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
For applicability, see the last page
VITORONDENS 200-T
5624 309 GB 2/2013 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 quali-
fied contractors.
■Work on gas installations must only be carried out by
a registered gas fitter.
■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
Observe the following when working on this system:
■Statutory regulations regarding the prevention of
accidents
■Statutory regulations regarding environmental pro-
tection
■Codes of practice of the relevant trade associations
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards
■Gas Safety (Installation & Use) Regulations
– the appropriate Building Regulation either the
Building regulations, the Building Regulation (Scot-
land), Building Regulations (Northern Ireland),
– the Water Fittings Regulation or Water Bylaws in
Scotland,
– the current I.E.E. Wiring Regulations.
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Do not smoke. Prevent naked flames and
sparks. Do not switch lights or electrical appli-
ances 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 supply utility from
outside the building.
■Shut off the electricity supply to the building
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 all doors in the living space.
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 a sufficient 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
Life-threatening poisoning caused by carbon
monoxide in the flue gas occurs as a result of
leaking or blocked flue systems or an insufficient
supply of combustion air.
Ensure the flue system is in proper working
order. It must not be possible to close apertures
for interconnected combustion air supply.
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 a sufficient supply of combustion air.
Safety instructions
Safety instructions
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Working on the system
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■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.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing any 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 your
system.
Defective components must be replaced 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 (cont.)
5624 309 GB

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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 ............................................................................................... 16
■Ordering parts ..................................................................................... 16
Overview of the assemblies ................................................................... 16
Boiler body assembly ............................................................................. 17
Heat exchanger assembly (20.2 to 35.4 kW) ......................................... 17
Heat exchanger assembly (42.8 and 53.7 kW) ...................................... 18
Thermal insulation assembly ................................................................. 20
4. Commissioning/service
reports
.................................................................................................................. 21
5. Specification .................................................................................................................. 22
6. Certificates Declaration of conformity ....................................................................... 23
Manufacturer's certificate according to the 1st BImSchV [Germany] .... 23
7. Keyword index .................................................................................................................. 24
Index
Index
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The appliance is only intended to be installed and
operated 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 the heating of water that is
of potable water quality.
Intended usage 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 does not comply with
regulations.
Any usage beyond this must be approved by the man-
ufacturer for the individual case.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and results in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended function (e.g.
if the flue gas and ventilation air paths are sealed).
Product information
Intended use
5624 309 GB

