Viessmann VB2 Series Bedienungsanleitung

VITOLA 200

Start-up/Service Instructions

for use by heating contractor

Vitola 200

VB2 Series

Oil-/Gas-Fired Boiler

Heating input 83 to 300 MBH

24 to 88 kW

Read and save these instructions

for future reference.

IMPORTANT

5167 405 v2.2 04/2008

Safety, Installation and Warranty Requirements

Please ensure that this manual is read and understood before commencing installation. Failure to comply with the issues listed below

and details printed in this manual can cause product/property damage,severe personal injury, and/or loss of life. Ensure all

requirements below are understood and fulfilled (including detailed information found in manual subsections).

HLicensed professional heating

contractor

The installation, adjustment, service,

and maintenance of this equipment

must be performed by a licensed

professional heating contractor.

"Please see section

entitled “Important

Regulatory and

Installation

Requirements.”

HProduct documentation

Read all applicable documentation

before commencing installation. Store

documentation near boiler in a readily

accessible location for reference in

the future by service personnel.

"For a listing of

applicable literature,

please see section

entitled “Important

Regulatory and

Installation Requirements.”

HAdvice to owner

Once the installation work is

complete, the heating contractor must

familiarize the system

operator/ultimate owner with all

equipment, as well as safety

precautions/

requirements, shut-down procedure,

and the need for professional service

annually before the heating season

begins.

HContaminated air

Air contaminated by chemicals can

cause by-products in the combustion

process which are poisonous to

inhabitants and destructive to

Viessmann equipment.

"For a listing of

chemicals which cannot

be stored in or near the

boiler room, please see

section entitled

“Combustion Air Supply”

in Installation Instructions.

HCarbon monoxide

Improper installation, adjustment,

service and/or maintenance can cause

flue products to flow into living space.

Flue products contain poisonous

carbon monoxide gas.

"For information

pertaining to the proper

installation, adjustment,

service and maintenance

of this equipment to

avoid formation of carbon monoxide,

please see sections entitled

“Combustion Air Supply” and “Venting

Connection” in Installation Instructions.

HFresh air

This equipment requires fresh air for

safe operation and must be installed

ensuring provisions for adequate

combustion and ventilation air exist.

"For information

pertaining to the fresh

air requirements of this

product, please see

section entitled

“Combustion Air Supply.”

in Installation Instructions.

HEquipment venting

Never operate boiler without an

installed venting system.Animproper

venting system can cause carbon

monoxide poisoning.

"For information

pertaining to venting

and chimney

requirements, please

see section entitled “Venting

Connection” in Installation Instructions.

All products of combustion must be

safely vented to the outdoors.

HWarranty

Information contained in

this and related product

documentation must be

read and followed. Failure

to do so renders warranty

null and void.

5167 405 v2.2

Installers must follow local

regulations with respect to

installation of carbon monoxide

detectors. Follow manufacturer’s

maintenance schedule of boiler.

WARNING

Safety, Installation and Warranty Requirements

Safety, Installation and Warranty Requirements (continued)

Please ensure that this manual is read and understood before commencing installation. Failure to comply with the issues

listed below and details printed in this manual can cause product/property damage,severe personal injury,and/orloss of life.

Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).

HFiberglass wool and ceramic fiber

materials

The state of California has listed the

airborne fibers of these materials as a

possible cancer hazard through

inhalation. When handling these

materials, special care must be applied.

Suppliers of ceramic fiber products

recommend the following first aid

measures:

-Respiratory tract (nose and throat)

irritation

If respiratory tract irritation develops,

movethepersontoadustfree

location.

-Eye irritation

If eyes become irritated, flush

immediately with large amounts of

lukewarm water for at least 15

minutes. Eyelids should be held away

from the eyeball to ensure thorough

rinsing. Do not rub eyes.

-Skin irritation

If skin becomes irritated, remove

soiled clothing. Do not rub or scratch

exposed skin. Wash area of contact

thoroughly with soap and water.

Using a skin cream or lotion after

washing may be helpful.

-Gastrointestinal irritation

If gastrointestinal tract irritation

develops, move the person to a dust

free environment.

Suppliers of fiberglass wool products

recommend the following precautions

be taken when handling these materials:

Precautionary measures

-Avoid breathing fiberglass dust and

contact with skin and eyes.

- Use NIOSH approved dust/mist

respirator.

- Wear long-sleeved, loose fitting

clothing, gloves and eye protection.

- Wash work clothes separately from

other clothing. Rinse washer

thoroughly.

- Operations such as sawing, blowing,

tearout and spraying may generate

airborne fiber concentration requiring

additional protection.

First aid measures

-If eye contact occurs, flush eyes with

water to remove dust. If symptoms

persist, seek medical attention.

