Viessmann VITOROND 200 User manual

Installation instructions
for contractors
VIESMANN
Vitorond 200
Type VD2, 320 to 1080 kW
Oil/gas boiler
VITOROND 200
5862444 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
3. Installation sequence Boiler section assembly ......................................................................... 7
■Overview of boiler body ...................................................................... 7
■Preparing the boiler sections .............................................................. 8
■Preparing the back section and first centre section ............................ 9
■Pressing the back section and first centre section together ............... 10
■Pressing further boiler sections together ............................................ 11
■Fitting the lower thermal insulation mat .............................................. 11
■Overview of the anchor rods ............................................................... 12
■Joining sections with anchor rods ....................................................... 13
■Removing the compression tool and aligning the boiler ..................... 14
Distributor pipe and drain installation ..................................................... 15
Checking the boiler block for leaks ........................................................ 17
Inserting turbulators and fitting the boiler door ...................................... 18
Connections on the heating water side .................................................. 19
Making the safety connection and testing for tightness ......................... 19
Fitting the thermal insulation .................................................................. 20
■Fitting the rails .................................................................................... 20
■Fitting the thermal insulation jacket and rear thermal insulation mat .. 22
Connections on the flue gas side ........................................................... 23
Fitting the side, front and back panels ................................................... 23
Fitting the control unit and power supply ............................................... 24
■Fitting the control unit and routing electrical cables/leads .................. 24
■Connections to the control unit base .................................................. 26
Fitting the top panels ............................................................................. 27
Mounting the burner ............................................................................... 27
Pressure switch ..................................................................................... 28
■Pressure switch .................................................................................. 28
Commissioning information ................................................................... 28
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 VD2
■Fuels: Fuel oil and natural gas
■Permissible operating pressure 6 bar (0.6 MPa)
■Rated heating output 320 to 1080 kW
System examples
Available system examples: See www.viessmann-
schemes.com.
Intended use (cont.)
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D
C
c
500
80
200
a
1000
500
152
955
b
A
B
(200)
(200)
(100)
Fig. 1
ABoiler
BBurner
CPlinth (accessory)
DAnti-vibration boiler supports (accessories)
Dimensions in brackets are minimum clearances. Note
We recommend installing the boiler on the plinth
(accessories) with anti-vibration boiler supports
(accessories).
Rated heating output kW 320 380 440 500 560 630
a mm 1660 1790 1920 2050 2180 2310
b mm 1240 1490 1740 1990
c mm Observe the installed burner length.
Rated heating output kW 700 780 860 950 1080
a mm 2440 2570 2700 2830 2960
b mm 1990 2240 2490
c mm Observe the installed burner length.
Clearance dimensions
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Overview of boiler body
Note
All parts required for boiler assembly are included in
the boiler accessory packs.
The boiler body consists of a back section with fitted
flue outlet, a front section with fitted boiler door and a
number of centre sections that depends on the rated
heating output.
The heating gas side is made leakproof by packing
cord that is inserted into the packing grooves at the
front of each section.
Connect the sections by connectors on the heating
water side; these are pressed into the sections.
A B C D E
Fig. 2
ABoiler door
BFront section
CCentre section
(see table for numbers)
DBack section
EFlue outlet
Rated heating output kW 320 380 440 500 560 630
Number of centre sections 7 8 9 10 11 12
Rated heating output kW 700 780 860 950 1080
Number of centre sections 13 14 15 16 17
Boiler section assembly
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Preparing the boiler sections
A
B
C
4.
5.
3.
1.
2.
Fig. 3
APacking cord
(not for the back section)
BSolvent
For all sections: Clean the hub sealing surfaces.
CAdhesive (supplied)
For all sections: Apply adhesive and allow to dry
for approx. 5 min.
Danger
Solvent vapours are produced while the adhe-
sive is being used.
Ensure that the boiler room is well ventilated.
Wear a protective mask if necessary.
Boiler section assembly (cont.)
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D
2.
1.
Fig. 4
DLinseed oil graphite (supplied)
For all sections: Clean the connectors with solvent
and apply the linseed oil graphite.
Preparing the back section and first centre section
5.
3.
A
Fig. 5
AObserve the wall clearance (see page 6)
Boiler section assembly (cont.)
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Pressing the back section and first centre section together
2.
3.
