Viessmann Vitorond 100 Operating instructions

VITOROND 100
Service instructions
for heating engineers
Vitorond100
TypeVR2B
40 to 100kW
Oil/gas fired boiler
5692659GB1/2006 Please keep safe

2
Safety instructions
Safety instructions
¨Please follow these safety instructions closely to prevent accidents and
material 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
environmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
HWork on gas equipment must only
be carried out by a registered gas
fitter.
HElectrical work must only be
carried out by a qualified
electrician.
HThe system must be
commissioned by the system
installer or a qualified person
authorised by the installer.
Regulations
Observe the following when working
on this system
Hall legal instructions regarding the
prevention of accidents,
Hall legal instructions regarding
environmental protection,
Hregulations issued by professional
bodies,
Hall current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
¨Danger
Escaping gas can lead to
explosions which may result in
serious injury.
HDo not smoke! Prevent
naked flames and sparks.
Never switch electrical lights
or equipment ON or OFF.
HClose the gas shut−off valve.
HOpen windows and doors.
HRemove all people from the
danger zone.
HNotify your gas and
electricity supplier from
outside the building.
HShut off the electricity supply
to the building from a safe
place (outside the building).
5692659GB

3
Safety instructions
Safety instructions (cont.)
If you smell flue gas
¨Danger
Flue gas can lead to
life−threatening poisoning.
HShut down the heating
system.
HVentilate the boiler room.
HClose the gas shut−off valve.
Working on the heating system
HWhen using gas as fuel, also close
the main gas shut−off valve and
safeguard against unauthorised
reopening.
HIsolate 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.
HSafeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electro−static
discharges.
Touch earthed objects, such as
heating or water pipes, to
discharge static loads.
Repair work
!Please note
Repairing components which
fulfil a safety function can
compromise the safe operation
of your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function.
Installing non−authorised
components and
non−approved modifications/
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only
original spare parts from or
those approved by Viessmann.
5692659GB

4
Index
Index
Page
General information
Safety instructions 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start−up, inspection and maintenance
Steps 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further details regarding the individual steps 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts list13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Specification 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service report 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Certificate of conformity 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer’s certificate 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyword index 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Initial start−up, inspection and maintenance
StepsInitial start−up, inspection and maintenance
For further instructions on individual steps, see pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
C I M 1. Starting the heating system 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 2. Shutting down the heating system
I M 3. Closing the Vitoair draught stabiliser
(if installed) 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M4. Opening the boiler door and removing/
cleaning the turbulators 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M5. Cleaning the heating surface,
flue outlet and flue pipe 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 6. Checking all seals/gaskets and packing cords
on the flue gas side
I M 7. Checking the gaskets and the boiler door thermal
insulation parts
M8. Inserting the turbulators and closing the boiler door 10
I M 9. Checking the tightness of electrical connections
and cable grommets
I M 10. Checking the thermal insulation
C I M 11. Checking connections on the primary and secondary
side and the sensor well for leaks
C I M 12. Checking the function of the safety equipment
C I M 13. Checking the diaphragm expansion vessel
and system pressure 11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 14. Checking the mixer for obstructions and leaks 11. . . . . . . . . . . .
C I M 15. Checking the Vitoair draught stabiliser (if installed) 11.
C M 16. Adjusting the burner 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C17. Operating and service documents 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692659GB

6
Initial start−up, inspection and maintenance
Further details regarding the individual steps
Starting the heating system
Operating instructions, service instructions  control unit and burner
1. Check that the boiler room
ventilation aperture is open.
2. Check the inlet pressure of the
diaphragm expansion vessel.
If the inlet pressure of the
diaphragm expansion vessel is
lower than the static system
pressure, top up with enough
nitrogen to raise the inlet pressure
higher than the static system
pressure (0.1 to 0.2bar).
The static pressure corresponds to
the static head.
3. Open the check valves.
4. Top up your heating system with
water and vent it, until the
pressure is higher (0.1 to 0.2bar)
than the inlet pressure of the
diaphragm expansion vessel.
Permiss. operating pressure:3bar
5. Mark this pressure at pressure
gaugeA.
6. Return the check valves to their
operating position.
7. Open the oil or gas shut−off valves.
5692659GB
A

7
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Closing the Vitoair draught stabiliser (if installed)
1. Press rotary selectorAon the
Vitoair motor and turn it to
position5.
2. Lock the control disc with latchB.
5692659GB
A
B

8
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Opening the boiler door and removing/cleaning the turbulators
Note
In case of gas burners, remove the gas supply pipe.
ATurbulators (see page15)
5692659GB
A
41

