Viessmann VITOROND 200 Instruction manual

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Triple-pass hot water heating boiler
1255 to 4387 MBH / 368 to 1285 kW
Product may not be exactly as illustrated.
Technical ata Manual
Model Nos. and pricing: see Price List
Vitorond 200
Oil-/Gas-fired boiler
sectional cast iron design
with Eutectoplex heat transfer surface, in triple-pass design
for operation with modulating water temperatures
Heating input: 1255 to 4387 MBH
368 to 1285 kW
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Product Information
2VITOROND 200, VD2
VITOROND 200
The modular sectional cast iron design of
the Vitorond 200, V 2 allows for
problem-free transport into
difficult-to-access boiler rooms and permits
easy assembly.
The triple-pass design ensures clean,
low-emission combustion, while the
Eutectoplex heat exchanger surface
guarantees economical energy consumption,
high operational reliability and a long service
life.
The benefits at a glance:
HEutectoplex heat exchanger surface for high
operational reliability and a long service life.
The homogeneous structure of the
Eutectoplex special gray cast iron ensures
uniform heat transfer, minimizing stress
fractures and counteracting the formation of
condensate.
Shape and geometry of the cast iron
sections, excellent water flow characteristics
and uniform temperature distribution further
increase the level of operational reliability.
HProblem-free transport into
difficult-to-access boiler rooms due to
sectional construction and low weight of
individual sections.
HEfficient and environmentally friendly
operation due to modulated boiler water
temperatures.
Combustion efficiency up to:
- oil 88.1%
.....................................................
- gas 85.5%...................................................
Thermal efficiency up to:
- oil 88.0%.....................................................
- gas 85.4%...................................................
HLow-emission combustion through
triple-pass design.
HSimple, quick assembly of the individual
cast iron sections is achieved with a
double-groove seal fit system for the flue
gas passageways. The gasket seal is
secured in place by the double groove,
and therefore not subject to mechanical
stresses.
HProblem-free cleaning access facilitated by
a hinged (left or right) swing-open
combustion chamber door, allowing easy
access to all three heat exchanger passes
from boiler front, reducing side clearance.
HEconomical and safe operation of the
heating system with Vitotronic or
ekamatik digital boiler and heating
system control. Tailored to every
requirement, this control covers all known
control strategies and applications.
HEconomical and hygienic HW production
with indirect-fired Vitocell 100 steel or
Vitocell 300 stainless steel tanks.
Tanks may be combined into multiple-tank
batteries for applications requiring larger
quantities of hot water.
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Product Information
Cut-Away Section
Product may not be exactly as illustrated.Product may not be exactly as illustrated.
VITOROND 200, VD2 3
E tremely effective Second Combustion Vitotronic 300 control -
4” / 100 mm thick pass chamber intelligent and easy to install,
insulation operate and service
Third Eutectople heat Wide water Burner door
pass e changer surface passageways insulation
constructed from
homogeneous special
gray cast iron
