Viessmann VB2 Series User manual

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
2
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
3
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
4
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
5
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
6
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
7
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
8
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
9
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
10
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