Viessmann VITOROND 200 Betriebsanleitung

for use by heating contractor

Please file in Service Binder

Read and save these instructions for future

reference.

IMPORTANT

Product may not be exactly as shown

5354 789 - 01 03/2015

Service Instructions

VITOROND 200

Vitorond 200

VD2A Series

Oil-/Gas-fired boiler

Heating input: 490 to 1096 MBH

144 to 321 kW

Vitorond 200, VD2A Series Service

5354 789 - 01

Safety, Installation and Warranty Requirements

Safety

Please ensure that these instructions are read and understood before commencing installation. Failure to comply with

the instructions 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).

WARNING

Installers must follow local regulations with respect

to installation of carbon monoxide detectors.

Follow the Viessmann maintenance schedule of the

boiler in the “Service Instructions” manual.

Carbon 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 section entitled “Combustion

air supply” and “Venting information”

in this manual.

Fresh 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 subsection entitled

“Mechanical Room” in this manual.

Equipment venting

Never operate boiler without an installed venting

system. An improper venting system can cause

carbon monoxide poisoning.

For information pertaining to

venting and chimney requirements,

please see section entitled “Venting

Information” in this manual. All

products of combustion must be

safely vented to the outdoors.

Product 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 Safety Requirements”.

Licensed 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”.

Contaminated 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 “Mechanical Room”.

in this manual.

Advice 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, shutdown procedure, and

the need for professional service annually before the

heating season begins.

Warranty

Information contained in this and

related product documentation must

be read and followed. Failure to do

so renders the warranty null and void.

5354 789 - 01

Vitorond 200, VD2A Series Service Safety

Safety, Installation and Warranty Requirements (continued)

WARNING

Inhaling of fiberglass wool and/or ceramic fiber

materials is a possible cancer hazard. These materials

can also cause respiratory, skin and eye irritation.

HFiberglass wool and ceramic fiber materials

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.

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 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, tear-out 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

Suppliers of ceramic fiber products recommend the

following first aid measures:

- Respiratory tract (nose and throat) irritation:

If respiratory tract irritation develops, move the

person to a dust free 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.

Page

Table of Contents

5354 789 - 01

Vitorond 200, VD2A Series Service

Safety

General Information

Safety, Installation and Warranty Requirements..............2

Product documentation...........................................2

Licensed professional heating contractor...................2

Contaminated air ...................................................2

Advice to owner ....................................................2

Warranty ..............................................................2

Carbon monoxide...................................................2

Fresh air ...............................................................2

Equipment venting .................................................2

Fiberglass wool and ceramic fiber materials...............3

Suppliers of ceramic fiber products recommend

the following first aid measures: ..............................3

Precautionary measures..........................................3

First aid measures..................................................3

Hazardous materials ...............................................3

Important Regulatory and Safety Requirements ..............6

Instructing the system user .....................................6

Initial start-up........................................................6

Working on the equipment ......................................6

Technical literature ................................................6

About these Installation Instructions .............................7

Necessary Tools.........................................................8

Tools ...................................................................8

Cleaning supplies ...................................................8

Testing/Analysis equipment.....................................8

Technical information .............................................8

Replacement parts .................................................8

Customer Site Information...........................................9

Site......................................................................9

Boiler ...................................................................9

Burner ..................................................................9

Installing Contractor...............................................9

Table of Contents

Page

5354 789 - 01

Vitorond 200, VD2A Series Service

Inspection and Maintenance

Additional Information

Shut Down Heating System.......................................10

Open Combustion Chamber Door and Remove

Clean-out Opening Covers .........................................10

Remove and Clean Turbulators...................................10

Clean Heat Exchanger, Flue Gas Collar and Chimney........11

Check all Gaskets and Sealant Ropes..........................11

Check Insulation of Combustion Chamber Door ............11

Reinstall Turbulators, Clean-out Covers and Close

Combustion Chamber Door........................................11

Check Proper Operation of Safety Header....................12

Check Proper Operation of Expansion Tank, Low Water

Cut-offs and Pumps..................................................12

Check Proper Expansion Tank and System Pressures ....13

Clean Sight Glass of Combustion Chamber Door ..........13

Check Water Hardness..............................................13

Ensure Proper Fit of Insulation Blanket ........................13

Ensure Proper Operation of Heating System Control ..........13

Ensure Proper Operation of Low Temperature Protection

Package ..................................................................13

Check Combustion Air Supply....................................14

Check Vent System..................................................14

Calibrate Burner .......................................................14

Two-stage burner ................................................14

Model.................................................................14

Flue gas resistance ..............................................14

Weishaupt / Riello burners.....................................15

Gas-fired ............................................................15

Oil-fired ..............................................................15

Vitorond 200 with Viessmann boiler controls ..........15

Model.................................................................15

Input ..................................................................15

Check Proper Operation of Door Safety Switch

(Oil Burners Only) .....................................................15

Maintenance Schedule ..............................................16

Maintenance .......................................................16

Frequency...........................................................16

Performed by ......................................................16

Service...............................................................16

Parts List.................................................................17

Maintenance Record .................................................20

Vitorond 200, VD2A Series Service

5354 789 - 01

Safety

Important Regulatory and Safety Requirements

Working on the equipment

The installation, adjustment, service, and maintenance

of this boiler must be performed 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, burners,

or control.

