Viessmann VD2-320 User manual

for use by heating contractor
Please file in Service Binder
Read and save these instructions for future
reference.
IMPORTANT
Product may not be exactly as shown
5285 429 - 03 12/2014
Installation Instructions
VITOROND 200
Vitorond 200
VD2 Series
Oil-/Gas-fired boiler
Heating input: 1255 to 4387 MBH
(368 to 1285 kW)
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.
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.

Vitorond 200, VD2 Series 320 to 1080 Installation
5285 429 - 03
2
Safety, Installation and Warranty Requirements
Safety
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with
the instructions 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).
WARNING
Installers must follow local regulations with respect
to installation of carbon monoxide detectors.
Follow the Viessmann maintenance schedule of the
boiler in the “Service Instructions” manual.
Product 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 Safety Requirements”.
Licensed 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”.
Contaminated 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 “Mechanical Room”.
in this manual.
Advice 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, shutdown procedure, and
the need for professional service annually before the
heating season begins.
Warranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.
Carbon 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 section entitled “Combustion
air supply” and “Venting information”
in this manual.
Fresh 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 subsection entitled
“Mechanical Room” in this manual.
Equipment venting
Never operate boiler without an installed venting
system. An improper venting system can cause
carbon monoxide poisoning.
For information pertaining to
venting and chimney requirements,
please see section entitled “Venting
Information” in this manual. All
products of combustion must be
safely vented to the outdoors.

3
5285 429 - 03
Vitorond 200, VD2 Series 320 to 1080 Installation Safety
Safety, Installation and Warranty Requirements (continued)
WARNING
Inhaling of fiberglass wool and/or ceramic fiber
materials is a possible cancer hazard. These materials
can also cause respiratory, skin and eye irritation.
HFiberglass wool and ceramic fiber materials
WARNING
Appliance materials of construction, products of
combustion and the fuel contain alumina, silica, heavy
metals, carbon monoxide, nitrogen oxides, aldehydes
and/or other toxic or harmful substances which can
cause serious injury or loss of life and which are
known to the State of California to cause cancer,
birth defects and other reproductive harm. Always
use proper safety clothing, respirators and equipment
when servicing or working nearby the appliance.
The state of California has listed the airborne fibers of
these materials as a possible cancer hazard through
inhalation. When handling these materials, special care
must be applied.
Suppliers of fiberglass wool products recommend the
following precautions be taken when handling these
materials:
Precautionary measures
- Avoid breathing fiberglass dust and contact with
skin and eyes.
- Use NIOSH approved dust/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 and
spraying may generate airborne fiber concentration
requiring additional protection.
First aid measures
- If eye contact occurs, flush eyes with water to
remove dust. If symptoms persist, seek medical
attention.
- If skin contact occurs, wash affected areas gently
with soap and warm water after handling.
HHazardous materials
Suppliers of ceramic fiber products recommend the
following first aid measures:
- Respiratory tract (nose and throat) irritation:
If respiratory tract irritation develops, move the
person to a dust free location.
-Eye irritation: If eyes become irritated, flush
immediately with large amounts of lukewarm water
for at least 15 minutes. Eyelids should be held away
from the eyeball to ensure thorough rinsing.
Do not rub eyes.
- Skin irritation: If skin becomes irritated, remove soiled
clothing. Do not rub or scratch exposed skin.
Wash area of contact thoroughly with soap and water.
Using a skin cream or lotion after washing may be
helpful.
- Gastrointestinal irritation: If gastrointestinal tract
irritation develops, move the person to a dust free
environment.

