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
For applicability, see the last page
VITORONDENS 200-T
5614 313 UAE 2/2013 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
!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 inten-
ded for qualified contractors.
■ 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:
■ National installation requirements
■ Legal instructions regarding the pre-
vention of accidents
■ Legal instructions regarding environ-
mental protection
■ The Code of Practice of relevant trade
associations
■ All current safety regulations as
defined by DIN, EN, DVGW, VDE and
all locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI and SWKI
Working on the system
■ 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 unau-
thorised reconnection.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Before beginning 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 your sys-
tem.
Replace faulty components only
with original Viessmann spare
parts.
Safety instructions
Safety instructions
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Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
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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Product information
Intended use......................................................................................................... 5
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 6
Further details regarding the individual steps....................................................... 7
Parts lists
Parts lists.............................................................................................................. 20
Overview of the assemblies................................................................................. 21
Heat exchanger assembly.................................................................................... 22
Boiler body assembly........................................................................................... 23
Thermal insulation assembly................................................................................ 24
Commissioning/service reports........................................................................ 26
Specification....................................................................................................... 27
Certificates
Declaration of conformity...................................................................................... 28
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 29
Keyword index.................................................................................................... 30
Index
Index
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The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions. It is only designed
for the heating of water that is of potable
water quality.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than heating the building or
DHW shall be deemed inappropriate.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect 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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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Commissioning the system........................................... 7
•2. Filling the heating system.............................................. 8
•3. Venting the heating system
• • 4. Shutting down the system
• • 5. Draining the heating system (if required)..................... 9
• • 6. Opening the boiler door................................................. 10
• • 7. Cleaning the heating surfaces....................................... 11
• • 8. Checking gaskets and thermal insulation sections.... 13
•9. Fitting the boiler door..................................................... 14
• • 10. Separating the neutralising system (if installed) from
the boiler and connecting the drain hose.................... 15
• • 11. Checking the neutralising system (if installed)........... 15
• • 12. Checking the connection on the flue gas side for leaks 16
• • 13. Cleaning the condensate drain pipe and siphon and
reconnecting to the drainage system........................... 17
•14. Filling the siphon and neutralising system
(accessories) with water................................................ 17
••• 15. Checking connections and sensor well on the heating
water side for tightness
••• 16. Checking the function of the safety equipment
• • 17. Checking the expansion vessel and system pressure 18
••• 18. Checking the thermal insulation for firm seating
• • 19. Checking the mixer for ease of operation and leaks... 18
••• 20. Adjusting the burner...................................................... 18
•21. Instructing the system user........................................... 19
•22. Operating and service documents................................ 19
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning the system
Operating instructions, service
instructions – control unit and
burner
1. Check that the installation room vent
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. 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 18).
Permiss. operating pressure: 3 bar
(0.3 MPa)
5.
A
Mark the charge pressure at pressure
gauge A.
6. Return the check valves to their oper-
ating position.
7. Open the oil shut-off valves.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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Filling the heating system
Fill water
!Please note
Unsuitable fill water increases
the level of deposits and corro-
sion and may lead to boiler dam-
age.
■ Flush the heating system thor-
oughly before filling.
■ Only use fill water of potable
quality.
■ An antifreeze additive suitable
for heating systems can be
added to the fill water. The anti-
freeze manufacturer must ver-
ify its suitability.
■ Fill and top-up water with a
water hardness in excess of
the following values must be
softened, e.g. with a small soft-
ening 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)
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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A
AFilling/draining
Note
Let the heating circuit pump run whilst
filling in order to vent the indirect coils.
Draining the heating system (if required)
Drain at filling/draining connector A.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Opening the boiler door
lÖ
fA
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the heating surfaces
Boiler heating surface
A
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
additives (e.g. Fauch 400*1).
Note
■ Ensure that no cleaning agent gets
between the boiler body and the ther-
mal insulation.
■ Only use solvent-free cleaning agents.
Manufacturer's instructions
about the cleaning agent
*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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Heating surface of the heat exchanger
!Please note
Prevent stainless steel compo-
nents 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. Use plastic brushes if
required.
A
AWater hose
Generally, heat exchangers are cleaned
with the aid of a water hose from the
boiler front through the hot gas flues.
Thoroughly flush the heating surface of
the heat exchanger with water.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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When using cleaning agents, please
note:
■ Combustion residues may create thin,
yellow-brown surface stains as well as
hard deposits that may only become
visible after removing the soot depos-
its. Use slightly acidic, chloride-free
cleaning agents based on phosphoric
acid to remove surface discolouration
and stubborn deposits (e.g. Antox 75
E).
■ Only use solvent-free cleaning
agents.
■ Flush the heating surface of the heat
exchanger thoroughly with water to
remove dissolved residues from the
heat exchanger.
Manufacturer's instructions
about the cleaning agent
Note
In the case of severe contamination (e.g.
through incorrect burner adjustment),
remove the heat exchanger to clean the
boiler.
Checking 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 sections.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Fitting the boiler door
fA lÖ
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Separating the neutralising system (if installed) from the boiler
and connecting the drain hose
C BA
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 drainage system.
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. Reinstall neutralising system in
reverse order.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the connection on the flue gas side for leaks
B
C
A
Note
Traces of condensate indicate a leak.
1. Remove thermal insulation hood
A.
2. Remove thermal insulation strip B
and pull thermal insulation mat C
out a little.
3. Check the heat exchanger fixings for
firm seating.
4. Check all sealing points on the heat
exchanger, boiler flue connection
and flue system.
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 drainage system
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.
Filling the siphon and neutralising system (accessories) 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 expansion vessel and system pressure
A
APressure gauge
Note
Please observe expansion vessel man-
ufacturer'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.
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 pres-
sure 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
expansion vessel.
Permiss. operating pressure: 3 bar
(0.3 MPa)
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.
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 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 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 supplier.
Parts lists
Parts lists
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