Viessmann Vitorond 200 VD2 320 Operating instructions

VITOROND 200
Service instructions
for heating engineers
VitorondĂ200
typeĂVD2, 320 to 1080ĂkW
Oil/Gas fired boilers
5692Ă51 ĂGBăăă2/2003 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 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 for gas installations specified
acc. to TRGI or TRF, or local
regulations.
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
In this instruction manual, this
heading denotes information which
must be observed to prevent
accidents and material losses.
Operating and service documents
1. Complete and detach the customer
registration card:
HGive the system user this part
for safe-keeping.
HRetain the heating engineer
portion.
2. File all parts lists, operating and
service instructions in the folder
and hand this over to the system
user.
5692Ă51 ĂGB

3
Contents
Index
Page
General information
Safety instructionsĂ 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating and service documentsĂ 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start-up, inspection and maintenance
StepsĂ 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further details regarding the individual stepsĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts listĂ14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Water quality requirementsĂ26
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SpecificationĂ 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service reportĂ 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of conformityĂ 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer's certificateĂ 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692Ă51 ĂGB

4
Initial start-up, inspection and maintenance
StepsĂćĂinitial start-up, inspection and maintenance
For further instructions concerning the individual steps, see pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
C M 1. System start-upĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M2. System shutdo n
M3. Opening boiler door and clean-out coverĂ 6. . . . . . . . . . . . . . . . . . . . . . . .
M4. Removing and cleaning turbulatorsĂ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M5. Cleaning heating surface, flue outlet and flue pipeĂ 8. . . .
I M 6. Checking all seals/gaskets and packing cords
on flue gas side
M7. Checking thermal insulation of boiler door
M8. Pushing turbulators into boiler and securing
boiler door and clean-out cover ith scre sĂ 9
. . . . . . . . . . . . . . . .
I M 9. Checking connections and sensor ell for leaks on
primary side
I M 10. Checking function of all safety equipment
I M 11. Checking diaphragm expansion vessel and
system pressureĂ 10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12. Checking tightness of electrical connections
and cable grommetsĂ
M13. Checking thermal insulation
M14. Checking ater qualityĂ 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 15. Cleaning sight glass in boiler doorĂ 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M16. Checking mixer for easy operation and leaksĂ 12. . . . . . . . . . . . . . .
M17. Checking function of return temperature
raising facility (if installed)
I M 18. Checking boiler room ventilation
I M 19. Checking flue pipe for leaks
I M 20. Checking draught stabiliser (if installed)Ă 12. . . . . . . . . . . . . . . . . . . . . . . . .
M21. Burner adjustmentĂ 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692Ă51 ĂGB

5
Initial start-up, inspection and maintenance
Further details regarding the individual steps
System start-up
Operating instructions, service instructions ć control unit and burner
1. Check that the turbulators are fully
pushed into the hot gas flues
(against their end stop) (open the
boiler door).
2. Check that the ventilation aperture
of the boiler room is open.
3. Fill the heating system with water
and ventilate the system.
Max. operating pressureĂ Ă6Ăbar
. . . . . . . .
Please note:
Enter the filling volume and the
calcium hydrogen carbonate
concentration on pageĂ ; see also
"Standard values for water
quality" on pageĂ26.
4. Check the system pressure.
5. Check the fuel oil level or the gas
supply pressure.
6. Open the flue gas damper (if
installed).
7. Check that the cleaning apertures
on the flue outlet are closed.
8. Open the shut-off valves in the oil
or gas supply pipe.
ă9. Switch ON the mains isolator, the
switch for the heating circuit
pump and the burner ON/OFF
switch in the order listed here
(observe the burner manufacturer's
instructions).
10. When heating the system from
cold (also after maintenance and
cleaning work) prevent the heat
transfer to heat consumers, in
order to quickly clear the dew
point range.
11. After the flow temperature has
been reached, sequentially switch
on the heat consumers and
change the burner to automatic
mode.
12. Check all gaskets/seals and plugs
for leaks and re-tighten, if
necessary.
13. Check the boiler door and
clean-out cover after approx.
50Ăhours' operation and re-tighten
all screws.
5692Ă51 ĂGB

6
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
¨ĂSafety instruction
Only open the heating water connections after the boiler has been
depressurised.
Drain the boiler with a vacuum pump only when the air-vent valve has been
cracked open.
Opening boiler door and clean-out cover
Please note:
Remove the gas supply pipe on gas burners.
5692Ă51 ĂGB

