Viessmann Vitorond 200 Series User manual

Installation instructions
for contractors
VIESMANN
Vitorond 200
Type VD2A, 125 to 270 kW
Oil/gas boiler
VITOROND 200
5592831 GB 9/2018 Dispose after installation.

2
Please follow these safety instructions closely to
prevent accidents and material losses.
Safety instructions explained
Danger
This symbol warns against the risk of injury.
!Please note
This symbol warns against the risk of material
losses and environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■Work on electrical equipment may only be carried
out by a qualified electrician.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW G K directives,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
Working on the system
■Isolate the system from the power supply (e.g. by
removing the separate fuse or by means of a mains
isolator) and check that it is no longer 'live'.
■Safeguard the system against reconnection.
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
Safety instructions
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1. Information Disposal of packaging ............................................................................ 4
Symbols ................................................................................................. 4
Intended use .......................................................................................... 4
Product information ................................................................................ 5
System examples .................................................................................. 5
2. Preparing for installation Clearance dimensions ........................................................................... 6
Standard delivery, standard boiler ......................................................... 7
3. Installation sequence Boiler section assembly ......................................................................... 8
■Preparing the back section ................................................................. 9
■Fitting the first centre section and pressing the sections together ...... 10
■Fitting further boiler sections and pressing them together .................. 12
■Joining sections with anchor rods ....................................................... 14
■Removing the compression tool and aligning the boiler ..................... 15
Distributor pipe and drain installation ..................................................... 16
Checking the boiler block for leaks ........................................................ 18
Turbulators (only up to 195 kW) and boiler door ................................... 19
Connections on the heating water side .................................................. 20
Making the safety connection ................................................................ 20
Fitting the thermal insulation mat ........................................................... 21
Connections on the flue gas side ........................................................... 22
Back panels and Therm-Control sensor ................................................ 22
Fitting the thermal insulation jacket ....................................................... 23
Fitting the panels ................................................................................... 24
■Fitting the side panels and front panel ................................................ 24
Control unit and electrical connection .................................................... 24
■Fitting the control unit and routing electrical cables/leads .................. 24
■Connections to the control unit base .................................................. 25
Fitting the top panels and control unit fascia ......................................... 26
Mounting the burner ............................................................................... 26
■Boilers with 125 kW: ........................................................................... 26
■Boilers from 160 kW: .......................................................................... 26
Pressure switch ..................................................................................... 27
■Pressure switch .................................................................................. 27
Commissioning information ................................................................... 27
Index
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Please dispose of packaging waste in line with statu-
tory regulations.
DE: Use the disposal system organised by
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.
Symbols
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions as well as the details in the datasheet.
It is only designed for the heating up of heating water.
Commercial or industrial usage for a purpose other
than the heating up of heating water shall be deemed
inappropriate.
Intended use presupposes that a fixed installation in
conjunction with permissible components designed for
this purpose has been carried out.
Disposal of packaging
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Every other use will be deemed to be inappropriate.
Any resulting losses are excluded from the manufac-
turer's liability.
Any usage beyond this must be approved by the man-
ufacturer for the individual case.
Intended use also includes the adherence to mainte-
nance and inspection intervals.
Product information
Vitorond 200, type VD2A
■Fuels: Fuel oil and natural gas
■Rated heating output 125 to 270 kW
■Permissible operating pressure 6 bar (0.6 MPa)
System examples
Available system examples: See www.viessmann-
schemes.com.
Intended use (cont.)
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430
600 170
b
200 (100)
a
500 (200)
500 (200)
Fig. 1
AOuter edge, plinth (accessories)
Dimensions in brackets are minimum clearances.
Rated heating output kW 125 160 195 230 270
a mm 1200 1400 1600 1800 2000
b mm Observe the installed burner length.
Clearance dimensions
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Fig. 2
ABurner plate, supplied
BBoiler door
CFront section
DTurbulators in the 2nd flues (only up to 195 kW)
EAnchor rods
FCentre section (for number see table)
GDistributor pipe in the upper hub
HBack section
KFlue outlet (fitted)
LBoiler accessories can be found in the combustion
chamber. When delivered as a pre-assembled
boiler block, there is no "pack of individual sec-
tions".
Rated heating output kW 125 160 195 230 270
Number of centre sections 2 3 4 5 6
Standard delivery, standard boiler
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Note
If the boiler is supplied as a pre-assembled block:
Remove the boiler accessories from the combustion
chamber.
To continue, see page 16.
7.
5.
3.
2.
6.
125-195 kW
4.
1.
Fig. 3
Note
We recommend siting the boiler on the plinth (acces-
sories) with adjustable anti-vibration feet.
Boiler section assembly
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Preparing the back section
2.
1.
