Viessmann VR2 Series User manual

VITOROND 200
Start-up/Service Instructions
Vitorond 200
VR2 Series
Oil-Fired Boiler
Heating input 77 to 140 MBH
23 to 41 kW
Read and save these instructions
for future reference.
IMPORTANT
5167 424 v1.1 04/2004

Safety, Installation and Warranty Requirements
2
Safety, Installation and Warranty Requirements
Please ensure that this manual is read and understood before commencing installation. Failure to comply with the issues 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).
HLicensed 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.”
HProduct 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
Installation Requirements.”
HAdvice 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, shut-down procedure,
and the need for professional service
annually before the heating season
begins.
HContaminated 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
“Combustion Air Supply”
in Installation Instructions.
HCarbon 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 sections entitled
“Combustion Air Supply” and “Venting
Connection” in Installation Instructions.
HFresh 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
section entitled
“Combustion Air Supply.”
in Installation Instructions.
HEquipment venting
Never operate boiler without an
installed venting system.Animproper
venting system can cause carbon
monoxide poisoning.
"For information
pertaining to venting
and chimney
requirements, please
see section entitled “Venting
Connection” in Installation Instructions.
All products of combustion must be
safely vented to the outdoors.
HWarranty
Information contained in
this and related product
documentation must be
read and followed. Failure
to do so renders warranty
null and void.
5167 424 v1.1
Installers must follow local
regulations with respect to
installation of carbon monoxide
detectors. Follow manufacturer’s
maintenance schedule of boiler.
WARNING

Contents
3
Page
Safety Important Regulatory and Installation Requirements 4....
General Information About these Service Instructions 5........................................
Necessary Tools 5.......................................................................
Start-up
and Service
Initial Start-up 6...........................................................................
Service 7........................................................................................
Additional Information Parts List 12....................................................................................
Maintenance Record 15...............................................................
5167 424 v1.1

Safety
4
Important Regulatory and Installation Requirements
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 page 5 for details.
Instructing the system user
The installer of the system is
responsible to ensure the system
operator/ultimate owner is made
familiar with the system functioning, its
activation, its shut-down, and the need
for periodic service.
Initial start-up
Initial start-up must be performed by a
qualified heating contractor; values and
calibrations specified in the burner test
sheet are to be verified at this time.
Completion of the Maintenance Record
by the heating contractor is also
required.
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.
Working on the equipment
The installation, adjustment, service,
and maintenance of this boiler must be
done 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, burner, or control.
Ensure main power supply to
equipment, the heating system, and all
external controls has been deactivated.
Close main oil or gas supply valve. Take
precautions in both instances to avoid
accidental activation of power during
service work.
Please carefully read this manual prior
to attempting start-up, maintenance
or service. 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.
We offer frequent installation and
service seminars to familiarize our
partners with our products. Please
inquire.
Technical literature
Literature applicable to all aspects of
the Vitorond:
- Technical Data Manual
- Installation Instructions
- Start-up/Service Instructions
- Installation codes mentioned
in this manual
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.
5167 424 v1.1

General InformationGeneral Information
5
About these Service Instructions
The following symbols and flag words are utilized in these
Service Instructions:
Indicates an imminently hazardous
situation which, if not avoided, could
result in death, serious injury or
substantial product/property damage.
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or
product/property damage.
Helpful hints for installation, operation
or maintenance which pertain to the
product.
Helpful hints for installation, operation
or maintenance which pertain to the
product.
This symbol indicates that additional
informationiswrittenincolumn3.
This symbol indicates that other
instructions must be referenced.
Necessary Tools
Testing/analysis equipment
Flue gas analyzer
Cleaning supplies
Hand brush
Rags
Vacuum cleaning
Cleaning brush (Standard equipment)
Possible replacement parts
O-Ring seals for mixing valve(s)
Rope sealant for combustion chamber
door
Refractory for combustion chamber
door
Technical information
Operating Instructions of boiler and all
accessories
Parts List of each accessory
Use only calibrated equipment.
5167 424 v1.1
Warnings draw your attention to the
presence of potential hazards or
important product information.
WARNING
Cautions draw your attention to the
presence of potential hazards or
important product information.
CAUTION
IMPORTANT
5167 424 v1.1

