Viessmann VITOROND 200 User manual

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IMPORTANT
Product may not be exactly as shown
5285 432 - 01 04/2014
Operating Instructions and
User’s Information Manual
VITOROND 200
Vitorond 200
VD2/VD2A Series
Oil- / Gas-fired boiler
Heating input: 490 to 4387 MBH
(144 to 1285 kW)
Do not store or use gasoline or other flammable
liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
HDo not try to light any appliances.
HDo not touch any electrical switches, do not use
any phone in your building.
HImmediately call your gas supplier from
a neighbor’s phone. Follow the gas supplier’s
instructions.
HIf you cannot reach your gas supplier, call the
fire department.
Installation and service must be performed by a
qualified installer, service agency or the gas supplier.
WARNING
Improper installation, adjustment, and/or
operation could cause carbon monoxide poisoning
resulting in injury or loss of life.
This product must be installed and serviced
by a professional service technician who
is experienced and qualified in hot water boiler
installation and gas/oil combustion.
WARNING
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.

Vitorond 200, VD2/VD2A Series Operating
5285 432 - 01
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).
2
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.
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”.
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”.
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.
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.
Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.
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.
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.
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.

Page
5285 432 - 01
Table of Contents
Vitorond 200, VD2/VD2A Series Operating
Safety
General Information
Operation
Service and Maintenance
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
Important Regulatory and Safety Requirements ..............4
Operation .............................................................4
Working on the equipment ......................................4
Dangerous conditions .............................................4
Gas smell..............................................................4
Flue gas smell .......................................................4
Combustion air and ventilation air openings...............4
Technical information .............................................4
Regular maintenance and service .............................4
For Your Safety .........................................................5
Important to know .................................................5
Carbon monoxide...................................................5
Frozen water pipe hazard ........................................5
For safe operation..................................................6
Installation area conditions......................................7
Replacement components, spare and wear parts........7
Sources of combustion and ventilation air
contaminants ........................................................7
Products containing contaminants:...........................7
About These Instructions ............................................8
Product Information....................................................8
High efficiency with reduced emissions ....................8
Operation ..................................................................9
Fuel(s)..................................................................9
Oil burner: ............................................................9
Gas burner:...........................................................9
For optimum operation ...........................................9
Operational faults ..................................................9
Shutdown.............................................................9
Brief shutdowns ....................................................9
Extended shutdowns..............................................9
Prior to seasonal start-up .....................................10
Seasonal start-up.................................................10
Maintenance............................................................10
Service Schedule......................................................11
Frequency...........................................................11
Performed by ......................................................11
Service...............................................................11
3

Vitorond 200, VD2/VD2A Series Operating
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4
Safety
Important Regulatory and Safety Requirements
HCombustion air and ventilation air openings
Ensure that combustion air openings and ventilation air
openings in the mechanical room are open.
HTechnical information
Literature applicable to the Vitorond
200, VD2 / VD2A series boiler:
– Installation Instructions
– Service Instructions
– Operating Instructions and User’s Information Manual
– Installation codes mentioned in this manual
HRegular maintenance and service
The entire heating system must be cleaned and serviced
on a regular basis by a qualified heating contractor or
service agency to ensure reliable, energy-efficient, and
environmentally friendly operation.
The build-up of soot on the heat exchanger raises the
flue gas temperature and reduces efficiency.
Indirect-fired domestic hot water storage tanks (if
installed) must be serviced within two years (at most) of
the installation date, and regularly thereafter (see Service
Schedule starting on page 11).
For an overview of scheduled service procedures, please
see section entitled “Service Schedule” on page 11 of
this manual.
WARNING
Improper installation, adjustment, service, or
maintenance can cause flue products to flow into
living space. Flue products contain poisonous carbon
monoxide gas which can cause nausea or asphyxiation
resulting in severe personal injury or loss of life.
WARNING
As there are no user-serviceable parts on the boiler,
burners or control, the end-user must not perform
service activities of any kind on system components.
Failure to heed this warning can cause property
damage, severe personal injury, or loss of life.
WARNING
The boiler must not be located in areas or rooms
where chemicals are stored, or aggressive vapors
from (i.e. bleach, hair spray, methyl chloride, carbon
tetrachloride or perchloroethylene) or high dust
levels or humidity levels are present. Heat exchanger
corrosion might occur and reduce the lifetime of the
boiler significantly. If above criteria are not properly
observed and boiler damage results, any warranty
on the complete boiler and related components will
be null and void.
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.
IMPORTANT
Keep all literature in a safe place at the installation site.
Contact Viessmann for additional copies.
CAUTION
Incomplete combustion and poisonous gases result if
the fresh air intakes in the mechanical room are closed.
Never close these openings.
HOperation
Before operating the boiler, make sure you fully
understand its method of operation. Your heating
contractor should always perform the initial start-up and
explain the system.
Any warranty is null and void if these instructions are not
followed.
HWorking on the equipment
All personnel working on the equipment or the heating
system must have the proper qualifications and hold all
necessary licenses.
Ensure main power to equipment, heating system, and
all external controls has been deactivated. Close main oil
or gas shut-off valve. Take precautions in all instances to
avoid accidental activation of power during service work.
HDangerous conditions
– Deactivate main power immediately.
– Close main gas or oil shut-off valve.
HGas smell
Follow the instructions on the front page of this manual.
HFlue gas smell
– Deactivate heating equipment.
– Open windows and doors.
– Inform your heating contractor.