4
Page
Table of Contents
5285 429 - 02
Vitorond 200, VD2 Series 320 to 1080 Installation
Safety
General Information
Set-up
Assembly
Safety, Installation and Warranty Requirements..............2
Product documentation...........................................2
Licensed professional heating contractor...................2
Contaminated air ...................................................2
Advice to owner ....................................................2
Warranty ..............................................................2
Carbon monoxide...................................................2
Fresh air ...............................................................2
Equipment venting .................................................2
Fiberglass wool and ceramic fiber materials...............3
Suppliers of ceramic fiber products recommend the
following first aid measures:....................................3
Precautionary measures..........................................3
First aid measures..................................................3
Hazardous materials ...............................................3
Important Regulatory and Safety Requirements ..............7
Codes ..................................................................8
Mechanical room ...................................................8
Working on the equipment ......................................8
Technical literature ................................................8
Installation tools and materials.................................8
About these Installation Instructions .............................9
Product Information....................................................9
Mechanical Room .....................................................10
Minimum Clearances.................................................10
Minimum Clearances to Combustibles ....................10
Boiler model VD2.................................................10
Recommended Minimum Service Clearances ...........10
Boiler Set-up and Location.........................................11
Transport into mechanical room.............................11
Foundation..........................................................11
Standard Equipment .................................................12
Number of cast iron sections per model ..................12
Cast Iron Section Assembly .......................................13
Boiler Model VD2.................................................16
Number of sections..............................................16
Tie rod layout 19 and 24 in. (480 and 610 mm) ......16
Water Distribution Pipe and Drain Installation ...............17
Hydrostatic Pressure Test..........................................18
Flue Gas Turbulators and Combustion Chamber Door....19

5
Page
Table of Contents
5285 429 - 02
Vitorond 200, VD2 Series 320 to 1080 Installation
Connections
Enclosure
Burner
Water Side Connections ............................................20
Return temperature elevation.................................21
Venting Connection ..................................................22
In Canada ...........................................................22
In U.S.A. ............................................................22
Venting Requirements...............................................22
Venting option #1 (Category I venting) ...................22
Chimney.............................................................22
Barometric draft regulator type ..............................23
Barometric draft regulator diameter ........................23
Venting option #1 (Category I venting) ...................22
Venting option #2 (Category III).............................24
ProTech Systems Inc............................................24
Selkirk Metalbestos..............................................24
Security Chimneys ...............................................24
Flue Gas Connection.................................................24
Flue gas test point location ...................................24
Removal of Existing Boiler .........................................25
Safety Connections and Pressure Testing ....................26
Pressure relief valve .............................................26
Boiler Pressure Test ..................................................26
Low Water Cut-off (LWCO) .......................................26
Enclosure Installation ................................................27
Boiler model VD2.................................................27
Boiler Control Installation...........................................31
Enclosure Installation ................................................32
Burner Installation ....................................................33
Combustion chamber sight glass............................33
Fuels..................................................................33
Burner calibration.................................................34
Two-stage burner ................................................34
Model.................................................................34
Flue gas resistance ..............................................34
Fully modulating burner ........................................34
Weishaupt burners / Riello burners .........................34
Vitorond 200, VD2 with Viessmann / Vitotronic
controls..............................................................34
Model.................................................................34
Input ..................................................................34
Min.1-stage .........................................................34

6
Page
Table of Contents
5285 429 - 02
Vitorond 200, VD2 Series 320 to 1080 Installation
Start-up
Appendix
System Preparation ..................................................35
Combustion air supply ..........................................35
Gas piping pressure test .......................................35
Initial System Fill......................................................35
Prior to Start-up .......................................................36
Start-up Information .................................................37
Initial start-up......................................................37
Instructing the system user ...................................37
Shut-down..........................................................37
Extended shut-down periods .................................37
Start-up after extended shut-down.........................37
Piping in Heating/Cooling Application ..........................38
Technical Data.........................................................39
Technical Data ....................................................39
Boiler Model........................................................39
Input (oil)............................................................39
Input (gas) ..........................................................39
Output (oil/gas) ...................................................39
Combustion efficiency (oil) ...................................39
Combustion efficiency (gas) .................................39
Thermal efficiency (oil) .........................................39
Thermal efficiency (gas) .......................................39
Number of cast iron sections.................................39
Cast iron block dimensions....................................39
Cast iron section dimensions .................................39
Technical Data.....................................................40
Boiler Model.........................................................40
Dimensions (with insul. jacket) .............................40
Weight ...............................................................40
Overall weight.....................................................40
Boiler water content.............................................40
Max. boiler temperature ........................................... 40
Max. allow. operating pressure ..............................40
Boiler connections................................................41
Heating surface area ............................................41
Flue gas .............................................................41
Vent pipe collar ..................................................41
Flue gas resistance - at upper end of rated input ......41
Required flue draft Category I................................41
Positive pressure Category III ................................41

