Viessmann VITOROND 200 Operating instructions

for use by heating contractor
Please file in Service Binder
Read and save these instructions for future
reference.
IMPORTANT
Product may not be exactly as shown
5285 431 - 01 04/2014
Service Instructions
VITOROND 200
Vitorond 200
VD2 Series
Oil-/Gas-fired boiler
Heating input: 1255 to 4387 MBH
(368 to 1285 kW)

Vitorond 200, VD2 Series 320 to 1080 Service
5285 431 - 01
2
Safety, Installation and Warranty Requirements
Safety
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with
the instructions 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).
WARNING
Installers must follow local regulations with respect
to installation of carbon monoxide detectors.
Follow the Viessmann maintenance schedule of the
boiler in the “Service Instructions” manual.
H Product 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 Safety Requirements”.
H Licensed 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”.
H Contaminated 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 “Mechanical Room”.
in this manual.
H Advice 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, shutdown procedure, and
the need for professional service annually before the
heating season begins.
H Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.
H Carbon 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 section entitled “Combustion
air supply” and “Venting information”
in this manual.
H Fresh 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 subsection entitled
“Mechanical Room” in this manual.
H Equipment venting
Never operate boiler without an installed venting
system. An improper venting system can cause
carbon monoxide poisoning.
For information pertaining to
venting and chimney requirements,
please see section entitled “Venting
Information” in this manual. All
products of combustion must be
safely vented to the outdoors.

3
5285 431 - 01
Vitorond 200, VD2 Series 320 to 1080 Service
WARNING
Inhaling of fiberglass wool and/or ceramic fiber
materials is a possible cancer hazard. These materials
can also cause respiratory, skin and eye irritation.
Fiberglass wool and ceramic fiber materials
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.
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 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, tear-out 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.
Hazardous materials
Safety
Safety, Installation and Warranty Requirements (continued)
Suppliers of ceramic fiber products recommend the
following first aid measures:
- Respiratory tract (nose and throat) irritation:
If respiratory tract irritation develops, move the
person to a dust free 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.

4
Page
Table of Contents
5285 431 - 01
Vitorond 200, VD2 Series 320 to 1080 Service
Safety, Installation and Warranty Requirements..............2
Product documentation .........................................2
Licensed professional heating contractor .................2
Contaminated air..................................................2
Advice to owner ..................................................2
Warranty.............................................................2
Carbon monoxide .................................................2
Fresh air..............................................................2
Equipment venting................................................2
Fiberglass wool and ceramic fiber materials .............3
Suppliers of ceramic fiber products recommend
the following first aid measures..............................3
Precautionary measures ........................................3
First aid measures ................................................3
Hazardous materials .............................................3
Important Regulatory and Safety Requirements ..............6
Instructing the system user ...................................6
Initial start-up ......................................................6
Working on the equipment.....................................6
Technical literature ...............................................6
About these Installation Instructions .............................7
Necessary Tools.........................................................8
Tools ..................................................................8
Cleaning supplies .................................................8
Testing/Analysis equipment ...................................8
Technical information ...........................................8
Replacement parts................................................8
Customer Site Information.....................................8
Boiler..................................................................8
Burner ................................................................8
Shut Down the Heating System ...................................9
Open Combustion Chamber Door and
Clean-out Opening Covers ...........................................9
Remove and Clean Turbulators.....................................9
Clean heat exchanger, flue gas collar
and chimney............................................................10
Check all Gaskets and Sealant Ropes..........................10
Check Insulation of Combustion
Chamber Door .........................................................10
Reinstall Turbulators, Clean-out Covers and
Close Combustion Chamber Door ...............................11
Check Proper Operation of Safety Header....................11
Check Proper Operation of Expansion Tank,
Low Water Cut-offs and Pumps .................................11
Check Proper Expansion Tank and
System Pressures.....................................................12
Safety
General Information
Inspection and Maintenance

