Viessmann Vitola VGA Retrofit User manual

Installation Instructions
Safety and Installation Requirements
Please ensure that these instructions are read and understood before installation. Failure to comply with the instructions
listed below can cause product/property damage, severe personal injury, and/or loss of life.
Working on the equipment
The installation, adjustment, service
and maintenance of this product 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 gas supply
valve. Take precautions in both
instances to avoid accidental
activation of power during service
work.
It is not permissible to perform service
work on any component part ensuring
safe operation of the heating system.
When replacing parts, use original
Viessmann or Viessmann approved
replacement parts.
NG burner to Vitoflame 200
5352 565 v1.0 07/2008
Please file in Service Binder
Vitoflame 200 NG burner is produced
and tested as the burner for Vitola
200 VB2 boilers with the assumption
that combustion air will be supplied
from beneath the original burner hood.
The retrofit burner hood is smaller in
size and therefore final burner
adjustment (air gate) is necessary.
The retrofit burner can be used only
with a 120V Viessmann control,
which has a 7-pole 41 plug on the
burner cable for direct connection to
the Viessmann 120V boiler control.
This is not a substitute for the original
Viessmann Vitoflame 200 technical
literature.
This document must be used in
conjunction with the Vitoflame 200
technical literature.
The Vitoflame 200 literature contains
all local/provincial/state safety rules,
codes and regulations, which, if not
followed, may cause property damage
and/or personal injuries/death.
Guidelines: Retrofit Natural Gas
burner Vitoflame 200 for Vitola
boilers. (120V control only)
Vitola VGA Retrofit
Retrofit Natural Gas burner Vitoflame 200 for Vitola boilers (120V only)
IMPORTANT
Vitola boilers model/size Input
BTU/h
BEA VNE VBC
18 18 18 90000
22 22 22 116000
33 33 33 146000
35 40 40 185000
46 50 50 238000
58 63 63 300000
Parts supplied:
Vitoflame 200 burner VGA-series ÆPart No. 7134 (431 to 436)
Retrofit burner hood for Vitoflame 200 ÆPart No. 7817 237
Support bracket (extension bolt) ÆPart No. 7820 960

2
NG burner to Vitoflame 200 (continued)
Older Vitola boilers, BEA series, have
boiler doors with only a four-bolt
pattern for mounting the burner.
Newer boilers, VNE and VBC series,
have doors with a three- and four-bolt
mounting pattern.
The Vitoflame 200 mounting plate can
be easily converted to the four-bolt
mounting pattern (Fig.1 and 2).
Conversion procedure:
• Remove three bolts and
remove mounting flange with
blast tube.
• Drill out the blank profile
mounting holes and finish the
holes with round file.
• Reinstall the mounting flange
to the burner body.
• Burner ceramic gasket must be
adapted to the four-bolt
pattern.
Installation
Fig. 2
Drill out the blank profile mounting holes and finish the holes with a round file.
Fig. 1
Remove three bolts and mounting flange with blast tube.
5352 565 v1.0

3
5352 565 v1.0
NG burner to Vitoflame 200 (continued)
1. Turn off power to the boiler
and shut off fuel line.
2. Remove old burner.
3. Open boiler door.
4. Remove combustion chamber.
5. Clean out the boiler.
6. Inspect combustion chamber.
7. Reinstall combustion chamber.
8. Close and tighten boiler door.
9. Replace burner gasket (Fig. 3).
10. Install burner on boiler (Fig. 4).
Installation
Fig. 2
Burner’s chassis installed on boiler door.
Fig. 3
New studs with nuts and burner gasket.

4
Fig. 5
Burner power cable connected to sub-base.
Fig. 6
Burner harnesses placed in strains relief.
NG burner to Vitoflame 200 (continued)
Installation
11. Connect gas train to burner and
support gas train with supplied
bracket as per the Vitoflame
200 supplied technical
literature.
12. Install supplied double acting
barometric MG1 vent damper
on vent connector.
13. Install FTS-4 spill switch as per
the FTS-4 supplied instruction.
14. Make final gas connection.
15. Connect power cable with 7-
pole plug to burner control sub
base (Fig. 5).
16. Connect gas train harness (blue
3-pole plug) and HST4 spill
switch (white 3-pole plug) into
plug sockets under burner
control.
17. Place the harnesses into strain
relief located on bottom of the
front burner plate (Fig. 6).
5352 565 v1.0

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Fig. 7
Remove blank screw using Allen key.
Fig. 8
Install burner support bracket (10mm hex extension bolt).
NG burner to Vitoflame 200 (continued)
5352 565 v1.0
Installation
18. Remove blank screw from front
burner plate and replace it with
support bracket - extension bolt
(Fig. 7 and 8).
19. Fire the burner and make final
burner adjustment using a
combustion analyzer.
20. For Natural gas the CO2 level
should be around
9.4%, Oxygen O2 - 4.1% and
CO<25 ppm.
21. Log the final setting results and
attach printout from the
analyzer to test sheet on the
last page.
22. Fax the test results to
[phone] immediately
after the installation.

6
Fig. 9
Filing out the gas pipe notch may be required.
Fig. 10
Filing out the gas pipe knock out.
NG burner to Vitoflame 200 (continued)
23. Attach burner hood to burner
(Fig. 9).
5352 565 v1.0
Installation
IMPORTANT
Sometimes the installer may
experience some fitting difficulties
with the gas pipe passing through
the cut-out opening in the retrofit
burner hood. In this case, the cut-
out opening may require slight
filing with a half round file (Fig.
10).

7
Fig. 11
Tighten burner hood to burner.
Fig. 12
Side view of wiring harnesses.
NG burner to Vitoflame 200 (continued)
5352 565 v1.0
Installation
24. Tighten burner hood to the burner
(Fig. 11).
IMPORTANT
If the installation is also a conversion
from #2 oil to Natural gas:
• Remember to cap the oil
tank filler neck and give a
conversion notice to the
local oil supplying company.
• Venting system must be
inspected and calculated
according to local
codes/jurisdiction.
• Use the new double acting
barometric damper supplied
with the Vitoflame 200
burner.
If a power vent system is used, it
must be integrated and calibrated for
new installation. Contact Viessmann
for more information.

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Printed on environmentally friendly (recycled and recyclable) paper.
5352 565 v1.0
Viessmann Manufacturing Company Inc.
750 McMurray Road
Waterloo, Ontario • N2V 2G5 • Canada
Tel. [phone] • Fax. [phone]
www.viessmann.com • [email protected]
Viessmann Manufacturing Company (U.S.) Inc.
45 Access Road
Warwick, Rhode Island • 02886 • USA
Tel. [phone] • Fax [phone]
www.viessmann-us.com • [email protected]
Technical information subject to change without notice