Viessmann VITORONDENS 200-T Istruzioni operative

Service instructions

for contractors

VIESMANN

Vitorondens 200-T

Type J2RA, 67.6 to 107.3 kW

Oil Unit condensing boiler

VITORONDENS 200-T

5831441 GB 11/2018 Please keep safe.

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 author-

ised contractors.

■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 to be observed

■National installation regulations

■Statutory regulations for the prevention of accidents

■Statutory regulations for environmental protection

■Codes of practice of the relevant trade associations

■All relevant safety regulations as defined by DIN, EN,

DVGW, VDE and locally applicable standards

aÖNORM, EN and ÖVE

cSEV, SUVA, SVTI and SWKI

Safety instructions for working on the system

Working on the system

■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.

Danger

Hot surfaces can cause burns.

■Before maintenance and service work, switch

OFF the appliance and let it cool down.

■Never touch hot surfaces on the boiler, burner,

flue system or pipework.

!Please note

Electronic assemblies can be damaged by elec-

trostatic discharge.

Prior to commencing 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 the

system.

Replace faulty components only 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

5831441

Safety instructions for operating the system

If you smell flue gas

Danger

Flue gas can lead to life threatening poisoning.

■Shut down the heating system.

■Ventilate the installation site.

■Close doors to living spaces to prevent flue

gases from spreading.

What to do if water escapes from the appliance

Danger

When water escapes from the appliance there is

a risk of electrocution.

Switch off the heating system by means of an

external isolator (for example fuse box, domestic

power distribution).

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 an adequate 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

Leaking or blocked flue systems, or an inade-

quate supply of combustion air can cause life

threatening poisoning from carbon monoxide in

the flue gas.

Ensure the flue system is in good working order.

Vents for supplying combustion air must be non-

closable.

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 an adequate supply of combustion air.

Safety instructions

Safety instructions (cont.)

5831441

1. Product information Intended use .......................................................................................... 5

2. Commissioning, inspec-

tion, maintenance

Steps - commissioning, inspection and maintenance ............................ 6

3. Parts lists Parts lists ............................................................................................... 19

■Ordering parts ..................................................................................... 19

Overview of assemblies ......................................................................... 19

Heat exchanger assembly ..................................................................... 20

Boiler body assembly ............................................................................. 20

Thermal insulation assembly ................................................................. 21

4. Commissioning/service

reports

................................................................................................................ 23

5. Specification ................................................................................................................ 24

6. Shutdown and disposal Final decommissioning and disposal ..................................................... 25

7. Certificates Declaration of conformity ....................................................................... 26

Manufacturer's certificate according to the 1st BImSchV [Germany] .... 26

8. Keyword index ................................................................................................................ 27

Index

5831441

The appliance is intended solely for installation and

operation 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 heating up heating water

that is of potable water quality.

Intended use 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 shall be deemed

inappropriate.

Any usage beyond this must be approved by the man-

ufacturer in each individual case.

Incorrect usage or operation of the appliance (e.g. the

appliance being opened by the system user) is prohibi-

ted and will result in an exclusion of liability. Incorrect

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

5831441

Commissioning steps

Inspection steps

Maintenance steps Page

••• 1. Filling and commissioning the heating system.............................................................. 7

•2. Venting the heating system

• • 3. Shutting down the system

• • 4. Draining the heating system (if required)........................................................................ 8

• • 5. Opening the boiler door..................................................................................................... 9

• • 6. Cleaning the boiler heating surfaces............................................................................... 10

• • 7. Checking the gaskets and thermal insulation sections................................................. 10

•8. Fitting the boiler door........................................................................................................ 11

• • 9. Separating the neutralising system (if installed) from the boiler and connecting the

drain hose........................................................................................................................... 12

• • 10. Checking the neutralising system (if installed)............................................................... 12

• • 11. Checking the connection on the flue gas side for leaks................................................ 13

• • 12. Removing the cover from the heat exchanger................................................................ 14

• • 13. Cleaning the heat exchanger............................................................................................ 15

• • 14. Cleaning the condensate drain pipe and trap and reconnecting to the drainage

system................................................................................................................................. 16

•15. Filling the trap with water.................................................................................................. 16

••• 16. Checking connections and sensor well on the heating water side for tightness

••• 17. Checking the function of the safety equipment

• • 18. Checking the expansion vessel and system pressure................................................... 17

••• 19. Checking the thermal insulation for firm seating

• • 20. Checking the mixer for ease of operation and leaks...................................................... 17

••• 21. Adjusting the burner.......................................................................................................... 17

•22. Instructing the system user.............................................................................................. 17

•23. Operating and service documents................................................................................... 18

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5831441

Operating instructions, service instructions –

control unit and burner

1. Check that the ventilation air aperture in the instal-

lation room 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.

Fig. 1

AFilling/draining

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 17).

Permiss. operating pressure: 3 bar (0.3 MPa)

Note

Let the heating circuit pump run whilst filling in

order to vent the indirect coils.

Fig. 2

Mark the charge pressure at pressure gauge A.

6. Return the check valves to their operating position.

7. Open the oil shut-off valves.

8. Fill trap with water (see page 16).

Fill water

According to EN 1717 with DIN 1988-100, as a heat

transfer medium for DHW heating, the heating water

must meet fluid category ≤ 3. This requirement is met if

water of potable quality is used as heating water. For

example, if additives are used, the additive manufac-

turer must specify which category the treated heating

water comes under.

Commissioning, inspection, maintenance

Filling and commissioning the heating system

5831441

!Please note

Unsuitable fill water increases the level of

deposits and corrosion and may lead to appli-

ance damage.

■Flush the heating system thoroughly before

filling.

■Only use fill water of potable water quality.

■Special antifreeze suitable for heating systems

can be added to the fill water. The antifreeze

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

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)

Venting the heating system

Shutting down the system

Draining the heating system (if required)

Fig. 3

AFilling/draining

Drain at filling/draining connector A.

Commissioning, inspection, maintenance

Filling and commissioning the heating system (cont.)

5831441

Note

If the sound insulation set (accessories) is installed,

detach the air supply hose from the burner before

opening the boiler door.

lÖ

Fig. 4

Commissioning, inspection, maintenance

Opening the boiler door

5831441

Fig. 5

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 additive (e.g. Fauch

400*1).

Note

■Ensure that no cleaning agent gets between the

boiler body and the thermal insulation.

■Only use solvent-free cleaning agents.

Manufacturer's instructions about the cleaning

agent

Checking the 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 components.

4. If a sound insulation set (accessories) is connec-

ted: Check the exterior grille of the vent on the

back of the boiler and clean if required.

*1 Manufacturer: Hebro Chemie GmbH, Rostocker Strasse 40, D-41199 Mönchengladbach

Commissioning, inspection, maintenance

Cleaning the boiler heating surfaces

5831441

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