Table of Contents
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Installation Instructions
for use by heating contractor
Vitorond 200
VD2A Series
Oil-/Gas-fired boiler
Heating input:
490 to 1096 MBH
144 to 321 kW
VITOROND 200
5354 788 - 03 03/2015
IMPORTANT
Please ensure that these instructions are read and
understood before commencing installation and
start-up. Failure to comply with these Installation
Instructions will render all warranties null and void.
Working on the equipment
The installation, adjustment, service and
maintenance of this product must be performed
by a licensed professional heating contractor,
who is qualified and experienced in the 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 all external controls has been
deactivated. Close main oil or gas supply valve.
Take precautions in all instances to avoid
accidental activation of power during service work.
Improper installation, service or maintenance can
cause product/property damage, severe personal
injury, and/or loss of life.
Product may not be exactly as shown
IMPORTANT
Read and save these instructions for future
reference.
Please file in Service Binder
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Table of Contents
Related Manuals for Viessmann VITOROND 200 VD2A-125
Summary of Contents for Viessmann VITOROND 200 VD2A-125
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Page 1: Installation Instructions
Installation Instructions for use by heating contractor Vitorond 200 VD2A Series Oil-/Gas-fired boiler Heating input: 490 to 1096 MBH 144 to 321 kW VITOROND 200 IMPORTANT Please ensure that these instructions are read and understood before commencing installation and start-up. Failure to comply with these Installation Instructions will render all warranties null and void. -
Page 2: Safety
WARNING entitled “Mechanical Room”. in this manual. Installers must follow local regulations with respect to installation of carbon monoxide detectors. Follow the Viessmann maintenance schedule of the Warranty boiler in the “Service Instructions” manual. Information contained in this and related product documentation must be read and followed. -
Page 3: Fiberglass Wool And Ceramic Fiber Materials
Safety Vitorond 200, VD2A Series Installation Safety, Installation and Warranty Requirements (continued) H Fiberglass wool and ceramic fiber materials Suppliers of fiberglass wool products recommend the WARNING following precautions be taken when handling these materials: Inhaling of fiberglass wool and/or ceramic fiber Precautionary measures materials is a possible cancer hazard. -
Page 4: Table Of Contents
Table of Contents Vitorond 200, VD2A Series Installation Page Safety Safety, Installation and Warranty Requirements ....2 Product documentation ...........2 Advice to owner ............2 Licensed professional heating contractor ....2 Contaminated air ...........2 Warranty ..............2 Carbon monoxide ...........2 Fresh air ...............2 Equipment venting ..........2 Fiberglass wool and ceramic fiber materials ....3 Suppliers of ceramic fiber products recommendations: ........3... - Page 5 Table of Contents Vitorond 200, VD2A Series Installation Page Connections Venting Connections ..........29 (continued) In Canada / In U.S.A..........29 Venting (option #1) ..........29 Chimney .............29 Barometric draft regulator type / diameter ....30 Venting requirements ...........30 Venting option #1 (Category I venting) ....30 Venting (option #2) ..........31 Flue Gas Connection ..........31 Burner...
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Page 6: Important Regulatory And Safety Requirements
Codes for Gas Burning Appliances for Canada. For U.S. installations, use the National Fuel Gas Code ANSI Z223.1. Always use latest editions of codes. Note : For information regarding other Viessmann System Technology componentry, please reference documentation of the respective product. -
Page 7: Working On The Equipment
- Operating Instructions and User’s Information Manual - Positive Pressure Venting Systems installation instructions - Instructions of other Viessmann products utilized with this installation - Installation codes mentioned in this manual Note : Leave all literature at the installation site and advise the system operator/ultimate owner where the literature can be found. -
Page 8: General Information
General Information Vitorond 200, VD2A Series Installation About these Instructions 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 below. Warnings draw your attention to the presence of WARNING potential hazards or important product information. -
Page 9: New Casting Design And Therm-Control Functionality
General Information Vitorond 200, VD2A Series Installation New Casting Design and Therm-Control Functionality A specific, matching boiler control is part of the standard equipment of the Vitorond 200, VD2A. Boiler protection is assured by the following: - Therm-Control - Control of a shunt pump - Flow rate reduction in the heating circuits - Constant return temperature control The cast iron mid-sections were re-designed to increase... -
Page 10: Therm-Control Low-Temperature Protection Logic
General Information Vitorond 200, VD2A Series Installation Therm-Control Low-Temperature Protection Logic Therm-Control is an integrated low-temperature protection Example: logic provided by the Vitotronic control. Take a heating system with one heating circuit and a mixing valve. The control uses a Therm-Control temperature sensor specifically positioned in the casting close to the boiler In the start-up phase, the set Therm-Control temperature return (shown on page 9 and 31) to capture the thermal... -
Page 11: Set-Up
Set-up Vitorond 200, VD2A Series Installation Mechanical Room Boiler must be located in a heated indoor space. Do not use exhaust fans without adding additional The Vitorond 200, VD2A boiler should be located near provisions for fresh combustion air (e.g. fresh air fan) a floor drain and as close as possible to the vertical in the boiler room and do not install the Vitorond 200, chimney or vent. -
Page 12: Removal Of Existing Boiler
Set-up Vitorond 200, VD2A Series Installation Removal of Existing Boiler When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in... -
Page 13: Assembly Of Boiler Base
Set-up Vitorond 200, VD2A Series Installation Assembly of Boiler Base 1. Install levelling bolts and adjust to lowest setting. 2. Level the boiler base with the levelling bolts. Anti-vibration feet available (optional). Legend a with adjustable feet (standard delivery) 1.26 in. (32 mm) a with adjustable anti-vibration feet (optional) 1.73 in. - Page 14 Set-up Vitorond 200, VD2A Series Installation Assembly of Boiler Base (continued) 3. Use a level and the levelling bolts to make sure the boiler base is level. 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.