7
5285 429 - 03
Vitorond 200, VD2 Series 320 to 1080 Installation Safety
Important Regulatory and Safety Requirements
For installations on the Commonwealth of Massachusetts, the following modifications to NFPA-54 chapter 10 apply:
Excerpt from 248 CMR 5-08:
2(a) For all side-wall horizontally vented gas fueled equipment installed in every dwelling, building or structure
used in whole or in part for residential purposes, including those owned or operated by the Commonwealth
and where the side-wall exhaust vent termination is less than (7) feet above finished grade in the area of
the venting, including but not limited to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side-wall
horizontal vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired
carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas
equipment is to be installed. In addition, the installing plumber or gas fitter shall observe that a battery
operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the
dwelling, building or structure served by the side-wall horizontal vented gas fueled equipment. It shall be
the responsibility of the property owner to secure the services of qualified licensed professional for the
installation of hard-wired carbon monoxide detectors.
a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or
an attic, the hard-wired carbon monoxide detector with alarm and battery back-up may be installed on
the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of
installation, the owner shall have a period of thirty (30) days to comply with the above requirements;
provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector
with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance
with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the
building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal
for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no
less than one-half (b) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
4. INSPECTION. The state or local gas inspector of the side-wall horizontally vented gas fueled equipment
shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide
detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current
edition of NFPA 54 as adopted by the Board; and
2. Product Approved side-wall horizontally vented gas fueled equipment installed in a room or structure
separate from the dwelling, building or structure used in whole or in part for residential purposes.

Vitorond 200, VD2 Series 320 to 1080 Installation
5285 429 - 03
8
Safety
Important Regulatory and Safety Requirements (continued)
Codes
The installation of this unit shall be in accordance with
local codes. In the absence of local codes, use:
CAN/CSA-B149.1 or .2 Installation
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.
For oil-fired boiler installation, use CSA B-139 in Canada
and NFPA 31 in the U.S. Always use latest editions of
codes.
In Canada all electrical wiring is to be done in accordance
with the latest edition of CSA C22.1 Part 1 and/or local
codes. In the U.S., use the National Electrical Code ANSI/
NFPA 70.
The heating contractor must also comply with the Standard
for Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1 where required by the
authority having jurisdiction.
Note: Please carefully read this manual prior to attempting
installation. 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.
Mechanical room
Ensure the mechanical room complies with the
requirements of the System Design Guidelines and/or
Technical Data Manual. In addition, see section entitled
“Mechanical Room” on page 7 in this manual.
Viessmann recommends installation of an additional
electrical disconnect switch and a fuel shut-off valve
(if possible) outside the mechanical room or enclosed area
of installation.
The maximum room temperature of the mechanical room
where the boiler is located must not exceed 104°F ( 40°C).
Working on the equipment
The installation, adjustment, service, and maintenance
of this boiler must be performed 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, burners,
or control.
Note: The completeness and functionality of field supplied
electrical controls and components must be verified
by the heating contractor. This includes low water
cut-offs, flow switches (if used), staging controls,
pumps, motorized valves, air vents, thermostats, etc.
Ensure main power supply to equipment, the heating
system, and all external controls has been deactivated.
Close main gas supply valve. Take precautions in all
instances to avoid accidental activation of power during
service work.
Technical literature
Literature for the Vitocrossal 200 VD2 boiler:
- Technical Data Manual
- Installation Instructions
- Service Instructions
- Operating Instructions and User’s Information Manual
- Instructions of other Viessmann products utilized with
this installation
- Installation codes mentioned in this manual
For installation of the heating system, refer to the
technical literature of other System Technology devices:
- Installation Instructions for Viessmann boiler control
- Installation Instructions for Viessmann indirect-fired hot
water storage tank(s)
- Installation Instructions for burner and accessories
Note: 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.
Installation tools and materials
In addition to standard tools and safety wear typically
necessary to install the boiler, the following are needed
to perform the assembly of this cast iron sectional boiler:
- draw tool kit
- wood/rubber mallet and regular hammer
- half-round metal file
- flat chisel
- lacquer solvent
- linseed oil
- cleaning rags