Fig. 4
ACleaning agent
BObserve clearance from the wall. See page 6.
1
2
4
3
2.
1.
3.
Fig. 5
ACleaning agent
BLinseed oil graphite, supplied
Note
The connectors must be seated straight and securely
in the hubs.
Boiler section assembly (cont.)
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Fitting the first centre section and pressing the sections together
Applying sealant to sealing contour on 1st centre section
BA
1.
2.
Fig. 6
ASealing contour on 1st centre section
BSealant supplied
Pressing the sections together
Danger
Escaping flue gas leads to breathing difficulties
and poisoning.
To prevent leaks, the sealant must not be
allowed to dry. Join the sections together no
later than 10 min after starting to apply it.
Handling the compression tool:
Compression tool installation instructions
Boiler section assembly (cont.)
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1.
4.
3.
2.
4.
Fig. 7
When assembling the boiler sections, observe the fol-
lowing
■Keep the distance between the sections the same at
the top and the bottom.
■Never secure the sections out of true.
■Never force the sections together.
■During the compression process, only pull together
one additional section at a time. This procedure pre-
vents leaks.
Removing the compression tool
Note
Release and remove the compression tool before fit-
ting the next boiler segments.
Boiler section assembly (cont.)
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Fitting further boiler sections and pressing them together
2.
1.
3.
A
B
B
1
2
4
3
1.
3.
2.
4.
Fig. 8
ACleaning agent
BLinseed oil graphite, supplied
Note
The connectors must be seated straight and securely
in the hubs.
Boiler section assembly (cont.)
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Applying sealant to the sealing contour of all additional sections
1.
2.
BA
Fig. 9
ASealing contour on all additional sections
BSealant supplied
Pressing the sections together
See pages 10 to 11.
Danger
Escaping flue gas leads to breathing difficulties
and poisoning.
To prevent leaks, the sealant must not be
allowed to dry. Join the sections together no
later than 10 min after starting to apply it.
Boiler section assembly (cont.)
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Joining sections with anchor rods
2.
2.
1.
Fig. 10
Note
The compression tool holds the boiler together. Only
release the compression tool when the sections have
been joined with anchor rods A.
Note
Only tighten nuts on anchor rods A by hand. Never
apply force.
Boiler section assembly (cont.)
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Removing the compression tool and aligning the boiler
2.
1.
Fig. 11
Note
All section feet must be firmly placed on the support
surface. If required, shim the section feet.
Boiler section assembly (cont.)
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1.
2.
Fig. 12
AGasket
BDistributor pipe
CStuds
DPlug R 2
EQuadrant for free-wheel ratchet, supplied with
compression tool
FNuts
GFlange
Distributor pipe and drain installation
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R1
2.
3.
1.
Fig. 13
ADistributor pipe
BSensor well
CGasket
DStuds
EReducer
FSpacer
GDrain & fill valve (on site)
HBoiler return gasket Ø 59 x 118 x 3 mm
Note
Check correct position of the distributor pipe.
Distributor pipe and drain installation (cont.)
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Only when delivered in individual sections
Note
Not required if the boiler is supplied as a single block
(factory tested)
1.
Fig. 14
ABlank flange (on site)
Carry out water pressure test in accordance with
TRD 702.
Test pressure: 9 bar (0.9 MPa)
Vent the boiler via the flow.
Note
No pressure, control or safety equipment should be
installed during the water pressure and tightness tests.
Test the pressure with a pressure gauge class 1.0.
Torque for cleaning cover 5 Nm
Checking the boiler block for leaks
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If the boiler is supplied in individual sections
M12
2.
4x4x
125-195 kW
1.
Fig. 15
Note
You may hang the boiler door for l.h. or r.h. opening.
Torque for boiler door 30 Nm
Turbulators (only up to 195 kW) and boiler door
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≥400
KV
KR
E
Fig. 16
E Drain, R 1
KR Boiler return, DN 65
KV Boiler flow, DN 65
ADrain & fill valve (on site)
BBoiler return gasket Ø 59 x 118 x 3 mm
Note
Install all pipe connections free of load and torque
stress.
Making the safety connection
Installation instructions, safety equipment block
and connection set
Installing safety lines
Safety connection DN 40
Permiss. operating pressure 6 bar (0.6 MPa)
Test pressure 9 bar (0.9 MPa)
Low water indicator
The boilers must be equipped with a low water indica-
tor.
Safety valve
Equip boilers with a safety valve that is type-tested to
TRD 721 [or local regulations] and is marked accord-
ing to the system version.
Note
Install all pipe connections free of load and torque
stress.
!Please note
Unsuitable water quality can damage the boiler
body.
Only fill the boiler with water that complies with
the "Water quality requirements" (see service
instructions).
Connections on the heating water side
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