Viessmann VITORONDENS 200-T Mode d'emploi
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
5624 309 GB
3
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
4
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
5624 309 GB
5
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
6
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
5624 309 GB
7
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
5624 309 GB
8
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.)
5624 309 GB
9
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)
5624 309 GB
10
!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
5624 309 GB
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5
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