Viessmann Vitorond 200 Type VR2 Operating instructions

VITOROND 200
Service instructions
for heating engineers
VitorondĂ200
TypeĂVR2, 40 to 100ĂkW
Oil/gas-fired boilers
5692Ă5 1ĂGBăăă8/200 Please keep safe

2
General information
Safety instructions
Please follow these safety instructions closely to prevent accidents and
material losses.
Work on the equipment
Installation, initial start-up,
inspection, maintenance and repairs
must only be carried out by a
competent person (heating
engineer/installation contractor).
Before working on the equipment/
heating system, isolate the mains
electrical supply (e.g. by removing a
separate mains fuse or by means of
a mains electrical isolator) and
safeguard against unauthorised
reconnection.
When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
Work on gas equipment
This must only be carried out by an
approved contractor.
Please observe all commissioning
work specified for gas installations to
TRGI or TRF and all local regulations.
Please observe all commissioning
work specified for gas systems.
Repair ork
It is not permitted to carry out
repairs on parts that fulfil a safety
function.
Use only original Viessmann spare
parts, or equivalent parts that have
been approved by Viessmann.
Initial start-up
The initial start-up must be carried
out by the system installer or a
designated commissioning engineer.
All actual values should be recorded
in a commissioning/service report.
Instructing the system user
The system installer must hand the
operating instructions to the system
user and instruct him/her in the
operation of the system.
¨ĂSafety instruction
Denotes information which must be
observed to prevent accidents and
material losses.
5692Ă5 1ĂGB

3
Contents
Index
Page
General information
Safety instructionsĂ 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start-up, inspection and maintenance
Initial start-upĂ 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating and service documentsĂ 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and maintenanceĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts listĂ10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
SpecificationĂ 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service reportĂ 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of conformityĂ 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer's certificateĂ 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692Ă5 1ĂGB

4
Initial start-up, inspection and maintenance
Initial start-up
Operating instructions, service instructions ć control unit and burner
1. Check that the boiler room
ventilation aperture is open.
2. Check the inlet pressure of the
diaphragm expansion vessel.
If the inlet pressure of the
diaphragm expansion vessel is
lower than the static system
pressure, top up with enough
nitrogen to raise the inlet pressure
higher than the static system
pressure (0.1 to 0.2Ăbar).
3. Open the check valves.
4. Top up your heating system with
water and vent until the filling
pressure is higher (0.1 to 0.2Ăbar)
than the inlet pressure of the
diaphragm expansion vessel.
Permiss. operating pressureĂ Ă Ăbar
. . .
5. Mark this pressure on pressure
gaugeĂA.
6. Return the check valves to their
operating position.
7. Open the oil or gas shut-off valves.
Operating and service documents
1. Complete and detach the
customer registration card:
HHand the system user this part
for safe-keeping.
HRetain the heating engineer part.
2. File all parts lists, operating and
service instructions in the folder
and hand this over to the system
user.
5692Ă5 1ĂGB
A

5
Initial start-up, inspection and maintenance
Inspection and maintenance
1. System shutdo n
2. Closing Vitoair control disc (if installed)
1. Press rotary selectorĂA on the
Vitoair motor and turn to
positionĂ5.
2. Arrest the control disc with
lockĂB.
3. Opening boiler door, extracting and cleaning turbulators
Please note:
Remove the gas supply pipe on gas burners.
5692Ă5 1ĂGB
A
B
ATurbulators (see pageĂ12)
41
A

6
Initial start-up, inspection and maintenance
Inspection and maintenance (cont.)
4. Cleaning heating surface and flue outlet
5. Checking gaskets/seals and thermal insulation
1. Check the gaskets and the boiler
door packing for damage.
2. Check the thermal insulation of the
combustion chamber and the
boiler door for damage.
3. Replace all faulty parts.
5692Ă5 1ĂGB

7
Initial start-up, inspection and maintenance
Inspection and maintenance (cont.)
6. Inserting turbulators and closing the boiler door
Please note:
Refit the gas supply pipe on gas burners.
¨ĂSafety instruction
Carry out a leak test on all gas supply connections.
7. Checking all primary and secondary connections for leaks
8. Checking the function of all safety valves
5692Ă5 1ĂGB
41
A
ATurbulators (see pageĂ12)