- Page 15 Set-up Vitorond 200, VD2A Series Installation Assembly of Boiler Base (continued) Cross bar larger cut-out moves to its end during cast assembly. Complete assembling the cast iron sections. Finish levelling the boiler by using a level and adjusting the levelling bolts as required.
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Page 16: Cast Iron Section Assembly
Set-up Vitorond 200, VD2A Series Installation Cast Iron Section Assembly Only applicable if the boiler is shipped in individual sections. All necessary parts needed to assemble the heating boiler are contained in the boiler accessory pack shipped inside the combustion chamber, as well as in the carton labeled “Installation Fittings”. - Page 17 Set-up Vitorond 200, VD2A Series Installation Cast Iron Section Assembly (continued) 1. Check both nipple ports for burrs, and if necessary, remove burrs with a half round file A. Never apply file in an in-and-out motion on the nipple port, only in a circular motion on the push nipple port sealing area.
- Page 18 Set-up Vitorond 200, VD2A Series Installation Cast Iron Section Assembly (continued) 1. Insert the two main draw tool rods from the rear section to the front section into the upper and lower push nipple ports. 2. Slide pressure flanges onto the draw tool rods and lock them with wedges, as shown in Fig.
- Page 19 Set-up Vitorond 200, VD2A Series Installation Cast Iron Section Assembly (continued) IMPORTANT During the compression procedure, draw in only one additional section at a time to prevent leaks at the joints. 1. Lay each section flat, gasket side facing up A. Apply supplied “Soudal”...
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Page 20: Water Distribution Pipe And Drain Installation
C and the rubberized gasket on the return port H. 3. Install reducing bushing E, extension pipe F and drain valve G into bottom opening. Use good quality sealing material (Viessmann recommends Hemp or Loctite 55) IMPORTANT Ensure that distribution pipe openings are facing upward. -
Page 21: Hydrostatic Pressure Test
Set-up Vitorond 200, VD2A Series Installation Hydrostatic Pressure Test A hydrostatic pressure test is mandatory after the assembly is complete and prior to the connection of any additional piping, control, or safety devices to the pressure vessel. Two metric flanges with welded NPT coupling connections are supplied with the boiler installation fittings. -
Page 22: Connections
Connections Vitorond 200, VD2A Series Installation Water Side Connections Boiler Supply Header IMPORTANT Ensure all requirements detailed in the Vitorond 200, VD2A System Design Guidelines and/or Technical Data Manual are met. The Vitorond 200, VD2A boiler is only for use in forced circulation hot water heating systems. -
Page 23: Removal Of Existing Boiler
Connections Vitorond 200, VD2A Series Installation Removal of Existing Boiler For information on the removal of an existing boiler, see page 12. Safety Connections and Pressure Testing Pressure relief valve Do not install any valve(s) between the pressure relief valve and the boiler. When installing a discharge pipe from relief valve to drain, adhere to the following excerpt from the ASME Boiler and Pressure Vessel Code: 1. -
Page 24: Boiler Pressure Test
(standard equipment) must be installed in all instances. The approved low water cut-off device must be installed by the mechanical contractor where required by local codes. Viessmann recommends the use of a LWCO in all instances. -
Page 25: Enclosure Installation
Connections Vitorond 200, VD2A Series Installation Enclosure Installation All components required for mounting the insulation are included with the insulation material. 1. Mount four threaded extension bolts A into threaded openings of the rear section. IMPORTANT Ensure all extension bolts and flue gas collar bolts on rear section are tightened. - Page 26 Connections Vitorond 200, VD2A Series Installation Enclosure Installation (continued) All components required for the enclosure panel assembly are included in the jacket carton. 1. Lay insulation blanket A over cast iron block (nylon backing facing outward and cut area B to boiler rear).
