Viessmann Vitorond 200 Series Operating instructions

Service instructions
for contractors
VIESMANN
Vitorond 200
Type VD2, 320 to 1080 kW
Oil/gas boiler
VITOROND 200
5692517 GB 9/2018 Please keep safe.

2
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 quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■Work on electrical equipment may 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 current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW G K directives,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
Safety instructions for working on the system
Working on the system
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■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.
■Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces and fluids can lead to burns or
scalding.
■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.
Safety instructions
Safety instructions
5692517

3
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 for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Do not smoke. Prevent naked flames and
sparks. Never switch lights or electrical appli-
ances on or off.
■Close the gas shut-off valve.
■Open windows and doors.
■Evacuate any people from the danger zone.
■Notify your gas or electricity supply utility from
outside the building.
■Have the power supply to the building shut off
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 installation site.
■Close doors to living spaces to prevent flue
gases from spreading.
What to do if water escapes from the appliance
Danger
If water escapes from the appliance there is a
risk of electrocution.
Switch OFF the heating system at the external
isolator (e.g. fuse box, domestic distribution
board).
Danger
If water escapes from the appliance there is a
risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be harmful to
health.
Never let condensate touch your skin or eyes
and do not swallow it.
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 external causes.
Avoid continuous condensate disposal with a wind pro-
tector.
Ensure an adequate supply of combustion air.
Inform 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-
sealable.
Extractors
Operating appliances that exhaust air to the outside
(extractor hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to a reverse flow of flue
gas.
Danger
The simultaneous operation of the boiler and
appliances that exhausts air to the outside can
result in life threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
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1. Information Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 7
3. Parts lists Ordering parts ........................................................................................ 15
Boiler door ............................................................................................. 16
Boiler sections ....................................................................................... 18
Back of boiler ......................................................................................... 20
Flange elements .................................................................................... 22
Thermal insulation, casing ..................................................................... 24
Thermal insulation, casing ..................................................................... 26
4. Layout of panels and ther-
mal insulation
................................................................................................................ 28
5. Water quality Water quality requirements .................................................................... 32
■Prevention of damage due to scaling ................................................. 32
■Prevention of damage due to corrosion on the water side ................. 33
6. Commissioning/service
reports
Fill and top-up water table ..................................................................... 34
Maintenance/service .............................................................................. 34
7. Specification ................................................................................................................ 36
8. Final decommissioning Final decommissioning and disposal ..................................................... 38
9. Certificates EU Declaration of Conformity ................................................................ 39
Manufacturer's certificate according to the 1st BImSchV ...................... 39
10. Keyword index ................................................................................................................ 40
Index
Index
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Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions as well as the details in the datasheet.
It is only designed for the heating up of heating water.
Commercial or industrial usage for a purpose other
than the heating up of heating water shall be deemed
inappropriate.
Intended use presupposes that a fixed installation in
conjunction with permissible components designed for
this purpose has been carried out.
Every other use will be deemed to be inappropriate.
Any resulting losses are excluded from the manufac-
turer's liability.
Any usage beyond this must be approved by the man-
ufacturer for the individual case.
Intended use also includes the adherence to mainte-
nance and inspection intervals.
Information
Symbols
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Information

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Vitorond 200, type VD2
■Fuels: Fuel oil and natural gas
■Permissible operating pressure 6 bar (0.6 MPa)
■Rated heating output 320 to 1080 kW
Information
Product information
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Information

