Installation instructions for contractors VIESMANN Vitorondens 200-T Type BR2A, 20.2 to 53.7 kw Oil Unit condensing boiler VITORONDENS 200-T 6/2011 Dispose after installation.
Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained 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 Working on the system Isolate the system from the power supply and check that it is no longer 'live', e.g. by removing a separate fuse or by means of a mains isolator. Safeguard the system against unauthorised reconnection. When using gas as fuel, also close the main gas shut-off valve and safeguard against unauthorised reopening. These instructions are exclusively designed for qualified personnel. Work on gas appliances must only be carried out by a qualified gas fitter. Work on electrical equipment must only be carried out by a qualified electrician. Regulations Observe the following when working on this system all legal instructions regarding the prevention of accidents, all legal instructions regarding environmental protection, the Code of Practice of relevant trade associations, all current safety regulations as defined by DIN, EN, DVGW, TRGI, TRF, VDE and all locally applicable standards. 2
Index Preparing for installation Siting... 4 Clearance dimensions... 4 Overview of connections... 5 Installation sequence Siting and levelling the boiler... 7 Siting without DHW cylinder... 7 Installation on a plinth... 7 Installation on a DHW cylinder... 8 Fitting the heat exchanger to the boiler... 10 Preparations for installation... 10 KV/KR distributor... 11 Vitorondens with stainless steel heat exchanger connector... 12 Vitorondens with cast iron heat exchanger connector... 13 Thermal insulation... 14 Pipework... 16 Condensate connection... 17 Connection on the heating water side... 17 Flow and return... 17 Filling connection... 18 Making the safety connections... 18 Fitting the safety equip block (acc.) and conn. on the htg. water side... 19 Making the electrical connections... 22 Installing the burner... 24 Commissioning and adjustment... 24 3
Siting Clearance dimensions 850 100 A Boiler B Heat exchanger C DHW cylinder (= 250) (= 650) A A Plinth (accessory) B C B Siphon 4
Siting (cont.) C Neutralising system (accessories) Overview of connections A B G H K L M N F E D C A P O S A Cable entry area B Air vent valve C Cylinder flow and heating flow G 1½ D Cylinder return and heating return G 1½ E Boiler fill valve R F Connection for the diaphragm expansion vessel (tee Rp ½) G Heating return Flat-packing connection: G 1½ Connection with the threaded inserts supplied: Rp 1 5
Overview of connections (cont.) H Heating flow Flat-packing connection: G 1½ Connection with the threaded inserts supplied: Rp 1 K Boiler flue connection (accessory) L Ventilation air connector for balanced flue operation M Silencer (accessory) N Flue gas connection O Siphon P Condensate drain R Drain S Oil pipe connection 6
Siting and levelling the boiler Siting without DHW cylinder M4 x 28 2. 1. 3. 4x Level the boiler with a slight incline towards the back. Installation on a plinth Installation instructions on the plinth packaging 7
Siting and levelling the boiler (cont.) Installation on a DHW cylinder 1. 2. M 10 3. 5. 4. 4x 6. 2x 8
Siting and levelling the boiler (cont.) 10. 9. 8. 2x 18 kw Ø 3.7 mm 7. 2x 11. 9
Fitting the heat exchanger to the boiler Preparations for installation 1. 4x 3. 2. 1. 4x 3. 2. 10
Fitting the heat exchanger to the boiler (cont.) KV/KR distributor 2. 1. Note Fit the return injector nozzle into the boiler return. 11
Fitting the heat exchanger to the boiler (cont.) Vitorondens with stainless steel heat exchanger connector 1. 3. 2. 4. 1. Note Use the installation aid (rectangular hollow section) supplied for inserting the M8 screws with the cramp. 12
Fitting the heat exchanger to the boiler (cont.) Vitorondens with cast iron heat exchanger connector 2x 3. 2x 1. 2. 4. 13
Fitting the heat exchanger to the boiler (cont.) Thermal insulation A 4. 3. B 1. 2. A Boiler flue connection (accessory) Only in balanced flue operation with coaxial flue outlet/ventilation air inlet. 14 B Silencer (accessory)
Fitting the heat exchanger to the boiler (cont.) Press the thermal insulation mat into the heat exchanger thermal insulation casing. 5. 15
