Viessmann VITOROND 200 Operating instructions

Service instructions
for contractors
VIESMANN
Vitorond 200
Type VD2A, 125 to 270 kW
Oil/gas boiler
For applicability, see the last page
VITOROND 200
5692 726 GB 3/2013 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■ Work on gas installations must only be
carried out by a registered gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental 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
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland), Build-
ing Regulations (Northern Ireland),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Do not smoke. Prevent naked
flames and sparks. Do not
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.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
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If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the installation site.
■ Close all doors in the living
space.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Life-threatening poisoning
caused by carbon monoxide in
the flue gas occurs as a result of
leaking or blocked flue systems
or an insufficient supply of com-
bustion air.
Ensure the flue system is in
proper working order. It must not
be possible to close apertures for
interconnected combustion air
supply.
Extractors
Operating appliances that extract air to
the outside (cooker hoods, extractors, air
conditioning units, etc.) can create neg-
ative pressure. If the boiler is operated at
the same time, this can lead to reverse
flow of the flue gas.
Danger
The simultaneous operation of
the boiler and appliances that
extract air to the outside can
result in life threatening poison-
ing due to reverse flow of the flue
gas.
Fit an interlock circuit or take suit-
able steps to ensure a sufficient
supply of combustion air.
Working on the system
■ Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■ Isolate the system from the power sup-
ply (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 recon-
nection.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Prior to commencing any 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 function can compromise
the safe operation of your sys-
tem.
Defective components must be
replaced with genuine
Viessmann spare parts.
Safety instructions
Safety instructions (cont.)
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Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5692 726 GB

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Product information
Intended use......................................................................................................... 6
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 7
Further details regarding the individual steps....................................................... 9
Parts lists............................................................................................................ 18
Water quality
Water quality requirements.................................................................................. 24
Commissioning/service reports........................................................................ 28
Specification....................................................................................................... 29
Certificates
Declaration of conformity...................................................................................... 30
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 31
Keyword index.................................................................................................... 32
Index
Index
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The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions 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 pur-
pose other than the heating up of heating
water shall be deemed inappropriate.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble components designed for this pur-
pose has been carried out.
Every other use will be deemed to be
inappropriate. Any resulting losses are
excluded from the manufacturer's liabil-
ity.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Intended use also includes the adher-
ence to maintenance and inspection
intervals.
Product information
Intended use
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
• • 1. Commissioning the system........................................... 9
•2. Shutting down the system
•3. Opening the boiler door and cleaning cover............... 10
•4. Removing and cleaning the turbulators (only up to
195 kW)............................................................................ 11
•5. Cleaning the heating surface, flue outlet and flue....... 12
• • 6. Checking all gaskets and packing cords on the flue
gas side
•7. Checking the thermal insulation parts of the boiler
door
•8. Inserting the turbulators, fitting the boiler door and
cleaning cover................................................................. 12
• • 9. Checking all connections and the sensor well on the
heating water side for leaks
• • 10. Checking the function of the safety equipment
• • 11. Checking the expansion vessel and system pressure 14
•12. Checking electrical plug-in connections and cable
entries for firm seating
•13. Checking the thermal insulation
• • 14. Checking the water quality............................................ 14
• • 15. Cleaning the sight glass in the boiler door.................. 16
•16. Checking the mixer for ease of operation and
tightness.......................................................................... 16
•17. Checking the function of the return temperature
raising facility (if installed)
• • 18. Checking the installation room ventilation
• • 19. Checking the flue for tightness
• • 20. Checking the draught stabiliser (if installed)............... 16
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
•21. Adjusting the burner...................................................... 17
•22. Instructing the system user........................................... 17
•23. Operating and service instructions.............................. 17
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
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Commissioning the system
Operating and service instruc-
tions for the control unit and the
burner
01. Check that the turbulators are fully
inserted into the hot gas flues (only
up to 195 kW, see page 12); open
the boiler door for this.
02. Check that the installation room
vent is open.
03. 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 sys-
tem is not operated with fully
softened heating water.
Observe the "Water quality
requirements" on
page 24.
04. Enter the amount of fill water and
water hardness into the table in
chapter "Checking the water qual-
ity".
05. Check the system pressure.
06. Check the oil level or the gas supply
pressure.
07. Open the flue gas damper (if instal-
led).
08. Check that the cleaning apertures
on the flue outlet are closed.
09. Open the shut-off valves in the oil or
gas line.
10. Switch ON the mains isolator, the
switch for the heating circuit pump
and the burner ON/OFF switch in
this order (observe the burner man-
ufacturer's instructions).
11. When heating the system from cold
(also when restarting after mainte-
nance and cleaning work), prevent
all heat supply to heat consumers to
clear the dew point range as quickly
as possible.
12. After the flow temperature has been
reached, switch ON the heat con-
sumers in sequence and change the
burner over to automatic mode.
13. Check all gaskets and plugs, and
retighten if necessary.
14. Check the boiler door and cleaning
cover after approx. 50 hours run and
retighten all screws.
Note
Only open the connections on the heat-
ing water side after the boiler has been
depressurised.
Only drain the boiler with the air vent
valve open; use a suction pump.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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Opening the boiler door and cleaning cover
Note
On gas burners, remove the gas supply
pipe.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Removing and cleaning the turbulators (only up to 195 kW)
A
ATurbulators
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the heating surface, flue outlet and flue
B CA
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
smaller 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.
Inserting the turbulators, fitting the boiler door and cleaning
cover
Note
On gas burners, mount the gas supply
pipe.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Danger
Escaping gas leads to a risk of explosion.
Check all gas connections for tightness.
Danger
Escaping flue gas can cause a
health hazard.
Always connect the condensate
drain with a siphon to prevent flue
gas escaping.