7
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Removing and cleaning turbulators
Aonly for 320 to 860ĂkW
5692Ă51 ĂGB
A

8
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Cleaning heating surface, flue outlet and flue pipe
1. Clean fluesĂA and combustion
chamberĂB with brushes.
Clean the spaces in between and
the fins with the narrow side of
the smallest brush.
Remove combustion residues with
a vacuum cleaner.
2. Remove combustion residues
from the flue pipe and the flue
outlet through the cleaning
apertures in flue outletĂC using a
vacuum cleaner.
5692Ă51 ĂGB
A B C

9
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Pushing turbulators into boiler and securing boiler door and
clean-out cover ith scre s
Please note:
Refit the gas supply pipe on gas burners.
¨ĂSafety instruction
Carry out a leak test on all gas supply connections.
AOnly for 320 to 860ĂkW:
Insert the respective number of turbulators into each hot gas channel of
the third flue (see page 15); in doing so, push the first turbulator element
approx. h into the hot gas channel, hook in the second and third element
and push in.
BTighten the screws on the boiler door evenly and diagonally.
5692Ă51 ĂGB
B A

10
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
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 with water, until the filling
pressure of a cool system is
higher than the inlet pressure of
the diaphragm expansion vessel
(0.1 to 0.2Ăbar).
Max. operating pressureĂ Ă6Ăbar
. . . . . . . .
5692Ă51 ĂGB

11
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking ater quality
For requirements see pageĂ26.
Enter the quantity of top-up water and the respective calcium hydrogen
carbonate concentration [Ca(HCO3)2] into the table.
Fill
water
Top-up
water
Meter
reading
Total
water
Concentration
[Ca(HCO3)2]
Water treatment Date
water
m3
water
m3
rea
di
ng
m3
water
volume
m3
[C
a
(HCO
3
)
2
]
mol/m3
Medium Metering
volume
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
Max. fill volume:Ă Ăm3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692Ă51 ĂGB

12
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Cleaning sight glass in boiler door
Check gaskets and hose connection
for leaks.
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.
Checking draught stabiliser (if installed)
Release the latch on the regulating
disc.
The regulating disc must swing
freely during burner operation.
5692Ă51 ĂGB

13
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Burner adjustment
Burner service instructions or separate documentation from the
burner manufacturer
Adjust the highest oil or gas
throughput of the burner to the rated
boiler output.
To protect the system against dew
point corrosion, the 2ndĂburner stage
(full capacity) must be set to the rated
boiler output and must not be
switched OFF during the summer
months (2ndĂburner stage on
constant standby).
Operation ith burner loadĂyĂ60Ă%
For oil fired operation, the minimum
boiler water temperature is 50ĂºC and
for gas fired operation 60ĂºC.
Adjust the return temperature raising
facility at least to 40ĂºC (oil fired
operation) or to 53ĂºC (gas fired
operation).
To protect the boiler, the minimum
output in the base load stage is set to
60Ă% of rated output.
Rated
output
kW
Minimum output
(to be set)
(1stĂburner stage)
kW
ă320
ă380
ă440
ă500
ă560
ă630
ă 00
ă 80
ă860
ă950
1080
192
228
264
300
336
3 8
420
468
516
5 0
648
A minimum flue gas temperature is
required for the base load stage,
whose value is subject to the
chimney design.
Operation ith burner loadĂ<Ă60Ă%
For oil fired operation, the minimum
boiler water temperature is 60ĂºC and
for gas fired operation 65ĂºC.
Adjust the return temperature raising
facility at least to 53ĂºC.
Set the minimum heating output for
the base load stage according to the
chimney conditions. Note that the
chimney must be suitable for the low
flue gas temperatures which may
arise.Ă
5692Ă51 ĂGB