9
5285 429 - 03
Vitorond 200, VD2 Series 320 to 1080 Installation General Information
Product Information
Sectional cast iron oil-/gas-fired hot water heating boiler.
For operation with modulating boiler water temperatures
in closed loop, forced circulation hot water heating
systems.
The Vitorond 200, VD2 boilers are Category I boilers
as defined by the ANSI 21.13/CSA 4.9-2000. See the
“Venting Connection” section in this manual for detailed
information.
The boiler model selected should be based on an accurate
heat loss calculation of the building. The boiler selected
must be compatible with the connected radiation.
Maximum working pressure. . . . . . . . . . 75 psig (5 bar)
Minimum working pressure. . . . . . .. . . .20 psig (1.5 bar)
Maximum boiler temperature. . . . . . . . . 248°F (120°C)
This boiler does not require a flow switch.
WARNING
Exposing the boiler to pressures and temperatures
in excess of those listed will result in damages,
and will render warranty null and void.
About these Installation 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.

IMPORTANT
Note: Warnings draw your attention to the presence of
potential hazards or important product information.
Note: 
Cautions draw your attention to the presence of
potential hazards or important product information.
Helpful hints for installation, operation or maintenance
which pertain to the product.
Note: 
This symbol indicates that additional, pertinent
information is to be found.
Note: 
This symbol indicates that other instructions must
be referenced.
WARNING
Indicates an imminently hazardous situation which,
if not avoided, could result in loss of life, serious
injury or substantial product/property damage.
CAUTION
Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product/
property damage.

Vitorond 200, VD2 Series 320 to 1080 Installation
5285 429 - 03
10
Mechanical Room
Boiler must be located in a heated indoor space.
The Vitorond 200, VD2 boiler should be located near
a floor drain and as close as possible to the vertical
chimney or vent.
Whenever possible, install boiler near an outside wall so
that it is easy to duct fresh air directly to the boiler area.
Install boiler on flooring capable of supporting the weight
of the boiler filled with water.
Set-up
Minimum Clearances
Legend
AOuter rim of boiler base (without insulation)
Minimum Clearances to Combustibles
Boiler model VD2- 320 380 440 500 560 630 700 780 860 950 1080
Top 6 in. (150 mm)
Sides 6 in. (150 mm)
Flue (oil) 9 in. (229 mm)
Flue (gas) 6 in. (150 mm)
Front 6 in. (150 mm)
Floor non-combustible
IMPORTANT
Maintain 1 in. air clearance from uninsulated hot water
pipes to combustible material.
Recommended Minimum Service Clearances
Boiler model VD2- 320 380 440 500 560 630 700 780 860 950 1080
a Minimum Clearance
in front of boiler
in.
(mm)
65b
1660
70
1790
76
1920
81
2050
86
2180
91
2310
96
2440
101
2570
106
2700
111
2830
117
2960
b Minimum Clearance
on boiler side
in.
(mm)
20
500
20
500
20
500
20
500
20
500
20
500
20
500
20
500
20
500
20
500
20
500
c Minimum Clearance
behind boiler
in.
(mm)
39
1000
39
1000
39
1000
39
1000
39
1000
39
1000
39
1000
39
1000
39
1000
39
1000
39
1000
d in.
(mm)
Dependent on burner model
IMPORTANT
Boiler must not be installed on carpeted surfaces.
Do not use exhaust fans without adding additional
provisions for fresh combustion air (e.g. fresh air fan)
in the boiler room and do not install the Vitorond 200,
VD2 boiler in rooms with refrigeration equipment.
This boiler requires uncontaminated air for safe operation
- do not install where chemicals are stored.
See section entitled “Combustion air supply” on page 35
for further details.