8
Initial start-up, inspection and maintenance
Inspection and maintenance (cont.)
9. Checking diaphragm expansion vessel and system pressure
Observe the diaphragm expansion vessel manufacturer s instructions.
Carry out this test on a cold system.
1. Drain the system or close the cap
valve on the diaphragm expansion
vessel and reduce the pressure
until the pressure gauge
indicatesĂ"0".
2. If the inlet pressure of the
diaphragm expansion vessel is
lower than the static system
pressure, top up with enough
nitrogen to raise the inlet pressure
higher than the static system
pressure (0.1 to 0.2Ăbar).
The static pressure corresponds to
the static height.
3. Top up the heating system with
water, until the filling pressure of a
cool system is higher (0.1 to
0.2Ăbar) than the inlet pressure of
the diaphragm expansion vessel.
Permiss. operating pressure: Ăbar.
10. Checking the tight fit of thermal insulation and cable
grommets
5692Ă5 1ĂGB

9
Initial start-up, inspection and maintenance
Inspection and maintenance (cont.)
11. Checking mixer for easy operation and leaks
1. Remove the motorised lever from
the mixer handle, and check the
mixer for ease of movement.
2. Check the mixer for leaks.
Replace the OĆrings if the mixer
leaks.
3. Snap the motorised lever into
place.
12. Checking the draught stabiliser (if installed)
Release the latch on the control disc.
The control disc must swing freely
during burner operation.
13. Burner settings
Burners up to 63ĂkW Burner service instructions
Burners from 80ĂkW
Adjust the max. burner oil or gas
throughput so that the stated
maximum rated boiler output will
not be exceeded.
Note that, for multi-stage or
modulating burners, the flue gas
system must be suitable for the low
flue gas temperatures which may
arise during partial load operation.
Select the lowest partial load stage,
also taking the respective flue gas
system design into consideration.
Two stage
The following minimum output is
required for the base load stage to
protect the system against dew point
corrosion:
Rated
output
kW
Minimum output to be set
(1stĂburner stage)
or base load
kW
ă80
100
48
60
Modulating
For oil-fired operation, the minimum
boiler water temperature is 60ĂºC and
for gas-fired operation 65ĂºC.
Adjust the return temperature raising
facility to at least 5 ĂºC.
5692Ă5 1ĂGB

10
Parts list
Parts list
When ordering spare parts
Quote the type and serial no. (see
type plate) and the item no. of the
required part (as per parts list).
Obtain common parts from your
local supplier.
Parts
001 Thermal insulation
002 Top plate
00 Side panel
004 Boiler insulating mat
005 Rear panel
006 Rear insulating mat
007 Top front plate
008 Bottom front panel
010 VitorondĂ200 inscription
01 Edge protector
014 Cover
015 Decorative adhesive tape
016 Fastenings
017 Decorative cap
018 Closure
021 Bottom panel
022 Sensor well
02 Boiler door thermal insulation
block
024 Boiler door
025 Hinge bracket
026 Gasket setĂ12Ă×Ă16Ă×Ă1845Ămm
027 Gasket setĂ12Ă×Ă16Ă×Ă 00Ămm
028 Packing cord ∅Ă Ămm
029 Flue outlet
0 0 Inspection aperture locking bolt
0 1 Return injector nozzle
0 2 Turbulator, 2ndĂflue*1
0 5 Gasket setĂ10Ă×Ă10Ă×Ă5 5Ămm
041 Brush handle
042 Cast turbulator, bottom, 2ndĂflue
04 Front section with installation
parts
044 Centre section with installation
parts
045 Rear section with installation
parts
047 Top turbulator, 2ndĂflue*1
048 Top turbulator, 2ndĂflue*2
049 Turbulator, rdĂflue*
Wear parts
0 7 Cleaning brush
Parts not shown
019 Touch-up spray, Vitosilver
020 Touch-up paint stick, Vitosilver
0 8 Installation instructions
0 9 Service instructions
046 Connection cone pack ( Ăpieces)
AType plate, optionally l.h. or r.h.
side
BBoiler control unit, see separate
parts list
*1Only for 40ĂkW.
*2Only for 50ĂkW.
*3Only for 50 and 63ĂkW.
5692Ă5 1ĂGB