Table of Contents
5
Page
5285 431 - 01
Vitorond 200, VD2 Series 320 to 1080 Service
Clean Sight Glass of Combustion
Chamber Door .........................................................12
Check Water Hardness..............................................12
Ensure Proper Fit of Insulation Blanket ........................12
Ensure Proper Operation of
Heating System Control ............................................12
Ensure Proper Operation of Low Temperature
Protection Package...................................................13
Check Combustion Air Supply....................................13
Check Vent System..................................................13
Check Proper Operation of
Door Safety Switch (oil burners only)..........................13
Calibrate Burner .......................................................14
Two-stage burner ...............................................14
Model ...............................................................14
Flue gas resistance .............................................14
Fully modulating burner.......................................14
Weishaupt / Riello burners ...................................14
Gas-fired ...........................................................14
Oil-fired.............................................................14
Vitorond 200 with Viessmann Vitotronic controls...14
Model ...............................................................14
Input ................................................................14
Min.1-stage input ...............................................14
Maintenance Schedule...............................................15
Maintenance .......................................................15
Frequency...........................................................15
Performed by ......................................................15
Service...............................................................15
Parts List.................................................................16
When ordering replacement parts...........................16
Parts ..................................................................16
Parts not shown ..................................................16
Maintenance Record .................................................20
Inspection and Maintenance
Additional Information

Vitorond 200, VD2 Series 320 to 1080 Service
5285 431 - 01
6
Safety
Important Regulatory and Safety Requirements
Working on the equipment
The installation, adjustment, service, and maintenance
of this boiler must be performed 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, burners,
or control.
Note: Please carefully read this manual prior to attempting
installation. 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.
Viessmann offers frequent installation and service
seminars to familiarize our partners with our
products. Please inquire.
Ensure main power supply to equipment, the heating
system, and all external controls has been deactivated.
Close main gas supply valve. Take precautions in all
instances to avoid accidental activation of power during
service work.
Note: The completeness and functionality of field supplied
electrical controls and components must be verified
by the heating contractor. This includes low water
cut-offs, flow switches (if used), staging controls,
pumps, motorized valves, air vents, thermostats, etc.
Instructing the system user
The installer of the system is responsible to ensure the
system operator/ultimate owner is made familiar with the
functioning of the system, its activation, and its shut-down.
Note: 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.
Initial start-up
Initial start-up must be performed by a qualified heating
contractor. Completion of the Maintenance Record by the
heating contractor is also required.
Note: The Maintenance Record is located on page 20
of this manual.
Technical literature
Literature for the Vitocrossal 200 VD2 boiler:
- Technical Data Manual
- Installation Instructions
- Service Instructions
- Operating Instructions and User’s Information Manual
- Instructions of other Viessmann products utilized with
this installation
- Installation codes mentioned in this manual
Additional applicable literature:
- Viessmann boiler controls manuals
Note: 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.

7
5285 431 - 01
Vitorond 200, VD2 Series 320 to 1080 Service General Information
About these Installation 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.
Note:
IMPORTANT
Note: Warnings draw your attention to the presence of
potential hazards or important product information.
Note: 
Cautions draw your attention to the presence of
potential hazards or important product information.
Note: 
Helpful hints for installation, operation or
maintenance which pertain to the product.
Note: 
This symbol indicates that additional, pertinent
information is to be found.

This symbol indicates that other instructions must be
referenced.
WARNING
Indicates an imminently hazardous situation which,
if not avoided, could result in loss of life, serious
injury or substantial product/property damage.
CAUTION
Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product/
property damage.

Vitorond 200, VD2 Series 320 to 1080 Service
5285 431 - 01
8
Necessary Tools
General Information
Tools
HAssortment of flathead and Phillips screwdrivers
HPipe wrenches
HOpen-ended wrenches
HPipe sealant
HAssortment of Allen keys
HFlashlight
HApproved leak detection fluid for natural gas and
propane gas
Cleaning supplies
HHand brush
HCleaning/service brush (supplied)
HVacuum cleaner
HRags
Testing/Analysis equipment
(use only calibrated equipment)
HFlue gas analyzer to measure % CO2or O2
(i.e. Bacharach fluid samplers or a suitable electronic
analyzer)
HMultimeter to measure 0 - 120 VAC, 0 - 12 AAC, and
0 - 20 microamps DC
HSmoke test gun (Bacharach)
HOil pump pressure gage
HOil pump vacuum gage
HPressure gage to measure gas pressure 0 - 7 ”w.c.
(accurately) and up to 28 ”w.c. gas pressure (or a non-
electric Magnehelicrpressure gage may also be utilized)
HCarbon monoxide measuring equipment (0 - 400 ppm)
HBacharach calculator or suitable tables to calculate
efficiency
HStack thermometer 0 to 500° F (0 to 260° C)
Hdin. NPT male to ¼ in. barb adaptor fitting, as well as
tubing for pressure measurement
CAUTION
Use only original Viessmann components when replacing
defective parts. Installation of incorrect replacement
parts can cause hazardous operation and will void
warranty.
Technical information
The following is a list of literature applicable to the
Vitorond 200, VD2 boiler:
HInstallation Instructions
HService Instructions
HOperating Instructions and User’s Information Manual
For installation of the heating system, please refer also
to the technical literature of other System Technology
devices:
HInstallation Instructions for Viessmann boiler control
HInstallation Instructions for Viessmann indirect-fired hot
water storage tank(s)
HInstallation Instructions for burner and accessories
Replacement parts
The materials listed below are recommended to be on
hand for all service calls.
For a complete listing of replacement components, please
see Parts List starting on page 19 of these instructions.
Order replacement components from your Viessmann
distributor.
HO-rings for mixing valve(s)
HSealant rope for combustion chamber door
HRefractory for combustion chamber door
HSealant rope for clean-out opening cover
HGlue for sealant rope
Boiler
Mfr.: Viessmann
Series:
Heating Input: MBH
Serial No.:
Burner
Mfr.:
Series:
Heating Input: MBH
Serial No.:
Customer Site Information