9
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Cleaning the heating surface, flue outlet and flue pipe
ACleaning brush (accessories)
5692659GB
A

10
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Inserting the turbulators and closing the boiler door
Note
Refit the gas supply pipe to the gas burner.
¨Danger
Escaping gas can lead to explosions which may result in serious injury.
Check all gas connections for soundness.
ATurbulators (see page15)
5692659GB
A
41

11
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the diaphragm expansion vessel and system pressure
Observe the diaphragm expansion vessel manufacturer’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
diaphragm expansion vessel, and
reduce the pressure on the
primary side of the diaphragm
expansion vessel.
2. If the inlet pressure of the
diaphragm expansion vessel is
lower than the static system
pressure, top up with enough
nitrogen to raise the inlet pressure
higher than the static system
pressure (0.1 to 0.2bar).
The static pressure corresponds to
the static head.
3. Top up with water, until the
pressure of a cold system is
higher (0.1 to 0.2bar) than the
inlet pressure of the diaphragm
expansion vessel.
Permiss. operating pressure:3bar
Checking the mixer for obstructions and leaks
1. Remove the motorised lever from
the mixer handle and check the
mixer for ease of movement.
2. Check the mixer for leaks.
Replace the Orings if the mixer
leaks.
3. Snap the frame into place.
Checking the Vitoair draught stabiliser (if installed)
Release the latch on the control disc.
The control disc must swing freely
during burner operation.
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Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Adjusting the burner
Burners up to 63kW
Burner and control unit service instructions
Burners from 80kW
Adjust the max. burner oil or gas
throughput so that the stated
maximum rated boiler output will
not be exceeded.
Note that, for stepped or modulating
burners, the flue gas system must be
suitable for the low flue gas
temperatures which may arise
during partial load operation.
Select the lowest partial load stage
also with the view to the respective
type of flue gas system design.
Two−stage
The following minimum output
values in the base load stage are
required to protect against dew point
corrosion:
Rated
output
kW
Minimum output to be
selected
(burnerstage 1)
or base load
kW
80
100
48
60
Modulating
The minimum boiler water
temperature for oil combustion is
60ºC and for gas combustion 65ºC.
Adjust the return temperature raising
facility at least to 53ºC.
Operating and service documents
1. Complete and detach the
customer registration card:
HGive the system user this part
for safe−keeping.
HRetain the heating engineer part.
2. Keep all parts lists, operating and
service instructions in the folder
and hand this over to the system
user.
The installation instructions are
not required after the installation
is complete and may therefore be
disposed of.
5692659GB

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Parts list
Parts list
When ordering spare parts
Quote the part no. and serial no. (see
type plate) and the item no. of the
required part (as per this parts list).
Obtain standard parts from your
local supplier.
Parts
001 Sensor well
002 Boiler door thermal insulation block
003 Boiler door
004 Hinge bracket
005 Gasket set12×16×1845mm
006 Packing cord ∅3mm
008 Sight hole locking bolt
009 Return injector nozzle
010 Gasket set12×16×300mm
011 Top turbulator, secondpass*1
012 Turbulator, thirdpass*2
013 Lower cast iron turbulator,
secondpass*3
014 Top turbulator, secondpass*2
015 Turbulator, thirdpass*4
016 Brush handle
018 Front section with assembly parts
019 Centre section with assembly parts
020 Rear section with assembly parts
021 Flue pipe adaptor*5
202 Front top plate
203 L.h. side panel
204 Boiler body thermal insulation
mat
205 Rear panel
206 Rear thermal insulation mat
207 Front panel
208 Retaining bracket
209 Rear top panel
210 R.h. side panel
211 Vitorond100 logo
212 Edge protector
213 Cover (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 Connecting cone pack (3pieces)
AType plate, optionally l.h. or r.h.
side
BBoiler control unit, see parts list
in the service instructions of the
boiler control unit
*1Only for 50kW.
*2Only for 40kW.
*3Only for 40 to 63kW.
*4Only for 50 and 63kW.
*5Only for 80 and 100kW.
5692659GB

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Parts list
Parts list (cont.)
5692659GB
209
A
212
205
203
214
206
208
202
B
210
207
211
208
204
213

15
Parts list
Parts list (cont.)
5692659GB
017
016
018
019
020
001
012 *2 014 *2
011 *1 015 *4
008 006 003 002 005 010 013
004
009
021*5
*3