- If skin contact occurs, wash affected

areas gently with soap and warm

water after handling.

HHazardous materials

5167 405 v2.2

Inhalation of fiberglass wool and/or

ceramic fiber materials is a possible

cancer hazard. These materials can

also cause respiratory, skin and eye

irritation.

WARNING Appliance materials of construction,

products of combustion and the fuel

contain alumina, silica, heavy metals,

carbon monoxide, nitrogen oxides,

aldehydes and/or other toxic or

harmful substances which can cause

serious injury or loss of life and which

are known to the State of California

to cause cancer, birth defects and

other reproductive harm. Always use

proper safety clothing, respirators and

equipment when servicing or working

nearby the appliance.

WARNING

Contents

Page

Safety Important Regulatory and Installation Requirements 5....

General Information About these Service Instructions 6........................................

Necessary Tools 6.......................................................................

Start-up

and Service

Initial Start-up 7...........................................................................

Service 8........................................................................................

Additional Information Parts List 13....................................................................................

Maintenance Record 16...............................................................

5167 405 v2.2

Safety

Important Regulatory and Installation Requirements

Instructing the system user

The installer of the system is

responsible to ensure the system

operator/ultimate owner is made

familiar with the system functioning, its

activation, its shut-down, and the need

for periodic service.

Initial start-up

Initial start-up must be performed by a

qualified heating contractor; values and

calibrations specified in the burner test

sheet are to be verified at this time.

Completion of the Maintenance Record

by the heating contractor is also

required.

The following topics must be covered:

Proper system operation sequence.

Explain the equipment as well as the

need for combustion air.

Demonstrate an emergency

shut-down, what to do and what not.

Explain that there is no substitute for

proper maintenance to help ensure

safe operation.

Workingontheequipment

The installation, adjustment, service,

and maintenance of this boiler must be

done by a licensed professional heating

contractor who is qualified and

experienced in the installation, service,

and maintenance of hot water boilers.

There are no user serviceable parts on

the boiler, burner, or control.

Ensure main power supply to

equipment, the heating system, and all

external controls has been deactivated.

Close main oil or gas supply valve. Take

precautions in both instances to avoid

accidental activation of power during

service work.

Please carefully read this manual prior

to attempting start-up, maintenance

or service. Any warranty is null and

void if these instructions are not

followed.

For information regarding other

Viessmann System Technology

componentry, please reference

documentation of the respective

product.

We offer frequent installation and

service seminars to familiarize our

partners with our products. Please

inquire.

Technical literature

Literature applicable to all aspects of

the Vitola:

- Technical Data Manual

- Installation Instructions

- Start-up/Service Instructions

- Installation codes mentioned

in this manual

Leave all literature at the installation

site and advise the system

operator/ultimate owner where the

literature can be found. Contact

Viessmann for additional copies.

5167 405 v2.2

General Information

About these Service Instructions

Take note of all symbols and notations intended to draw attention to potential hazards or important product information.

These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below.

Warnings draw your attention to the

presence of potential hazards or

important product information.

Cautions draw your attention to the

presence of potential hazards or

important product information.

Helpful hints for installation, operation

or maintenance which pertain to the

product.

This symbol indicates that additional,

pertinent information is to be found in

column three.

This symbol indicates that other

instructions must be referenced.

Necessary Tools

Special Items

Approved leak detection fluid

Testing/analysis equipment

Flue gas analyzer

Cleaning supplies

Hand brush

Rags

Vacuum cleaner

Cleaning brush (Standard equipment)

Parts

Rope sealant for combustion chamber

door

Refractory for combustion chamber

door

Burner refractory for combustion

chamber

Technical information

Operating Instructions of boiler and all

accessories

Parts List of each accessory

Use only calibrated equipment.

5167 405 v2.2

Indicates an imminently hazardous

situation which, if not avoided, could

result in death, serious injury or

substantial product/property damage.

WARNING

Indicates an imminently hazardous

situation which, if not avoided, may

result in minor injury or

product/property damage.

CAUTION

IMPORTANT

5167 405 v2.2

Start-up and Service

See Operating Instructions, Service Instructions of

Power Burner and Boiler Control

1. Ensure combustion and ventilation air

openings of boiler room are open and

that chimney and all flue pipes are

connected, sealed and unobstructed

inside. Verify that all requirements in

the Combustion Air Supply section of

the boiler Installation Instructions are

met.

2. Ensure proper operation of expansion

tank (see Maintenance/Service

manual).

3. Ensure that system piping is flushed

out to remove debris and/or sludge.

Failure to do so could cause

settlement in the boiler causing

overheating and damage not covered

by warranty.

4. Fill heating system with water and

bleed out air completely. Ensure

complete system is properly vented

of air.