9
5285 431 - 01
Vitorond 200, VD2 Series 320 to 1080 Service
Shut Down the Heating System
Inspection and Maintenance
1. Shut down heating system
1. Deactivate main power supply to heating system and
secure against accidental reactivation.
2. Disconnect plug fA from burner.
3. Close main oil or gas supply valve.
1. When using a gas power burner:
Disconnect gas train.
2. Loosen four M 12 bolts on combustion chamber door
Aand open.
3. Remove clean-out opening covers B.
Open Combustion Chamber Door and Clean-out Opening Covers
Remove and Clean Turbulators
1. On models VD2-320 to VD2-860 only:
Remove turbulators Aand clean.

Vitorond 200, VD2 Series 320 to 1080 Service
5285 431 - 01
10
Inspection and Maintenance
Clean Heat Exchanger, Flue Gas Collar and Chimney
1. Clean flue gas passageways Aand combustion
chamber Bwith the supplied cleaning brush. Clean
tight areas between ribs with the smaller cleaning
brush. Remove combustion residues with a vacuum
cleaner.
2. Remove combustion residues of chimney connection
and flue gas collar via the clean-out openings Cat
rear of boiler.
Check all Gaskets and Sealant Ropes
Check Insulation of Combustion Chamber Door
Replace worn items.
Replace if worn.

11
5285 431 - 01
Vitorond 200, VD2 Series 320 to 1080 Service
Reinstall Turbulators, Clean-out Covers and Close Combustion Chamber Door
Inspection and Maintenance
1. On models VD2-320 to VD2-860 only:
Completely insert turbulators Ainto the third flue
gas passageway. In doing so, push first turbulator
element approximately two thirds of the way into the
flue gas passageway, hook in the second and third
element and push in.
2. Tighten bolts Bof combustion chamber door in a
cross-wise fashion.
When using a gas power burner:
Connect gas train and perform necessary leak
detection tests.
3. Install clean-out opening covers C.
Check pressure gage, air vent and pressure relief valve.
Ensure pressure relief valve does not leak. Also ensure
pressure relief valve operates in accordance with
information provided by the manufacturer.
Ensure proper system water pressure in diaphragm
expansion tanks, low water cut-offs, pumps, and pressure
relief valve.
Note: Observe the instructions by the expansion tank
manufacturer. Perform all tests on a cold system.
Flush float water type low water cut-offs (if used).
The usual water fill pressure is between 12 and 15 psig
with the system cold. A lower pressure gage reading
usually indicates loss of water due to leakage. All leaks
must be corrected.
Note: Refer to instructions packaged with automatic
fill valve. Follow local regulations with respect
to backflow preventers.
If oil-lubricated pumps are used, ensure proper lubrication.
If motorized zone valves are used, refer to maintenance
instructions provided with zone valves.
If an older non-diaphragm expansion tank is used, ensure
the correct water level is present (approx. hfull).
Check Proper Operation of Safety Header
Check Proper Operation of Expansion Tank, Low Water Cut-offs and Pumps

