VIESMANN. Service instructions VITORONDENS 200-T. for contractors. Vitorondens 200-T Type BR2A, 20.2 to 53.7 kw Oil Unit condensing boiler

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1 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 6/2011 Please keep safe.

2 Safety instructions Safety instructions 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 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 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 all legal instructions regarding the prevention of accidents, all legal instructions regarding environmental 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 explosions which may lead to serious injury. Do not smoke. Prevent naked flames and sparks. Never switch lights or electrical appliances 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 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 boiler room. Close all doors in the living space. 2

3 Safety instructions Safety instructions (cont.) 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 supply 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 unauthorised reconnection. Please note! Electronic modules can be damaged by electrostatic discharges. Touch earthed objects, such as heating or water pipes, to discharge static loads. Ancillary components, spare and wearing parts Please note! Spare and wearing parts that have not been tested together with the heating system can compromise its function. Installing non-authorised components and non-approved modifications or conversions can compromise safety and may invalidate our warranty. For replacements, use only original spare parts supplied or approved by Viessmann. 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. 3

4 Index Index Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance... 5 Further details regarding the individual steps... 7 Parts lists Parts lists Overview of the assemblies Boiler body assembly Heat exchanger assembly (20.2 to 35.4 kw) Heat exchanger assembly (42.8 and 53.7 kw) Thermal insulation assembly Commissioning/service reports Specification Certificates Declaration of conformity Manufacturer's certificate according to the 1st BImSchV [Germany] Keyword index

5 Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page 1. Filling the heating system Vent the boiler at the safety equipment block (accessory) Venting the heating system 4. Shutting down the system 5. Draining the heating system (if required) Opening the boiler door Cleaning the heating surfaces Checking gaskets and thermal insulation components Fitting the boiler door Separating the neutralising system or active charcoal filter (if installed) from the boiler and connecting the drain hose Checking the neutralising system (if installed) Checking the active charcoal filter (if installed) Checking the connections on the flue gas side for tightness Cleaning the condensate drain pipe and siphon and reconnecting to the drain Filling the siphon and neutralising system (accessory) with water 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 Checking the thermal insulation for firm seating 5

6 Commissioning, inspection, maintenance Steps - commissioning, inspection and (cont.) Commissioning steps Inspection steps Maintenance steps Page 20. Checking the mixer for ease of operation and leaks Checking the ventilation air connection to the burner (if installed) Adjusting the burner Instructing the system user Operating and service instructions

7 Further details regarding the individual steps 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/m 3 ), e.g. using a small softening 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 Commissioning, inspection, maintenance 1. Check the pre-charge pressure of the diaphragm expansion vessel. A B 2. Close the bypass valve on the KV/KR distributor. 3. If using a top-mounted Divicon heating 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. A Bypass valve "OPEN" B Bypass valve "CLOSED" 7

8 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 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. (Minimum 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 heating 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. 8

9 Draining the heating system (if required) Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) A A Drain Opening the boiler door 41 9

10 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 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 A Cleaning brush (accessory) 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. 10 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 containing surfactant additives (e.g. Fauch 600 *1 ). *1 Manufacturer: Hebro Chemie GmbH, Rostocker Strasse 40, D Mönchengladbach

11 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 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, chloridefree cleaning agents based on phosphoric acid to remove surface discolouration 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 A Water 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 connector 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 Mönchengladbach 11

12 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking gaskets and thermal insulation components 1. Check gaskets and packing cords in the boiler door for damage. 3. Replace any damaged parts. 2. Check the thermal insulation components of the combustion chamber and the boiler door for damage. Fitting the boiler door 41 Balanced flue operation: Refit the ventilation air line after closing the boiler door. 12

13 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Separating the neutralising system or active charcoal filter (if installed) from the boiler and connecting the drain hose. C A B 1. Separate hose A to the neutralising system from siphon B. 2. Connect drain hose C to the condensate drain of the siphon and run to a drain. Checking the neutralising system (if installed) 1. Check the ph value of the condensate downstream of the neutralising system with a ph test strip. Replace the granulate if the ph value is < Refit neutralising system in reverse order. Note Part no. for ph test strips: Observe the neutralising system manufacturer's instructions. 13

14 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the active charcoal filter (if installed) Observe the active charcoal filter manufacturer's instructions. Checking the connections on the flue gas side for tightness A B 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. 14

15 Cleaning the condensate drain pipe and siphon and reconnecting to the drain Check that the hoses are routed without kinks and that the condensate can drain freely. Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 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. 15

16 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the diaphragm expansion vessel and system pressure 1. Drain the system until the pressure gauge A indicates "0" or close the cap valve on the diaphragm expansion vessel and reduce the pressure in this vessel. 2. If the pre-charge pressure of the diaphragm 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. Note Observe the diaphragm expansion vessel manufacturer's instructions. Carry out this test on a cold system. 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 leaking. 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 16

17 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 service 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.) 17

18 Parts lists Parts lists 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. 18

19 Parts lists Overview of the assemblies B C A D A Type plate B Boiler body assembly C Heat exchanger assembly D Thermal insulation assembly 19

20 Parts lists Boiler body assembly 0001 Brush handle 0002 Hinge bracket 0003 Sensor well 0004 Cleaning brush 0005 Water distribution jet 0006 Packing 16 x Ventilation air hose 0008 Hose clip (2 pce) 0009 Ventilation air hose adaptor (connector) 0010 Inlet adaptor 0011 Thermal insulation block 0012 Boiler door

