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
5600 259 UAE 6/2011 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on gas equipment must only be
carried out by a qualified gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental protection,
■ the Code of Practice of relevant trade
associations.
■ all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may lead to serious
injury.
■ Do not smoke. Prevent naked
flames and sparks. Never
switch lights or electrical appli-
ances ON or OFF.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the build-
ing.
■ 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-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors in the living
space.
Safety instructions
Safety instructions
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Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electrostatic dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your heating
system.
Replace faulty components only
with original Viessmann spare
parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the heating system can com-
promise its function. Installing
non-authorised components and
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
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Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 7
Parts lists
Parts lists.............................................................................................................. 18
Overview of the assemblies................................................................................. 19
Boiler body assembly........................................................................................... 20
Heat exchanger assembly (20.2 to 35.4 kW)....................................................... 21
Heat exchanger assembly (42.8 and 53.7 kW).................................................... 23
Thermal insulation assembly................................................................................ 25
Commissioning/service reports........................................................................ 27
Specification....................................................................................................... 28
Certificates
Declaration of conformity...................................................................................... 29
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 29
Keyword index.................................................................................................... 31
Index
Index
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system.............................................. 7
•2. Vent the boiler at the safety equipment block
(accessory)...................................................................... 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
components.................................................................... 12
•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........................................................................ 13
• • 11. Checking the neutralising system (if installed)........... 13
• • 12. Checking the active charcoal filter (if installed).......... 14
• • 13. Checking the connections on the flue gas side for
tightness.......................................................................... 14
• • 14. Cleaning the condensate drain pipe and siphon and
reconnecting to the drain............................................... 15
•15. Filling the siphon and neutralising system
(accessory) with water................................................... 15
••• 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 diaphragm expansion vessel and
system pressure............................................................. 16
••• 19. Checking the thermal insulation for firm seating
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
• • 20. Checking the mixer for ease of operation and leaks... 16
••• 21. Checking the ventilation air connection to the burner
(if installed)...................................................................... 16
••• 22. Adjusting the burner...................................................... 16
•23. Instructing the system user........................................... 17
•24. Operating and service instructions.............................. 17
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
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Filling the heating system
!Please note
Unsuitable fill water increases the level of deposits and corrosion and may
lead to boiler damage.
■ Thoroughly flush the entire heating system prior to filling it with water.
■ Only use fill water of potable quality
■Soften fill water harder than 16.8 °dH (3.0 mol/m3), e.g. using a small soft-
ening system for heating water (see Viessmann Vitoset pricelist)
■ An antifreeze suitable for heating systems can be added to the fill water.
The antifreeze manufacturer must verify its suitability.
With on-site boiler fill valve in the heating water return
A B
ABypass valve "OPEN"
BBypass valve "CLOSED"
1. Check the pre-charge pressure of the
diaphragm expansion vessel.
2. Close the bypass valve on the KV/KR
distributor.
3. If using a top-mounted Divicon heat-
ing circuit distributor (accessory):
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 KV/KR
distributor again.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5600 259 UAE

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With safety equipment block (accessory)
1. Check the pre-charge pressure of the
diaphragm expansion vessel.
2. Close the bypass valve on the KV/KR
distributor.
3. Remove front insulation shell A.
4. Open air vent valve B.
5. Fill the system via the boiler fill
valve C in the heating return. (Mini-
mum system pressure 0.8 bar).
6. Close air vent valve B when no
more air escapes.
7. Close boiler fill valve C.
8. Open the bypass valve on the KV/KR
distributor again.
Vent the boiler at the safety equipment block (accessory)
1. Close the shut-off valves on the heat-
ing water side.
2. Remove front insulation shell A (if
already fitted).
3. Connect the drain hose on air vent
valve B with a drain.
4. Open valves B and C and vent
using mains pressure until no more
air noise can be heard.
5. Close valves B and C, and open
the shut-off valves on the heating
water side.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Draining the heating system (if required)
A
ADrain
Opening the boiler door
41
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Balanced flue operation: Remove the
ventilation air line before opening the
boiler door.
Cleaning the heating surfaces
!Please note
Prevent components that come into contact with flue gas from being scratched
or otherwise damaged. Prevent components that come into contact with flue
gas 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
ACleaning brush (accessory)
For conventional cleaning, flush the
heating surfaces thoroughly with water.