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Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system................................................................................................. 7
•2. Vent the boiler at the safety equipment block (accessories)......................................... 8
•3. Venting the heating system
• • 4. Shutting down the system
• • 5. Draining the heating system (if required)........................................................................ 9
• • 6. Opening the boiler door..................................................................................................... 9
• • 7. Cleaning the heating surfaces.......................................................................................... 10
• • 8. Checking gaskets and thermal insulation sections........................................................ 11
•9. Fitting the boiler door........................................................................................................ 12
• • 10. Separating the neutralising system or active charcoal filter (if installed) from the
boiler and connecting the drain hose.............................................................................. 12
• • 11. Checking the neutralising system (if installed)............................................................... 13
• • 12. Checking the active charcoal filter (if installed).............................................................. 13
• • 13. Checking the connection on the flue gas side for leaks................................................ 13
• • 14. Cleaning the condensate drain pipe and siphon and reconnecting to the drainage
system................................................................................................................................. 13
•15. Filling the siphon and neutralising system (accessories) with water........................... 14
••• 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................................................... 14
••• 19. Checking the thermal insulation for firm seating
• • 20. Checking the mixer for ease of operation and leaks...................................................... 15
••• 21. Checking the ventilation air connection to the burner (if installed).............................. 15
••• 22. Adjusting the burner.......................................................................................................... 15
•23. Instructing the system user.............................................................................................. 15
•24. Operating and service documents................................................................................... 15
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Fill water
!Please note
Unsuitable fill water increases the level of
deposits and corrosion and may lead to boiler
damage.
■Flush the heating system thoroughly before
filling.
■Only use fill water of potable quality.
■An antifreeze additive suitable for heating sys-
tems can be added to the fill water. The anti-
freeze 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 (Conversion rate 1 mol/m3 = 100 ppm)
kW < 20 l/kW ≥ 20 l/kW to < 50 l/kW ≥ 50 l/kW
≤ 50 ≤ 3.0 mol/m3 ≤ 2.0 mol/m3 < 0.02 mol/m3
> 50 to ≤ 200 ≤ 2.0 mol/m3 ≤ 1.5 mol/m3 < 0.02 mol/m3
> 200 to ≤ 600 ≤ 1.5 mol/m3 ≤ 0.02 mol/m3 < 0.02 mol/m3
> 600 < 0.02 mol/m3 < 0.02 mol/m3 < 0.02 mol/m3
Conversion rate 1 mol/m3 = 100ppm
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 dis-
tributor.
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 dis-
tributor 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 dis-
tributor.
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 dis-
tributor again.
Vent 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 taps 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
In balanced flue operation: Remove the ventilation air
line before opening the boiler door.
Commissioning, inspection, maintenance
Draining the heating system (if required)
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!Please note
Prevent components that come into contact with
hot gases from being scratched or otherwise
damaged. Prevent components that come into
contact with hot gases from contact with pure
iron, as corrosion damage can result.
Never use a wire brush or sharp objects. Use
plastic brushes if required.
Boiler heating surface
A
Fig.6
ACleaning brush (accessories)
For conventional cleaning, flush the heating surfaces
thoroughly with water. You may use cleaning agents if
you notice stubborn residues, surface discolouration or
soot deposits.
For this, observe the following:
■Only use solvent-free cleaning agents. Ensure that
no cleaning agent gets between the boiler body and
the thermal insulation.
■Remove soot deposits with alkaline agents contain-
ing surfactant additives (e.g. Fauch 600*1).
■Combustion residues may create thin, yellow-brown
surface stains as well as hard deposits that may only
become visible after removing the soot deposits. Use
slightly acidic, chloride-free cleaning agents based
on phosphoric acid to remove surface discolouration
and stubborn deposits (e.g. Antox 75 E*1).
■Remove loosened deposits from the heat exchanger,
flush the heating surface thoroughly with water.
Cleaning agent manufacturer's details
*1 Manufacturer: Hebro Chemie GmbH, Rostocker Straße 40, D-41199 Mönchengladbach
Commissioning, inspection, maintenance
Cleaning the heating surfaces
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Heating surface of the heat exchanger
A
Fig.7
AWater hose
Generally, heat exchangers are cleaned with the aid of
a water hose from the boiler front through the hot gas
flues.
1. Remove contamination from the connector using a
vacuum cleaner.
2. Thoroughly flush the heating surface with water.
Note
In the case of severe contamination (e.g. through
incorrect burner adjustment), remove the heat
exchanger from the boiler for cleaning.
Checking gaskets and thermal insulation sections
1. Check gaskets and packing cords in the boiler door
for damage.
2. Check the thermal insulation components of the
combustion chamber and the boiler door for dam-
age.
3. Replace any damaged sections.
Commissioning, inspection, maintenance
Cleaning the heating surfaces (cont.)
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41
Fig.8
In balanced flue operation: Refit the ventilation air line
after closing the boiler door.
Separating the neutralising system or active charcoal filter (if installed)
from the boiler and connecting the drain hose
A
C
B
Fig.9
1. Separate hose A to the neutralising system from
siphon B.
2. Connect drain hose C to the condensate drain of
the siphon and run to a drainage system.
Commissioning, inspection, maintenance
Fitting the boiler door
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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 neutralising system in reverse order.
Checking the active charcoal filter (if installed)
Observe the active charcoal filter manufacturer's
instructions.
Checking the connection on the flue gas side for leaks
B
A
Fig.10
Note
Traces of condensate indicate a leak.
1. Remove thermal insulation strip A and pull thermal
insulation mat B off a little.
2. Check the heat exchanger fixings for firm seating.
3. Check the connector on the heat exchanger for
leaks.
Cleaning the condensate drain pipe and siphon and reconnecting to the
drainage system
Check that the hoses are routed without kinks and that
the condensate can drain freely.
Commissioning, inspection, maintenance
Checking the neutralising system (if installed)
5624 309 GB

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Fig.11
Pull the supply hose (to the siphon) 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 indicates
"0" or close the cap valve on the expansion vessel
and reduce the pressure in the expansion vessel.
Commissioning, inspection, maintenance
Filling the siphon and neutralising system (accessories) with water
5624 309 GB

