Viessmann Vitorond 100 Operating instructions

Service instructions
for contractors
VIESMANN
Vitorond 100
Type VR2B, 40 to 100 kW
Oil/gas boiler
For applicability, see the last page
VITOROND 100
5692 659 GB 2/2013 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively inten-
ded for qualified 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 elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental 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
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Do not smoke. Prevent naked
flames and sparks. Do not
switch lights or electrical appli-
ances on or off.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Evacuate any people from the
danger zone.
■ Notify your gas or electricity
supply utility from outside the
building.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
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If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the installation site.
■ Close all doors in the living
space.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Life-threatening poisoning
caused by carbon monoxide in
the flue gas occurs as a result of
leaking or blocked flue systems
or an insufficient supply of com-
bustion air.
Ensure the flue system is in
proper working order. It must not
be possible to close apertures for
interconnected combustion air
supply.
Extractors
Operating appliances that extract air to
the outside (cooker hoods, extractors, air
conditioning units, etc.) can create neg-
ative pressure. If the boiler is operated at
the same time, this can lead to reverse
flow of the flue gas.
Danger
The simultaneous operation of
the boiler and appliances that
extract air to the outside can
result in life threatening poison-
ing due to reverse flow of the flue
gas.
Fit an interlock circuit or take suit-
able steps to ensure a sufficient
supply of combustion air.
Working on the system
■ Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■ Isolate the system from the power sup-
ply (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 recon-
nection.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Prior to commencing any work,
touch earthed objects, such as
heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of your sys-
tem.
Defective components must be
replaced with genuine
Viessmann spare parts.
Safety instructions
Safety instructions (cont.)
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Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
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Product information
Intended use......................................................................................................... 6
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 7
Further details regarding the individual steps....................................................... 8
Parts lists............................................................................................................ 16
Commissioning/service reports........................................................................ 19
Specification....................................................................................................... 20
Certificates
Declaration of conformity...................................................................................... 21
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 22
Keyword index.................................................................................................... 23
Index
Index
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The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions. It is only designed
for the heating of water that is of potable
water quality.
Intended usage presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than heating the building or
DHW does not comply with regulations.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect usage also occurs if the components
in the heating system are modified from
their intended function (e.g. if the flue
gas and ventilation air paths are
sealed).
Product information
Intended use
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the system........................................................... 8
••• 2. Commissioning the system........................................... 9
• • 3. Shutting down the system
• • 4. Closing the Vitoair draught stabiliser (if installed)...... 10
•5. Opening the boiler door, extracting and cleaning the
turbulators....................................................................... 10
•6. Cleaning the heating surface, flue outlet and flue....... 12
• • 7. Checking all gaskets and packing cords on the flue
gas side
• • 8. Checking gaskets and thermal insulation sections.... 12
•9. Inserting the turbulators and fitting the boiler door.... 12
• • 10. Checking the firm seating of electrical plug-in
connections and cable grommets
• • 11. Checking the thermal insulation
••• 12. Checking connections on the heating water and DHW
side and the sensor well for leaks
••• 13. Checking the function of the safety equipment
••• 14. Checking the expansion vessel and system pressure 13
• • 15. Checking the mixer for ease of operation and
tightness.......................................................................... 14
••• 16. Checking the Vitoair draught stabiliser (if installed)... 14
• • 17. Adjusting the burner...................................................... 14
•18. Operating and service documents................................ 15
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Filling the system
Fill water
!Please note
Unsuitable fill water increases
the level of deposits and corro-
sion and may lead to boiler dam-
age.
■ Flush the heating system thor-
oughly before filling.
■ Only use fill water of potable
quality.
■ An antifreeze additive suitable
for heating systems can be
added to the fill water. The anti-
freeze manufacturer must ver-
ify its suitability.
■ Fill and top-up water with a
water hardness in excess of
the following values must be
softened, e.g. with a small soft-
ening system for heating water.
