Viessmann Vitola 200, Installation Instructions Manual

Page 1: ...lation Instructions for use by heating contractor Vitola 200 VB2 Series Oil Gas Fired Boiler Heating input 83 to 300 MBH 24 to 88 kW Read and save these instructions for future reference IMPORTANT 5167 404 v1 9 01 2004 ...

Page 2: ...icals can cause by products in the combustion process which are poisonous to inhabitants and destructive to Viessmann equipment For a listing of chemicals which cannot be stored in or near the boiler room please see section entitled Combustion Air Supply H Carbon monoxide Improper installation adjustment service and or maintenance can cause flue products to flow into living space Flue products con...

Page 3: ... Minimum Clearances to Combustibles 11 Combustion Chamber 12 Product Installation Alternatives 12 Boiler Set up and Location 13 Enclosure Panel Installation 14 Connections Venting Connection 18 Water Side Connections 21 Safety Connections and Pressure Testing 22 DHW Connections 23 Installation Examples 24 Electrical Connections 29 Top Panel Installation 30 Burner Burner Installation 31 Burner Info...

Page 4: ...echnology componentry please reference documentation of the respective product We offer frequent installation and service seminars to familiarize our partners with our products Please inquire Working on the equipment The installation adjustment service and maintenance of this boiler must be done by a licensed professional heating contractor who is qualified and experienced in the installation serv...

Page 5: ...with modulating boiler water temperatures in closed loop forced circulation hot water heating systems The circulator may run continuously The boiler does not require a flow switch The Vitola boiler is a special low temperature heating boiler designed to cold start For the vast majority of installations the Vitola biferral can cold start without low water temperature limit Do not use the Vitola boi...

Page 6: ...codes use H CSA B 139 for oil installations in Canada H CAN CGA B149 1 or 2 for gas installations in Canada H ANSI Z223 1 section 5 3 National Fuel Gas Code for gas installations in the US H NFPA 31 Standard for the installation of Oil Burning Equipment in the US Always use latest editions of codes Whenever possible install boiler near an outside wall so that it is easy to duct fresh air directly ...

Page 7: ...t not reduce the free area of the air opening It must not be blocked by snow 5 Manually operated combustion air dampers are not allowed The air opening must not be of a type that could lead to situations where the air supply may be closed off while the burners are in operation 6 If the combined MBH input exceeds 400 MBH for all gas burning appliances the following excerpt to the right from the CAN...

Page 8: ...per combustion H Ambient air temperatures must be maintained within safe operating limits H When a damper is provided in any opening intended to admit combustion air into the room within which the appliance is installed the damper shall be interlocked to prevent any burner from starting before the damper is fully open H Each duct used to convey air from the outdoors shall have 1 A cross sectional ...

Page 9: ...l communicate directly or by means of ducts with the outdoors or to such spaces such as a crawl space that freely communicate with the outdoors and shall be sized in accordance with the following methods H Vertical duct s with a free area of not less than 1 in2 4000 Btu h or 5 5 cm2 kWh of the total input rating of all appliances in the enclosure H Horizontal duct s with an equivalent length of le...

Page 10: ...22 33 40 50 63 Dim a 1 Necessary clearance in front of the boiler for maintenance and service inches mm 24 620 26 680 33 850 33 850 36 920 43 1090 Dim b Necessary clearance beside the boiler Ensure sufficient clearance if installing Divicon inches mm 24 600 24 600 24 600 24 600 24 600 24 600 Dim c Necessary clearance behind a Vitocell H installed below the boiler inches mm 16 425 16 425 17 450 17 ...

Page 11: ... 6 150 6 150 6 150 6 150 6 150 Alcove installation side view Boiler Model VB2 18 22 33 40 50 63 Rear inches mm 6 150 6 150 6 150 6 150 6 150 6 150 Sides inches mm 0 0 0 0 0 0 0 0 0 0 0 0 Flue oil inches mm 9 230 9 230 9 230 9 230 9 230 9 230 gas inches mm 6 150 6 150 6 150 6 150 6 150 6 150 Top inches mm 6 150 6 150 6 150 6 150 6 150 6 150 Front AL inches mm 6 150 6 150 6 150 6 150 6 150 6 150 Vie...