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Technical ata
4VITOROND 200, VD2
Technical data*1
Boiler model VD2- 320 380 440 500 560 630 700 780 860 950 1080
Input (oil)*1 MBH 1255 1490 1726 1961 2196 2471 2745 3059 3373 3727 4236
kW 368 436 506 574 643 724 804 896 988 1091 1241
Input (gas)*1 MBH 1300 1544 1787 2031 2275 2559 2843 3168 3493 3860 4387
kW 381 452 523 595 666 750 833 928 1023 1130 1285
Output (oil/gas)*2 MBH 1110 1319 1526 1732 1941 2183 2425 2699 2976 3288 3738
kW 325 387 447 508 569 640 711 791 872 963 1095
Combustion efficiency (oil) % 88.1 88.0 88.0 87.9 87.8 87.8 87.7 87.6 87.5 87.4 87.3
Combustion efficiency (gas) % 85.5 85.4 85.4 85.3 85.2 85.1 85.1 85.0 84.9 84.8 84.6
Thermal efficiency (oil) % 88.0 88.0 88.0 88.0 88.0 87.9 87.9 87.9 87.9 87.8 87.8
Thermal efficiency (gas) % 85.4 85.4 85.4 85.3 85.3 85.3 85.3 85.2 85.2 85.2 85.2
Number of cast iron sections 9 10 11 12 13 14 15 16 17 18 19
Cast iron block dimensions
Length
Width
Height
inches
mm
inches
mm
inches
mm
57
1450
40½
1030
45¼
1150
62
1580
40½
1030
45¼
1150
67
1710
40½
1030
45¼
1150
72
1840
40½
1030
45¼
1150
77½
1970
40½
1030
45¼
1150
82½
2100
40½
1030
45¼
1150
88
2230
40½
1030
45¼
1150
93
2360
40½
1030
45¼
1150
98
2490
40½
1030
45¼
1150
103
2620
40½
1030
45¼
1150
108
2750
40½
1030
45¼
1150
Cast iron section dimensions
Front section (with combustion
chamber door)
Intermediate section
Rear section (with flue gas
collar)
inches
mm
inches
mm
inches
mm
45¼ x 40½ x 10¾
1150 x 1030 x 270
45¼ x 36¼ x 5
1150 x 920 x 125
45¼ x 36¼ x 9
1150 x 920 x 290
Dimensions (with insul. jacket)
Total length
Total width with NR2 control
(side-mounted)
Total width with ekamatik
(side-mounted)
Total width with KR control
(side-mounted)
Total height
inches
mm
inches
mm
inches
mm
inches
mm
inches
mm
58¾
1490
49¼
1250
52¾
1340
54¾
1390
50¾
1290
63¾
1620
49¼
1250
52¾
1340
54¾
1390
50¾
1290
68¾
1750
49¼
1250
52¾
1340
54¾
1390
50¾
1290
73¾
1870
49¼
1250
52¾
1340
54¾
1390
50¾
1290
78¾
2000
49¼
1250
52¾
1340
54¾
1390
50¾
1290
83¾
2130
49¼
1250
52¾
1340
54¾
1390
50¾
1290
89
2260
49¼
1250
52¾
1340
54¾
1390
50¾
1290
93¾
2380
49¼
1250
52¾
1340
54¾
1390
50¾
1290
98¾
2510
49¼
1250
52¾
1340
54¾
1390
50¾
1290
104
2640
49¼
1250
52¾
1340
54¾
1390
50¾
1290
108¾
2760
49¼
1250
52¾
1340
54¾
1390
50¾
1290
Weight
Front section (with combustion
chamber door)
Intermediate section
Rear section (with flue gas
collar)
Cast iron heat exchanger block
Overall weight
complete with insulation
lbs
kg
lbs
kg
lbs
kg
lbs
kg
lbs
kg
529
240
353
160
507
230
3748
1700
3924
1780
529
240
353
160
507
230
4100
1860
4299
1950
529
240
353
160
507
230
4453
2020
4652
2110
529
240
353
160
507
230
4762
2160
4982
2260
529
240
353
160
507
230
5115
2320
5335
2420
529
240
353
160
507
230
5423
2460
5666
2570
529
240
353
160
507
230
5776
2620
6019
2730
529
240
353
160
507
230
6085
2760
6349
2880
529
240
353
160
507
230
6437
2920
6702
3040
529
240
353
160
507
230
6790
3080
7070
3210
529
240
353
160
507
230
7143
3240
7429
3370
*1 Input ratings are based on ANSI Z21.13a*CSA 4.9a-2005 - Gas Fired Steam and Hot Water Boilers; CSA B140.7-05 - Oil Burning
Equipment - Steam and Hot Water Boilers; CSA B140.0-03 - Oil Burning Equipment - General Requirements; UL 726 - 7th ed. - Oil-Fired
Boiler Assemblies; and UL 795 - Commercial Industrial Gas Heating Equipment.
*2 Output ratings are based on the IBR BTS-2000 “method to determine efficiency of commercial space heating boilers”.