Total permissible hardness of the fill and top-up water
Total heating
output
Specific system volume (Conversion rate 1 mol/m3 = 100
ppm)
kW < 20 l/kW ≥ 20 l/kW to
< 50 l/kW
≥ 50 l/kW
≤ 50 ≤ 3.0 mol/m3 ≤ 2.0 mol/m3 < 0.02 mol/m3
> 50 to ≤ 200 ≤ 2.0 mol/m3 ≤ 1.5 mol/m3 < 0.02 mol/m3
> 200 to ≤ 600 ≤ 1.5 mol/m3 ≤ 0.02 mol/m3 < 0.02 mol/m3
> 600 < 0.02 mol/m3 < 0.02 mol/m3 < 0.02 mol/m3
Commissioning, inspection, maintenance
Further details regarding the individual steps
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1. Check the pre-charge pressure of the
expansion vessel.
If the pre-charge pressure is lower
than the static system pressure, top
up with nitrogen until the pre-charge
pressure is 0.1 to 0.2 bar (10 to
20 kPa) higher.
2. Close the oil or gas shut-off valves.
3. Open the check valve.
4. Top up the heating system with water
and vent until the charge pressure is
0.1 to 0.2 bar (10 to 20 kPa) higher
than the pre-charge pressure of the
expansion vessel.
Permiss. operating pressure: 3 bar
(0.3 MPa)
Test pressure: 4 bar (0.4 MPa)
5. Mark the charge pressure at pressure
gauge A.
6. Return the check valves to their oper-
ating position.
Commissioning the system
Operating and service instruc-
tions for the control unit and the
burner
1. Check that the installation room vent
is open.
2. Open the oil or gas shut-off valves.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Closing the Vitoair draught stabiliser (if installed)
1. Press rotary selector A on the
Vitoair motor and turn to position 5.
2. Lock the control disc with latch B.
Opening the boiler door, extracting and cleaning the turbulators
Note
Remove the gas supply pipe on gas
burners.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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A
fA
ATurbulators (see page 17)
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the heating surface, flue outlet and flue
A
ACleaning brush (accessories)
Checking gaskets and thermal insulation sections
1. Check gaskets and packing cords in
the boiler door for damage.
2. Check the thermal insulation sections
in the combustion chamber and the
boiler door for damage.
3. Replace any damaged sections.
Inserting the turbulators and fitting the boiler door
Note
Mount the gas supply pipe on gas burn-
ers.
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
Check all gas connections for
tightness.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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A
fA
ATurbulators (see page 17)
Checking the expansion vessel and system pressure
Note
Please observe expansion vessel man-
ufacturer's instructions.
Carry out this test on a cold system.
1. Drain the system until the pressure
gauge indicates "0" or close the cap
valve on the expansion vessel and
reduce the pressure in the expansion
vessel.
2. If the pre-charge pressure of the
expansion vessel is lower than the
static system pressure, top up with
nitrogen until the pre-charge pres-
sure is 0.1 to 0.2 bar (10 to 20 kPa)
higher.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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3. Top up with water until the charge
pressure of the cooled system is 0.1
to 0.2 bar (10 to 20 kPa) higher than
the pre-charge pressure of the
expansion vessel.
Permiss. operating pressure: 3 bar
(0.3 MPa)
Checking the mixer for ease of operation and tightness
1. Remove the motorised lever from the
mixer handle and check the mixer for
ease of operation.
2. Check the mixer for leaks. Replace
the O-ring gaskets if the mixer is leak-
ing.
3. Snap the motorised lever into place.
Checking the Vitoair draught stabiliser (if installed)
Release the latch on the control disc.
Note
The control disc must swing freely during
burner operation.
Adjusting the burner
Burners up to 63 kW
Burner service instructions
Burners from 80 kW
Adjust the maximum burner oil or gas
throughput so that the stated maximum
boiler heating output will not be excee-
ded.
Note that, for multi stage or modulating
burners, the flue system must be suitable
for the low flue gas temperatures that
may arise during partial load operation.
Select the lowest partial load stage also
with regard to the respective type of flue
system design.
