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Viessmann VITOROND 200 Installation Instructions Manual

Type vd2, 320 to 1080 kw oil/gas boiler
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VIESMANN

Installation instructions

for contractors
Vitorond 200
Type VD2, 320 to 1080 kW
Oil/gas boiler
VITOROND 200
Dispose after installation.
5862444 GB
9/2018

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Summary of Contents for Viessmann VITOROND 200

  • Page 1: Installation Instructions

    VIESMANN Installation instructions for contractors Vitorond 200 Type VD2, 320 to 1080 kW Oil/gas boiler VITOROND 200 Dispose after installation. 5862444 GB 9/2018...

  • Page 2: Safety Instructions

    Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained Danger Note This symbol warns against the risk of injury. Details identified by the word "Note" contain additional information. Please note This symbol warns against the risk of material losses and environmental pollution.

  • Page 3: Table Of Contents

    Index Information Disposal of packaging ................Symbols ....................Intended use ..................Product information ................System examples .................. Preparing for installation Clearance dimensions ................Installation sequence Boiler section assembly ................. Overview of boiler body ..............■ Preparing the boiler sections .............. ■...

  • Page 4: Information Disposal Of Packaging

    Please dispose of packaging waste in line with statu- DE: Use the disposal system organised by tory regulations. Viessmann. AT: Use the ARA statutory disposal system (Altstoff Recycling Austria AG, licence number 5766). CH: Packaging waste is disposed of by the HVAC contractor.

  • Page 5: Product Information

    Intended use also includes the adherence to mainte- nance and inspection intervals. Product information Vitorond 200, type VD2 ■ Fuels: Fuel oil and natural gas Permissible operating pressure 6 bar (0.6 MPa) ■...

  • Page 6: Preparing For Installation Clearance Dimensions

    Clearance dimensions 1000 (100) Fig. 1 Boiler Plinth (accessory) Burner Anti-vibration boiler supports (accessories) Dimensions in brackets are minimum clearances. Note We recommend installing the boiler on the plinth (accessories) with anti-vibration boiler supports (accessories). Rated heating output 1660 1790 1920 2050 2180...

  • Page 7: Installation Sequence Boiler Section Assembly

    Boiler section assembly Overview of boiler body Note All parts required for boiler assembly are included in the boiler accessory packs. The boiler body consists of a back section with fitted flue outlet, a front section with fitted boiler door and a number of centre sections that depends on the rated heating output.

  • Page 8: Preparing The Boiler Sections

    Boiler section assembly (cont.) Preparing the boiler sections Fig. 3 Packing cord (not for the back section) Solvent For all sections: Clean the hub sealing surfaces. Adhesive (supplied) For all sections: Apply adhesive and allow to dry for approx. 5 min. Danger Solvent vapours are produced while the adhe- sive is being used.

  • Page 9: Preparing The Back Section And First Centre Section

    Boiler section assembly (cont.) Fig. 4 Linseed oil graphite (supplied) For all sections: Clean the connectors with solvent and apply the linseed oil graphite. Preparing the back section and first centre section Fig. 5 Observe the wall clearance (see page 6)

  • Page 10: Pressing The Back Section And First Centre Section Together

    Boiler section assembly (cont.) Pressing the back section and first centre section together Fig. 6 Note To avoid leaks at the hub connections, when pressing, only pull together one section at a time. When adding further sections, maintain the same dis- tance at the top and bottom between the sections.

  • Page 11: Pressing Further Boiler Sections Together

    Boiler section assembly (cont.) Pressing further boiler sections together Fig. 7 Fitting the lower thermal insulation mat Fig. 8 Note The support timber can be removed after 3 sections have been assembled. Position the lower rolled up thermal insulation mat (supplied with the thermal insu- lation part 2) behind the back section.

  • Page 12: Overview Of The Anchor Rods

    Boiler section assembly (cont.) Overview of the anchor rods Fig. 9 Plan view Side view Arrangement of the anchor rods 480 and 610 mm 1080 Rated heating output No. of sections Anchor rod 480 mm long Anchor rod 610 mm long...

  • Page 13: Joining Sections With Anchor Rods

    Boiler section assembly (cont.) Joining sections with anchor rods M 16 Fig. 10 Note Note The compression tool holds the boiler together. Only tighten nuts on anchor rods by hand. Never Only release the compression tool when the sections apply force. have been joined with anchor rods...

