Viessmann VITOROND 200 VD2A-125 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
5354 788 - 03 03/2015
Installation Instructions
VITOROND 200
Vitorond 200
VD2A Series
Oil-/Gas-fired boiler
Heating input: 490 to 1096 MBH
144 to 321 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, VD2A Series Installation
2
5354 788 - 0c
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”.
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.
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.
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
Vitorond 200, VD2A Series Installation
5354 788 - 03
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
Safety
Safety, Installation and Warranty Requirements (continued)
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
5354 788 - 03
Vitorond 200, VD2A Series Installation
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
Precautionary measures..........................................3
First aid measures..................................................3
Hazardous materials ...............................................3
Important Regulatory and Safety Requirements ..............6
Codes ..................................................................6
Mechanical room ...................................................6
Working on the equipment ......................................7
Technical literature ................................................7
Installation tools and materials.................................7
About these Instructions .............................................8
Product 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 Clearances.................................................11
Recommended Service Clearances .........................11
Minimum Clearances to Combustibles ....................11
Removal of Existing Boiler .........................................12
Assembly of Boiler Base............................................13
Cast Iron Section Assembly .......................................16
Number of cast iron sections per model ..................16
Water Distribution Pipe and Drain Installation ...............20
Hydrostatic Pressure Test..........................................21
Boiler Assembly .......................................................21
Installing turbulator and boiler door ........................21
Water Side Connections ............................................22
Boiler Supply Header ............................................22
Removal of Existing Boiler .........................................23
Safety Connections and Pressure Testing ....................23
Pressure relief valve .............................................23
Boiler pressure test ..............................................24
Low Water Cut-Off (LWCO).......................................24
Enclosure Installation ................................................25
Boiler Control Installation...........................................27
Safety
General Information
Set-up
Connections

Table of Contents
5
Page
5354 788 - 03
Vitorond 200, VD2A Series Installation
Venting Connections ................................................29
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 Installation ....................................................32
Burners ..............................................................32
Combustion chamber sight glass............................32
Fuels..................................................................32
Burner calibration ................................................33
Weishaupt burners / Riello burners .........................33
Flue gas resistance ..............................................33
Burner manufacturer ............................................33
Burner/Gas train approval......................................33
Electrical requirements .........................................33
Natural gas pressure ............................................33
System Preparation ..................................................34
Combustion air supply ..........................................34
Initial System Fill .....................................................34
Gas piping pressure test .......................................35
Prior 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 Application ..........................37
Boiler piping in a heating/cooling application............37
Technical Data.........................................................38
Boiler Model........................................................38
Input (oil) / (gas) ..................................................38
Output (oil) / (gas) ...............................................38
Combustion efficiency (oil) / (gas) .........................38
Thermal efficiency (oil) / (gas) ..............................38
Number of cast iron sections.................................38
Cast iron block dimensions....................................38
Cast iron section dimensions .................................38
Dimensions (with insulation jacket) .......................38
Weight / Overall weight ........................................38
Boiler water content.............................................38
Boiler Model.........................................................39
Max. boiler temperature........................................39
Max. allow. operating pressure..............................39
Heating surface area ............................................39
Flue gas .............................................................39
Vent pipe collar outer ..........................................39
Flue gas resistance ..............................................39
Flue gas volume ..................................................39
Required flue draft ...............................................39
Positive pressure .................................................39
Connections (continued)
Burner
Start-up
Additional Information

Vitorond 200, VD2A Series Installation
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5354 788 - 03
Safety
Important Regulatory and Safety Requirements
Codes
The installation of this unit shall be in accordance with
local codes. In the absence of local codes, use:
Note :Please carefully read this manual prior to attempting
installation. Any warranty is null and void if these
instructions are not followed.
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.
Note :For information regarding other Viessmann System
Technology componentry, please reference
documentation of the respective product.
For oil-fired boiler installation, use CSA B-139 in Canada
and NFPA 31 in the U.S. Always use latest editions of
codes.
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 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.
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 6 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).