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Technical ata
VITOROND 200, VD2 5
Technical data
Boiler model VD2- 320 380 440 500 560 630 700 780 860 950 1080
Boiler water content USG
ltr
65
247
73
275
80
303
87
331
95
359
102
387
110
415
117
443
124
471
132
499
139
527
Ma . boiler temperature*2
(= fixed high limit)
°F
°C
248
120
248
120
248
120
248
120
248
120
248
120
248
120
248
120
248
120
248
120
248
120
Ma . allow. operating
pressure*3 psig 75 75 75 75 75 75 75 75 75 75 75
Boiler connections
Boiler supply and return
Safety supply*4
Safety return*4
rain valve
inches
inches
inches
inches
4
2½
2½
¾
4
2½
2½
¾
4
2½
2½
¾
4
2½
2½
¾
4
2½
2½
¾
4
2½
2½
¾
4
2½
2½
¾
4
2½
2½
¾
4
2½
2½
¾
4
2½
2½
¾
4
2½
2½
¾
Heating surface area
Flue gas side ft.2
m2170 15.8
196
18.2
212
19.7
232
21.5
254
23.6
274
25.5
296
27.5
317
29.5
339
31.5
358
33.3
380
35.3
Water side ft.2
m298 9.1
109
10.1
120½
11.2
131
12.2
142
13.2
153
14.2
165
15.3
175
16.3
187
17.4
198
18.4
209
19.4
Flue gas*5
– Temperature (gross)*6
– Flue gas mass flow rate
With minimum heating input
and a 2-stage burner
(operation of stage 1)
– Temperature
– Flue gas mass flow rate at
minimum input rate
°F
°C
lbs/h
kg/h
°F
°C
lbs/h
kg/h
374
190
1301
590
266
130
710
322
374
190
1598
725
266
130
842
382
374
190
1854
841
266
130
974
442
374
190
2081
944
266
130
1109
503
374
190
2337
1060
266
130
1241
563
374
190
2601
1180
266
130
1398
634
374
190
2897
1314
266
130
1552
704
374
190
3196
1450
266
130
1730
785
374
190
3527
1600
266
130
1907
865
383
195
3825
1735
275
135
2110
957
383
195
4277
1940
275
135
2394
1086
Boiler standby loss based on
max. heating input and hot
water supply and return
temperatures of 167 / 140°F
75 / 60 °C
% 0.40 0.38 0.35 0.32 0.31 0.29 0.28 0.27 0.26 0.25 0.24
Vent pipe collar outer ∅* in
mm
12
300
12
300
12
300
12
300
12
300
12
300
12
300
12
300
12
300
12
300
12
300
Flue gas resistance “w.c. 0.20 0.35 0.51 0.67 0.75 0.83 1.10 1.54 1.93 1.77 2.28
- at upper end of rated input mbar 0.5 0.9 1.3 1.7 1.9 2.1 2.8 3.9 4.9 4.5 5.8
Required flue draft
Category I
Pa
“w.c.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Positive pressure
Category III
Pa
“w.c.
20
0.08
20
0.08
20
0.08
20
0.08
20
0.08
20
0.08
20
0.08
20
0.08
20
0.08
20
0.08
20
0.08
*1 Inch dimensions are rounded to the nearest ¼”.
*2 The maximum supply operating temperature (= max. adjustable high limit) lies approx. 2 °F / 15°C below the fixed high limit setting.
*3 May be less in some Canadian provinces.
*4 Connections for boiler connection kit (standard equipment).
*5 Combustion results are based on 13.0% CO2with fuel oil #2 and 10% CO2with natural gas, as well as
a system supply temperature of 16 °F / 5 °C, and a system return temperature of 140 °F / 60 °C.
*6 Measured flue gas temperature with a combustion air temperature of 68 °F / 20 °C and a boiler water temperature of 1 6 °F / 80 °C.
* Vent pipe collar diameter does not automatically indicate vent/chimney size. See page 13 for details.