A B
3
2
4
1
ATighten the screws on the boiler
door evenly and diagonally.
BOnly up to 195 kW: Fully insert the
turbulators into the second flue.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the expansion vessel and system pressure
Note
Observe instructions of the expansion
vessel manufacturer.
Carry out this test on a cold system.
1. Drain the system until the pressure
gauge indicates "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 pres-
sure is 0.1 to 0.2 bar (10 to 20 kPa)
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 (10 to 20 kPa) higher than
the pre-charge pressure of the
expansion vessel.
Permiss. operating pressure: 6 bar
(0.6 MPa)
Checking the water quality
Observe the instructions in chapter
"Water quality requirements".
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Enter the volume of top-up water and the
total hardness of the feed and boiler
water into the table.
Meter
reading
Fill and
top-up
water
Total
water
volume
Total hardness pH val-
ue
Water treat-
ment
Date
Feed-
water
Boiler
water
Me-
dium
Meter-
ing vol-
ume
m3m3m3
The total hardness of the feed and top-
up water must not exceed a sum of all
alkaline earths ≤ 0.02 mol/m3.
The pH value should be between 8.2 and 9.5.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the sight glass in the boiler door
Check the gaskets and hose connection
for leaks.
Checking the mixer for ease of operation and tightness
1. Remove the motorised lever from the
mixer handle.
2. Check the mixer for ease of opera-
tion.
3. Check the mixer for leaks. Replace
the O-ring gaskets if the mixer is leak-
ing.
4. Snap the motorised lever into place.
Checking the draught stabiliser (if installed)
Release the latch on the control disc. The control disc must swing freely during
burner operation.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Adjusting the burner
Burner service instructions or
separate documentation from the
burner manufacturer.
Adjust the maximum oil or gas through-
put of the burner to the rated boiler heat-
ing output.
To protect the system against dew point
corrosion, burner stage 2 (full capacity)
must be set to the rated boiler heating
output and must not be switched off dur-
ing summertime (burner stage 2 on con-
stant standby).
Operation with burner load ≥ 60 %
The minimum boiler water temperature
is 50 °C for operation with oil and 60 °C
for operation with gas.
To protect the boiler, the minimum heat-
ing output at the base load stage is set
to 60 % of rated heating output.
A minimum flue gas temperature is
required for the base load stage, the
value of which is subject to the chimney
design.
Rated heat-
ing output
Minimum heating out-
put to be selected
(burner stage 1)
kW kW
125 75
160 96
195 117
230 138
270 162
Operation with burner load < 60 %
The minimum boiler water temperature
is 60 °C for operation with oil and 65 °C
for operation with gas.
Set the minimum heating output for the
base load stage according to the actual
chimney conditions. Note that the chim-
ney must be suitable for the low flue gas
temperatures that may occur.
Instructing the system user
The installer should instruct the user in
the operation of the system.
Operating and service instructions
1. Complete and detach the customer
registration card:
■ Hand system users their section for
safekeeping.
■ Retain the heating contractor's
section.
2. File all parts lists, operating and serv-
ice instructions in the folder and hand
this over to the system user.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Spare parts information
Quote the part no. and serial no. (see
type plate) and the position number of
the required part (as per this parts list).
Standard parts are available from your
local supplier.
001 Hinge pin
002 Adjusting cams
003 Anchor rod with nuts
004 Nipple
005 Threaded stud M 10 x 40
006 Back section*1
007 Centre section*1
008 Front section*1
009 Boiler door
010 Thermal insulation mat
011 Thermal insulation mat
012 Thermal insulation block
013 Packing 20 x 15 mm
014 Sensor well
015 Flue outlet
016 Hose nozzle ¼"
017 Hose
018 Sight glass incl. gasket
019 Sight glass installation set
020 Burner plate
021 Plug 2"
022 Handle
023 Turbulator, 2nd pass*2
024 Turbulator, 2nd pass*2
027 Burner plate gasket
028 Extension
030 Measuring hose installation set
031 Threaded stud M 12 x 50
032 Thermal insulation mat
033 Gasket DN 65
034 Cleaning cover
035 Packing 10 x 10 mm
036 Packing 12 x 12 mm
037 Distributor pipe
038 Boiler return gasket
7 59 x 118 x 3 mm
039 Distributor pipe flange
041 Gasket
200 Control unit fascia
201 Top panel, front
202 Front panel, top
203 Side panel, left
204 Side panel, right
205 Top panel, back
206 Thermal insulation jacket
207 Rail left, with strain relief (pos. 212)
208 Rail right, with logo (pos. 213) and
strain relief (pos. 212)
209 Back panel left, with edge protec-
tion (pos. 214)
210 Back panel right, with edge protec-
tion (pos. 214)
211 Thermal insulation mat, back
212 Double strain relief
213 Vitorond 200 logo
214 Edge protector
215 Threaded pin SW 17
Wearing parts
312 Cleaning brush 20 x 40 mm
313 Cleaning brush 44 x 100 mm
Parts not shown
301 Single section pack
302 Assembly elements
(for pos. 006, 007 and 008)
303 Sealant
305 Thermal insulation pack
306 Decorative adhesive tape
307 Spray paint, Vitosilver
308 Touch-up paint stick, Vitosilver
309 Installation instructions
310 Service instructions
*1 When replacing sections, order 1 x pos. 302 for each section joint.
*2 Only up to 195 kW.
Parts lists
Parts lists
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ABurner cable, see parts list in the
service instructions of the boiler
control unit
BBoiler control unit, see parts list in
the service instructions
CType plate, optionally on the r.h. or
l.h. side
Parts lists
Parts lists (cont.)
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206
202
200
B
205201
Parts lists
Parts lists (cont.)
5692 726 GB