Installation Instructions for use by heating contractor Vitorond 200 VD2 Series Oil-/Gas-fired boiler Heating input: 1255 to 4387 MBH (368 to 1285 kW) VITOROND 200 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.
Safety Vitorond 200, VD2 Series 320 to 1080 Installation Safety, Installation and Warranty Requirements 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).
Safety Vitorond 200, VD2 Series 320 to 1080 Installation Safety, Installation and Warranty Requirements (continued) H Fiberglass wool and ceramic fiber materials 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. The state of California has listed the airborne fibers of these materials as a possible cancer hazard through inhalation.
Table of Contents Vitorond 200, VD2 Series 320 to 1080 Installation Page Safety Safety, Installation and Warranty Requirements..............2 Product documentation...........................................2 Licensed professional heating contractor ...................2 Contaminated air ...................................................2 Advice to owner ....................................................2 Warranty ..............................................................2 Carbon monoxide...........
Vitorond 200, VD2 Series 320 to 1080 Installation Table of Contents Page Connections Water Side Connections ............................................20 Return temperature elevation.................................21 Venting Connection ..................................................22 In Canada ...........................................................22 In U.S.A. ............................................................22 Venting Requirements ...............................................
Table of Contents Vitorond 200, VD2 Series 320 to 1080 Installation Page Start-up System Preparation ..................................................35 Combustion air supply ..........................................35 Gas piping pressure test .......................................35 Initial System Fill ......................................................35 Prior to Start-up .......................................................36 Start-up Information ...............................................
Vitorond 200, VD2 Series 320 to 1080 Installation Safety Important Regulatory and Safety Requirements For installations on the Commonwealth of Massachusetts, the following modifications to NFPA-54 chapter 10 apply: Excerpt from 248 CMR 5-08: 2(a) For all side-wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side-wall exhaust vent terminatio
Vitorond 200, VD2 Series 320 to 1080 Installation Important Regulatory and Safety Requirements Codes Working on the equipment The installation of this unit shall be in accordance with local codes. In the absence of local codes, use: 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.
Vitorond 200, VD2 Series 320 to 1080 Installation General Information About these Installation 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. WARNING Note: W arnings draw your attention to the presence of potential hazards or important product information.
Set-up Vitorond 200, VD2 Series 320 to 1080 Installation Mechanical Room Boiler must be located in a heated indoor space. The Vitorond 200, VD2 boiler should be located near a floor drain and as close as possible to the vertical chimney or vent. 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, VD2 boiler in rooms with refrigeration equipment.
Set-up Vitorond 200, VD2 Series 320 to 1080 Installation Boiler Set-up and Location Boiler Base 5b in. (140 mm) >=4 in. (100 mm) 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 in. (100 mm).
Set-up Vitorond 200, VD2 Series 320 to 1080 Installation Standard Equipment All necessary parts to assemble the heating boiler are packaged and shipped in the carton labeled “Boiler Accessories”. Boiler front The heat exchanger block consists of a rear section with mounted flue gas collar, a front section with mounted combustion chamber door, and depending on the size of the boiler, the appropriate number of intermediate sections.
Assembly Vitorond 200, VD2 Series 320 to 1080 Installation Cast Iron Section Assembly 1. Cut individual glass fiber rope seals and secure each cut end against fraying by taping it with the supplied masking tape. CAUTION The rope gaskets must be cut to exact lengths. No openings between gaskets are acceptable. Working from the rear section to the front section requires the gasket only on the front side of the section. Do not double gasket. 2. Lay each section flat, the side to be gasketed facing up.
Assembly Vitorond 200, VD2 Series 320 to 1080 Installation Cast Iron Section Assembly (continued) 8. Align the prepared intermediate section with push nipples of the rear section. 9. Lift the rear section onto the boiler foundation. Align the section legs against the rear strip panel of the boiler foundation (not shown). Properly position rear section and secure against tipping. 10. Mount intermediate section with wood or rubber mallet by tapping it onto the push nipples of the rear section.
Assembly Vitorond 200, VD2 Series 320 to 1080 Installation Cast Iron Section Assembly (continued) 14. Loosen draw tool and remove pressure nuts. 15. Repeat steps 1 through 10 until the draw tool kit can be used again. Do not glue glass fiber rope into center of pre-cast groove of intermediate section attached to front section (see page 10). 16. Attach extension rods to the main draw rods and sections according to steps 11 and 12, until heat exchanger block is completely assembled. 17.
Assembly Vitorond 200, VD2 Series 320 to 1080 Installation Cast Iron Section Assembly (continued) Top view Boiler front Side view Rear section Placement of tie rods Number of sections Note: Number 1 refers to rear section. 16 Tie rod layout 19 and 24 in.
Assembly Vitorond 200, VD2 Series 320 to 1080 Installation Water Distribution Pipe and Drain Installation 1. To assemble the water distribution pipe, pipe together - rod end and extension rod and secure with supplied sheet metal screws. Number and length of the rods vary for different boiler sizes. - Mount gasket on flange rod and secure flange rod with supplied brass screws. 2. Slide water distribution pipe through lower nipple ports.