21 Parts lists Heat exchanger assembly (20.2 to 35.4 kw) 0001 Spring hook (3 pce) 0002 Fixing element (2 pce) 0003 Boiler flue connection 0004 Boiler flue connection 0005 Viton gasket 0006 Hose clip (2 pce) 0007 Thermal insulation mat, heat exchanger, back 0008 Thermal insulation mat, flue pipe, heat exchanger 0009 Flue outlet gasket 0010 Inlet adaptor 0011 Siphon, complete 0012 Flue gas gasket 0013 Heat exchanger 0014 Heat exchanger gaskets 0015 Ventilation air hose 0016 Corrugated pipe, back, heat exchanger 0017 Corrugated pipe, front, heat exchanger 0018 Thermal insulation mat, heat exchanger, front 0019 Bypass valve with O-rings 0020 Distributor, heating water flow and return 0021 Thermal insulation, distributor, heating water flow and return 0022 Flue gas connection 0023 Thermal insulation, heat exchanger 0024 Siphon 0025 Corrugated hose 0026 Gasket 0027 Plug M14 with O-ring 0028 Plug M14 with sealing sleeve 0029 Plug (d=12.5) 21

22 Parts lists Heat exchanger assembly (20.2 to 35.4 kw) (cont.)

23 Parts lists Heat exchanger assembly (42.8 and 53.7 kw) 0001 Spring hook (3 pce) 0002 Fixing element (2 pce) 0003 Boiler flue connection 0004 Boiler flue connection 0005 Viton gasket 0006 Hose clip (2 pce) 0007 Thermal insulation mat, heat exchanger, back 0008 Thermal insulation mat, flue pipe, heat exchanger 0009 Flue outlet gasket 0010 Inlet adaptor 0011 Siphon, complete 0012 Flue gas gasket 0013 Heat exchanger 0014 Heat exchanger gaskets 0015 Ventilation air hose 0016 Corrugated pipe, back, heat exchanger 0017 Corrugated pipe, front, heat exchanger 0018 Thermal insulation mat, heat exchanger, front 0019 Bypass valve with O-rings 0020 Distributor, heating water flow and return 0021 Thermal insulation, distributor, heating water flow and return 0022 Flue gas connection 0023 Thermal insulation, heat exchanger 0024 Siphon 0025 Corrugated hose 0026 Gasket 0030 Sealing set, test ports 23

24 Parts lists Heat exchanger assembly (42.8 and 53.7 kw) (cont.)

25 Parts lists Thermal insulation assembly 0001 Service instructions 0002 Installation instructions 0003 Spring hook (3 pce) 0004 Touch-up spray paint, Vitosilver 0005 Touch-up paint stick, Vitosilver 0006 Thermal insulation mat, back 0007 Retaining bracket 0008 Top panel, front 0009 Top panel, back 0010 Side panel, left 0011 Thermal insulation, outer jacket 0012 Side panel, right 0013 Front panel 0014 Vitorondens 200 logo 0015 Coding card 0016 Back panel 0017 Edge protector A Type plate (r.h. or l.h. side) 25

26 Parts lists Thermal insulation assembly (cont.) A A

27 Commissioning/service reports Commissioning/service reports date: by: Commissioning Service Service date: by: Service Service Service date: by: Service Service Service date: by: Service Service Service date: by: Service Service Service 27

28 Specification Specification Rated heating output T V /T R = 50/30 C kw T V /T R = 80/60 C kw CE designation CE-0035 CL 102 Power consumption *2 at 100 % of rated heating W output 30 % of rated heating output W Available draught *3 Pa mbar Flue gas temperature *4 At 30 C return temperature C At 60 C return temperature C *2 Standard parameter (in conjunction with Vitoflame 300 blue flame oil burner). *3 Observe when sizing the chimney. *4 Flue gas temperatures as average gross values to EN 304 (measured with 5 thermocouples) at 20 C combustion air temperature. 28

29 Certificates Declaration of conformity We, Viessmann Werke GmbH&Co KG, D Allendorf, confirm as sole responsible body that the product Vitorondens 200-T complies with the following standards: EN 267 EN 303 EN EN (for balanced flue operation) EN EN EN EN EN EN EN In accordance with the following Directives, this product is designated with _ : 2004/108EC 2006/42/EC 2006/95/EC This product meets the requirements of the Efficiency Directive (92/42/EEC) for low temperature boilers. Allendorf, 01 February 2011 Viessmann Werke GmbH&Co KG pp. Manfred Sommer Manufacturer's certificate according to the 1st BImSchV [Germany] We, Viessmann Werke GmbH&Co KG, D Allendorf, confirm that the following product meets the NO x limits specified by first German Immissions Order para. 7 (2) [Germany]: 29

30 Certificates Manufacturer's certificate according to the 1st (cont.) Oil Unit condensing boiler Vitorondens 200-T Allendorf, 01 February 2011 Viessmann Werke GmbH&Co KG pp. Manfred Sommer 30

31 Keyword index Keyword index B Balanced flue operation...10, 12, 16 Boiler door Fitting...12 Opening...9 C Checking the active charcoal filter...14 Cleaning the heating surfaces...10 Commissioning...7 Connections on the flue gas side...14 D Diaphragm expansion vessel...7, 8, 16 F Filling The system...7 Fill water...7 G Gaskets and packing cords...12 H Heat exchanger...14 Heating system Draining...9 Filling...7, 8 O Operating pressure...16 P Parts list Boiler body...20 Heat exchanger (20.2 to 35.4 kw)..21 Heat exchanger (42.8 and 53.7)...23 Thermal insulation...25 Parts lists...18 S Siphon Cleaning...15 Filling...15 Small softening system...7 System Draining...9 Filling...8 System pressure...8 T Thermal insulation components...12 V Venting the boiler...8 N Neutralising system

32 Printed on environmentally friendly, chlorine-free bleached paper Applicability Serial no. (see boiler type plate): Viessmann Werke GmbH&Co KG D Allendorf Telephone: Fax: Subject to technical modifications.

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