7
Vitorond 200, VD2A Series Installation
5354 788 - 03
Safety
Important Regulatory and Safety Requirements (continued)
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 oil or gas supply valve. Take precautions in all
instances to avoid accidental activation of power during
service work.
Technical literature
Literature for the Vitorond 200 VD2A boiler:
- Technical Data Manual
- Installation Instructions
- Service Instructions
- 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. Contact Viessmann for
additional copies.
For installation of the heating system as a whole, please
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
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 * with graphite based sealant*
- cleaning rags
* Do NOT use straight linseed oil.

Vitorond 200, VD2A Series Installation
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8
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, VD2A boilers are Category I and III
boilers as defined by the ANSI 21.13/CSA 4.9. 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...................85 psig (5.9 bar)
Minimum working pressure....................20 psig (1.5 bar)
Maximum boiler temperature.................250°F (121°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 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
Warnings draw your attention to the presence of
potential hazards or important product information.
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.
This symbol indicates that additional, pertinent
information is to be found.
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.

9
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Vitorond 200, VD2A Series Installation General Information
New Casting Design and Therm-Control Functionality
System return water enters the cast iron sections of the
VD2A boiler via a return water distribution tube now
located at the top of the cast iron block (see illustration).
Heated supply water flows at the bottom of the cast iron
block towards the rear section and upward to the supply
connection. The return water temperature is elevated
when passing through the rear cast iron section where
the supply water flows upward to the boiler supply
connection.
The pre-heated return water is then distributed to the
cast iron sections through two upward-pointing openings
in the distribution tube at each section. The size of the
opening is proportional to the amount of heat input of
each cast iron section. In each section the return water
flows downward and mixes with heated water. Once fully
heated, the supply water flows through the bottom of
the cast iron block up the rear section and out the boiler
supply to the system.
The even temperature distribution ensured by this design
reduces the thermal stress 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
pump or return temperature elevation provided by a Low
Temperature Protection (LTP) Package.
Return water
distribution tube
Therm-Control
sensor
Boiler
return
Boiler supply
VD2A cast iron section
VD2 cast iron section
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
the heat exchanger surface area and water volume, and
the number of cast iron sections was reduced by one
section.
Together with the redesigned return water distribution
system and the Therm-Control low-temperature protection
logic, this eliminates the need for a minimum return water
temperature.
The larger water volume and increased width of the flue
passages also ensure even heating of the water and
reduced burner cycling.
A new tongue-and-groove system with silicone sealant
replaces the fiber-rope seal between sections used with
the VD2 Series.
Redesigned Return Water Distribution System

Vitorond 200, VD2A Series Installation
5354 788 - 03
10
General Information
Therm-Control Low-Temperature Protection Logic
Therm-Control is an integrated low-temperature protection
logic provided by the Vitotronic control.
The control uses a Therm-Control temperature sensor
specifically positioned in the casting close to the boiler
return (shown on page 9 and 31) to capture the thermal
state of the boiler (i.e. the temperature of the system
return mixed with the boiler water) and react as early
as possible. The Therm-Control Logic shuts off the system
pump (and, if applicable, closes the mixing valve) and
brings the burner to full fire until the boiler minimum
setpoint temperature is reached during start-up,
preventing the formation of flue gas condensation and
allowing for maximum heat transfer to the system.
This ensures steady supply temperatures with only
minimal fluctuations, and eliminates the need 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 phase, the set Therm-Control temperature
is not achieved at the Therm-Control sensor.
The mixing valve downstream of the boiler receives
a signal via the control to reduce the flow rate and to
operate the burner at full fire (Phase 1).
The boiler temperature and that captured by the Therm-
Control sensor now rapidly rise. The mixing valve opens
when the set temperature is exceeded at the Therm-
Control sensor, and the flow rate (in this example 50%)
inside the boiler is steadily increased (Phase 2).
The return water temperature rises after a certain time
has elapsed which is a function of the system water
volume. As the return temperature rises, the mixing
valve opens further until the maximum flow rate (100%
in Phase 3) is achieved. Now the control will modulate
the burner firing rate to achieve the required setpoint
(burner modulation), and weather-responsive boiler water
temperature modulation will take place.