Assembly Vitorond 200, VD2 Series 320 to 1080 Installation Hydrostatic Pressure Test A hydrostatic pressure test is mandatory after the assembly is complete and prior to the connection of any additional piping, control, or safety devices to the pressure vessel. 1. In the e in. tapping on top of the rear section, install supplied R e in. plug B. After pressure test has been completed, replace R e in. plug with supplied manual or automatic air vent C (watch for proper pressure rating). 2. In the c in.
Assembly Vitorond 200, VD2 Series 320 to 1080 Installation Flue Gas Turbulators and Combustion Chamber Door Turbulators may not be exactly as illustrated. 1. For models VD2-320 to VD2-860 only: Insert the respective number of turbulators into each flue gas passageway (see table below). Push the first turbulator element approximately one third of the way into the flue gas passageway, hook in the second and third elements and push in. 2. Attach the combustion chamber door to the front section and align.
Connections Vitorond 200, VD2 Series 320 to 1080 Installation Water Side Connections IMPORTANT Ensure all requirements detailed in the Vitorond 200, VD2 System Design Guidelines and/or Technical Data Manual are met. The Vitorond 200, VD2 boiler is only for use in forced circulation hot water heating systems. 1. Thoroughly rinse heating system (particularly when retrofitting the Vitorond 200, VD2 to an existing heating system). 2. Install supply and return headers (see following page).
Connections Vitorond 200, VD2 Series 320 to 1080 Installation Water Side Connections (continued) Return temperature elevation Metric flange c/w weld-on 2½ in. NPT coupling A suitable low temperature protection package from Viessmann is necessary for Vitorond 200, VD2 boilers. System Selection of the appropriate package typically takes place supply header prior to boiler delivery. (ANSI), 4 in. Please specify correct package at time of order. Metric flange c/w weld-on 2½ in.
Connections Vitorond 200, VD2 Series 320 to 1080 Installation Venting Connection WARNING When installing or insulating (overhead) piping or venting, do not stand on top panel of boiler. Advise other trades accordingly! Never operate boiler without an installed venting system which safely vents all products of combustion to the outdoors. The vent system must comply with all applicable local and/or national codes. Vitorond 200, VD2 boilers are Category I boilers as defined in ANSI Z21.
Connections Vitorond 200, VD2 Series 320 to 1080 Installation Venting Requirements (continued) Venting option #1 (Category I venting) For natural gas or liquid propane use Type B vent or Type L vent for the entire vent whenever possible. H Use approved vent material only. Consult reputable chimney manufacturer such as Security Chimney Ltd., Laval, PQ, Canada. H The vent connector of this boiler must not be connected to any portion of mechanical draft systems operating under positive pressure.
Connections Vitorond 200, VD2 Series 320 to 1080 Installation Venting Requirements (continued) Venting option #2 (Category III) The Vitorond 200 boiler is a Category III positive pressure non-condensing boiler. Each boiler must be vented individually. The vent system must be properly designed and suitable materials must be selected. The chimney must be gas tight.
Connections Vitorond 200, VD2 Series 320 to 1080 Installation Removal of Existing Boiler 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.
Connections Vitorond 200, VD2 Series 320 to 1080 Installation Safety Connections and Pressure Testing Pressure relief valve Do not install any valve(s) between the pressure relief valve and the boiler. When installing a discharge pipe from relief valve to drain, adhere to the following excerpt from the ASME Boiler and Pressure Vessel Code: 1.
Enclosure Vitorond 200, VD2 Series 320 to 1080 Installation Enclosure Installation All components required for mounting the insulation are included with the insulation material. 1. Install cross bar supports according to measurements listed in table below to casting notches, using the 16 x 80 bolts, washers and flat nuts. Boiler front 5285 429 - 03 Crossbar supports Boiler model VD2- 320 380 440 500 560 630 700 780 860 950 1080 a in.
Enclosure Vitorond 200, VD2 Series 320 to 1080 Installation Enclosure Installation (continued) All components required for the enclosure panel assembly are included in the jacket carton. For positions of cross bar supports, please see table on previous page. 2. Attach rear mounting brackets with the M 8 bolts. Place the mounting brackets at a span of 41 in, (1044 mm) (outside), in alignment with the outer edges of the tie bar(s). 3.
Vitorond 200, VD2 Series 320 to 1080 Installation Enclosure Enclosure Installation (continued) 6. Lay insulation blankets onto outside of boiler, making sure the black side is facing outward. 7. Secure rear insulation blanket (with cut-out facing to the rear) with tension spring to outside insulation blanket. Cover the cuts with supplied fiber rope seal. 8. From behind the rear section, insert the insulation mat underneath the assembled cast iron block.