Vitorond 200, VD2 Series 320 to 1080 Service
5285 431 - 01
12
Inspection and Maintenance
Check Proper Expansion Tank and System Pressures
IMPORTANT
Do not over tighten to avoid leaks and potential damage.
Clean Sight Glass of Combustion Chamber Door
1. Drain system or close cap valve on the diaphragm
expansion tank and reduce the pressure until the
pressure gage indicates “0”.
2. If the inlet pressure of the diaphragm expansion tank
is lower than the static system pressure, top up with
enough nitrogen to raise the inlet pressure higher than
the static system pressure 1.5 to 3 psig (0.1 to 0.2 bar).
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 tank 1.5 to 3 psig (0.1 to 0.2 bar).
Max. operating pressure is 75 psig (5 bar) [58 psig
(3.9 bar) in some Canadian provinces].
Ensure gasket Aand hose Bto sight glass are air-tight.
Check Water Hardness
Water treatment should be considered in areas where it
is known that boiler feed water contains a high mineral
content and hardness. Test and establish proper chemical
make-up of system water.
Note: Contact a local water treatment company for advice.
Ensure Proper Fit of Insulation Blanket
Ensure proper fit of the insulation blanket.
Ensure Proper Operation of Heating System Control
Remove motorized arm from mixing valve and check
the motor for ease of movement. If mixing valve is not
water-tight, replace O-ring seals and snap the motorized
arm back into place.

13
5285 431 - 01
Vitorond 200, VD2 Series 320 to 1080 Service
Ensure Proper Operation of Low Temperature Protection Package
Ensure proper operation of the low temperature protection
package.
Inspection and Maintenance
Check Combustion Air Supply
Installation Instructions
Oil Door Safety Switch
See Installation Instruction
Supplement for Barometric Draft Regulator.
Ensure an adequate supply of combustion and ventilation
air is available. If an outside air duct is required, ensure it
is installed.
Note: See subsection entitled “Combustion air supply” in
the Installation Instructions.
Ensure that nothing is obstructing the flow of combustion
and ventilation air and no chemicals, garbage, gasoline,
combustible materials, flammable vapors and liquids are
stored (not even temporarily) in the vicinity of the boiler.
Check Vent System
Ensure proper operation of the barometric draft regulator
(barometric damper).
Check Proper Operation of Door Safety Switch (oil burners only)

Vitorond 200, VD2 Series 320 to 1080 Service
5285 431 - 01
14
Gas-fired
10% volume CO2, 280° F (138° C) net stack temperature,
CO in ppm < 50 temperature
Oil-fired
13% volume CO2, 300° F (149° C) net stack
temperature, smoke spot 0 - 1 (on the Bacharach Scale)
The maximum input published for each boiler size cannot
be exceeded.
Model Flue gas resistance
mbar “w.c.
VD2-320 0.5 0.20
VD2-380 0.9 0.35
VD2-440 1.3 0.51
VD2-500 1.7 0.67
VD2-560 1.9 0.75
VD2-630 2.1 0.83
VD2-700 2.8 1.10
VD2-780 3.9 1.54
VD2-860 4.9 1.93
VD2-950 4.5 1.77
VD2-1080 6.7 2.70
Fully modulating burner
When the Vitorond 200, VD2 is operated with a fully
modulating burner, the minimum boiler water temperature
is as follows:
Oil-fired burner. . . . . . . . . . . . . . . . . . . 140° F (60° C)
Gas-fired burner. . . . . . . . . . . . . . . . . . 149° F (65° C)
Return water temperature elevation must be adjusted
to a minimum temperature of 129° F (54° C).
Weishaupt / Riello burners
A Vitorond 200, VD2 boiler with a high-performance gas
burner can achieve a combustion efficiency of up to 85%,
and up to 88% if equipped with a #2 oil burner.
Vitorond 200 with Viessmann Vitotronic controls
To further protect the Vitorond 200, VD2 from dew-point
corrosion, the following minimum inputs on a 2-stage
burner must be adjusted for the first stage when the
boiler is used in conjunction with a Viessmann Vitotronic
controls, and when operating with modulating boiler
water temperatures.
Model Input Input Min.1-stage
input
Min.1-stage
input
Oil
MBH
Gas
MBH
Oil
MBH
Gas
MBH
VD2-320 1255 1300 753 780
VD2-380 1490 1544 895 926
VD2-440 1726 1787 1036 1072
VD2-500 1961 2031 1177 1219
VD2-560 2196 2275 1318 1365
VD2-630 2471 2559 1483 1535
VD2-700 1745 2843 1647 1706
VD2-780 3059 3168 1835 1901
VD2-850 3373 3493 2024 2096
VD2-950 3727 3860 2236 2316
VD2-1080 4236 4387 2542 2632
See separate instructions supplied with the burner.
The maximum input published for each boiler size must
not be exceeded.
Two-stage burner
With a two-stage burner, when the boiler water
temperature falls below the minimum (140º F (60º C), the
burner automatically switches to the second stage (full
input) to protect the boiler from the effects of dew-point
condensation, i.e. condensation/corrosion.
In order to provide this protection, the burner must not be
limited to first stage operation during the summer months.
Under partial load conditions, a minimum flue gas
temperature must be met. How high that minimum
flue gas temperature must be depends largely on the
configuration of the chimney insulation and height of the
chimney; however, it should be a minimum of 248° F
(120° C).
See separate instructions supplied with burner
Calibrate Burner
Inspection and Maintenance