11
5285 429 - 03
Vitorond 200, VD2 Series 320 to 1080 Installation Set-up
Boiler Set-up and Location
Boiler
model
VD2-
320
VD2-
380
VD2-
440
VD2-
500
VD2-
560
VD2-
630
VD2-
700
VD2-
780
VD2-
860
VD2-
950
VD2-
1080
a
in. (mm)
45
(1140)
49c
(1265)
54c
(1390)
59c
(1515)
64b
(1640)
69b
(1765)
74b
(1890)
79a
(2015)
84a
(2140)
87
(2205)
94
(2390)
b
in. (mm)
52a
(1330)
57a
(1455)
62a
(1580)
67
(1705)
72
(1830)
77
(1955)
82
(2080)
86c
(2205)
91c
(2330)
96b
(2460)
101b
(2580)
The boiler must be installed on a levelled base or
foundation, which must be designed to carry the entire
weight of the boiler, water fill, burner and attached
piping. To ease the installation of the individual sections,
angle-iron or flat steel may be incorporated into the
concrete foundation. Surface width of steel strips should
be 4 in. (100 mm).
Boiler Base
>=4 in. (100 mm)
35bin. (900 mm)
43ain. (1100 mm)
2 in. (50 mm)
4 in.
(100 mm)
4 in.
(100 mm)
5bin.
(140 mm)
ab
Note: Inch dimensions rounded to the nearest ¼ in.

Vitorond 200, VD2 Series 320 to 1080 Installation
5285 429 - 03
12
Set-up
Standard Equipment
Legend
ACombustion chamber door
BFront section
CIntermediate section
DRear section
EFlue gas collar
Number of cast iron sections per model
Boiler model VD2- 320 380 440 500 560 630 700 780 860 950 1080
Total number of
sections
9 10111213141516171819
Number of
intermediate
sections
7 8 9 1011121314151617
All necessary parts to assemble the heating boiler are
packaged and shipped in the carton labeled “Boiler
Accessories”.
The heat exchanger block consists of a rear section with
mounted flue gas collar, a front section with mounted
combustion chamber door, and depending on the size
of the boiler, the appropriate number of intermediate
sections.
Individual cast iron sections are sealed by inserting
glass fiber rope gaskets which are glued into the pre-
cast groove system on each section to seal the flue gas
passageways.
The water side seal between the sections is achieved with
cast iron push nipples.
IMPORTANT
Observe directional arrows on cast iron sections. See Fig.
3, as well as step 7 on the following page.
Boiler front

13
5285 429 - 03
Vitorond 200, VD2 Series 320 to 1080 Installation
Cast Iron Section Assembly
Assembly
3. Press the three glass fiber rope seals properly into the
grooves while the cast iron section is still flat on the
ground. The ends of the rope must properly meet.
No openings between gaskets are acceptable.
4. Check both nipple ports for burrs and, if necessary,
remove burrs with a file. 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. Clean the nipple
ports and nipple port face with solvent, dry properly
and paste with supplied linseed oil.
5. Clean both push nipples with solvent, dry and paste
with supplied linseed oil.
6. Insert push nipples into nipple ports and secure with
gentle hammer taps (wood or rubber mallet only).
Ensure push nipples are inserted evenly by tapping
in a cross-wise fashion. Remove any burrs, if necessary.
7. Prepare an intermediate section according to steps
1 through 6. Arrows on the intermediate section must
point toward the rear section.
Legend
ANot to be installed on rear section
BNot for the last to be installed intermediate section
CRemove flanges from rear section prior to boiler
assembly
CAUTION
The rope gaskets must be cut to exact lengths.
No openings between gaskets are acceptable.
Working from the rear section to the front section
requires the gasket only on the front side of the
section. Do not double gasket.
CAUTION
During the application of the glue, ensure proper
ventilation of the work area.
1. Cut individual glass fiber rope seals and secure each
cut end against fraying by taping it with the supplied
masking tape.
2. Lay each section flat, the side to be gasketed facing
up. Apply the supplied glue into the pre-cast grooves.
Allow the glue to dry approximately five minutes.