Page 12: ...5 335 8 854 335 8 854 385 8 982 431 4 1096 b inches mm 93 16 232 105 16 262 115 8 295 137 8 353 151 8 385 151 8 385 Product Installation Alternatives Installation with Boiler Stand Packaging of Boiler Stand Installation on Vitocell Installation Instructions Domestic Hot Water Tank Flexible Piping a b 5167 404 v1 9 Boiler must be installed in such a way that gas or oil ignition system components ar...

Page 13: ...or later installation Installation without domestic hot water tank 2 Mount four levelling bolts into boiler base plate 3 Position boiler and arrange levelling bolts so boiler is slightly inclined to the rear Boiler must be installed on non combustible floor if not installed on a boiler stand or on a DHW tank Installation on domestic hot water tank Installation Instructions Domestic Hot Water Tank ...

Page 14: ...he insulation 1 Push the insulation blanket with black side facing outwards under the boiler and wrap the mat around the boiler shell 2 Allow the two ends to overlap and fasten with three spring clips 3 Insert the front retaining brackets and twist the tabs 4 Insert the rear retaining brackets and twist the tabs 5167 404 v1 9 IMPORTANT ...

Page 15: ...r insulation blanket in position with black side facing outwards 6 Place the rear panel over the safety supply connection and position in hooks on the base plate 7 Place the rear panel up against the retaining brackets and bend over the tabs approx 90 5167 404 v1 9 ...

Page 16: ...he base plate and hook onto the retaining brackets 6 Run the plug in connector of the burner cable through the strain relief clamp and through the opening in the front wall of the boiler and place on the boiler shell 7 Insert the control base in front panel Fasten with supplied rivets shipped with boiler control 8 Position the bottom of the side panels with the hooks in the openings of the front a...

Page 17: ...e right or left hand side depending on whether the door is required to swing out to the right or left Push combustion chamber insert to the rear as far as possible ensure retaining bracket is on the bottom 3 Fasten the combustion chamber door with M 10 hexagon bolts 4 Mount the sight glass on the combustion chamber door 5167 404 v1 9 IMPORTANT ...

Page 18: ...conforms with the National Fuel Gas Code ANSI Z223 1 latest edition When resizing any portion of the common venting system should be resized to approach the minimum size as determined using the appropriate tables in the CSA B149 1 or 2 National Fuel Gas Code Canada or ANSI Z223 1 latest edition USA Installation of boiler venting Use approved vent material only For gas or propane use B vent C vent ...

Page 19: ...rsely affect the operation of the oil burning appliance and its venting system If such is the case the building owner shall be informed of the situation in writing H The chimney shall be inspected to ensure that the material construction condition and size are suitable for the application H This boiler burner combination shall not be connected to an unlined chimney Such chimneys shall be lined in ...

Page 20: ...al vent pipe adaptor supplied with boiler to the cast iron flue collar Use high temperature silicone to seal between sheet metal adaptor and boiler cast iron vent connection Drill pilot holes with 11 64 cobalt HSS drill bit and fasten using three equally spaced screws Reinforce with locking band Vent pipe adaptors are shipped in Connection Fitting Package 4 Connect vent pipe adaptor with chimney v...

Page 21: ...ing valves This serves to avoid uncontrolled gravity circulation of heat into the heating system during prioritized DHW production or during summer months 5167 404 v1 9 Safety supply for pressure relief valve and air vent NPT 1 Boiler water supply non NPT 11 2 Boiler water return non NPT 11 2 Safety return for precharged expansion tank boiler drain and automatic feed NPT VB2 18 to 40 1 VB2 50 to 6...

Page 22: ...meter Do not pipe discharge to outdoors Minimum connection diameters Pressure relief valve 3 4 Discharge pipe 3 4 Piping to precharged expansion tank 3 4 This boiler does not require a flow switch Install the approved factory supplied pressure relief valve Removal of air from the system must occur via use of air vent s in the system supply To ensure the boiler can be purged of all air ensure suppl...