11
5354 788 - 03
Vitorond 200, VD2A Series Installation
Mechanical Room
Boiler must be located in a heated indoor space.
The Vitorond 200, VD2A 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
ABoiler base
Minimum Clearances to Combustibles
Boiler model
VD2A- 125 160 195 230 270
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. (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)
47¼
(1200)
53
(1400)
59
(1600)
65
(1800)
71
(2000)
b* Burner length 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,
VD2A 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 34
for further details.
*plus 8 in. (200 mm) for door clearance to the wall
Recommended Service Clearances
20 in.
(500 mm)
17 in.
(430 mm)
24 in.
(600 mm)
6cin.
(170 mm)
Top Views
8 in.
(200 mm)
20 in.
(500 mm)
a
b
A

Vitorond 200, VD2A Series Installation
5354 788 - 03
12
Set-up
Removal of Existing Boiler
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine there
is no blockage or restriction, leakage, corrosion,
or any other deficiency which could cause an unsafe
condition.
3. To determine whether the building is operating
under negative pressure, insofar as is practical,
close all building doors and windows and all doors
between the space in which the appliances remaining
connected to the common venting system are located
and other spaces of the building. Turn on any exhaust
fans, such as range hoods and bathroom exhausts,
so they will operate at maximum speed. (Do not
operate a summer exhaust fan). Close fireplace
dampers.
4. Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.
5. Test for spillage at the barometric draft control
relief 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 common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers
and any other gas burning appliance to their previous
condition of use.
7. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1 or latest edition. When resizing, any portion
of the common venting system should be resized
to approach the minimum size as determined using
the appropriate tables in Appendix G in the National
Fuel Gas Code, ANSI Z223.1.
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
operation, while the other appliances remaining connected
to the venting system are not in operation.

13
5354 788 - 03
Vitorond 200, VD2A Series Installation Set-up
Assembly of Boiler Base
1. Install levelling bolts and adjust to lowest setting.*1
2. Level the boiler base with the levelling bolts.
*1 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. (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 mm)
Boiler model 270 - 50 in. (1280 mm)
1. Screw in bolts or anti-vibration bolts (levelling foot B
only for boiler sizes 230 and 270).
2. Install crossbar Awith its larger cut-out pointing
to the front of the boiler.
IMPORTANT
For recommended service clearance from the boiler to the
wall C, see page 11.

Vitorond 200, VD2A Series Installation
5354 788 - 03
14
Set-up
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.
4. The cast iron support leg section must be firmly placed
on the boiler base. If necessary, shim the cast iron leg.
5. See the following pages for assembly of the cast iron
sections.

15
5354 788 - 03
Vitorond 200, VD2A Series Installation 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 level and
adjusting the levelling bolts as required.

Vitorond 200, VD2A Series Installation
5354 788 - 03
16
Set-up
Number of cast iron sections per model
Boiler door VD2A- 125 160 195 230 270
Total number of
sections
45678
Number of
intermediate
sections
23456
CAUTION
During the application of the silicone, ensure proper
ventilation of the work area.
Cast Iron Section Assembly
1. Unscrew the four bolts and remove the boiler door
from its hinges.
2. Remove installation accessory from combustion
chamber.
3. Remove turbulator inserts from secondary flue gas
passes (models VD2A 125-195).
4. Unscrew M12 nuts from distribution tube 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 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”.
IMPORTANT
Do not lose or misplace any of the removed hardware.
Legend
ABoiler plate
B Boiler door
CFront section
D Turbulators in second flue pass (only up to 195 kW)
E Tie rods
FIntermediate section
GDistributor pipe in upper hub
HRear section
KFlue outlet (part of mounted back section)
LBoiler accessories inside the combustion chamber