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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 leaks. Replace the O-ring gas-
kets if the mixer is leaking.
3. Snap the motorised lever into place.
Checking the ventilation air connection to the burner (if installed)
In balanced flue 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.
Operating and service documents
1. Complete and detach the customer registration
card:
■Hand system users their section for safekeeping.
■Retain the heating contractor's section.
2. File all parts lists, operating and service instructions
in the folder and hand this over to the system user.
Commissioning, inspection, maintenance
Checking the expansion vessel and system… (cont.)
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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 the assemblies
D
B C
A
Fig.13
AType plate
BBoiler body assembly
CHeat exchanger assembly
DThermal insulation assembly
Parts lists
Parts lists
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0001 Brush handle
0002 Hinge panel
0003 Sensor well
0004 Cleaning brush
0005 Water distribution jet
0006 Pack 16 x 12
0007 Ventilation air hose
0008 Hose clip (2 pce)
0009 Ventilation air hose adaptor (connector)
0010 Inlet adaptor
0011 Thermal insulation block
0012 Boiler door
0005
0004
0001
0008
0009
0007
0012
0011
0006
0003
0002
0010
0008
0006
0011
0006
Fig.14
Heat exchanger assembly (20.2 to 35.4 kW)
0001 Spring hooks (3 pce)
0002 Fixing elements (2 pce)
0003 Boiler flue connection
0004 Boiler flue connection
0005 Viton gasket
0006 Hose clip (2 pce)
0007 Thermal insulation mat, heat exchanger, back
0008 Thermal insulation mat, flue pipe, heat
exchanger
0009 Flue outlet gasket
0010 Inlet adaptor
0011 Siphon, complete
0012 Flue gasket
0013 Heat exchanger
0014 Heat exchanger gaskets
0015 Ventilation air hose
0016 Corrugated pipe, back, heat exchanger
0017 Corrugated pipe, front, heat exchanger
0018 Thermal insulation mat, heat exchanger, front
0019 Bypass valve with O-rings
0020 Distributor, heating water flow and return
0021 Thermal insulation, distributor, heating water
flow and return
0022 Flue gas connection
0023 Thermal insulation, heat exchanger
0024 Siphon
0025 Corrugated hose
0026 Gasket
0027 Plug M 14 with O-ring
0028 Plug
Parts lists
Boiler body assembly
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0029 Plug
0031 Silencer
0032 Diaphragm grommet
0033 Connection piece with bend
0034 Flue gasket D = 80 mm
0035 Sealing set, test ports
0012
0021
001700080002
0009
0009
0001
0014
0010
0006
0015
0026
0024
0026
0033 0035
0025
0034
0006
0003
0012
0028
0029
0028
0029
0012
0023
0023
0004
0027
0027 0018
0031
0007
0016
0014
0020
0019
0012
0005
0014
0032
0013
0026
0025
0024
0002
0005
0014
0032
0011
0014
0014
0032
0022
0032
Fig.15
Heat exchanger assembly (42.8 and 53.7 kW)
0001 Spring hooks (3 pce)
0002 Fixing elements (2 pce)
0003 Boiler flue connection
0004 Boiler flue connection
0005 Viton gasket
0006 Hose clip (2 pce)
0007 Thermal insulation mat, heat exchanger, back
0008 Thermal insulation mat, flue pipe, heat
exchanger
0009 Flue outlet gasket
Parts lists
Heat exchanger assembly (20.2 to 35.4 kW) (cont.)
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0010 Inlet adaptor
0011 Siphon, complete
0012 Flue gasket
0013 Heat exchanger
0014 Heat exchanger gaskets
0015 Ventilation air hose
0016 Corrugated pipe, back, heat exchanger
0017 Corrugated pipe, front, heat exchanger
0018 Thermal insulation mat, heat exchanger, front
0019 Bypass valve with O-rings
0020 Distributor, heating water flow and return
0021 Thermal insulation, distributor, heating water
flow and return
0022 Flue gas connection
0023 Thermal insulation, heat exchanger
0024 Siphon
0025 Corrugated hose
0026 Gasket
0030 Sealing set, test ports
0031 Silencer
0032 Diaphragm grommet
0025
0026
0015
0006
0010
0006 0012
0030
0003
0030
0013
0023
0012
0004
0030
0032 0030
0012
0018
0007
0016
0014
0031
0032
0014
0017 0021000800020002
0001
0022
0009
0009
0005
0013
0005
0014
0014
0014
0014
0020
0019
0032
0032
0011
0025
0026
0024
0024
0026
Fig.16
Parts lists
Heat exchanger assembly (42.8 and 53.7 kW) (cont.)
5624 309 GB

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0001 Service instructions
0002 Installation instructions
0003 Spring hooks (3 pce)
0004 Touch-up spray paint, Vitosilver
0005 Touch-up paint stick, Vitosilver
0006 Thermal insulation mat, back
0007 Retaining bracket
0008 Top panel, front
0009 Top panel, back
0010 Side panel, left
0011 Thermal insulation, outer jacket
0012 Side panel, right
0013 Front panel with logo (0014)
0014 Vitorondens 200 logo
0015 Coding card
0016 Back panel
0017 Edge protector
AType plate (r.h. or l.h. side)
0009
0008
0007
0010
00050004000100020013 0012
0015
0016
0003
0006
00030011
A
A
0017
0017
0014
0014
Fig.17
Parts lists
Thermal insulation assembly
5624 309 GB