Viessmann Sub Mounting Kit User manual

Installation instructions
for contractors
VIESMANN
Sub-mounting kit
Heating circuit distributor for Vitodens 200-W up to 35 kW
Sub-mounting kit
5785 284 GB 6/2016 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.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for author-
ised contractors.
■Work on gas installations must only be carried out by
a registered gas fitter.
■Work on electrical equipment must 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-TR Gas, 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. Preparing for installation Installation requirements ........................................................................ 4
Installation preparations ......................................................................... 4
■Drain outlet positioning ....................................................................... 4
2. Installation sequence Fitting the sub-mounting kit .................................................................... 5
■Fitting connection pipes ...................................................................... 6
■Connecting the DHW cylinder (gas condensing system boiler) or
DHW lines (gas condensing combi boiler) .......................................... 7
Fitting the boiler ..................................................................................... 8
Connecting the heating circuits .............................................................. 9
■Connecting heating circuits with permeable pipework ........................ 10
Electrical connections ............................................................................ 11
■Connecting the mixer control to the boiler control unit ....................... 11
■Connecting the maximum temperature limiter or controller to the
mixer control ....................................................................................... 11
Commissioning and adjustment ............................................................. 11
■Filling and commissioning the heating system ................................... 11
■Venting the heating circuit with mixer ................................................. 11
■Position of switch on the mixer motor ................................................. 12
■Adjusting the flow rate ........................................................................ 12
■Adjusting the bypass .......................................................................... 13
■Fitting the casing ................................................................................ 13
Connection and wiring diagram ............................................................. 14
Index
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A pre-plumbing jig for installation on finished walls is
required for fitting the sub-mounting kit.
Connection pipes and clips are supplied with the pre-
plumbing jig.
Provide a gas shut-off valve on site with min. DN 15
and thermally actuated gas shut-off device.
Pre-plumbing jig installation instructions
Note
A DHW cylinder cannot be installed below the boiler
when a sub-mounting kit is used.
Ambient temperature max. 35 °C
Installation preparations
Drain outlet positioning
A
180
440
Fig. 1
Position drain outlet for condensate A (if available) as
shown in the diagram.
Installation requirements
5785 284 GB

5
6.
5.
4.
7.
2.
1.
4x
3.
Ø 10
4x
R1/2
Fig. 2
1. Align the drilling template below the fitting assem-
bly of the pre-plumbing jig.
2. Drill holes 7 10 mm and insert rawl plugs.
3. Fit the clips to the sub-mounting kit.
4. Secure the sub-mounting kit to the wall with the
screws and washers supplied.
5. Secure the mounting plate to the fitting assembly
using screws M 4 x 10 (self-tapping).
6. Secure the gas pipe with clip to the mounting plate.
7. Seal the on-site gas shut-off valve to the gas pipe.
Fitting the sub-mounting kit
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Fitting connection pipes
1.
2.
Fig. 3 Gas condensing system boiler
1.
Fig. 4 Gas condensing combi boiler
Insert flat gaskets and fit the connection pipes.
Fitting the sub-mounting kit (cont.)
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Connecting the DHW cylinder (gas condensing system boiler) or DHW lines (gas condensing
combi boiler)
1.
2x
A
B
Fig. 5
AHeating water flow, DHW cylinder/DHW
BHeating water return, DHW cylinder/cold water
1. Route the connection lines to the DHW cylinder or
cold water line and DHW line below the sub-
mounting kit.
2. Connect on-site connection lines to the fitting
assembly of the pre-plumbing jig.
Pre-plumbing jig installation instructions
Fitting the sub-mounting kit (cont.)
5785 284 GB