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Commissioning steps
Inspection steps
Maintenance steps Page
• • 1. Commissioning the system............................................................................................... 8
•2. Shutting down the system
•3. Opening the boiler door and cleaning cover................................................................... 8
•4. Withdrawing and cleaning the turbulators...................................................................... 9
•5. Cleaning the heating surface, flue outlet and flue.......................................................... 10
• • 6. Checking all gaskets and packing cords on the flue gas side
•7. Checking the thermal insulation components on the boiler door................................. 10
•8. Inserting the turbulators, fitting the boiler door and cleaning cover............................ 10
• • 9. Checking all connections on the heating water side and the sensor well for leaks
• • 10. Checking the function of the safety equipment
••• 11. Checking the pressure switch function........................................................................... 11
••• 12. Checking the temperature controller setting if a building management system is
used (DCC system)............................................................................................................ 12
• • 13. Checking the expansion vessel and system pressure................................................... 12
•14. Checking the firm seating of electrical plug-in connections and cable grommets
•15. Checking the thermal insulation
• • 16. Checking the water quality................................................................................................ 12
• • 17. Cleaning the sight glass in the boiler door...................................................................... 13
•18. Checking the mixer for ease of operation and tightness............................................... 13
•19. Checking the function of the return temperature raising facility (if installed)
• • 20. Checking the installation room ventilation
• • 21. Checking the flue pipe for tightness
•22. Adjusting the burner.......................................................................................................... 13
•23. Instructing the system user.............................................................................................. 14
•24. Operating and service documents................................................................................... 14
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Operating and service instructions for the control
unit and the burner
01. Close the gas shut-off valve and open the boiler
door.
02. Check that the turbulators are fully inserted into
the hot gas flues (see page 10); open the boiler
door for this.
03. Check that the ventilation air aperture in the instal-
lation room is open.
04. Fill the heating system with water and vent the
system.
Permissible operating pressure: 6 bar (0.6 MPa)
!Please note
Scaling may result if the system is not oper-
ated with fully softened heating water.
Observe the instructions in chapter "Water
quality requirements".
05. Enter the amount of fill water and water hardness
into the table in the appendix on page 34.
06. Check the system pressure.
07. Check the oil level or the gas supply pressure.
08. Open the flue gas damper (if installed).
09. Check that the cleaning apertures on the flue out-
let are closed.
10. Open the shut-off valves in the oil or gas line.
11. Switch ON the mains isolator, the switch for the
heating circuit pump and the burner ON/OFF
switch in this order (observe the burner manufac-
turer's instructions).
12. The dew point range must be cleared as quickly
as possible. To do so, prevent any heat supply to
the consumers when heating the system from
cold. This also applies when restarting after main-
tenance and cleaning work.
13. Once the flow temperature has been reached,
successively switch on the heat consumers.
Switch the burner over to automatic mode.
14. Check all gaskets and plugs, and retighten if nec-
essary.
15. Check the boiler door and cleaning cover after
approx. 50 hours run and retighten all screws.
Danger
There is a risk of injury when working on pres-
surised components.
Only open the connections on the heating water
side after the boiler has been depressurised.
!Please note
Negative pressure in the boiler can cause mate-
rial damage.
Only drain the boiler with a suction pump when
the air vent valve is open.
Note
When commissioning the heating system, scaling in
the boiler can be influenced by the way the heating
system is started.
Start the boiler with a low heating output or slow heat-
ing up in stages. This results in scaling over the entire
heating surface, not predominantly on the walls with
the greatest thermal density.
For multi boiler systems, commission all boilers
simultaneously. Where only one boiler in a multi
boiler system is commissioned, the entire scaling (cal-
cium content) would be concentrated on the heating
surface of that one boiler only.
If commissioning with only one boiler cannot be avoi-
ded, the maximum fill and top-up water volume is
determined only on the heating output of the one
boiler.
No further steps are required if the heating system is
filled with fully softened heating water.
Shutting down the system
Opening the boiler door and cleaning cover
Note
On gas burners, disconnect the gas supply pipe.
Commissioning, inspection, maintenance
Commissioning the system
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Fig. 1
Withdrawing and cleaning the turbulators
A
Fig. 2
AOnly up to 860 kW
Commissioning, inspection, maintenance
Opening the boiler door and cleaning cover (cont.)
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C
A B
Fig. 3
1. Clean flues A and combustion chamber B with
the brushes.
Clean the spaces in between and the fins with the
narrow side of the brush.
Remove combustion residues with a vacuum
cleaner.
2. Remove combustion residues from the flue and the
flue outlet through the cleaning apertures in flue
outlet C using a vacuum cleaner.
Checking all gaskets and packing cords on the flue gas side
Checking the thermal insulation components on the boiler door
Danger
When working with high temperature insulation
materials that contain zirconium or aluminium
silicate ceramic fibres, fibre dust may
develop. This fibre dust can be harmful to
health.
Only trained personnel may adjust or replace
the insulation. Wear suitable protective clothing,
especially breathing equipment and safety gog-
gles.
Inserting the turbulators, fitting the boiler door and cleaning cover
Note
On gas burners, mount the gas supply pipe.
Danger
Escaping gas leads to a risk of explosion.
Check all gas connections for tightness.
Commissioning, inspection, maintenance
Cleaning the heating surface, flue outlet and flue
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!
B A
C
Fig. 4
AOnly up to 860 kW:
Insert the appropriate number of turbulators into
each hot gas channel of the third pass (see
page 19). Insert approx. ⅔ of the first turbulator
element, hook in the second and (if necessary)
third element and push them in.
Tighten screws for boiler door B and cleaning cover C evenly and diagonally.
Torque
Boiler door B30 Nm
Cleaning cover C5 Nm
Checking all connections on the heating water side and the sensor well for
leaks
Checking the function of the safety equipment
Checking the pressure switch function
Installation instructions, pressure switch set
Commissioning, inspection, maintenance
Inserting the turbulators, fitting the boiler… (cont.)
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!Please note
Shutting down from full load can result in high
material stress and material damage.
If a system with a higher ranking building man-
agement system takes over the temperature
control of the boiler, adjust the settings at the
temperature controller TR. Set the electronic
temperature controller to at least 10 K below the
mechanical temperature controller.
Checking the expansion vessel and system pressure
Expansion vessel manufacturer's documentation
Note
Carry out this test on a cold system.
1. Drain the system until the pressure gauge indi-
cates "0" or close the cap valve on the expansion
vessel and reduce the pressure in the expansion
vessel.
2. If the pre-charge pressure of the 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 (0.01 to 0.02 MPa) higher.
The static pressure corresponds to the static head.
3. Top up with water until the charge pressure of the
cooled system is 0.1 to 0.2 bar (0.01 to 0.02 MPa)
higher than the pre-charge pressure of the expan-
sion vessel.
Permissible operating pressure: 6 bar (0.6 MPa)
Checking the firm seating of electrical plug-in connections and cable
grommets
Checking the thermal insulation
Checking the water quality
Observe the instructions in chapter "Water quality
requirements".
Enter the amount of top-up water and the total hard-
ness of the feed and boiler water into the table in the
appendix on page 34.
The total hardness of the feed and top-up water must
not exceed the sum of all alkaline earths of
≤ 0.02 mol/m3.
The pH value should be between 8.2 and 9.5.
Commissioning, inspection, maintenance
Checking the temperature controller setting if a building management system
is used (DCC system)
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Fig. 5
Check the gaskets and hose connection for tightness.
Checking the mixer for ease of operation and tightness
1. Remove the motorised lever from the mixer han-
dle.
2. Check the mixer for ease of operation.
3. Check the mixer for leaks. Replace the O-rings if
the mixer is leaking.
4. Snap the motorised lever into place.
Checking the function of the return temperature raising facility (if
installed)
Checking the installation room ventilation
Checking the flue pipe for tightness
Adjusting the burner
Burner service instructions or separate docu-
mentation by the burner manufacturer
Adjust the maximum oil or gas throughput of the
burner to the rated boiler heating output.
To protect the system against dew point corrosion,
burner stage 2 (full heating output) must be set to the
rated boiler heating output. It must remain switched on,
even during the summer months (burner stage 2 on
constant standby).
Operation with burner load ≥ 60 %
The minimum boiler water temperature for oil operation
is 50 °C and for gas operation 60 °C.
Adjust the return temperature raising facility to a mini-
mum of 40 °C (oil operation) or 53 °C (gas operation).
To protect the boiler, the minimum heating output at
the base load stage is set to 60 % of rated heating out-
put.
A minimum flue gas temperature is required for the
base load stage, the value of which is subject to the
chimney design.
Commissioning, inspection, maintenance
Cleaning the sight glass in the boiler door
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Rated heating out-
put
Minimum heating output to
be set (burner stage 1)
kW kW
320 192
380 228
440 264
500 300
560 336
630 378
700 420
780 468
860 516
950 570
1080 648
Operation with burner load < 60 %
The minimum boiler water temperature for oil operation
is 60 °C and for gas operation 65 °C.
Adjust the return temperature raising facility to a mini-
mum temperature of 53 °C.
Set the minimum heating output for the base load
stage according to the actual chimney conditions. The
chimney must be suitable for the resulting low flue gas
temperatures.
Instructing the system user
The installer should instruct the user in the operation of
the system.
Operating and service documents
1. Complete and detach the customer registration
card:
■Hand the system user this part for safekeeping.
■Retain the heating contractor's part.
2. File all parts lists, operating and service instruc-
tions in the folder and hand this over to the system
user.
The installation instructions are no longer required
after the installation and, therefore, do not need to
be retained.
Commissioning, inspection, maintenance
Adjusting the burner (cont.)
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The following details are required when ordering parts:
■Serial no. (see type plate A)
■Position number of the part (from this parts list)
Parts not shown
0167 Set of studs
0300 Thermal insulation accessories
0301 Decorative strip
0302 Touch-up spray paint, Vitosilver, 150 ml can
0303 Touch-up paint stick, Vitosilver
0304 Contact adhesive
0306 Fitting elements RL5
0307 Installation instructions
0308 Service instructions
Parts lists
Ordering parts
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Components