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Vitorond 200, VD2/VD2A Series Operating Safety
For Your Safety
HImportant to know
Do not use this boiler if any part has been under or
exposed to water.
Immediately call a qualified heating contractor to inspect
the boiler and to replace any part of the control system
and any gas control which has been under or exposed to
water.
HCarbon monoxide
The U.S. Consumer Product Safety Commission strongly
recommends the installation of carbon monoxide
detectors in buildings in which gas-burning equipment
is installed.
Carbon monoxide (CO) is a colorless, odorless gas, which
may be produced during incomplete combustion of fuel
and/or when the flame does not receive an adequate
supply of combustion air.
Carbon monoxide can cause severe personal injury or loss
of life.
Therefore, carbon monoxide detectors that are in
compliance with a nationally recognized standard (e.g.
ANSI/UL 2034-2002, CSA 6.19-01) should be installed
and maintained in buildings that contain gas-burning
equipment.
Note: Viessmann does not test any detectors and makes
no representation regarding any brand or type of
detector.
Your heating boiler is designed to provide a warm and
comfortable living environment. It is NOT designed to
ensure against freezing of water pipes.
The boiler is equipped with several safety devices that
are designed to shut down the boiler and to prevent it
from restarting in the event of various unsafe conditions.
If your boiler remains off for an extended period of time
during cold weather, water pipes may freeze and burst,
resulting in extensive water damage and conditions in
which mold could grow. Certain molds are known to
cause respiratory problems, as well as to pose other
serious health risks. In case of water damage, immediate
measures should be taken to dry out affected areas as
quickly as possible to prevent mold from developing.
If your home will be unattended for an extended period
of time during cold weather, you should...
HShut off the water supply to the building, drain the
water pipes and add an antifreeze for potable water
to drain traps and toilet tanks. Open faucets where
appropriate.
Or..
HHave someone check the building frequently during cold
weather and call a qualified service agency if required.
Or...
HInstall a reliable remote temperature sensor that will
notify somebody of freezing conditions within the
home.
WARNING
Failure to protect against frozen pipes could result in
burst water pipes, serious property damage and/or
personal injury. Boiler may shut down.
Do not leave your home unattended for long periods
of time during freezing weather conditions without
turning off the water supply and draining water pipes
or otherwise protecting against the risk of frozen
pipes.
Frozen water pipe hazard