15
5285 431 - 01
Vitorond 200, VD2 Series 320 to 1080 Service Inspection and Maintenance
Maintenance Schedule
The following is an overview of scheduled service steps.
Where indicated have a qualified heating contractor or
service agency perform the service work at the frequency
shown.
Regular service work ensures reliable, energy-efficient,
and environmentally friendly operation.
Frequency Performed by Service
Monthly Owner /
Operator
Check the system pressure frequently (min. 20 psig).
Ensure proper operation of the boiler control.
Inspect all seals; retighten or replace as necessary.
Ensure an adequate supply of combustion air and ventilation air into and out
of the mechanical room is being maintained.
Annually Owner /
Operator
Ensure service work/test is conducted at least annually by qualified personnel,
and that any deficiencies are corrected immediately.
Mechanical
Contractor
Test functionality of safety high limits.
Test burner with burner accessories according to their corresponding maintenance
checklist.
Test and establish proper chemical makeup of system water.
Check flue pipe condition, chimney connection and chimney itself.
Check pressure relief valve and system pressure, and verify proper operation
of automatic feed if installed.
Check heating pipe joints, valves, air vents, etc. System leaks must be corrected
immediately to avoid further defects.
The cause of defect must also be determined in order to avoid further problems.
Check for proper combustion air supply and ventilation to boiler / mechanical room.
Check for combustible materials or chemicals stored too close to the boiler.
Test high limits by dialing lower settings, switching burner on/off to verify
functioning of same. Test low water cut-off, check and verify proper function
according to manufacturer’s instructions.
When circulating pump is field-installed or existing, check requirements
for maintenance or lubrication according to manufacturer’s specifications.
Check for oil-tight fuel lines; clean or exchange fuel oil filters annually.
Check and inspect oil tank.
Check for gas-tight connection of gas piping, unions, gas valve and manifold.
Check proper ignition on oil or gas burner operation.
Combustion test must be performed by a qualified service technician.
Ensure proper operation of door safety switch.
Ensure functionality of low water cut-offs, including flushing of float types (if used)
during operation, based on supplier’s instructions.
Inspect low- and/or high pressure gas switch (if used).
Inspect main burner flame and follow burner manufacturer’s instruction manual
for detailed service and maintenance guidelines. Manual shipped with burner.
All boilers and the boiler room must be kept free of high dust levels, high humidity,
aggressive vapors and/or chemicals containing chlorine.
Ensure proper boiler room ventilation and combustion air is maintained.
Valves, fittings and pipes not pressure tight must be repaired.
Combustion chamber door, clean-out opening covers, glass fiber rope seals and
flanges may need to be retightened and resealed.
IMPORTANT
Keep boiler and boiler room clear and free from combustible
materials, gasoline and other flammable vapors and liquids.
Do not obstruct the flow of combustion and ventilation air.
All inspection, maintenance, and service must be performed
by a qualified heating contractor.
Maintenance
The boiler must be cleaned at least once a year by
a qualified heating contractor or service agency.

