Viessmann VITORONDENS 200-T Operating instructions

Service instructions
for contractors
VIESMANN
Vitorondens 200-T
Type J2RA, 67.6 to 107.3 kW
Oil Unit condensing boiler
VITORONDENS 200-T
5831441 GB 11/2018 Please keep safe.

2
Please follow these safety instructions 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 environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for author-
ised contractors.
■Work on electrical equipment must only be carried
out by a qualified electrician.
■The system must be commissioned by the system
installer or a qualified person 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
■All relevant safety regulations as defined by DIN, EN,
DVGW, VDE and locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI and SWKI
Safety instructions for working on the system
Working on the system
■Isolate the system from the power supply (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 reconnection.
Danger
Hot surfaces can cause burns.
■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 pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion 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 tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions
Safety instructions
5831441

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Safety instructions for operating the system
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 spreading.
What to do if water escapes from the appliance
Danger
When water escapes from the appliance there is
a risk of electrocution.
Switch off the heating system by means of an
external isolator (for example fuse box, domestic
power distribution).
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of conden-
sate or other causes. Ensure an adequate supply of
combustion air.
Instruct system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion 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-
closable.
Extractors
Operating appliances that extract air to the outside
(cooker hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to reverse flow of the
flue gas.
Danger
The simultaneous operation of the boiler and
appliances that extract air to the outside can
result in life threatening poisoning due to
reverse flow of the flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
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1. Product information Intended use .......................................................................................... 5
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 6
3. Parts lists Parts lists ............................................................................................... 19
■Ordering parts ..................................................................................... 19
Overview of assemblies ......................................................................... 19
Heat exchanger assembly ..................................................................... 20
Boiler body assembly ............................................................................. 20
Thermal insulation assembly ................................................................. 21
4. Commissioning/service
reports
................................................................................................................ 23
5. Specification ................................................................................................................ 24
6. Shutdown and disposal Final decommissioning and disposal ..................................................... 25
7. Certificates Declaration of conformity ....................................................................... 26
Manufacturer's certificate according to the 1st BImSchV [Germany] .... 26
8. Keyword index ................................................................................................................ 27
Index
Index
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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).
Product information
Intended use
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Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Filling and commissioning the heating system.............................................................. 7
•2. Venting the heating system
• • 3. Shutting down the system
• • 4. Draining the heating system (if required)........................................................................ 8
• • 5. Opening the boiler door..................................................................................................... 9
• • 6. Cleaning the boiler heating surfaces............................................................................... 10
• • 7. Checking the gaskets and thermal insulation sections................................................. 10
•8. Fitting the boiler door........................................................................................................ 11
• • 9. Separating the neutralising system (if installed) from the boiler and connecting the
drain hose........................................................................................................................... 12
• • 10. Checking the neutralising system (if installed)............................................................... 12
• • 11. Checking the connection on the flue gas side for leaks................................................ 13
• • 12. Removing the cover from the heat exchanger................................................................ 14
• • 13. Cleaning the heat exchanger............................................................................................ 15
• • 14. Cleaning the condensate drain pipe and trap and reconnecting to the drainage
system................................................................................................................................. 16
•15. Filling the trap with water.................................................................................................. 16
••• 16. Checking connections and sensor well on the heating water side for tightness
••• 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. Adjusting the burner.......................................................................................................... 17
•22. Instructing the system user.............................................................................................. 17