"The combustion burner head material must be suitable for temperatures of at least 932 °F / 500 °C.
"Vitorond 200, VD2-950 and VD2-1080 boiler sizes have unique characteristics, including differences in insulation jacket and dimensions.
"For information regarding other Viessmann System Technology componentry, please reference documentation of respective product.
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Technical ata
6VITOROND 200, VD2
Legend
B Boiler drain ¾”
BWR Boiler water return
BWS Boiler water supply
CO Clean-out opening
FGC Flue gas collar
SG Sight glass
a 10½” / 270 mm
b 5” / 125 mm
c 11½” / 290 mm
d 5½” / 140 mm
e 4” / 100 mm
Burner Installation
The burner must be fitted to the burner
plate; installations direct to the boiler
door are not feasible.
Viessmann supplies a pre-drilled end
burner plate in accordance with the
supplied burner dimensions.
Note
For mounting burners with blast tube
diameters of 180 mm / 7” to
280 mm / 11”, the door insulation
(refractory material) can be cut to the
required size.
The blast tube must protrude from the
thermal insulation on the boiler door.
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CO
FGC
BWS
SG
Total length
Length
Total width
Width
Total height
B BWR CO
50¾”/1290 mm
41”/1040 mm 33¼”/845 mm
22¾”/580 mm
22¾”/580 mm
a
e
d
abc
Viessmann North America offers the
side-mounted control option only. Refer to
the side-mounted control dimension on
page 4.
Attention
580 mm/22 7/8”
845 mm/33 1/4”
450 mm/17 3/4”
130 mm/5”
180 mm/7”

Technical ata
Legend
TCP Additional temperature control port, ½”
AQW Aquastat well tapping, ½”
BWR Boiler water return
BWS Boiler water supply
ACP Additional control port, ½” (pressure gage)
S1Return temperature sensor port
S2Boiler pump temperature sensor, ½”
RWE Return water elevation, 2½”
SR Safety return - connection to precharged
membrane expansion tank
SS Safety supply - connection to pressure relief valve
Air Vent
BWS
AQW
ACP TCP
BWS
SS/RWE LWCO SS/RWE
BWR
SR/RWE
SR/RWE
BWR
S1
S2
31½” / 800 mm 15¾” / 400 mm
25¼” / 640 mm
9½” / 240 mm
15¾” / 400 mm
2
6
”
/
6
6
0
m
m
8¼” / 210 mm
3
1
½
”
/
8
0
0
m
m
15¾” / 400 mm
VITOROND 200, VD2 7
Boiler Connection Kit (Standard Equipment)
consisting of boiler supply and return header
Boiler supply header
Boiler return header (top view)
Low Temperature Protection
Boiler model VD2- 320 380 440 500 560 630 700 780 860 950 1080
30% Boiler Flow Package Ø” 1½ 1½ not applicable
100% Boiler Flow Package Ø” 3 4 4 5 5 6
Low temperature protection packages from
Viessmann are required for Vitorond 200
boilers. A 30% Boiler Flow Package is
typically utilized in single-boiler installations.
100% Boiler Flow Packages are utilized in
single- and multiple-boiler installations.
Selection of the correct package depends on
the characteristics of the heating system
and the degree of control necessary to
protect the boiler. Contact Viessmann for
assistance.
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Technical ata
Boiler supply header
Boiler return header
Boiler
supply
connection
Boiler
return
connection
Boiler supply header
Boiler return header
Boiler
supply
connection
Boiler
return
connection
8VITOROND 200, VD2
30% Boiler Flow Package
The 30% boiler flow package consists of:
H1 boiler pump
H2 ball valves
H1 flow check valve
Low water cut-off
(standard equipment)
Boiler shunt pump for return water
temperature elevation
Flow check valve
Location of Honeywell aquastat
(to control boiler pump)
Location of sensor
(installed in stainless steel well)
All boiler piping field supplied.