Vitorond 200, VD2/VD2A Series Operating
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6
Safety
For Your Safety (continued)
HFor safe operation
We recommend that you frequently:
- Check for debris which could obstruct the flow of
flue gases. The vent or chimney must not be blocked.
A blocked or partially blocked vent or chimney can
cause flue gases to leak into the structure. Flue gases
leaking into the house can cause injury or loss of life.
Blocked or partially blocked chimneys must have the
blockage removed by a qualified heating contractor.
- Check pressure gage for correct system (water) pressure.
Check for water on the floor from the discharge pipe
of the pressure relief valve or any other pipe, pipe joint,
valve or air vent.
- Check for moisture, water, or appearance of rust on
the flue gas pipes, their joints as well as vent dampers,
or side wall vent terminals (if so equipped).
- 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.
- Do not allow unsupervised children near the boiler.
Service/inspection of the boiler and the system is
recommended once a year.
Maintenance, service and cleaning are specified in the
Installation Instructions.
Before the heating season begins, it is recommended that
the boiler and burner be serviced by a qualified heating
contractor. Service contracts may be established through
gas suppliers or other licensed contractors in your area.
WARNING
Improper installation, adjustment, service,
or maintenance can cause flue products to flow into
living space. Flue products contain poisonous carbon
monoxide gas which can cause nausea or asphyxiation
resulting in severe personal injury or loss of life.
WARNING
The operator/ultimate owner is required to have the
heating boiler, burners, and controls checked, as a
minimum once per year, by the original installer or
by a competent heating contractor familiar with the
equipment. Defects must be corrected immediately.
WARNING
As there are no user-serviceable parts on the boiler,
burner or control, the end-user must not perform
service activities or adjustments of any kind on system
components. Failure to heed this warning can cause
property damage, severe personal injury, or loss of life.
CAUTION
Should overheating occur or the gas supply fail to
shut off, do not disconnect the electrical supply to the
pump. Instead, shut off the gas supply at a location
external to the appliance.
CAUTION
Do not use this boiler if any part has been under water.
Immediately call a qualified heating contractor to inspect
the boiler and to replace any part of the control system
and any gas control which has been under water.

7
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Vitorond 200, VD2/VD2A Series Operating Safety
For Your Safety (continued)
WARNING
Fire causes a risk of burns and explosion!
HShut down the boiler
HClose fuel shut-off valves
HUse a tested fire extinguisher, class ABC.
WARNING
Incorrect ambient conditions can lead to damage to
the heating system and put safe operation at risk.
HEnsure ambient temperatures are higher than 32° F (0° C)
and lower than 104° F (40° C).
HPrevent the air from becoming contaminated by
halogenated hydrocarbons (e.g. as contained in paints
solvents or cleaning fluids) and excessive dust (e.g.
through grinding or polishing work).
Combustion air for the heating process, and ventilation
of the boiler room must be free of corrosive contaminants.
To that end, any boiler must be installed in an area that
has no chemical exposure.
The list to the right indicates the main, currently known
sources.
HAvoid continuously high levels of humidity (e.g. through
frequent drying of laundry).
HNever close existing ventilation openings.
If you notice fire coming from the appliance, call the fire
department immediately! Do not attempt to extinguish the
fire unless qualified to do so. IMPORTANT
Components which are not tested with the heating system
may damage the heating system, or affect its functions.
Installation or replacement may only be carried out
by a qualified heating contractor.
Sources of combustion and ventilation air contaminants
Areas likely to contain contaminants:
HNew building construction
HSwimming pools
HRemodelling areas, hobby rooms
HGarages with workshops
HFurniture refinishing areas
HDry cleaning/laundry areas and establishments
HAuto body shops
HRefrigeration repair shops
HMetal fabrication plants
HPlastic manufacturing plants
HPhoto processing plants
HBeauty salons
Products containing contaminants:
HChlorine-type bleaches, detergents and cleaning
solvents found in household laundry rooms
HPaint and varnish removers
HHydrochloric acid, muriatic acid
HChlorine-based swimming pool chemicals
HSpray cans containing chlorofluorocarbons
HChlorinated waxes and cleaners
HCements and glues
HRefrigerant leaks
HCalcium chloride used for thawing
HSodium chloride used for water softening salt
HPermanent wave solutions
HAdhesives used to fasten building products and other
similar items
HAntistatic fabric softeners used in clothes dryers
Installation area conditions
Replacement components, spare and wear parts

Vitorond 200, VD2/VD2A Series Operating
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8
General Information
Product Information
High efficiency with reduced emissions
With the Vitorond 200, VD2 / VD2A boiler you have
purchased an oil-/gas-fired sectional cast iron boiler that
features high efficiency and environmentally friendly
operation.
The three-pass design of the boiler combustion chamber
allows for low-emission combustion, while the uniform
temperature distribution raises the operational reliability
even further.
About These 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.

IMPORTANT
Warnings draw your attention to the presence of
potential hazards or important product information.
Cautions draw your attention to the presence of
potential hazards or important product information.
Helpful hints for installation, operation or maintenance
which pertain to the product.
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.

