Viessmann VITORONDENS 200-T Betriebsanleitung

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.

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

5600 259 UAE

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.)

5600 259 UAE

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

5600 259 UAE

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

5600 259 UAE

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.)

5600 259 UAE

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

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.)

5600 259 UAE

Draining the heating system (if required)

ADrain

Opening the boiler door

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5600 259 UAE

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

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.)

5600 259 UAE

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