100% Boiler Flow Package
The 100% boiler flow package consists of:
H1 3-way mixing valve
H1 actuator
H1 boiler pump
Boiler pump
3-way mixing valve
Low water cut-off
(standard equipment)
Location of sensor
(installed in stainless steel well)
All boiler piping field supplied.
It is essential that the heating system
designer review the sizing of all pumps
including the boiler pump normally supplied
with the 100% Boiler Flow Package to
verify that all pumps in the system will
operate correctly. The responsibility for the
distribution system design, including all
circulation pumps, remains with the system
designer.
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IMPORTANT

Technical ata
35½” / 900 mm
43¼” / 1100 mm
4” /
100 mm
2” / 50 mm
>=4” / 100 mm
4” /
100 mm
5½” / 140 mm
a
b
39½” / 19¾” /
500 mm
19¾” /
500 mm
8” / 200 mm
d
c
1000 mm
VITOROND 200, VD2 9
Boiler Base
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” / 100 mm.
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 inches
mm
45
1140
49¾
1265
54¾
1390
59¾
1515
64½
1640
69½
1765
74½
1890
79¼
2015
84¼
2140
87
2205
94
2390
b inches
mm
52¼
1330
57¼
1455
62¼
1580
67
1705
72
1830
77
1955
82
2080
86¾
2205
91¾
2330
96½
2460
101½
2580
Inch dimensions rounded to the nearest ¼”.
Recommended Minimum Clearances
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.
Boiler
model
VD2-
320
VD2-
380
VD2-
440
VD2-
500
VD2-
560
VD2-
630
VD2-
700
VD2-
780
VD2-
860
VD2-
950
VD2-
1080
c inches
mm
65¼
1660
70½
1790
75½
1920
80¾
2050
85¾
2180
91
2310
96
2440
101¼
2570
106¼
2700
111½
2830
116½
2960
d inches
mm
Dependent on burner model size
Inch dimensions rounded to the nearest ¼”.
Front clearances (dimension “c” above) will allow for easy removal of flue gas
turbulator inserts, as well as for full insertion of bristle brush for heat exchanger
cleaning.
Minimum side clearance of 19¾” / 500 mm
must be maintained for side-mounted KR or
Dekamatik controls.
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IMPORTANT

10 VITOROND 200, VD2
Waterside Flow
The Vitorond 200 is designed for closed loop, forced
circulation, hot water heating systems only.
The recommended water flow rate through the Vitorond 200
is based on a temperature difference of between 20°F and
40°F / 11°C and 22°C. When a balancing valve is used for
proper balancing and water flow through the boiler, the valve
should be installed 5 pipe diameters from any fittings and 10
pipe diameters from circulation pumps to allow for laminar
flow.
The consulting engineer or contractor should review the
system design if more balancing valves are required to
properly balance the system.
Viessmann can supply TA (Victaulic) balancing valves upon
request. The balancing should be carried out by a certified
balancing firm prior to boiler start-up. Please contact
Viessmann for your closest certified balancing firm.
V 2-320, V 2-380 and V 2-440
V 2-500, V 2-560 and V 2-630
V 2-700, V 2-780 and V 2-860
V 2-950 and V 2-1080
Recommended Flow Rates
Boiler model VD2- 320 380 440 500 560 630 700 780 860 950 1080
20°F ∆t
40°F ∆t
11°C ∆t
22°C ∆t
GPM
GPM
ltrs/s
ltrs/s
109
55
6.9
3.4
130
65
8.2
4.1
150
75
9.5
4.7
171
85
10.8
5.4
191
96
12.1
6.0
215
108
13.6
6.8
239
119
15.1
7.5
266
133
16.8
8.4
293
147
18.5
9.3
324
162
20
10.2
369
184
23.2
11.6
"∆t= temperature difference
Note:
This boiler does not require a flow switch.
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500
400
300
200
100
50
40
30
25
20
15
10
10 15 20 30 10050 806040
Pressure rop
Flow Rate
200
160
120
80
40
20
16
12
10
8
6
4
44 66 88 132 176 220 264 352 440
”w.c. mbar
GPM
m3/h