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8.1.
2.
Fig. 6
1. Fit the retaining rails for the casing. 2. Hook the boiler onto the pre-plumbing jig.
Boiler and pre-plumbing jig installation
instructions
Fitting the boiler
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HV1
HR2
HV2
HR1
4x
Fig. 7
HR1 Heating water return, heating circuit without
mixer G ¾
HR2 Heating water return, heating circuit with mixer
G ¾
HV1 Heating water flow, heating circuit without mixer
G ¾
HV2 Heating water flow, heating circuit with mixer G ¾
1. Secure the twin connectors with flat gaskets to the
connections of the sub-mounting kit.
If available:
Fit a flow indicator (accessories) with flat gasket in
place of the twin connector to the heating water
return of the heating circuit without mixer.
2. Connect the heating circuits to the connection
pipes of the sub-mounting kit.
Do not alter the position of the heating circuit con-
nections, so the casing can be fitted later.
Connecting the heating circuits
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System scheme with sub-mounting kit
M
A B
H
G
F
E
C
D
K
Fig. 8
AHeating circuit without mixer
BHeating circuit with mixer (underfloor heating cir-
cuit)
CBypass
DVolume balancing line
EPlate heat exchanger for system separation
F3-way mixer
GHeating circuit pump
HFlow temperature sensor
KTemperature limiter to restrict the maximum tem-
perature of underfloor heating systems
Information regarding the heating circuit with
mixer
Install a drain & fill valve on site, in the flow of the heat-
ing circuit with mixer. This is required during commis-
sioning for filling and venting the heating circuit.
The expansion vessel integrated into the boiler can
also be used for the heating circuit with mixer.
Check whether the size of the integral expansion ves-
sel is adequate for the connected heating circuits.
Information on the underfloor heating circuit
Fit maximum temperature limiter K to the heating flow
line at least 1 m downstream of the circulation pump.
Connecting heating circuits with permeable pipework
When connecting heating systems with permeable
pipework (DIN 4726), seal off the volume balancing
line between the two heating circuits.
Note
If the volume balancing line has been removed, install
a separate expansion vessel in the regulated heating
circuit.
Removing the volume balancing line
2.
1.
Fig. 9
1. Undo the union nuts and remove the balancing line
and locking rings.
2. Seal the connections with the plugs and union nuts
supplied.
Lubricate the O-rings with the valve grease sup-
plied.
Connecting the heating circuits (cont.)
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Connecting the mixer control to the boiler control unit
Connection to the boiler control unit:
Boiler installation instructions
2035100
3 2 15 4
X3 28
X14
A
aVG fÖ
145 40
1 2 N L
S1
2
3
4
5
6
1
0
9
8
7
2 1 N?L1
B
96
145
Fig. 10
AMixer control, sub-mounting kit
BControl unit, wall mounted gas boiler
1. Connect the cable with plug aVG to plug aVG of the
control unit or to the KM-BUS distributor.
2. Connect the power cable with plug fÖ to plug lH of
the control unit.
3. Route the power cable and KM-BUS cable individ-
ually. Secure the cables so they cannot come into
contact with the circulation pump.
Connecting the maximum temperature limiter or controller to the mixer control
Separate installation instructions
Commissioning and adjustment
Filling and commissioning the heating system
Boiler service instructions Danger
Escaping gas leads to a risk of explosion.
Check all gas connections for tightness.
Venting the heating circuit with mixer
A
B
Fig. 11
1. Connect a hose to air vent valve A and route it
into a drain connection.
2. Connect the fill hose to on-site drain & fill valve B.
3. Flush the heating circuit under mains pressure until
sound of escaping air is no longer heard.
Electrical connections
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Position of switch on the mixer motor
Fig. 12
The rotary selector on the mixer servomotor must be
set to automatic (arrow towards "A"). In the event of
mixer control faults, turn the rotary selector to "manual"
and adjust the mixer manually (emergency mode).
Adjusting the flow rate
A
Fig. 13
1. Adjust the flow rate at ball valve A.
2. Check the flow rate on the flow indicator (accesso-
ries, if installed).
Commissioning and adjustment (cont.)
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Adjusting the bypass
Fig. 14
A bypass is integrated into the heating circuit with
mixer. In the delivered condition, the bypass is closed.
If required, open the bypass to minimise temperature
peaks (turn anti-clockwise).
Fitting the casing
2.
Ø 10
3.
1.
Fig. 15
1. Secure retaining bracket with B 3.9 x 13 self-tap-
ping screw to the casing.
2. Slide the casing into the fixing rails from the front.
3. Secure retaining bracket with screw and rawl plug
to the wall.
Commissioning and adjustment (cont.)
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Fig. 16
?Flow temperature sensor
aJ No function
sÖ Heating circuit pump
fÖ Power supply
fÖAPower outlet
gS Mixer motor
aVG KM-BUS
A1 Main PCB
A2 PCB
S1 DIP switch (shown in factory setting)
X ... Electrical interfaces
Connection and wiring diagram
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5785 284 GB

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Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Viessmann Werke GmbH & Co. KG
D-35107 Allendorf
Telephone: [phone]
Fax: [phone]
www.viessmann.com
5785 284 GB Subject to technical modifications.