17
5354 788 - 03
Vitorond 200, VD2A Series Installation Set-up
Cast Iron Section Assembly (continued)
1. Clean all push nipples with solvent, dry and paste
one half of the nipple with supplied linseed oil and
graphite based sealant B(mix the graphite before
using).
2. 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 cross-wise fashion.
3. Paste second half of the nipple with supplied linseed
oil and graphite based sealant B.
IMPORTANT
To ensure no leaks, steel push nipples must be lubricated
by using linseed oil and graphite based sealant B.
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. Clean the nipple ports with solvent 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
pointing
up
1. Lay each section flat, gasket side facing up A.
Apply supplied “Soudal” silicone Binto grooves
while section is laying flat. The first intermediate
section requires sealing only on second and third
pass, as shown in Fig. 15.
2. Align the prepared intermediate section with push
nipples on the rear section. Using a pry bar, make
sure that the push nipples are evenly inserted into
the intermediate section.
IMPORTANT
For all sections, clean nipples with solvent and apply
supplied linseed oil and graphite based sealant.
IMPORTANT
During the entire compression procedure, all threads on the
draw tool assembly must be properly lubricated 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 during assembly they must point to the rear of the
boiler.

Vitorond 200, VD2A Series Installation
5354 788 - 03
18
Set-up
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. 16.
3. 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.
4. Start to tighten evenly with ratchets. Once the push
nipple ports touch, do not apply further pressure.
Do not use excessive force if push nipple ports do not
touch.
Note: Release and remove the compression tool
before fitting the next boiler section.
IMPORTANT
For all sections, clean nipples with solvent and apply
supplied linseed oil and graphite based sealant.
IMPORTANT
During the entire compression procedure, all threads on the
draw tool assembly must be properly lubricated 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 during assembly they must point to the rear of the
boiler.
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.
Clean the nipple ports with solvent and dry properly.
2. Clean all push nipples with solvent, dry and paste one
half of the nipple with supplied linseed oil and graphite
based sealant B(mix the graphite before using).
3. 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
cross-wise fashion.
4. Paste second half of the nipple with supplied linseed oil
and graphite based sealant B.
IMPORTANT
During the compression procedure, draw in only one
additional section at a time to prevent leaks at the joints.
IMPORTANT
To ensure no leaks, steel push nipples must be lubricated
by using linseed oil and graphite based sealant B.

19
5354 788 - 03
Vitorond 200, VD2A Series Installation
Cast Iron Section Assembly (continued)
Set-up
1. Lay each section flat, gasket side facing up A.
Apply supplied “Soudal” silicone Binto grooves
while the cast iron section is laying flat. The next
intermediate sections require sealing all passes,
as shown in Fig. 18.
2. Align the prepared intermediate section with push
nipples on the assembled section. Using a pry bar,
make sure that the push nipples are evenly inserted
into the incoming intermediate section.
IMPORTANT
During the compression procedure, draw in only one
additional section at a time to prevent leaks at the joints.
CAUTION
During the application of the silicone, 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 section legs
must properly rest on boiler base.
3. Please clean draw tool kit before crating, ensure that
all parts are included and crate is properly closed
before return shipment.
IMPORTANT
Only release the draw tool once the sections have been
joined with the tie rods.
IMPORTANT
All section feet must be firmly placed on the boiler base.
If necessary, shim section feet.
1. Prepare front section in the same way as previous
sections and align with heat exchanger block utilizing
the draw tool kit in the same fashion as before.
2. Tie rods with washers to top and bottom of heat
exchanger block. Do not overtighten.
Note: Only hand tighten the nuts on the rods.
Never apply force.

Vitorond 200, VD2A Series Installation
5354 788 - 03
20
Set-up
Water Distribution Pipe and Drain Installation
IMPORTANT
Ensure that distribution pipe openings are facing upward.
1. Install M12 studs C. Insert distribution tube with
gasket A. Install distribution tube cover plate G.
The notch on the distribution tube cap is facing
up and matching the slot in the cast iron piece.
2. Install 2 in. plug on bottom port with good quality
sealing material (Viessmann recommends Hemp
or Loctite 55). Use adaptor and ratchet from draw
tool kit to tighten plug.
Ensure that 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
D 2 in. plug
E Adaptor (from draw tool kit)
F M12 nut
G Distribution pipe cover
Legend
A Distribution pipe
B Four-point well
C Gasket
D M12 studs
E Reducing bushing, 2 in. x 1 in.
F Extension nipple, 1 in.
G Fill and drain valve
1. Install supplied four-point well B into ¾ in. opening
in rear section.
2. Install M12 studs D, the gasket on the supply port
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)
R1