16
024
012
011
009
016017
018
020
021 023 014 015
010
Fig. 6
Parts lists
Boiler door
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Components

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Pos. Part
0009 Boiler door
0010 Thermal insulation mat 35 x 467 x 467
0011 Thermal insulation mat, 3-part
0012 Door insulation
0014 Hose nozzle 1/4"
0015 Hose 800 mm
0016 Sight glass with gaskets
0017 Sight tube/test pipe plug
0018 Burner plate
0020 Seal ring 35 x 45 x 2 mm
0021 Packing cord 7 8 mm
0023 Thermal insulation mat 7 408 mm
0024 Packing cord 12 x 12 mm
Parts lists
Boiler door (cont.)
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Components

18
001 013
004
005
002
008
003
022
006 004 003 002019 007
001
006
022
Fig. 7
Parts lists
Boiler sections
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Components

19
Pos. Part
0001 Hinge pin
0002 Anchor rod 480 mm
0003 Anchor rod 610 mm
0004 Connector
0005 Packing cord 7 12 mm
0006 Adjusting cam
0007 Centre section*1
0008 Front section*1
0013 Packing cord 7 16 x 16 mm
0019 Turbulator
Number per 3rd pass:
320 to 440 kW 3 pce
500 to 560 kW 2 pce
630 to 860 kW 1 pce
0022 Plug R2
*1 When replacing sections, order 1 × pos. 306 per section joint.
Parts lists
Boiler sections (cont.)
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Components

20
043
033
031
044
034
035
310
044
044042 032
027 026
036
Fig. 8
Parts lists
Back of boiler
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Components