Enclosure Vitorond 200, VD2 Series 320 to 1080 Installation Enclosure Installation (continued) Boiler front 30 Boiler model VD2- 320 380 440 500 560 630 700 780 860 950 1080 a in. (mm) 24c (628) 24c (628) 24c (628) 19c (502) 19c (502) 19c (502) 24c (628) 24c (628) 24c (628) 29c (755) 19c (502) b in. (mm) 19c (502) 24c (628) 24c (628) 19c (502) 19c (502) 19c (502) 24c (628) 24c (628) 29c (755) 29c (755) 19c (502) c in.
Enclosure Vitorond 200, VD2 Series 320 to 1080 Installation Boiler Control Installation 1. Drill four Ø d in. (3 mm) holes on the side panels A and B as shown. For left-side mount use a mirror image of the drawing. 2. Punch a Ø 7/8 in. (22 mm) opening. Note: On VD2-500, -560, 630 and -1080 boilers, the bracket mounting overlaps side panel B. 5285 429 - 03 3. Install control harness bracket using supplied 8-32 self-tapping screws. 4. Install burner harness bracket and tighten the two supplied screws.
Enclosure Vitorond 200, VD2 Series 320 to 1080 Installation Boiler Control Installation (continued) 6. Remove two plugs located on the back of the boiler control housing using a flathead screw driver. Mount control housing on the side panel. 7. Secure control housing using two supplied screws. For electrical and boiler control connections, see Installation Instructions of boiler control. 8.
Burner Vitorond 200, VD2 Series 320 to 1080 Installation Burner Installation IMPORTANT After burner installation, the gap remaining between the burner blast tube and the insulation insert on combustion chamber door must be filled with the insulating material supplied. Viessmann has made Weishaupt and Riello burners standard on all Vitorond 200, VD2 boilers; for details see Technical Data Manual and/or Weishaupt burner manuals (supplied with burner).
Burner Vitorond 200, VD2 Series 320 to 1080 Installation Burner Installation System Preparation(continued) (continued) See separate instructions supplied with the burner. The maximum input published for each boiler size must not be exceeded.
Start-up Vitorond 200, VD2 Series 320 to 1080 Installation System Preparation WARNING Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter living space which can cause severe personal injury or loss of life. WARNING Never cover the boiler or store debris or other materials near the boiler, or in any way block the flow of adequate fresh air to the boiler. Never cover the combustion air opening or put anything inside the draft hood.
Start-up Vitorond 200, VD2 Series 320 to 1080 Installation Initial System Fill Ensure that spring-loaded flow check valves are manually opened prior to filling the heating system with water. Once the system is completely filled and purged of air, ensure that spring-loaded flow check valves are again closed (set into “flow-check” operation). Water treatment should be considered in areas where it is known that boiler feed water contains a high mineral content and hardness.
Start-up Vitorond 200, VD2 Series 320 to 1080 Installation Start-up Information Initial start-up Start-up after extended shut-down Initial start-up must be performed by qualified personnel; values and calibrations specified in the Technical Data section on page 36 in this manual are to be recorded at this time. If the system was shut down for an extended period of time, restart and recondition the system.
Appendix Vitorond 200, VD2 Series 320 to 1080 Installation Piping in Heating/Cooling Application The boiler, when used in connection with a refrigeration system, must be installed so the chilled medium is piped in parallel to the boiler with appropriate valves to prevent the chilled medium from entering the boiler.
Appendix Vitorond 200, VD2 Series 320 to 1080 Installation Technical Data Technical Data Boiler Model *1 VD2- 320 380 440 500 560 630 700 780 860 950 1255 (368) 1490 (436) 1726 (506) 1961 (574) 2196 (643) 2471 (724) 2745 (804) 3059 (896) Input (gas)*1 MBH (kW) 1300 (381) 1544 (452) 1787 (523) 2031 (595) 2275 (666) 2559 (750) 2843 (833) 3168 3493 3860 4387 (928) (1023) (1130) (1285) Output MBH (kW) 1110 (325) 1319 (387) 1526 (447) 1732 (508) 1941 (569) 2183 (640) 2425
Appendix Vitorond 200, VD2 Series 320 to 1080 Installation Technical Data (continued) Technical Data Boiler Model VD2320 Dimensions (with insul. jacket) Total length Total width with Vitotronic control (sidemounted) Total height 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 Boiler water content Max. boiler temperature*3 (= fixed high limit) Max. allow.
Appendix Vitorond 200, VD2 Series 320 to 1080 Installation Technical Data (continued) Technical Data Boiler Model VD2320 380 440 500 Boiler connections Boiler supply in. 4 4 4 4 and return Safety supply*5 in. 2b 2b 2b 2b Safety return*5 in. 2b 2b 2b 2b Drain valve in. c c c c Heating surface area Flue gas side ft2 170 196 212 232 (m2) (15.8) (18.2) (19.7) (21.5) Water side ft2 98 109 120b 131 (m2) (9.1) (10.1) (11.2) (12.
5285 429 - 03 Vitorond 200, VD2 Series 320 to 1080 Installation
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5285 429 - 03 Technical information subject to change without notice. Printed on environmentally friendly (recycled and recyclable) paper.
