Viessmann VITROND 200 User manual

VITOROND 200
Installation instructions
for heating engineers
VitorondĂ200
typeĂVD2, 320 to 1080 kW
Oil/Gas fired boilers
5862Ă444ĂGB 2/2003

2
Safety instructions
Please follow these safety instructions closely to prevent accidents and
material losses.
Safety regulations
Installation, initial start-up, inspection,
maintenance and repairs must only
be carried out by a competent person
(heating engineer/installation
contractor).
Observe all current safety regulations
as defined by DIN, EN, DVGW, TRGI,
TRF and VDE or locally applicable
standards.
See also the safety instructions sheet
in the Vitotec technical documentation
folder.
Before working on the equipment/
heating system, isolate the mains
electrical supply (e.g. by removing a
separate mains fuse or by means of
a mains electrical isolator) and
safeguard against unauthorised
reconnection.
When using gas as fuel, also close
the main shut-off valve and safeguard
against unauthorised re-opening.
Work on gas equipment
This must only be carried out by an
approved contractor.
Please observe all commissioning
work for gas installations specified
acc. to TRGI or TRF, or local
regulations.
¨ĂSafety instruction
In this instruction manual, this
heading denotes information which
must be observed to prevent
accidents and material losses.
¨This symbol denotes information
which must be observed to
prevent material losses.
5862Ă444ĂGB

3
Index
Page
Safety instructionsĂ2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
learancesĂ4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler section assemblyĂ5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distributor pipe and drain installationĂ13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water pressure testĂ15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insertion of turbulators and fitting the boiler doorĂ16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating water (primary) connectionĂ17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety connection and testing for leaksĂ18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of the thermal insulationĂ19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flue gas connectionsĂ22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of additional thermal insulationĂ23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner installationĂ28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important notes on commissioningĂ28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5862Ă444ĂGB

4
learances
Dimensions inside brackets are minimum clearances
Rated
output
kW 320 380 440 500 560 630 700 780 860 950 1080
a mm 1660 1790 1920 2050 2180 2310 2440 2570 2700 2830 2960
b mm Observe the burner length
5862Ă444ĂGB5862Ă444ĂGB
a
1000 500 (200)
500 (200)
b
200 (100)

5
Boiler section assembly
Please note:
All parts required for the boiler assembly are contained in the boiler
accessory pack.
The boiler body consists of a rear section with fitted flue outlet, a front
section with fitted boiler door and a number of centre sections, subject to
rated output.
ABoiler door
BFront section
CCentre section
DRear section
EFlue outlet
Rated output kW 320 380 440 500 560 630 700 780 860 950 1080
Number of
sections
910 11 12 13 14 15 16 17 18 19
Number of
centre
sections
7 8 9 10 11 12 13 14 15 16 17
5862Ă444ĂGB
AB C D E

6
Boiler section assembly (cont.)
ANot for the rear section
For all sections:
BClean the hub sealing faces with
solvent.
CApply the enclosed adhesive and
allow to dry for approx. 5 min.
¨ĂSafety instruction
Provide adequate ventilation when
handling the adhesive.
5862Ă444ĂGB
A
B
C
2.
3.
4.
1.
5.

7
Boiler section assembly (cont.)
For all sections:
AClean the nipples with solvent and apply the enclosed anti-seize agent.
5862Ă444ĂGB
1.
2.
A
3.
5.
4.
!
!

8
Boiler section assembly (cont.)
Please note:
uring the compression process, draw in only one additional section at the
time to prevent leaks at the hub joints.
Please note:
Maintain the same distance between the individual sections at the top and
bottom. Never secure the sections out of true.
The packing cord prevents the sections being pressed close together. Do not
force the sections together.
5862Ă444ĂGB
4.
3.
1.
2.

9
Boiler section assembly (cont.)
Please note:
The support timber may be removed after three sections have been
assembled; locate the roll of insulation mat (enclosed with part two of the
thermal insulation) behind the rear section and pull underneath the
assembled sections, as the installation progresses (every two sections),
until it is also located underneath the front section.
5862Ă444ĂGB
1.