Page 23: ...r 15 minutes During time of pressure testing do not leave boiler unattended 5 Inspect all pipe joint connections the safety devices Safety Header if applicable and boiler base with flashlight for leaks 6 After 15 minutes release water pressure from boiler by opening boiler drain valve slowly remove caps from supply and return connections as well as cap from safety nipple and install pressure relie...

Page 24: ...e relationship between boiler flow rate and temperature rise is according to the formula Boiler output Btu h 500 x flow USGPM x Rise F The following chart lists typical flow rates for the Vitola boiler Boiler Model VB2 18 22 33 40 50 63 20 F rise 30 F rise USGPM m3 h USGPM m3 h 7 5 1 7 5 0 1 1 9 7 2 2 6 4 1 4 12 2 2 8 8 1 1 8 15 4 3 5 10 2 2 3 20 0 4 5 13 2 3 0 25 7 5 8 17 2 3 9 5167 404 v1 9 For ...

Page 25: ...lve Circulation pump Safety header with automatic air vent pressure relief valve and pressure gage Expansion tank Heating circuit Spring loaded flow check valve Circulation pump Safety header with automatic air vent pressure relief valve and pressure gage Expansion tank Domestic hot water storage tank indirect fired DHW Pump Module 5167 404 v1 9 ...

Page 26: ...ating circuit Spring loaded flow check valve Circulation pump Safety header with automatic air vent pressure relief valve and pressure gage Expansion tank Domestic hot water storage tank indirect fired 3 Way mixing valve 4 Way mixing valve With two low temperature circuits with mixing valves one high temperature circuit and with domestic hot water production e g with Vitotronic 300 KW3 combined wi...

Page 27: ...ssure relief valve and pressure gage Expansion tank Heat exchanger Circulation pump for heat exchanger Pressure relief valve Boiler in a heating cooling application Cooling season starts close valve v1 and open valve v2 Heating season starts close valve v2 and open valve v1 Heating Cooling unit Spring loaded flow check valve Circulation pump Safety header with automatic air vent pressure relief va...

Page 28: ...lled in all instances Do not install an isolation valve between boiler and low water cut off See piping to left for detailed connection of low water cut off Follow the installation instructions of the low water cut off manufacturer Use hemp when connecting short nipple to 90 elbow 5167 404 v1 9 Low water cut off connection Safety supply NPT 1 Tee field supplied 1 x 1 x 3 4 Short nipple field suppl...

Page 29: ...nic 200 300 and all other 120 VAC cabling through strain reliefs toward boiler control 3 Channel low voltage cables i e sensor cables through cable opening toward boiler control 4 Coil excess cabling and tuck between side panel and insulation 5 Tighten strain reliefs 5167 404 v1 9 IMPORTANT Always route all cables and capillaries between nylon backed insulation and metal enclosure panels Never all...

Page 30: ...ns 30 Top Panel Installation 1 Hook top panel into side panels and orient flush with front panel 2 Fasten top panel to rear panel with sheet metal screw supplied 3 Fasten boiler logo to front panel 5167 404 v1 9 ...

Page 31: ...ture due to chimney vent condensation drill out the necessary number of openings in the base of the combustion chamber using a 13 mm dia drill bit The flue gas temperature is increased by approx 18 F 10 C for each hole drilled An increase in flue gas temperature of 18 F 10 C reduces the energy efficiency by 0 4 per hole drilled This measure should therefore only be taken if absolutely necessary Ot...

Page 32: ...e Service Binder in this location Technical Data Boiler Model Model No VB2 18 VB2 22 VB2 33 VB2 40 VB2 50 VB2 63 Required draft 1 w c 0 02 0 02 0 02 0 02 0 02 0 02 Flue gas 2 gross temperature 3 at 40 C boiler water temperature 75 C boiler water temperature F C F C 300 149 329 165 300 149 329 165 300 149 329 165 300 149 329 165 300 149 329 165 300 149 329 165 1 Ensure compatibility with chimney sy...