Max. system operating press.

<30 psig

....................................................

Pressure relief discharge press.

30 psig

........................................................

5. Perform a pressure test of the boiler

and the water piping. Pressure test

must not exceed 1½ times the

maximum system operating pressure

(45 psig ) of the boiler. Pressure

relief valve must be removed during

pressure test. Any leaks must be

corrected.

6. Ensure fuel proper/adequate fuel

supply exists; open oil or gas shut-off

valve.

7. Verify completeness of all discussion

points on the following pages in the

section entitled Service before

starting up system.

If the nitrogen pressure of the

precharged expansion tank is less

than the static pressure of the

system, inflate membrane pressure to

slightly exceed pressure of system.

The static pressure required at the

tank is based upon the static height

of the system.

Water treatment should be considered

in areas where it is known that boiler

feed water contains a high mineral

content and hardness.

In areas where freezing might occur,

an antifreeze may be added to the

system water to protect the system.

Please adhere to the specifications

given by the antifreeze manufacturer.

Do not use automotive silicate-based

antifreeze.

Please observe that an

antifreeze/water mixture may require

a backflow preventer within the

automatic water feed and influence

components such as diaphragm

expansion tanks, radiation, etc. A

40% antifreeze content will provide

freeze-up protection to -10°F / -23°C.

Do not use antifreeze other than

specifically made for hot water

heating systems. System also may

contain components which might be

negatively affected by antifreeze.

Check total system frequently when

filled with antifreeze.

Initial Start-up

5167 405 v2.2

DO NOT USE GASOLINE

CRANKCASE DRAININGS OR ANY

OIL CONTAINING GASOLINE.

WARNING

Keep boiler clear and free from

combustible materials, gasoline, and

other flammable vapors and liquids.

Do not obstruct the flow of

combustion and ventilation air.

WARNING

Start-up and Service

1. Shut down heating system

1. Ensure main power supply to

equipment, the heating system, and

all external controls has been

deactivated. Take precautions in both

instances to avoid accidental

activation.

2. Close main gas or oil supply valve

near burner (and near oil tank if

applicable).

2. Open combustion chamber door

Illustration shows Viessmann Chassis

Burner installed on Vitola 200 boiler.

1. Disconnect and remove burner hood

(Viessmann Chassis burner only).

2. Disconnect plug-in connector

from burner.

Disconnect gas supply piping if a gas

burner is installed.

Remove oil lines if an oil burner is

installed.

3. Remove four bolts of combustion

chamber door andopen(hingepin

must remain inserted).

Service

5167 405 v2.2

Always keep the manual fuel supply

valve shut off if the burner is shut

downforanextendedperiodoftime.

WARNING

IMPORTANT

Never burn garbage or paper in the

unit, and never leave combustible

material around it.

WARNING

Start-up and Service

3. Clean chimney, flue pipe and heat exchanger

1. Check flue pipe condition, chimney

connection, and chimney itself, both

inside and outside, for rust,

deterioration, blockage, or leakage.

Repair or replace as necessary.

2. Ensure combustion and ventilation air

openings of boiler room are open and

unobstructed.

3. Remove combustion chamber insert

and clean.

4. Clean heat exchanger surfaces with

the cleaning brush and using a

vacuum cleaner.

4. Check all gaskets and insulation

1. Check all gaskets and the sealant

rope of the combustion chamber door

for wear or damage.

2. Check the combustion chamber door

refractory and burner refractory for

wear or damage.

3. Replace worn or damaged parts.

Service (continued)

5167 405 v2.2

Start-up and Service

5. Close combustion chamber door

1. Push in combustion chamber insert

as far as it will go. Handle

must be at bottom.

The combustion chamber insert has a

lip at the back. Push combustion

chamber insert into combustion

chamber so that lip slides into matching

notch at the back of the combustion

chamber. Failure to do so will damage

door refractory when door is closed.

2. Close combustion chamber door

and tighten four bolts in a cross-wise

fashion.

3. Reconnect burner fuel line(s).

4. Mount burner hood (if applicable).

6. Check heating system and domestic hot water connections

Ensure all connections are pressure

tight.

7. Ensure proper operation of all safety devices

Ensure proper operation of low water

cut-off(s), pressure relief valve, and

pump(s).

Flush float type low water cut-offs (if

used).

If oil-lubricated pumps are used, ensure

proper lubrication.

If motorized zone valves are used,

check and service as necessary.

Refer to manufacturer’s instructions for

each of the components listed above.

Follow local regulations with respect to

backflow preventers.

Service (continued)

5167 405 v2.2

IMPORTANT

Reconnect oil burner and follow

instructions found in burner

installation/start-up manual.

WARNING

For gas burner, perform necessary

leak detection tests.

WARNING

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