Note: Please carefully read this manual prior to attempting

installation. 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.

Viessmann offers frequent installation and service

seminars to familiarize our partners with our

products. Please inquire.

Ensure main power supply to equipment, the heating

system, and all external controls has been deactivated.

Close main gas supply valve. Take precautions in all

instances to avoid accidental activation of power during

service work.

Note: The completeness and functionality of field supplied

electrical controls and components must be verified

by the heating contractor. This includes low water

cut-offs, flow switches (if used), staging controls,

pumps, motorized valves, air vents, thermostats, etc.

Instructing the system user

The installer of the system is responsible to ensure the

system operator/ultimate owner is made familiar with the

functioning of the system, its activation, and its shut-down.

Note: 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.

Initial start-up

Initial start-up must be performed by a qualified heating

contractor. Completion of the Maintenance Record by the

heating contractor is also required.

Note: The Maintenance Record is located on page 20

of this manual.

Technical literature

Literature for the Vitorond 200 VD2A* boiler:

- Technical Data Manual

- Installation Instructions

- Service Instructions

- Operating Instructions and User’s Information Manual

- Instructions of other Viessmann products utilized with

this installation

- Installation codes mentioned in this manual

Additional applicable literature:

- Viessmann boiler controls manuals

Note: 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.

5354 789 - 01

Vitorond 200, VD2A Series Service General Information

About these Installation 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.



IMPORTANT

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.

This symbol indicates that other instructions must

be referenced.

WARNING

Indicates an imminently hazardous situation which,

if not avoided, could result in loss of life, serious

injury or substantial product/property damage.

CAUTION

Indicates an imminently hazardous situation which,

if not avoided, may result in minor injury or product/

property damage.

Vitorond 200, VD2A Series Service

5354 789 - 01

Necessary Tools

General Information

Tools

HAssortment of flathead and Phillips screwdrivers

HPipe wrenches

HOpen-ended wrenches

HPipe sealant

HAssortment of Allen keys

HFlashlight

HApproved leak detection fluid for natural gas and

propane gas

Cleaning supplies

HHand brush

HCleaning/service brush (supplied)

HVacuum cleaner

HRags

Testing/Analysis equipment

(use only calibrated equipment)

HFlue gas analyzer to measure % CO2or O2

(i.e. Bacharach fluid samplers or a suitable electronic

analyzer)

HMultimeter to measure 0 - 120 VAC, 0 - 12 AAC, and

0 - 20 microamps DC

HSmoke test gun (Bacharach)

HOil pump pressure gage

HOil pump vacuum gage

HPressure gage to measure gas pressure 0 - 28 ”w.c.

(a non-electric Magnehelicrpressure gage may also be

used)

HCarbon monoxide measuring equipment (0 - 400 ppm)

HBacharach calculator or suitable tables to calculate

efficiency

HStack thermometer 0 to 500° F (0 to 260° C)

Hdin. NPT male to ¼ in. barb adaptor fitting, as well as

tubing for pressure measurement

CAUTION

Use only original Viessmann components when replacing

defective parts. Installation of incorrect replacement

parts can cause hazardous operation and will void

warranty.

Technical information

The following is a list of literature applicable to the

Vitorond 200, VD2A boiler:

HInstallation Instructions

HService Instructions

HOperating Instructions and User’s Information Manual

For installation of the heating system, please refer also

to the technical literature of other System Technology

devices:

HInstallation Instructions for Viessmann boiler control

HInstallation Instructions for Viessmann indirect-fired hot

water storage tank(s)

HInstallation Instructions for burner and accessories

Replacement parts

For a complete listing of replacement components, please

see Parts List starting on page 17 of these instructions.

Order replacement components from your Viessmann

distributor.

5354 789 - 01

Vitorond 200, VD2A Series Service

Customer Site Information

General Information

Site

Name:

Street:

City:

Tel.:

Boiler

Mfr.: Viessmann

Series:

Heating Input: MBH

Serial No.:

Burner

Mfr.:

Series:

Heating Input: MBH

Serial No.:

Installing Contractor

Firm:

Technician:

Address:

Tel.:

Installed on:

Please complete the information below.

Vitorond 200, VD2A Series Service

5354 789 - 01

Shut Down Heating System

Inspection and Maintenance

1. Deactivate main power supply to heating system and

secure against accidental reactivation.

2. Disconnect plug fA and lÖ from burner.

3. Close main oil or gas supply valve.

1. When using a gas power burner: Disconnect gas train.

2. Loosen four M12 bolts on combustion chamber door

Aand open.

3. Remove clean-out opening covers B.

1. On models VD2A-125 to VD2A-195 only:

Remove turbulators Aand clean.

Open Combustion Chamber Door and Remove Clean-out Opening Covers

Remove and Clean Turbulators

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