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Page 27: Boiler Control Installation
Connections Vitorond 200, VD2A Series Installation Boiler Control Installation 1. Drill four Ø 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 Ø in. (Ø 22 mm). opening. 3. - Page 28 Connections Vitorond 200, VD2A Series Installation Boiler Control Installation (continued) 1. Install the centre top panel. 2. Install rear top panel and fasten with long self-tapping screws. For electrical and boiler control connections, see Installation Instructions of boiler control. 3. Install control and apply cover strip. 4.
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Page 29: Venting Connections
Connections Vitorond 200, VD2A Series Installation Venting Connections Venting (option #1) WARNING The Vitorond 200, VD2A boiler is approved as a Category I appliance and must be vented accordingly. When installing or insulating (overhead) piping or venting, do not stand on top panel of boiler. Advise other trades accordingly! CAUTION The Vitorond 200, VD2A boiler is not approved for side... -
Page 30: Barometric Draft Regulator Type / Diameter
Connections Vitorond 200, VD2A Series Installation Venting Connections (continued) Venting requirements IMPORTANT Venting option #1 (Category I venting) The size of the flue gas outlet on the boiler does not For natural gas or liquid propane use Type B vent or Type automatically determine the horizontal breeching, or the L vent for the entire vent whenever possible. -
Page 31: Venting (Option #2)
Vitorond 200 boiler. Stoney Creek, ON L8E 4A5 For more details on the positive pressure venting option, Tel.: (905) 662-6600 see the Viessmann installation instructions for the positive Fax: (905) 662-5352 pressure venting system. (US) 1-800-992-8368 (Canada) 1-888-735-5475 IMPORTANT Email: info@selkirkcorp.com... -
Page 32: Burner
Burner Vitorond 200, VD2A Series Installation Burner Installation Burners For technical details see Technical Data Manual and/or manufacturer’s burner manuals (supplied with burner). Only oil- or gas-fired burners of the approved type can be utilized with the Vitorond 200, VD2A boiler. The boiler must be fired with positive pressure in the combustion chamber. -
Page 33: Burner Calibration
Burner Vitorond 200, VD2A Series Installation Burner Installation (continued) Burner calibration Weishaupt burners / Riello burners A Vitorond 200, VD2A boiler with a high-performance gas burner installed can achieve a combustion efficiency of up to 85.2%, and up to 87.9% if equipped with a #2 oil burner as follows: Gas-fired 10% volume CO... -
Page 34: Start-Up
Start-up Vitorond 200, VD2A Series Installation System Preparation Combustion air supply WARNING Provisions for combustion and ventilation air must be made in accordance with applicable local codes. Failure to provide an adequate supply of fresh In the absence of local codes, use CAN/CSA-B149.1 or .2 combustion air can cause poisonous flue gases Installation Codes for Gas Burning Appliances for Canada. -
Page 35: Gas Piping Pressure Test
Start-up Vitorond 200, VD2A Series Installation System Preparation (continued) Gas piping pressure test 1. Connect and size gas supply piping in accordance with local and national codes. A sediment trap/dirt pocket must be provided upstream of all gas controls. Provisions for connecting vent lines 2. -
Page 36: Start-Up Information
Start-up Vitorond 200, VD2A Series Installation Start-up Information Initial start-up Start-up after extended shut-down Initial start-up must be performed by qualified personnel; If the system was shut down for an extended period values and calibrations specified in the Technical Data of time, restart and recondition the system. -
Page 37: Additional Information
Additional Information Vitorond 200, VD2A Series Installation Piping in Heating/Cooling Application Boiler piping in a heating/cooling application The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped Heating/ in parallel to the boiler with appropriate valves to prevent Cooling Unit the chilled medium from entering the boiler. -
Page 38: Technical Data
Additional Information Vitorond 200, VD2A Series Installation Technical Data Boiler Model VD2A- Input (oil) MBH (kW) 490 (144) 628 (184) 765 (224) 902 (264) 1059 (310) Input (gas) MBH (kW) 508 (149) 650 (190) 792 (232) 934 (274) 1096 (321) Output (oil/gas) MBH (kW) 433 (127) -
Page 39: Boiler Model
Vent pipe collar diameter does not automatically indicate vent/chimney size. See page 30 for different venting options (categories). The combustion burner head material must be suitable for temperatures of at least 932°F (500°C). For information regarding other Viessmann System Technology componentry, please reference documentation of respective product. - Page 40 Vitorond 200, VD2A Series Installation...