  • Page 14: Removing The Compression Tool And Aligning The Boiler

    Boiler section assembly (cont.) Removing the compression tool and aligning the boiler Fig. 11 Note Plinth installation instructions All section feet must be firmly placed on the plinth (accessories up to 860 kW) or on the floor. If required, shim the section feet.

  • Page 15: Distributor Pipe And Drain Installation

    Distributor pipe and drain installation Fig. 12 Plug R 2, max. overhang "a" 5 to 7 mm. Quadrant insert for ratchet, supplied with the compression tool.
  • Page 16 Distributor pipe and drain installation (cont.) B 3.9 x 6.5 Fig. 13 Distributor pipe, orient the outlet apertures upwards. Intermediate or end element, for installation, see parts list in the service instruc- tions Drain & fill valve, on site Tighten screws diagonally, torque 7 Nm.

  • Page 17: Checking The Boiler Block For Leaks

    Checking the boiler block for leaks R 3/8 R 3/4 R 3/8 Fig. 14 Sensor well Manual air vent valve, on site Dummy plug Blank flange, on site Carry out water pressure test in accordance with TRD 702. Test pressure: 9 bar (0.9 MPa) Note No pressure, control or safety equipment must be fitted during the water pressure and tightness tests.

  • Page 18: Inserting Turbulators And Fitting The Boiler Door

    Inserting turbulators and fitting the boiler door M 16 Fig. 15 Turbulator Only up to 860 kW: Insert the appropriate number of turbulators into each hot gas channel of the third pass (see table). Insert approx. of the first ⅔ turbulator element, hook in the second or (if neces- sary) third element and push them in.

  • Page 19: Connections On The Heating Water Side

    Connections on the heating water side Fig. 16 Boiler flow, DN 100 Drain, R ¾ (drain & fill valve on site) Boiler return, DN 100 Torque for cleaning cover 7 Nm Note Install all pipe connections free of load and torque Danger stress.

  • Page 20: Fitting The Thermal Insulation

    All required components are included in the thermal insulation box. Fitting the rails = B 3.9 x 9.5 M 12 M 16 1044 mm 1090 mm Fig. 17 Vitorond 200 logo Note For the position of the lateral tie-bars, see the following table.
  • Page 21 Fitting the thermal insulation (cont.) Fig. 18 Rated heating output — — — — — — — — — Rated heating output 1080 — — — —...

  • Page 22: Fitting The Thermal Insulation Jacket And Rear Thermal Insulation Mat

    Fitting the thermal insulation (cont.) Fitting the thermal insulation jacket and rear thermal insulation mat Note Burner cables are supplied in the thermal lÖ insulation pack. Fig. 19 Black side outwards Cut-out to the back...

  • Page 23: Connections On The Flue Gas Side

    Connections on the flue gas side 1. Connect the flue outlet with the shortest possible run to the chimney and maintain a slight incline. External Ø, flue outlet: 300 mm 2. Create a test port 10 mm. 3. Seal in and thermally insulate the flue pipe (all con- nections/joints must be gas-tight).

  • Page 24: Fitting The Control Unit And Power Supply

    Fitting the side, front and back panels (cont.) Note Hook in the side panels as shown in the following table. If required, align the side panels by turning the hexa- gon screws in the lateral tie-bar. Fig. 22 Rated heating output —...
  • Page 25 Fitting the control unit and power supply (cont.) § B 3.9 x 30 Fig. 23...

  • Page 26: Connections To The Control Unit Base

    Fitting the control unit and power supply (cont.) Fig. 24 LV leads 230 V cables Burner cables (apply strain relief) Note Please note Route 230 V cables and LV leads separately. Never allow cables/leads to come into contact with hot components. Secure all cables/leads with cable ties.

  • Page 27: Fitting The Top Panels

    Fitting the top panels B 3.9 x 9.5 B 3.9 x 9.5 B 3.9 x 9.5 Fig. 25 Top panel, centre (from 500 kW) Boiler type plate Mounting the burner Danger ■ Max. flame tube aperture Ø 360 mm. Fibre dust can be produced if working with high Cut out the thermal insulation mat in the boiler door temperature insulation materials that contain zir- to suit the blast tube diameter.

  • Page 28: Pressure Switch

    Commissioning information Service instructions for boiler, burner and boiler control unit Viessmann Werke GmbH & Co. KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0...

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