Fitting the heat exchanger to the boiler (cont.) Pipework 1. 2. 3. Manually bend flexible pipe into the required shape. Fit all connections on the heating water side with matching flat gaskets. Tighten the fittings with a torque of 15 Nm. Seal the opening in the heat exchanger thermal insulation with the cover provided. Note Never grease or oil the siphon fitting and gaskets. 16
Condensate connection Connect the condensate drain by the shortest route, with a constant fall and a pipe vent to the public sewage system. Install a neutralising system if required. A Supply from the boiler B Neutralising system or active charcoal filter C Drain to the public sewage system Note ATV-DVWK-A 251 permits boiler use without a neutralising system when operating with low sulphur fuel oil DIN 51605-EL-1 (sulphur content 50 mg/kg). Use an active charcoal filter (accessory) if no neutralising system is connected. Connection on the heating water side Flow and return 17
Connection on the heating water side (cont.) The flow and return pipes with the heat exchanger connection are fitted to the boiler. Connect all consumers, so that the heat exchanger will receive a heating water flow in any operating condition. Note Connect the heating circuits and DHW cylinder to the common flow and return. Never connect any consumers to the remaining connectors available at the back of the boiler. Filling connection Fill the system via the fill valve at the safety equipment block (accessory) or via the on-site connection in the return. Making the safety connections Permiss. operating pressure: 3 bar Test pressure: 4 bar Minimum cross-sections Safety valve inlet connection 20.2 to 53.7 kw: DN 15 (R ½) Safety valve discharge pipe 20.2 to 53.7 kw: DN 20 (R ¾) Pipe to the expansion vessel 20.2 kw: DN 12 (R ½) 24.6 to 53.7 kw: DN 20 (R ¾) Low water indicator Tests have verified that the low water indicator specified by EN 12828 is not required. Note Equip boilers with a safety valve that is type-tested according to TRD 721 and which is marked in accordance with the relevant system version. 18
Fitting the safety equip block (acc.) and conn. on the htg. water side 3. 2. 4. 1. A Pressure gauge B Air vent valve C Automatic shut-off valve D Quick-action air vent valve E Safety valve F Tee Rp ½ (if the expansion vessel is to be connected here) G Boiler fill valve Note Counterhold the safety equipment block when tightening the fittings. 19
Fitting the safety equip block (acc.) and conn. (cont.) 5. 6. A Heating circuit connections with fittings or Divicon heating circuit distributor (accessory) B Heating flow C Heating return 20
Fitting the safety equip block (acc.) and conn. (cont.) 7. 8. A Caps G 1½ (if no DHW cylinder is to be connected) B Expansion vessel connection Note Fit front thermal insulation C only after the system has been filled and tested for leaks. Service instructions 21
Making the electrical connections! Please note Damage to the capillary tubes can impair the sensor function. Never kink the capillary tubes. For opening the control unit and its connections, see the boiler control unit installation instructions Note The power cable plug fö is packaged together with the parts for mounting the control unit and can be found below the top panel of the boiler thermal insulation. Contrary to the statement in the control unit installation instructions, the coding card is already fitted at the factory. 22
Making the electrical connections (cont.) B A 3.9 x 9.5 2. 1. M4 x 28 3. C Note Secure all 230 V cables and the LV cables with the cable ties supplied. Bundle and route 230 V cables A and LV cables B separately. Use cable ties (snap hooks) to secure the burner cable at hole C on the inside of the side panel; on the r.h. or l.h. side panel depending on whether the burner is fitted on the right or left. 23
Making the electrical connections (cont.)! Please note Cables/leads can be damaged by hot components. Cables must not come into contact with any hot components once installation work is complete. Installing the burner Separate burner documentation Commissioning and adjustment Service instructions for boiler, burner and boiler control unit Printed on environmentally friendly, chlorine-free bleached paper 24 Viessmann Werke GmbH&Co KG D-35107 Allendorf Telephone: +49 6452 70-0 Fax: +49 6452 70-2780 www.viessmann.com Subject to technical modifications.