Vitorond 200, VD2 Series 320 to 1080 Service
5285 431 - 01
16
Additional Information
Parts List
When ordering replacement parts
Please provide boiler Model and Serial Number from rating
plate when ordering replacement parts.
Order replacement parts from your Viessmann distributor.
Parts
001 Door hinge
002 Tie rod, length 24 in. (610 mm)
003 Tie rod, length 19 in. (480 mm)
004 Push nipple
005 Fiber rope seal, 7½ in. (12 mm)
006 Door hinge, stop
007 Intermediate section*1
008 Front section*1
009 Combustion chamber door
010 Insulation blanket, 18½ x 18½ in. (467 x 467 mm)
011 Insulation blanket (three part) 34 x 38 in.
(868 x 968 mm)
012 Combustion chamber door insulation block
013 Fiber rope seal, gx gin. (16 x 16 mm)
014 Hose nipple,¼ in. (6 mm)
015 Plastic hose, 31½ in. (800 mm)
016 Sight glass c/w gasket
017 Sight glass cover
018 Burner plate
019 Turbulator insert*2
020 Gasket, 1½×1¾×1/10 in. (35×45×2 mm)
021 Gasket, 7¼ in (8 mm)
022 Plug , 2 in. (51 mm)
023 Insulation blanket, 716 in. (408 mm)
024 Fiber rope seal, 7½ in. (10 mm)
Parts not shown
300 Accessory pack (insulation)
301 Decorative stripe [1 roll = 33 ft. (10 m)]
302 Touch-up spray paint, Vitosilver
303 Touch-up paint stick, Vitosilver
304 Glue, 150 ml (for Position No. 005)
306 Split kit (for Position Nos. 007, 008 and 025)
307 Installation Instructions
308 Service Instructions
309 Operating Instructions and User’s Information Manual
*1 Order item 306 for every section joint.
*2 Number of turbulators for every third flue
– for VD2-320 to VD2-440 kW:
3 pieces
– for VD2-500 to VD2-560 kW:
2 pieces
– for VD2-630 to VD2-860 kW:
1 piece

17
5285 431 - 01
Vitorond 200, VD2 Series 320 to 1080 Service Additional Information
Parts List (continued)
Parts
025 Rear section*1
026 Refractory insert
027 Clean-out opening cover
028 4-point sensor well
031 Flue outlet (with Position Nos. 027 and 042)
032 Blind plate
033 Cleaning brush handle
034 Extension rod, length 14 in. (355 mm*2)
035 Extension rod, length 39 in. (1000 mm*3)
036 Extension rod, length 43¼ in. (1100 mm*4)
037 Flange, water distribution pipe
038 Water distribution pipe, triple element*5
039 Water distribution pipe, quadruple element*6
040 Water distribution pipe, double end element*7
041 Water distribution pipe, quadruple end element*8
042 Fiber rope seal, 7gin. (8 mm)
043 Fiber rope seal, 7gin. (8 mm)
044 Support bracket
045 Gasket, DN 100
Maintenance parts
310 Cleaning brush head
*1 Order item 306 for every section joint.
*2 Only for VD2-380 to 630, 950 and 1080.
*3 Only for VD2-380, 500, 560, 700, 780, 950 and
1080.
*4 Only for VD2-320, 440, 630, 780, 860 and 1080.
*5 Only for VD2-380, 500, 630, 700, 780, 950 and
1080.
*6 Only for VD2-440, 560, 630,780, 860 and 1080.
*7 Only for VD2-380, 440 and 630.
*8 Only for VD2-320, 500, 560, 700, 780, 860, 950
and 1080.

Vitorond 200, VD2 Series 320 to 1080 Service
5285 431 - 01
18
Additional Information
Parts List (continued)
Parts
200 Front panel
201 Bracket
202 Cover strip
203 Front left cover (included with item 224)
204 Front right cover (with Position No. 224)
205 Rear mounting bracket
206 Rear panel - right (with Position No. 226)
207 Rear panel - left (with Position No. 226)
208 Top panel - front
209 Top panel - middle
210 Top panel - rear
211 Connecting panel
212 Spacer
213 Side panel, 19¾ in. (502 mm)
214 Side panel, 24¾ in. (628 mm)
215 Side panel, 29¾ in. (755 mm)
216 Tie bar
217 Insulation blanket front
218 Insulation blanket front
219 Insulation blanket rear, width 18¼ in. (466 mm)
220 Insulation blanket rear, width 24 in. (612 mm)
221 Insulation blanket rear, width 27¾ in. (706 mm)
222 Insulation blanket rear
223 Insulation blanket - bottom
224 Strain relief (2-channel)
225 Nameplate “Vitorond 200”
226 Cover, edgemolding
ARating plate*1
B Boiler control (see Parts List of control)
C Arrangement of panels and insulation blankets (VD2-
320 to VD2-1080)
D Burner cable (see Parts List of control)
*1 May be located at a different location.

19
5285 431 - 01
Vitorond 200, VD2 Series 320 to 1080 Service Additional Information
Parts List (continued)

Technical information subject to change without notice. Printed on environmentally friendly
(recycled and recyclable) paper.
5285 431 - 01
Vitorond 200, VD2 Series 320 to 1080 Service
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