Two-stage
The following minimum heating output
values in the base load stage are
required to protect against dew point cor-
rosion:
Rated heating
output
Minimum heating out-
put to be selected
(burner stage 1) or
base load
kW kW
80 48
100 60
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Modulating
The minimum boiler water temperature
for operation with oil is 60 ºC and for
operation with gas 65 ºC.
Adjust the return temperature raising
facility to a minimum temperature of
53 ºC.
Operating and service documents
1. Complete and detach the customer
registration card:
■ Hand the system user this part for
safekeeping.
■ Retain the heating contractor's
part.
2. File all parts lists, operating and serv-
ice instructions in the folder and hand
this over to the system user.
The installation instructions are no
longer required after the installation
and, therefore, do not need to be
retained.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Spare parts information
Quote the part and serial numbers (see
type plate) and the position number of
the required part (as per this parts list).
Standard parts are available from your
local supplier.
Parts
001 Sensor well
002 Thermal insulation block for boiler
door
003 Boiler door
004 Hinge bracket
005 Gasket 12 x 16 x 1845 mm
006 Packing cord 7 3 mm
008 Sight hole locking latch
009 Return injector nozzle
010 Gasket 12 x 16 x 300 mm
011 Turbulator, top, 2nd pass
(only for 50 kW)
012 Turbulator, 3rd pass
(only for 40 kW)
013 Cast iron turbulator, bottom, 2nd
pass
(only for 40 to 63 kW)
014 Turbulator, top, 2nd pass
(only for 40 kW)
015 Turbulator, 3rd pass
(only for 50 and 63 kW)
016 Brush handle
018 Front section with assembly parts
019 Centre section with assembly parts
020 Rear section with assembly parts
021 Flue outlet adaptor
(only for 80 and 100 kW)
202 Top panel, front
203 Side panel, left
204 Thermal insulation mat for the
boiler body
205 Back panel
206 Thermal insulation mat, back
207 Front panel with logo (211)
208 Retaining bracket
209 Top panel, back
210 Side panel, right
211 Vitorond 100 logo
212 Edge protector
213 Cover panel (accessory for third
party burners)
214 Double strain relief
Wearing part
017 Cleaning brush
Parts not shown
300 Spray paint, Vitosilver
301 Touch-up paint stick, Vitosilver
302 Service instructions
303 Installation instructions
304 Connecting elements
305 Connection cone (3 pce)
AType plate, either on the left or right
BBoiler control unit
See separate parts list
Parts lists
Parts lists
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017
016
018
019
020
001
012 014 011 015
008 006 003 002 005 010 013
004
009
021
Parts lists
Parts lists (cont.)
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209
A
212
205
203
214
206
208
202
B
210
207
211
208
204
213
211
Parts lists
Parts lists (cont.)
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Commissioning Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Commissioning/service reports
Commissioning/service reports
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Rated heating output kW 40 50 63 80 100
Product ID CE-0645AU114
Pressure drop on the hot gas side Pa 8 10 13 25 45
mbar 0.08 0.10 0.13 0.25 0.45
Required draught*1 Pa 5
mbar 0.05
Flue gas temperature*2
■ At boiler water temperature 40 °C °C 155
■ At boiler water temperature 75 °C °C 180
Product parameters (to EnEV)
Efficiency η at
■ 100 % of rated heating output % 92.8 93.2 93.1 92.3 93.0
■ 30 % of rated heating output % 94.7 94.3 94.9 94.0 94.2
Standby loss qB,70 % 0.7 0.6 0.5 0.5 0.4
Power consumption*3 at
■ 100 % of rated heating output W 264 294 329 369 410
■ 30 % of rated heating output W 88 98 110 123 137
*1 Observe when sizing the chimney.
*2 Flue gas temperatures as average gross values to EN 304 (captured with 5 ther-
mocouples) at 20 °C combustion air temperature.
*3 Standard parameter (in conjunction with Vitoflame 200 pressure-jet oil burner).
Specification
Specification
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