You may use cleaning agents if you
notice stubborn residues, surface disco-
louration 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 ther-
mal insulation.
■ Remove soot deposits with alkaline
agents containing surfactant additives
(e.g. Fauch 600*1).
*1 Manufacturer: Hebro Chemie GmbH, Rostocker Strasse 40, D-41199 Mönchen-
gladbach
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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■ Combustion residues may create thin,
yellow-brown surface discolouration
as well as hard deposits that may only
become visible after removing the soot
deposits. Use slightly acidic, chloride-
free cleaning agents based on phos-
phoric acid to remove surface disco-
louration and hard deposits (e.g. Antox
75 E*1)
■ Remove loose deposits from the heat
exchanger; flush the heating surface
thoroughly with water.
Cleaning agent manufacturer's
details
Heating surface of the heat exchanger
A
AWater hose
Generally, heat exchangers are cleaned
with the aid of a water hose from the
boiler front through to the hot gas flues.
1. Remove contamination from the con-
nector 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 to clean the
boiler.
*1 Manufacturer: Hebro Chemie GmbH, Rostocker Strasse 40, D-41199 Mönchen-
gladbach
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking gaskets and thermal insulation components
1. Check gaskets and packing cords in
the boiler door for damage.
2. Check the thermal insulation compo-
nents of the combustion chamber
and the boiler door for damage.
3. Replace any damaged parts.
Fitting the boiler door
41
Balanced flue operation: Refit the venti-
lation air line after closing the boiler
door.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Separating the neutralising system or active charcoal filter (if
installed) from the boiler and connecting the drain hose.
A
C
B
1. Separate hose A to the neutralising
system from siphon B.
2. Connect drain hose C to the con-
densate drain of the siphon and run
to a drain.
Checking the neutralising system (if installed)
1. Check the pH value of the conden-
sate 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. Refit neutralising system in reverse
order.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the active charcoal filter (if installed)
Observe the active charcoal filter manu-
facturer's instructions.
Checking the connections on the flue gas side for tightness
B
A
Note
Traces of condensate indicate a leak.
1. Remove thermal insulation strip A
and pull thermal insulation mat B
out a little.
2. Check the heat exchanger fixings for
firm seating.
3. Check the connector on the heat
exchanger for leaks.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the condensate drain pipe and siphon and reconnect-
ing to the drain
Check that the hoses are routed without
kinks and that the condensate can drain
freely.
Filling the siphon and neutralising system (accessory) with
water
Pull the supply hose (to the siphon) from
the boiler condensate drain and fill with
a little water.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the diaphragm expansion vessel and system pressure
Note
Observe the diaphragm expansion ves-
sel manufacturer's instructions.
Carry out this test on a cold system.
1. Drain the system until the pressure
gauge A indicates "0" or close the
cap valve on the diaphragm expan-
sion vessel and reduce the pressure
in this vessel.
2. If the pre-charge pressure of the dia-
phragm 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 higher.
3. Top up with water until the charge
pressure of the cooled system is 0.1
to 0.2 bar higher than the pre-charge
pressure of the diaphragm expansion
vessel.
Permiss. operating pressure: 3 bar
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 gaskets if the mixer is leak-
ing.
3. Snap the motorised lever into place.
Checking the ventilation air connection to the burner (if installed)
Balanced flue operation: Checking the
ventilation air connection for damage.
Adjusting the burner
Burner service instructions
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Instructing the system user
The installer should instruct the user in
the operation of the system.
Operating and service instructions
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 serv-
ice instructions 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
Further details regarding the individual steps (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 dealer.
Parts lists
Parts lists
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D
B C
A
AType plate
BBoiler body assembly
CHeat exchanger assembly
DThermal insulation assembly
Parts lists
Overview of the assemblies
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0001 Brush handle
0002 Hinge bracket
0003 Sensor well
0004 Cleaning brush
0005 Water distribution jet
0006 Packing 16 x 12
0007 Ventilation air hose
0008 Hose clip (2 pce)
0009 Ventilation air hose adaptor (con-
nector)
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
Parts lists
Boiler body assembly
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