•23. Operating and service documents................................................................................... 18
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Operating instructions, service instructions –
control unit and burner
1. Check that the ventilation air aperture in the instal-
lation room is open.
2. Check the pre-charge pressure of the expansion
vessel.
If the pre-charge pressure of the expansion vessel
is lower than the static system pressure, top up
with sufficient nitrogen to raise the pre-charge
pressure higher (0.1 to 0.2 bar/10 to 20 kPa) than
the static system pressure.
The static pressure corresponds to the static head.
3. Open the check valves.
4.
A
Fig. 1
AFilling/draining
Fill the heating system with water and vent it until
the charge pressure is higher (0.1 to 0.2 bar/10 to
20 kPa) than the pre-charge pressure of the
expansion vessel (see page 17).
Permiss. operating pressure: 3 bar (0.3 MPa)
Note
Let the heating circuit pump run whilst filling in
order to vent the indirect coils.
5.
A
Fig. 2
Mark the charge pressure at pressure gauge A.
6. Return the check valves to their operating position.
7. Open the oil shut-off valves.
8. Fill trap with water (see page 16).
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.
Commissioning, inspection, maintenance
Filling and commissioning the heating system
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!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)
Venting the heating system
Shutting down the system
Draining the heating system (if required)
A
Fig. 3
AFilling/draining
Drain at filling/draining connector A.
Commissioning, inspection, maintenance
Filling and commissioning the heating system (cont.)
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Note
If the sound insulation set (accessories) is installed,
detach the air supply hose from the burner before
opening the boiler door.
lÖ
fA
Fig. 4
Commissioning, inspection, maintenance
Opening the boiler door
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A
Fig. 5
ACleaning brush (accessories)
1. Clean the boiler heating surfaces with cleaning
brush and vacuum cleaner.
2. Remove stubborn soot deposits with alkaline
agents containing surfactant additive (e.g. Fauch
400*1).
Note
■Ensure that no cleaning agent gets between the
boiler body and the thermal insulation.
■Only use solvent-free cleaning agents.
Manufacturer's instructions about the cleaning
agent
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 boiler
door for damage.
3. Replace any damaged components.
4. If a sound insulation set (accessories) is connec-
ted: Check the exterior grille of the vent on the
back of the boiler and clean if required.
*1 Manufacturer: Hebro Chemie GmbH, Rostocker Strasse 40, D-41199 Mönchengladbach
Commissioning, inspection, maintenance
Cleaning the boiler heating surfaces
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fA lÖ
Fig. 6
Note
If the sound insulation set (accessories) is installed, re-
attach the air supply hose to the burner.
Commissioning, inspection, maintenance
Fitting the boiler door
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C BA
Fig. 7
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.
Commissioning, inspection, maintenance
Separating the neutralising system (if installed) from the boiler and
connecting the drain hose
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B
C
A
D
Fig. 8
Note
Traces of condensate indicate a leak.
1. Remove thermal insulation hood A.
2. Remove thermal insulation strip B and pull ther-
mal insulation mat C out a little.
3. Remove mat D.
4. Check the heat exchanger fixings are firmly
seated.
5. Check all sealing points on the heat exchanger,
boiler flue connection and flue system.
Commissioning, inspection, maintenance
Checking the connection on the flue gas side for leaks
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B
A
Fig. 9
1. Remove heat exchanger cover A by undoing the
4 hexagon nuts.
2. Remove gasket B and clean the sealing face.
Commissioning, inspection, maintenance
Removing the cover from the heat exchanger
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A
B
C
Fig. 10
1. Detach condensate hose A from the trap and
drain into a suitable container B.
2. Using a cleaning spatula, loosen heavy deposits
on the heat exchanger coils and gaps via cleaning
aperture C and remove with a vacuum cleaner.
Then flush out the heat exchanger with a powerful
jet of water.
!Please note
Prevent stainless steel components that
come into contact with hot gas 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. If
necessary, use plastic brushes or the
Viessmann cleaning spatula.
Note
Viessmann cleaning spatula: Part no. 7840 112
3. Coat the heat exchanger coils with cleaning agent
(e.g. Fauch 400/410) through cleaning aperture C
and proceed in accordance with the cleaning agent
manufacturer's instructions.
Flush the heating surface of the heat exchanger
thoroughly with water to remove loosened residues
from the heat exchanger.
When using cleaning agents, please note:
■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.
■Use slightly acidic, chloride-free cleaning agents
based on phosphoric acid to remove surface
stains and hard deposits (e.g. Antox 75 E).
■Only use solvent-free cleaning agents.
4. Refit the heat exchanger components in reverse
order.
Note
Tighten the hexagon nuts on the cover of cleaning
aperture C evenly and diagonally.
Torque: 5 Nm
Commissioning, inspection, maintenance
Cleaning the heat exchanger
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1. Before installation, check the stench trap and con-
densate drain for contamination and clean if
required.
Danger
Escaping flue gas poses a risk to health.
Always connect the condensate drain with a
stench trap to prevent flue gas escaping.
2. Check that the hoses are routed without kinks and
that the condensate can drain freely.
Note
Always route the condensate pipe with a constant
fall.
3. Check the neutralising system (accessories).
Neutralising system installation and operat-
ing instructions
Filling the trap with water
Fig. 11
Remove the supply hose (to the trap) from the boiler
condensate drain and fill with a little water.
Checking connections and sensor well on the heating water side for tight-
ness
Checking the function of the safety equipment
Commissioning, inspection, maintenance
Cleaning the condensate drain pipe and trap and reconnecting to the
drainage system
5831441

