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Vitorond 200, VD2A Series Installation

5354 788 - 03

36

Start-up

Start-up Information

Start-up after extended shut-down

If the system was shut down for an extended period 

of time, restart and recondition the system.

 

H

Ensure all national and/or local rules and regulations 

have been adhered to in this installation. Do not  

attempt to start the boiler if you smell gas. If you smell 

gas, open windows. Do not touch electrical switches, 

extinguish any open flame, close all gas valves 

immediately. Call your gas supplier immediately from    

a neighbor’s phone.

 

H

For oil burners, do not reset the burner flame safeguard 

control more than two times.

 

H

Check system for proper water fill (cold fill pressure). 

Ensure that complete system is properly vented.   

Adjust automatic feed valve to proper desired fill 

pressure. Do not tamper with the unit or controls.  

Never burn garbage or paper in the unit or leave 

combustible materials around it.

Initial start-up

Initial start-up must be performed by qualified personnel; 

values and calibrations specified in the Technical Data 

section on page 38 in this manual are to be recorded 

at this time.

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. The following topics must be covered:

 

H

Proper system operation sequence.

 

H

Explain the equipment as well as the need for 

combustion air.

 

H

Demonstrate an emergency shut-down,                    

what to do and what not.

 

H

Explain that there is no substitute for proper 

maintenance to help ensure safe operation.

 

H

Annual inspection is recommended.

Shut-down

Deactivate main power to heating boiler(s) and burner(s) 

if burners have separate power supply, and deactivate 

power to circulating pump(s). Close all boiler isolation 

valve(s) as well as all fuel supply valve(s).

Extended shut-down periods

If after the heating period the boiler is shut down for 

the summer months (no domestic hot water production), 

the boiler should be properly cleaned, incl. combustion 

chamber, flue gas passageways, and, as necessary,

vent pipe connector, to avoid corrosion.
The boiler and system must remain filled with water. 

Do not drain boiler or heating system.

WARNING

If system is subject to freezing temperatures and 

is not filled with antifreeze for protection, the system 

including the boiler must be drained of water. 

The valve before the automatic feed valve (if installed) 

must be closed; any other valves, air vents and drain 

valves must stay open.

Depending on the control system utilized, reprogramming 

of the control system might be necessary in the event 

of lengthy power interruption.

Summary of Contents for VITOROND 200 VD2A-125

Page 1: ...he installation service and maintenance of hot water heating boilers There are no user serviceable parts on the boiler burner or control Ensure main power supply to equipment the heating system and al...

Page 2: ...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...

Page 3: ...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 a...

Page 4: ...t Information 8 New Casting Design and Therm Control Functionality 9 Redesigned Return Water Distribution System 9 Therm Control Low Temperature Protection Logic 10 Mechanical Room 11 Minimum Clearanc...

Page 5: ...rior to Start up 35 Start up Information 36 Initial start up 36 Instructing the system user 36 Shut down 36 Extended shut down periods 36 Start up after extended shut down 36 Piping in Heating Cooling...

Page 6: ...Note We offer frequent installation and service seminars to familiarize our partners with our products Please inquire In Canada all electrical wiring is to be done in accordance with the latest editi...

Page 7: ...boiler Technical Data Manual Installation Instructions Service Instructions Operating Instructions and User s Information Manual Positive Pressure Venting Systems installation instructions Instructio...

Page 8: ...mperatures in excess of those listed will result in damages and will render warranty null and void About these Instructions Take note of all symbols and notations intended to draw attention to potenti...

Page 9: ...ess on the heat exchanger and in conjunction with the Vitotronic Therm Control logic prevents the formation of flue gas condensate at all return water temperatures eliminating the need for a shunt pum...

Page 10: ...eed for a shunt pump or return temperature elevation provided by a Low Temperature Protection LTP Package Example Take a heating system with one heating circuit and a mixing valve In the start up phas...

Page 11: ...e IMPORTANT Maintain 1 in 25 mm air clearance from uninsulated hot water pipes to combustible material Boiler model VD2A 125 160 195 230 270 a Minimum Clearance in front of boiler in mm 47 1200 53 140...

Page 12: ...ief opening 5 minutes of high fire full load burner operation Use the flame of a match or a candle or an approved test 6 After it has been determined that each appliance remaining connected to the com...

Page 13: ...a with adjustable anti vibration feet optional 1 73 in 44 mm 1 Boiler base length Boiler model 125 24 in 600 mm Boiler model 160 30 in 770 mm Boiler model 195 37 in 940 mm Boiler model 230 44 in 1110...

Page 14: ...el CAUTION The tilting of the cast iron section could cause injuries and damage to the boiler The cast iron sections have to be supported before assembling with the field supplied support A 4 The cast...