Vitorond 200, VD2 Series 320 to 1080 Installation
5285 429 - 03
14
Assembly
Cast Iron Section Assembly (continued)
IMPORTANT
For all sections, clean nipples with solvent and apply
supplied linseed oil.
IMPORTANT
During the entire compression procedure, all threads on
the draw tool assembly must be properly lubricated with
the supplied grease before use.
8. Align the prepared intermediate section with push
nipples of the rear section.
9. Lift the rear section onto the boiler foundation. Align
the section legs against the rear strip panel of the
boiler foundation (not shown). Properly position rear
section and secure against tipping.
10. Mount intermediate section with wood or rubber
mallet by tapping it onto the push nipples of the rear
section. Do not hammer in place.
11. Insert the two main draw tool rods from the rear
section to the front section into the upper and lower
push nipple ports.
12. Slide pressure flanges onto the draw tool rods and
attach locking plates as shown.
13. Attach pressure nuts and align both parallel to each
other (same thread depth) by utilizing the ratchet
tool. Ensure that all sections are aligned parallel
to each other before applying pressure. Start to
tighten evenly. Once the push nipple ports touch,
do not apply further pressure. Do not use excessive
force if push nipple ports do not touch.
IMPORTANT
During the compression procedure, draw in only one
additional section at a time to prevent leaks at the joints.

15
5285 429 - 03
Vitorond 200, VD2 Series 320 to 1080 Installation
Cast Iron Section Assembly (continued)
Assembly
14. Loosen draw tool and remove pressure nuts.
15. Repeat steps 1 through 10 until the draw tool kit can
be used again. Do not glue glass fiber rope into center
of pre-cast groove of intermediate section attached
to front section (see page 10).
16. Attach extension rods to the main draw rods and
sections according to steps 11 and 12, until heat
exchanger block is completely assembled.
17. Remove supports after three sections have been
assembled.
18. Remove combustion chamber door from front section
by loosening threaded M 16 nuts.
19. Prepare front section in the same way as previous
sections and align with remainder of heat exchanger
block utilizing the draw tool kit in the same fashion as
before.
20. Tie rods with washers to top and bottom of heat
exchanger block according to pattern and table on
following page. Space threads on front and rear
sections evenly. Do not overtighten.
21. Loosen pressure nuts and remove draw tool kit.
Retighten all tie rods.
IMPORTANT
Only release the draw tool once the sections have been
joined with the tie rods.
22. Ensure that the heat exchanger block is level and
vertical on boiler base. All individual section legs must
properly rest on boiler foundation. Where necessary,
fill gaps with strips of sheet metal.
Please clean draw tool kit before re-crating, ensure that
all parts are included and crate is properly closed before
return shipment.
IMPORTANT
All section feet must be firmly placed on the boiler base.
If necessary, shim section feet.

Vitorond 200, VD2 Series 320 to 1080 Installation
5285 429 - 03
16
Assembly
Cast Iron Section Assembly (continued)
Top view
Side view
Rear
section
Boiler
front
Placement of tie rods
Note: Number 1 refers to rear section.
Tie rod layout 19 and 24 in. (480 and 610 mm)
Number
of
sections
Boiler
model
VD2-

17
5285 429 - 03
Vitorond 200, VD2 Series 320 to 1080 Installation Assembly
Water Distribution Pipe and Drain Installation
1. To assemble the water distribution pipe, pipe together
- rod end and extension rod and secure with supplied
sheet metal screws.
Number and length of the rods vary for different
boiler sizes.
- Mount gasket on flange rod and secure flange rod
with supplied brass screws.
2. Slide water distribution pipe through lower nipple
ports.
3. Insert supply nipple into R cin. opening on rear cast
iron section and install supplied fill and drain valve.
IMPORTANT
Ensure that distribution pipe openings are facing
upward.
Ensure that distribution pipe openings are facing upward.
Front section
“a” max, of
9/32 in. (7 mm).
R 2 in.
plug
Rear section
R cin.
4. Apply hemp and pipe dope to R 2 in. plugs and insert
into openings in the front section as shown.
5. Tighten R 2 in. plugs into front section using a 1 in.
square pipe tube or a 1” ratchet. Ensure that R 2 in.
plugs do not protrude beyond a maximum of 9/32 in.
(7 mm).
IMPORTANT