14
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 (from this
parts list).
Obtain common parts from your
local supplier.
Parts
001 Hinge pin
002 Anchor rod (610Ămm long)
003 Anchor rod (480Ămm long)
004 Nipple
005 Packing cord ∅Ă12Ămm
006 Adjusting cams
00 Centre section*1
008 Front section*1
009 Boiler door
010 Insulating mat 46 Ă×Ă46 Ămm
011 Insulating mat, three part
868Ă×Ă968Ămm
012 Insulating block
013 Packing 16Ă×Ă16Ămm
014 Hose coupling nippleĂ¼"
015 Hose
016 Sight glass incl. gasket
01 Sight and test pipe cover
018 Burner plate
019 Turbulator*2
020 Seal washer 35Ă×Ă45Ă×Ă2
021 Packing cord ∅ 8Ămm
022 PlugĂ2"
023 Insulating mat ∅ 408Ămm
024 Packing cord ∅Ă10Ămm
Parts not shown
300 Insulation pack
301 Decorative adhesive tape
302 Touch-up spray, Vitosilver
303 Touch-up paint stick, Vitosilver
304 Adhesive (incl. itemsĂ005)
306 Installation parts (for itemsĂ00 ,
008 and 025)
30 Installation instructions
308 Service instructions
* Order Ă×ĂitemĂ306 each for every
section joint.
*2Number of turbulators for every third
flue
ćĂfor 320 toĂ440ĂkW: 3Ăpieces
ćĂfor 500 toĂ560ĂkW: 2Ăpieces
ćĂfor 630 toĂ860ĂkW: Ăpiece
5692Ă51 ĂGB

Parts list
Parts list (cont.)
15/16
5692Ă51 ĂGB
020
021 023 014 015
010 022
006 004 003 002
003
01 016
009
011
012
024
001 013
004
005
002
019*2 00 *1
008*1
018

Parts list
Parts list (cont.)
17/18
5692Ă51 ĂGB
033
034*2
03
028
043
044
310
02 042 032 026044
031
045
044
045
040*
039*6
038*5
041*8
025*1
035*3
036*4

19
Parts list
Parts list (cont.)
Parts
025 Rear section*1
026 Combustion chamber back wall
02 Clean-out cover
028 Sensor well
031 Flue outlet
032 blanking plate
033 Handle
034 Extension (length ăĂ355Ămm)*2
035 Extension (length 1Ă000Ămm)*3
036 Extension (length 1Ă100Ămm)*4
03 Flange element
038 Triple intermediate element*5
039 Quadruple intermediate
element*6
040 Double end element*
041 Quadruple end element*8
042 Packing cord ∅Ă8Ămm
043 Packing cord ∅Ă8Ămm
044 Fixing bracket
045 Gasket DNĂ100
Wear parts
310 Cleaning brush
* Order Ă×ĂitemĂ306 each for every section
joint.
*2 Only for 380 to 630, 950 and Ă080ĂkW.
*3 Only for 380, 500, 560, 700, 780, 950 and
Ă080ĂkW.
*4 Only for 320, 440, 630, 780, 860 and
Ă080ĂkW.
*5 Only for 380, 500, 630, 700, 780, 950 and
Ă080ĂkW.
*6 Only for 440, 560, 630, 780, 860 and
Ă080ĂkW.
*7 Only for 380, 440 and 630ĂkW.
*8 Only for 320, 500, 560, 700, 780, 860,
950 and Ă080ĂkW.
5692Ă51 ĂGB

20
Parts list
Parts list (cont.)
Parts
200 Front panel
201 Bracket
202 Cover strip
203 L.h. rail (incl. with itemĂ224)
204 R.h. rail (incl. with itemĂ224)
205 Rear mounting bracket
206 R.h. rear panel (incl. with itemĂ226)
20 L.h. rear panel (incl. with itemĂ226)
208 Front top panel
210 Rear top panel
211 Connecting panel
212 Spacer
213 Side panel 502Ămm
214 Side panel 628Ămm
216 Tie-bar
21 Front insulating casing
219 Rear insulating casing
(width 466Ămm)
222 Rear insulating mat
223 Bottom insulating mat
224 Double strain relief
225 Vitorond logo
226 Edge protector
AType plate, optionally l.h. or r.h.
side
BBoiler control unit, see separate
parts list
CPanel and insulating mat
arrangement (320ĂkW)
DBurner cable, see separate parts
list for boiler control unit
5692Ă51 ĂGB

Parts list
Parts list (cont.)
21/22
5692Ă51 ĂGB
204
200
208
C320 kW
B
202
225
224 214
212 211
213
A
20
226
223
21
219
212211214203 213 210 205216 222 201
226
206
D
D
205
201
224

Parts list
Parts list (cont.)
23/24
5692Ă51 ĂGB
214
208210
208210
220
221
21
21
215 214 C440 kW
219
218
213 219 213 C500 kW
218
221215 213 C630 kW
21
220
220214 214 C00 kW
208210
21
221
220215 214 C80 kW
208210
21
221
221215 214 C860 kW
C380 kW
208210
22
221
221215 215 C950 kW
208210
221 218
214 219 213 C1080 kW
210
215 220
219
218
220
219214 213
208210
C560 kW
208210
208210
208210
209
209
209
209
209
209
209
209