Page 15: ...ion Set up Assembly of Boiler Base continued 6 Cross bar larger cut out moves to its end during cast assembly 7 Complete assembling the cast iron sections 8 Finish levelling the boiler by using a leve...

Page 16: ...cover and remove it also remove studs 5 Remove distribution tube from boiler 6 Loosen and remove the tie rods 7 Remove rear section also remove studs from boiler return port Only applicable if the bo...

Page 17: ...and dry properly 2 Lift rear section onto the boiler base Make sure the section legs are in the base channel Properly position rear section and secure against tipping B Arrow pointing to rear Arrow p...

Page 18: ...ted with the supplied linseed oil and graphite based sealant before use IMPORTANT Each intermediate section has arrows on sides of the casting The arrows must be pointing up when laying flat and durin...

Page 19: ...icone ensure that the work area is properly ventilated 1 Loosen pressure nuts and remove draw tool kit 2 Ensure that the heat exchanger block is level and vertical on boiler base All individual sectio...

Page 20: ...distribution pipe openings are facing upward IMPORTANT Ensure the notch of the distribution tube cap is facing up and matching the slot in the cast iron Legend A Gasket B Distribution pipe C M12 studs...

Page 21: ...ple ports for leakage by sliding a piece of cardboard or paper underneath the cast iron block 7 When pressure vessel is tight release pressure carefully and slowly A hydrostatic pressure test is manda...

Page 22: ...oriented to prevent scalding of attendants IMPORTANT Removal of air from system water must occur via use of air vent s To ensure the boiler can be purged of all air ensure supply return water lines d...

Page 23: ...l be located close to the valve outlet 2 The discharge from safety or safety relief valves shall be so arranged that there will be no danger of scalding attendants When the safety or safety relief val...

Page 24: ...f a LWCO in all instances 1 Install supply and return headers complete with pressure gage temperature gage air vent low water cut off boiler drain valve and bypass pump Pipe up to isolation valves Clo...

Page 25: ...lts A into threaded openings of the rear section 2 Install rear insulation blanket 3 Install rear panels 4 Install Temp control sensor aJA A between third and fourth section counting from the back 5 T...

Page 26: ...mm 3 Run thermal sensor through cut outs on the back 4 Mount front brackets 5 Use butterfly nuts 6 Use supplied spring and tighten the blanket to the boiler as illustrated All components required for...

Page 27: ...on 1 Drill four d in 3 mm holes on the side panel as shown For left side mount use a mirror image of the drawing 2 Punch a 7 8 in 22 mm opening 3 Install control harness bracket using supplied 8 32 se...

Page 28: ...athead screw driver Mount control housing on the side panel 7 Secure control housing using two supplied screws 8 Run capillaries and boiler temperature sensor through 7 8 in 22 mm opening on side pane...

Page 29: ...t 1 to 2 m from the breeching outlet located at the rear of the boiler Venting Connections WARNING When installing or insulating overhead piping or venting do not stand on top panel of boiler Advise o...

Page 30: ...t possible way with a minimal number of elbows If necessary rearrange existing water piping to achieve closest possible chimney connection Avoid long horizontal runs of vent pipe H Horizontal runs mus...

Page 31: ...tions for the positive pressure venting system 1 Connect the flue outlet with the shortest possible run and with a slight upward slope to the chimney stack Avoid sharp bends in the flue path Flue outl...

Page 32: ...d 200 VD2A boiler series in the Technical Data Manual Burners For technical details see Technical Data Manual and or manufacturer s burner manuals supplied with burner Only oil or gas fired burners of...

Page 33: ...64 Burner manufacturer Weishaupt or Riello Burner Gas train approval Standard approvals are CSA for Canada and UL for U S IRI and FM approved equipment is also available please inquire Electrical requ...

Page 34: ...ht 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 W...

Page 35: ...system and switch the burner to automatic j Check all gaskets and connections and retighten if necessary j Check and retighten bolts of combustion chamber door and clean out opening covers several day...

Page 36: ...owner is made familiar with the functioning of the system its activation and its shut down The following topics must be covered H Proper system operation sequence H Explain the equipment as well as th...

Page 37: ...ust be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle Check installation instructions of chiller manufacturer ca...

Page 38: ...th with Vitotronic control side mounted dimension e in mm 40b 1030 40b 1030 40b 1030 40b 1030 40b 1030 Total width dimension d in mm 34 860 34 860 34 860 34 860 34 860 Total height with boiler base di...

Page 39: ...erature 4 fixed high limit F C 250 121 250 121 250 121 250 121 250 121 Max allow operating pressure 5 psig 85 85 85 85 85 Boiler connections 6 Boiler supply and return in 2 2 2 2 2 Drain valve sedimen...

Page 40: ...Technical information subject to change without notice Printed on environmentally friendly recycled and recyclable paper 5354 788 03 Vitorond 200 VD2A Series Installation...

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