Vitorond 200, VD2 Series 320 to 1080 Installation
5285 429 - 03
18
Assembly
Hydrostatic Pressure Test
*Two metric weld-neck flanges Dare supplied with the
boiler (shipped inside combustion chamber). Use these
flanges to perform the hydrostatic test.
Use a metal plate of sufficient gage between these
flanges and the boiler supply/return connection during
the hydrostatic test. After successful completion of the
hydrostatic test, remove the metal plate and discard.
Legend
ASensor well
BR ein. plug
CAir vent
DMetric flanges*
1. In the ein. tapping on top of the rear section, install
supplied R ein. plug B. After pressure test has
been completed, replace R ein. plug with supplied
manual or automatic air vent C(watch for proper
pressure rating).
2. In the cin. opening install the enclosed stainless
steel sensor well Ausing the supplied hemp and
pipe dope.
3. Close off main boiler supply and return with a blanc
metal plate and flanges Dand attach a pressure
gage (0-150 psig range) to safety header, as well as
another automatic air vent (watch for proper pressure
rating) to bleed all air properly from safety header.
4. Fill pressure vessel with room temperature water
and check for proper venting of air.
5. The minimum hydrostatic test pressure must be
110 psig, the maximum at 1½ times the maximum
operating pressure of the boiler (not to exceed 120
psig). Should the city water pressure not be enough,
utilize a hand pump connected to the drain valve
of the boiler.
6. The test pressure should be maintained for 30
minutes. Inspect all top push nipple ports for leakage
using a flashlight. Inspect bottom push nipple 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 remove automatic air vent.
Close opening with plug supplied, utilizing hemp
and pipe dope.
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.
Installation of sensor well and preliminary air vent

19
5285 429 - 03
Vitorond 200, VD2 Series 320 to 1080 Installation Assembly
Flue Gas Turbulators and Combustion Chamber Door
1. For models VD2-320 to VD2-860 only:
Insert the respective number of turbulators into each
flue gas passageway (see table below).
Push the first turbulator element approximately one
third of the way into the flue gas passageway, hook
in the second and third elements and push in.
2. Attach the combustion chamber door to the front
section and align.
Observe the hinge side of the door.
The combustion chamber door is factory assembled
to hinge on the left-hand side. A right-hand hinge
is feasible by rebuilding the door hinge hardware.
3. Tighten combustion chamber door with M 16 screws.
4. Insert sight glass into provided opening in combustion
chamber door.
Boiler model VD2- 320 to 440 500 and 560 630 to 860
Turbulator elements per
flue gas passageway
321
Turbulator elements per
boiler
12 8 4
Turbulators may not be exactly as illustrated.
See Installation Instructions Supplement for
Door Safety Switch (oil-fired boilers only).

Vitorond 200, VD2 Series 320 to 1080 Installation
5285 429 - 03
20
Connections
Water Side Connections
Cast iron block, rear view
Legend
BR Boiler water supply connection
BS Drain
D Boiler water return connection
The Vitorond 200, VD2 boiler is only for use in forced
circulation hot water heating systems.
1. Thoroughly rinse heating system (particularly when
retrofitting the Vitorond 200, VD2 to an existing
heating system).
2. Install supply and return headers (see following page).
Make all heating system connections.
Installation of a spring-loaded flow check valve, immediately
downstream of the circulation pump in the heating circuit
supply as a mechanical “break”, is recommended to prevent
water from flowing unintentionally to (space) heating
circuits during DHW priority or summer operation (when
only DHW is produced).
WARNING
Do not install an isolation valve between boiler and
safety header. Discharge pipe must be 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 do not contain restrictive
piping where air could be trapped.
IMPORTANT
Ensure all requirements detailed in the Vitorond 200, VD2
System Design Guidelines and/or Technical Data Manual
are met.
3. Install safety piping.