Viessmann VR2 Series Manuel utilisateur

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

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

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

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

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

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

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

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

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. 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

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