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A
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.
3. Click the motorised lever into place.
Adjusting the burner
Burner service instructions
Instructing the system user
The installer should instruct the user in the operation of
the system.
Commissioning, inspection, maintenance
Checking the expansion vessel and system pressure
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1. Complete and detach the customer registration
card:
■Hand the system user their section for safekeep-
ing.
■Retain the heating contractor's section.
2. File all parts lists, operating and service instruc-
tions in the folder and hand this over to the system
user.
The installation instructions are no longer required
after the installation is complete and therefore do
not need to be retained.
Commissioning, inspection, maintenance
Operating and service documents
5831441

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Ordering parts
The following information is required:
■Serial no. (see type plate A)
■Assembly (from this parts list)
■Position number of the individual part within the
assembly (from this parts list)
Standard parts are available from your local supplier.
Overview of assemblies
B C
D
A
Fig. 13
AType plate
BHeat exchanger assembly
CBoiler body assembly
DThermal insulation assembly
Parts lists
Parts lists
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0001 Spring hooks (3 pce)
0002 Boiler flue connection
0003 Safety valve
0004 Silencer
0005 Trap, complete
0006 Thermal insulation, heat exchanger
0007 Automatic shut-off valve
0008 Quick-action air vent valve
0009 Test port plug set (2 pce)
0010 Elbow G 1¼
0011 Pressure gauge
0012 Flue gasket
0013 Flue gas connection gasket
0014 Gasket set G 2 (5 pce)
0015 Gasket set G 1¼ (5 pce)
0016 Heat exchanger
0017 Diaphragm grommet
0018 BF/BR distributor
0019 Heat exchanger support
0020 Compensator
0021 Corrugated pipe
0022 Thermal insulation mat, flue gas connection
0023 Thermal insulation mat, heat exchanger
0024 Studs (2 pce)
0025 Trap
0026 Corrugated hose
0027 Flat gasket
0028 Hose, support
0029 Gasket
0030 Cover
0023
0003
0011
0012
0027
0026
0025
0027
0017
0015
0013
0012
0017
0009
0017
0004
0002
0009
0013
0023
0016
0017
0024
0024
0006
0001
0022
0008
0014
0007
0015
0014
0005
0025
0026
0027
0021
0018
0018
0014
0015
0015
0010
0015
0020
0015
0015
0015
0028
0019
0028
0030
0029
0029
0030
Fig. 14
Boiler body assembly
0001 Hinge panel
0002 Brush handle
0003 Cleaning brush
0004 Sensor well
0005 Water distribution nozzle
0006 Packing 16 x 12 x 2000
0007 Packing 16 x 12 x 1000
0008 Boiler door
0009 Thermal insulation block
Parts lists
Heat exchanger assembly
5831441