heating surfaces of the boiler and heat
exchanger are only slightly soiled, the heat exchanger
can be cleaned by flushing it thoroughly via the flue
inspection cover.
To do so, detach condensate hose A from trap B
and drain the dirty water into a suitable container C.
B A C
Fig. 7
For heavier soiling, proceed as follows:
1. Detach the heat exchanger from the boiler to clean
it.
2. Remove contamination from the connector using a
vacuum cleaner.
3. Loosen heavy deposits on the coil and gaps of the
heat exchanger with a cleaning spatula*2 and
remove using a vacuum cleaner.
4. Thoroughly flush the heating surface of the heat
exchanger with water.
5. After cleaning, attach the heat exchanger in the
reverse order.
!Please note
Prevent components of the stainless steel heat
exchanger that come into contact with hot gases
from being scratched or otherwise damaged.
Prevent stainless steel components that come
into contact with hot gas from contact with pure
iron, as corrosion damage can result.
Never use a wire brush or sharp objects. Use
plastic brushes if required.
*1 Manufacturer: Hebro Chemie GmbH, Rostocker Strasse 40, D-41199 Mönchengladbach
*2 Part no. 7840112
Commissioning, inspection, maintenance
Cleaning the heating surfaces
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For stubborn residues, surface stains or soot deposits,
cleaning agents can be used.
For this, observe the following:
■Only use solvent-free cleaning agents.
■Remove soot deposits with alkaline agents contain-
ing surfactant additives (e.g. Fauch 400/410*1).
■Combustion residues may create thin, yellow-brown
surface stains as well as hard deposits. These may
only become visible after the soot deposits have
been removed. Discolouration on the surface of the
stainless steel heat exchanger is a normal sign of
use. It has no bearing on the function and service life
of the heat exchanger. To remove hard deposits, use
slightly acidic, chloride-free cleaning agents based
on phosphoric acid (e.g. Antox 75 E*1).
■Remove loosened deposits from the heat exchanger
and rinse the heating surface thoroughly with water.
Checking the gaskets and thermal insulation sections
1. Check gaskets and packing cords in the boiler door
for damage.
2. Check the thermal insulation sections of the com-
bustion chamber and the boiler door for damage.
3. Replace any damaged components.
Fitting the boiler door
41
Fig. 8
For room sealed operation: Refit the ventilation air pipe
after closing the boiler door.
*1 Manufacturer: Hebro Chemie GmbH, Rostocker Strasse 40, D-41199 Mönchengladbach
Commissioning, inspection, maintenance
Cleaning the heating surfaces (cont.)
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A
C
B
Fig. 9
1. Separate hose A to the neutralising system from
trap B.
2. Connect drain hose C to the condensate drain of
the trap and run to a drainage system.
Checking the neutralising system (if installed)
1. Check the pH value of the condensate downstream
of the neutralising system with a pH test strip.
Replace the granulate if the pH value is < 6.5.
Note
Part no. for pH test strips: 9517 678.
Observe the neutralising system manufacturer's
instructions.
2. Reinstall the neutralising system in reverse order.
Checking the active charcoal filter (if installed)
Observe the active charcoal filter manufacturer's
instructions.
Commissioning, inspection, maintenance
Separating the neutralising system or active charcoal filter (if installed)
from the boiler and connecting the drain hose
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B
A
Fig. 10
Note
Traces of condensate indicate a leak.
1. Remove thermal insulation strip A and pull ther-
mal insulation mat B out a little.
2. Check the heat exchanger fixings are firmly
seated.
3. Check the connector on the heat exchanger for
leaks.
Cleaning the condensate drain pipe and trap and reconnecting to the
drainage system
Check that the hoses are routed without kinks and that
the condensate can drain freely.
Filling the trap and neutralising system (accessories) with water
Fig. 11
Commissioning, inspection, maintenance
Checking the connection on the flue gas side for leaks
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Remove the supply hose (to the trap) from the boiler
condensate drain and fill with a little water.
Checking connections on the heating water and DHW sides and the sensor well
for leaks
Checking the function of the safety equipment
Checking the expansion vessel and system pressure
Fig. 12
APressure gauge
Note
Please observe expansion vessel manufacturer's
instructions.
Carry out this test on a cold system.
1. Drain the system until the pressure gauge indi-
cates "0" or close the cap valve on the expansion
vessel and reduce the pressure in the expansion
vessel.
2. If the pre-charge pressure of the expansion vessel
is lower than the static system pressure, top up
with nitrogen until the pre-charge pressure is 0.1 to
0.2 bar (10 to 20 kPa) higher.
3. Top up with water until the charge pressure of the
cooled system is 0.1 to 0.2 bar (10 to 20 kPa)
higher than the pre-charge pressure of the expan-
sion vessel.
Permiss. operating pressure: 3 bar (0.3 MPa)
Checking the thermal insulation for firm seating
Checking the mixer for ease of operation and leaks
1. Remove the motorised lever from the mixer handle
and check the mixer for ease of operation.
2. Check the mixer for tightness. Replace the O-rings
if the mixer leaks.
Commissioning, inspection, maintenance
Filling the trap and neutralising system… (cont.)
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3. Click the motorised lever into place.
Checking the ventilation air connection to the burner (if installed)
For room sealed operation: Check the ventilation air
connection for damage.
Adjusting the burner
Burner service instructions
Instructing the system user
The system installer should hand the operating instruc-
tions to the system user and instruct the user in oper-
ating the system.
This includes all components installed as accessories,
e.g. remote control units. In addition, the system instal-
ler must make the user aware of the required mainte-
nance work.
Commissioning, inspection, maintenance
Checking the mixer for ease of operation and… (cont.)
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Commissioning Maintenance/service Maintenance/service
Date:
By:
Maintenance/service Maintenance/service Maintenance/service
Date:
By:
Maintenance/service Maintenance/service Maintenance/service
Date:
By:
Maintenance/service Maintenance/service Maintenance/service
Date:
By:
Maintenance/service Maintenance/service Maintenance/service
Date:
By:
Commissioning/service reports
Commissioning/service reports
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Rated heating output
TF/TR = 50/30 °C kW 20.2 24.6 28.6 35.4 42.8 53.7
TF/TR = 80/60 °C kW 18.8 22.9 27.0 33.0 40.0 50.0
CE designation CE-2456 CL 102
Power consumption*3 at
■100 % of rated heating output W 226 215 235 235 340 340
■30 % of rated heating output W 60 66 73 80 113 113
Available draught*4
Pa 100 100 100 100 100 100
mbar 1.0 1.0 1.0 1.0 1.0 1.0
Flue gas temperature*5
■At a return temperature of 30 °C °C 32 34 37 39 36 40
■At a return temperature of 60 °C °C 62 63 65 67 64 67
*3 Standard parameter (in conjunction with Vitoflame 300 blue flame oil burner).
*4 Observe when sizing the chimney.
*5 Flue gas temperatures as average gross values to EN 304 (captured with 5 thermocouples) at 20 °C combustion air tem-
perature.
Specification
Specification
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