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Vitorond 200, VD2/VD2A Series Operating
Operation
Operation
Fuel(s)
As a dual fuel boiler the Vitorond 200, VD2 /VD2A can
be operated with either an oil or a gas burner.
Depending on the burner, use fuel type specified below.
Oil burner:
Fuel oil #2
Gas burner:
Natural gas and/or propane gas
For optimum operation
To ensure optimum operation of your heating system do
the following:
HKeep the boiler and the boiler room clean and free of
dust and dirt.
HEnsure proper and adequate system pressure by
occasionally checking the pressure gage.
HHave a qualified heating contractor service and maintain
your heating system on a regular basis. See Service
Schedule starting on page 11 for details.
Operational faults
In the event of an apparent operational fault of the boiler,
do the following:
- Refer to the operating instructions of the oil or gas
burner (shipped with burner).
- Refer to the operating instructions of the boiler control
(shipped with control unit).
- If unable to reset operation successfully, call your
heating contractor.
Shutdown
Brief shutdowns
Operation with a Vitotronic control.
1. Leave power button of control ”8” in the ””
position; leave power supply to entire heating system
activated.
2. Place operating program of control in the ”9” stand-by
position (see Operating Instructions of boiler control).
Extended shutdowns
1. Close valve(s) in oil or gas fuel supply lines.
2. Deactivate all switches for the heating system
(heating system pump(s), burner power supply,
control power button ”8”).
3. Deactivate power of circuit which supplies all heating
system componentry with energy. If installed, use the
disconnect switch located outside of the mechanical
room.
4. Close all isolation valves.
If the system is shut down for an extended period of
time (several months), have a qualified heating contractor
restart and recondition the system. In this manner,
the appropriate precautions, such as system freeze-up
protection or heat exchanger maintenance can be taken.
CAUTION
Should overheating occur or the gas/oil supply fail to
shut off, do not disconnect the electrical supply to the
circulating pump. Instead, shut off the gas/oil supply
at a location external to the appliance.
WARNING
The boiler must not be located in areas or rooms
where chemicals are stored, or aggressive vapors
from (i.e. bleach, hair spray, methyl chloride, carbon
tetrachloride or perchloroethylene) or high dust
levels or humidity levels are present. Heat exchanger
corrosion might occur and reduce the lifetime of the
boiler significantly. If above criteria are not properly
observed and boiler damage results, any warranty
on the complete boiler and related components will
be null and void.
IMPORTANT
The system remains powered with 120 VAC in this case.

Vitorond 200, VD2/VD2A Series Operating
5285 432 - 01
10
Operation
Operation (continued)
Initial start-up must be performed by a qualified heating
contractor.
Prior to seasonal start-up
(also for start-up after extended shutdown)
1. Check cold fill pressure of heating system.
2. Ensure that combustion air openings and ventilation
air openings in mechanical room are open.
3. Open valve in oil or gas fuel supply line.
4. Ensure proper operation of barometric draft regulator.
5. Ensure clean-out openings near flue gas collar are
closed tightly.
6. Activate all switches for the heating system (system
switch ”8”, heating system pump, burner power
supply, etc.)
Observe the instructions by burner manufacturer.
Your heating system is now ready for operation.
Seasonal start-up
1. Check all gaskets and connections and retighten if
necessary.
2. Check and retighten bolts of combustion chamber
door and clean-out opening covers several days after
start-up.
The boiler controls monitor the operation of your heating
system in conjunction with installed system controls (if
applicable) based upon indoor/outdoor control, setback
programming and other settings. Please refer to the
respective documentation of the boiler controls, or other
system controls, to make adjustments.
The boiler must be cleaned at least once a year by
a qualified heating contractor or service agency.
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 preceding inspection, maintenance, service and
cleaning work must be performed by a qualified heating
contractor or service agency.
Refer to Vitorond 200 Service Instructions
Maintenance

11
5285 432 - 01
Vitorond 200, VD2/VD2A Series Operating
Service Schedule
Service and Maintenance
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 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.

Technical information subject to change without notice. Printed on environmentally friendly
(recycled and recyclable) paper.
5285 432 - 01
Vitorond 200, VD2/VD2A Series Operating