1.
4.
Fig. 6
Note
To avoid leaks at the hub connections, when pressing,
only pull together one section at a time.
When adding further sections, maintain the same dis-
tance at the top and bottom between the sections.
Never secure the sections out of true.
The packing cord prevents the sections being pressed
too close together. Never force the sections together.
Boiler section assembly (cont.)
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Pressing further boiler sections together
1.
Fig. 7
Fitting the lower thermal insulation mat
Fig. 8
Note
The support timber can be removed after 3 sections
have been assembled. Position the lower rolled up
thermal insulation mat (supplied with the thermal insu-
lation part 2) behind the back section. Pull the thermal
insulation mat under the sections as they are assem-
bled (every 2 sections) until it reaches the front sec-
tion.
Boiler section assembly (cont.)
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Overview of the anchor rods
A
B
Fig. 9
APlan view
BSide view
C D Arrangement of the anchor rods 480 and 610 mm
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
kW
320 9 E E
E
380 10 E E
E
440 11 E E
F
500 12 E F
F
560 13 E E
E E
630 14 E E
E F
700 15 E F
F E
780 16 F E
F F
860 17 E E E
F E
950 18 E E F
F E
1080 19 E E F
F F
CRated heating output
DNo. of sections
EAnchor rod 480 mm long
FAnchor rod 610 mm long
Boiler section assembly (cont.)
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Joining sections with anchor rods
2.
3.
M 16
1.
3.
A
A
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 plinth
(accessories up to 860 kW) or on the floor. If required,
shim the section feet.
Plinth installation instructions
Boiler section assembly (cont.)
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R 2
A
B
a
1.
Fig. 12
APlug R 2,
max. overhang "a" 5 to 7 mm.
BQuadrant insert for ratchet,
supplied with the compression tool.
Distributor pipe and drain installation
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B 3.9 x 6.5
!
A
B
C
8.
3.
4.
1.
2.
Fig. 13
ADistributor pipe,
orient the outlet apertures upwards.
BIntermediate or end element,
for installation, see parts list in the service instruc-
tions
CDrain & fill valve, on site
Tighten screws diagonally, torque 7 Nm.
Distributor pipe and drain installation (cont.)
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2x
BA
C
D
R 3/8
R 3/4
R 3/8
4.
3.
2. 1.
Fig. 14
ASensor well
BDummy plug
CManual air vent valve, on site
DBlank flange, on site
Carry out water pressure test in accordance with
TRD 702.
Test pressure: 9 bar (0.9 MPa)
Note
No pressure, control or safety equipment must be fitted
during the water pressure and tightness tests.
Test the pressure with a pressure gauge class 1.0.
Checking the boiler block for leaks
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M 16
A
!
4.
1.
2.
3.
Fig. 15
ATurbulator
Only up to 860 kW: Insert the appropriate number
of turbulators into each hot gas channel of the
third pass (see table). Insert approx. ⅔ of the first
turbulator element, hook in the second or (if neces-
sary) third element and push them in.
Tighten boiler door screws diagonally, torque 25 Nm. Note
In the delivered condition, the boiler door opens to the
left.
Reposition the hinges if required.
Rated heating output kW 320 to 440 500 and 560 630 to 860
Turbulator elements per hot gas flue 3 2 1
Turbulator elements per boiler 12 8 4
Inserting turbulators and fitting the boiler door
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A
B
C
Fig. 16
ABoiler flow, DN 100
BDrain, R ¾
(drain & fill valve on site)
CBoiler return, DN 100
Torque for cleaning cover 7 Nm
Danger
Opening the boiler connections whilst the boiler
is under pressure can cause serious injury.
Only open the connections on the water side
after the boiler has been depressurised.
Note
Install all pipe connections free of load and torque
stress.
Connection set installation instructions
Making the safety connection and testing for tightness
Safety equipment block installation instructions
Install the safety lines.
Safety connection: DN 65
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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Note
All required components are included in the thermal
insulation box.
Fitting the rails
M 16
= B 3.9 x 9.5
M 12
2x
M 8
2x
2x
2x
1090 mm
1044 mm
4.
6.
2.
3.
5.
1.
1.
A
Fig. 17
AVitorond 200 logo
Note
For the position of the lateral tie-bars, see the following
table.
Fitting the thermal insulation
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