16
Appendix
Specification
Rated output kW 40 50 63 80 100
Product ID
according to Efficiency Directive
according to Gas Equipment Directive
CE0645 AU114
CE0197 AU21
Hot gas pressure drop Pa
mbar
8
0.08
10
0.10
13
0.13
25
0.25
45
0.45
Required draught*1 Pa
mbar
5
0.05
5
0.05
5
0.05
5
0.05
5
0.05
Flue gas parameters
Temperature*2 at
boiler water temp. 40ºC
boiler water temp. 75ºC
ºC
ºC
155
180
155
180
155
180
155
180
145
170
Product parameters (according to EnEV)
Efficiencyηat
 100% of the rated output
 30% of the rated output
%
%
92.8
94.7
93.2
94.3
93.1
94.9
92.3
94.0
93.0
94.2
Standby lossesqB,70 % 0.7 0.6 0.5 0.5 0.4
Power consumption*3 at
 100% of the rated output
 30% of the rated output
W
W
264
88
294
98
329
110
369
123
410
137
*1Observe when sizing the chimney.
*2Flue gas temperatures as average gross values to EN304 (measured with
5thermocouples) at 20ºC combustion air temperature.
*3Standard parameter (in conjunction with Vitoflame200 pressure−jet oil burner).
5692659GB

17
Appendix
Commissioning/service report
Initial start−up Maintenance/service Maintenance/service
date:
by:
Maintenance/service Maintenance/service Maintenance/service
date:
by:
Maintenance/service Maintenance/service Maintenance/service
date:
by:
Maintenance/service Maintenance/service Maintenance/service
date:
by:
Maintenance/service Maintenance/service Maintenance/service
date:
by:
5692659GB

18
Appendix
Declaration of conformity for Vitorond100
We, Viessmann Werke GmbH&CoKG, D35107 Allendorf, declare as sole
responsible body, that the product
Vitorond100
corresponds to the following
standards:
EN267
EN303
EN676
EN500821
EN50165
EN55014
EN60335
EN6100032
EN6100033
This product is identified in
accordance with the following
Directives
73/23/EEC
89/336/EEC
90/396/EEC
92/42/EEC
98/37/EC
as follows:
_0197
This product meets the requirements of the Efficiency Directive (92/42/EEC) for:
Low temperature (LT) boilers
The product parameters determined as system values for the product
Vitorond100 as part of EC type testing according to the Efficiency Directive
(see specification table) can be utilised to assess the energy consumption of
heating and ventilation equipment to DINV470110 which is specified by the
EnEV.
Manufacturer’s certificate according to the 1stBImSchV
We, Viessmann Werke GmbH&CoKG, D35107 Allendorf, confirm that the
following product meets the NOxlimits specified by the
1stBImSchVparagraph7(2):
Boiler and burner units
Vitorond100 with Vitoflame pressure−jet oil burner
Allendorf, 2 January2006 Viessmann Werke GmbH&CoKG
pp. Manfred Sommer
5692659GB

19
Appendix
Keyword index
A
Adjusting the burner,12
B
Boiler door, opening,8
Boiler room ventilation, checking,6
Burner adjustment,12
C
Certificate of conformity,18
Checking the boiler room
ventilation,6
Checking the diaphragm expansion
vessel,11
Cleaning the flue outlet and flue
pipe,9
Checking the mixer for obstructions
and leaks,11
Checking the system pressure,11
Checking the Vitoair draught
stabiliser,11
Cleaning the heating surfaces,9
Closing the Vitoair draught
stabiliser,7
Commissioning/service report,17
D
Diaphragm expansion vessel,
checking,11
F
Filling the heating system with
water,6
Fitting the boiler door,10
Flue outlet and flue pipe,
cleaning,9
Further details regarding the
individual steps,6
H
Heating surfaces, cleaning,9
I
Inserting the turbulators,10
M
Manufacturer’s certificate,18
Mixer, checking for obstructions and
leaks,11
O
Opening the boiler door,8
Operating and service
documents,12
P
Parts list,13
Product characteristics to EnEV
[Germany],16
R
Removing and cleaning the
turbulators,8
S
Safety instructions,2
Specification,16
Starting the system,6
Steps,5
System pressure, checking,11
T
Turbulators, removal and
cleaning,8
V
Ventilation checking,6
Vitoair draught stabiliser,
checking,11
Vitoair draught stabiliser, closing,7
5692659GB

Viessmann Werke GmbH&Co KG
D35107 Allendorf
Tel: [phone]0
Fax: [phone]2780
www.viessmann.de
Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Tel: [phone]
Fax: [phone]
E−mail: info−[email protected]
20
5692659GBSubject to technical modifications.
Printed on environmentally friendly, chlorine−free bleached paper