Initial Start-up and Service
6
Operating Instructions, Service Instructions of Burner
1. Ensure fresh air intake of boiler room
is open and that chimney and all flue
pipes are connected, sealed and
unobstructed inside.
2. Ensure proper operation of expansion
tank (see Maintenance/Service
manual).
3. Fill heating system with water and
bleed out air completely. Ensure
complete system is properly vented
of air.
Max. operating pressure
45 psig / 310 kPa
.....................................
Max. testing pressure
68 psig / 465 kPa
.....................................
Max. boiler temperature
248°F / 120°C
.........................................
4. Perform a pressure test of the boiler
and the water piping. Pressure test
must not exceed 1½ times the
maximum operating pressure (45 psi)
of the boiler. Pressure relief valve
must be removed during pressure
test. Any leaks must be corrected.
5. Ensure proper and adequate fuel
supply exists; open oil shut-off valve.
6. Verify completeness of all discussion
points on the following pages in the
section entitled Service before
starting-up system.
If the nitrogen pressure of the
precharged expansion tank is less
than the static pressure of the
system, inflate membrane pressure to
slightly exceed pressure of system.
The static pressure required at the
tank is based upon the static height
of the system.
Water treatment should be considered
in areas where it is known that boiler
feed water contains a high mineral
content and hardness.
In areas where freezing might occur,
an antifreeze may be added to the
system water to protect the system.
Please adhere to the specifications
given by the antifreeze manufacturer.
Do not use automotive silicate-based
antifreeze. Ensure a copy of the
Material Safety Data Sheet is left on
site.
Please observe that an
antifreeze/water mixture may require
a backflow preventer within the
automatic water feed and influence
components such as diaphragm
expansion tanks, radiation, etc. A
40% antifreeze content will provide
freeze-up protection to -10°F / -23°C.
Do not use antifreeze other than
specifically made for hot water
heating systems. System also may
contain components which might be
negatively affected by antifreeze.
Check total system frequently when
filled with antifreeze.
Initial Start-up
5167 424 v1.1
DO NOT USE GASOLINE
CRANKCASE DRAININGS OR ANY
OIL CONTAINING GASOLINE.
WARNING

Initial Start-up and Service
7
1.Shut-downheatingsystem
1. Ensure main power supply to
equipment, the heating system, and
all external controls has been
deactivated. Take precautions in both
instances to avoid accidental
activation.
2. Close main oil supply valve near
burner and near tank.
2. Open combustion chamber door
1. Disconnect and remove burner hood
.
2. Disconnect plug-in connector
from burner.
3. Remove lower front panel .
4. Remove two bolts of combustion
chamber door and open.
5. Pull out turbulators .
Service
5167 424 v1.1
Always keep the manual fuel supply
valve shut off if the burner is shut
down for an extended period of time.
WARNING
Never burn garbage or paper in the
unit, and never leave combustible
material around it.
WARNING

Initial Start-up and Service
8
3. Clean heat exchanger and flue pipe
1. Remove flue gas turbulators (if
applicable). Clean heat exchanger
with cleaning brush and use
vacuum cleaner to remove all
sediment.
2. Remove the combustion chamber
insert. Inspect insert for damages.
3. Remove all sediment from flue pipe
and flue gas collector via clean-out
openings using vacuum cleaner.
4. Reinsert flue gas turbulators (if
applicable). Push combustion
chamber insert fully and completely
into combustion chamber.
4. Check all gaskets and insulation
1. Check all gaskets and the sealant
rope of the combustion chamber door
for wear or damage.
2. Check the combustion chamber door
refractory for wear or damage.
3. Replace worn or damaged parts.
5. Close combustion chamber door
1. Insert turbulators .
2. Close combustion chamber door
and tighten two bolts in an even
fashion.
3. Install lower front panel .
4. Connect the plug-in connector
of the burner.
5. Fasten burner hood and lock in
place.
Service (continued)
5167 424 v1.1
Reconnect oil burner and follow
instructions found in burner
installation/start-up manual.
WARNING

Initial Start-up and Service
9
6. Check heating system and domestic hot water connections
Ensure all connections are pressure
tight.
7. Ensure proper operation of all safety devices
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.
8. Ensure proper operation of expansion tank, low water cut-off (if applicable) and pumps
Refer to maintenance instructions
supplied with diaphragm expansion
tanks, low water cut-offs, pumps, etc.
Flush float water type low water
cut-offs (if used).
The usual water fill pressure is between
10 and 15 psi with the system cold. A
lower pressure gage reading usually
indicates loss of water due to leakage.
All leaks must be corrected. 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.
9. Ensure all plug-in connectors make positive contact and are seated properly
1. Remove top panel .
2. Check all plug-in connections.
Service Instructions
Boiler Control
3. Reinstall top panel .
Service (continued)
5167 424 v1.1
Do not tamper with the unit or
controls.
WARNING

Initial Start-up and Service
10
10. Ensure enclosure panels are correctly fitted
1. Ensure all enclosure panels are
seated properly; adjust as necessary.
2. Ensure strain reliefs on rear panel are
tight and seated properly.
11. Ensure mixing valve(s) rotates easily and is pressure tight
1. Remove mixing valve lever.
2. Check if mixing valve rotates easily.
3. Ensure mixing valve is pressure tight
(does not leak). Replace O-Ring seals
if necessary.
4. Reinstall mixing valve lever.
12. Ensure that an adequate combustion air supply exists in the boiler room
Ensure fresh air intake of boiler room is
open. This opening must never be
blocked or partially covered.
13. Ensure functionality of the barometric draft regulator of the burner
During operation of the burner, the
barometric draft regulator installed in
the vent system must move freely.
Service (continued)
5167 424 v1.1