10
Boiler section assembly (cont.)
Rated
output
Number
of
Anchor rod layout 480Ămm and 610Ămm
ou
t
pu
t
kW
o
f
sections 12345678910 11 12 13 14 15 16 17 18 19
320 9 480
480
480
380 10 480
480
480
440 11 480 480
610
500 12 480 610
610
560 13 480
480
480
480
630 14 480
480
480
610
700 15 480 610
610 480
780 16 480
610 610
610
860 17 480
480
480
610
480
950 18 480
480
610480
610
1080 19 480 480
610
610
610
5862Ă444ĂGB
Plan view
Side view

11
Boiler section assembly (cont.)
¨Only release the compression tool
when the sections have been
joined with the anchor rods.
5862Ă444ĂGB
M 16
2.
1.
3.
3.

12
Boiler section assembly (cont.)
Please note:
All section feet must be firmly placed
on the plinth (accessory) or the floor.
If necessary, shim the section feet.
Installation instructions
Plinth
5862Ă444ĂGB
2.
1.

13
Distributor pipe and drain installation
APlugĂRĂ2":
Overhang "a" max. 5 to 7mm
BQuadrant insert for ratchet included with the compression tool
5862Ă444ĂGB
a
R 2"
1.
A
B

14
Distributor pipe and drain installation (cont.)
ADistributor pipe:
Orient the drain apertures upwards
BInsertion of the respective intermediate and end sections see service
instructions, page 17
CFill and drain valve (on site)
5862Ă444ĂGB
B 3.9 x 6.5
!
4.
2.
1.
3.
A
B
C

15
Water pressure test
Please note:
No pressure, control or safety equipment must be fitted during any water
pressure or leak tests.
Test the pressure with a class 1.0 pressure gauge.
Test pressure: 9Ăbar
ASensor well
BDummy plug
CManual air-vent valve (on site)
DBlanking flange
5862Ă444ĂGB
Re
Rc
Re
2x
2.
4.
3.
1.
BA
C
D

16
Insertion of turbulators and fitting the boiler door
*1In the delivered condition, the boiler door opens to the l.h. side.
Reposition the hinge and catch components, if necessary.
AOnly for 320 to 860ĂkW:
Insert the respective number of turbulators into each hot gas channel of
the third flue (see table); in doing so, push the first turbulator element
approx. h into the hot gas channel, hook in the second or third element
and push in.
Rated output kW 320 to 440 500 and 560 630 to 860
Turbulator elements
per hot gas flue
321
Turbulator elements
per boiler
12 8 4
5862Ă444ĂGB
M 16
1.
4.
2.
3.
A
*1

17
Heating water (primary) connection
*1Fill and drain valve (on site)
E Drain Ă ĂRĂĂ¾". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KR Boiler returnĂ ĂDNĂ100. . . . . . . . . . . . . . . . . . . . . . . .
KV Boiler flowĂ ĂDNĂ100. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Please note:
Only open the heating water
connections after the boiler has been
de-pressurised.
Install all pipe runs free of load and
torque stresses.
Installation instructions
Connection set
5862Ă444ĂGB
*1
KV
E
KR

18
Safety connection and testing for leaks
Installation instructions
Safety equipment block
Install safety lines.
Safety connectionĂ ĂDNĂ65
. . . . . . . . . . . . . . . . . . . . . . . .
Max. operating pressureĂ Ă6Ăbar. . . . . . . . . . . . .
Test pressureĂ Ă9Ăbar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low water indicator
Boilers must be equipped with a low
water indicator.
Please note:
Equip boilers with a safety valve
which is type-tested and meets the
requirements of TR Ă721, and which
must be marked subject to the
respective system version.
Install all pipe runs free of load and
torque stresses.
5862Ă444ĂGB

19
Installation of the thermal insulation
Please note:
All components required for the assembly of the thermal insulation are
included in the insulation carton.
Please note:
Position of cross members see table,
page 20.
5862Ă444ĂGB
M 16
= B 3.9 x 9.5
M 12
2x
M 8
1,090 mm
1,044 mm
2x
6.
1.
5.
2x
4.
2x
3.
1.
2.

20
Installation of the thermal insulation (cont.)
Rated
output
kW 320 380 440 500 560 630 700 780 860 950 1080
a mm 805 805 805 679 679 679 805 805 805 932 679
b mm ĈĈĈ ĈĈĈ ĈĈĈ 502 502 502 628 628 755 755 502
c mm ĈĈĈ ĈĈĈ ĈĈĈ ĈĈĈ ĈĈĈ ĈĈĈ ĈĈĈ ĈĈĈ ĈĈĈ ĈĈĈ 628
5862Ă444ĂGB
b ac