Viessmann Vitorond 100 User manual

VITOROND 100
Installation instructions
for heating engineers
Vitorond100
TypeVR2B
Rated output 40 to 100kW
Oil/gas fired boilers
5862915GB1/2006 Dispose after installation

2
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.
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.
Working on the heating system
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.
HWhen using gas as fuel, also close
the main gas shut−off valve and
safeguard against unauthorised
reopening.
5862915GB

3
Index
Page
Safety instructions2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler section assembly
(if the boiler is supplied in sections) 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly with
Hthe boiler lying down 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hthe boiler standing up 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water pressure test (if the boiler is supplied in sections) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the turbulators, the boiler door and flue pipe adaptor (if required)
(if the boiler is supplied in sections) 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Splitting boiler block for easier transport into the boiler room
(if the boiler is supplied as an assembled block)
Dismantling 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly with
Hthe boiler lying down 24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hthe boiler standing up 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance dimensions30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler positioning and levelling31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the thermal insulation32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flue gas connections38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary connections38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety connections and testing for leaks39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DHW connections39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing additional thermal insulation40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner installation41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important information on commissioning41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5862915GB

4
Boiler section assembly
If the boiler is supplied in sections
Note
All parts required for the boiler assembly are contained in the boiler
accessory pack.
The boiler body consists of a back section with cast−on flue outlet, a front
section with fitted boiler door and a number of centre sections, subject to the
rated output.
The primary side is made watertight by sealant, which is inserted into the
sealing grooves at the front of each section.
The sections are connected by nipples on the primary side; these are pressed
into the sections.
ABoiler door
BFront section
CCentre section
DBack section with cast−on flue
outlet
AFlue pipe adaptor
(for 80 and 100kW)
Rated output kW 40 50 63 80 100
Number of centre
sections
1 2 3 4 5
5862915GB
AB C D E

5
Boiler section assembly (cont.)
Assembly with the boiler lying down
For all sections:
AClean the sealing faces (hub, grooves and tongues) with solvent
BFill the sealing grooves with sealant
CApply additional Dirko sealant in the marked area
For all sections:
DClean the nipples with solvent and apply the enclosed linseed oil graphite
5862915GB
1.
2.
B
A
C
D
3.

6
Boiler section assembly (cont.)
5862915GB
2.
1.
3.

7
Boiler section assembly (cont.)
Note
During the compression process, draw in only one additional section at a
time to prevent leaks at the hub joints.
Before use, lubricate the moving threads of the compression tool with the
enclosed lubricant.
During compression, maintain the same distance at the top and bottom
between the individual sections. Never secure the sections out of true.
5862915GB
5. 6.
2.
4.
3.
1.

8
Boiler section assembly (cont.)
5862915GB
1.
2.

9
Boiler section assembly (cont.)
!Please note
Only release the compression tool when the sections have been joined
with anchor rodsA.
5862915GB
M 12
A
2.
1.
A
A
3.

10
Boiler section assembly (cont.)
Continue on page19.
5862915GB
1.
2.

11
Boiler section assembly (cont.)
Assembly with the boiler standing up
5862915GB
M 12
1.
2.

12
Boiler section assembly (cont.)
For all sections:
AClean the sealing faces (hub, grooves and tongues) with solvent
BFill the sealing grooves with sealant
CApply additional Dirko sealant in the marked area
5862915GB
1.
A
B
2.
C

13
Boiler section assembly (cont.)
For all sections:
AClean the nipples with solvent and apply the enclosed linseed oil graphite
5862915GB
1.
A

14
Boiler section assembly (cont.)
5862915GB
2.
1.

15
Boiler section assembly (cont.)
Note
During the compression process, draw in only one additional section at a
time to prevent leaks at the hub joints.
Before use, lubricate the moving threads of the compression tool with the
enclosed lubricant.
During compression, maintain the same distance at the top and bottom
between the individual sections. Never secure the sections out of true.
5862915GB
1.
2.
5.
3. 4.
6.

16
Boiler section assembly (cont.)
5862915GB
2.
1.

17
Boiler section assembly (cont.)
!Please note
Only release the compression tool when the sections have been joined
with anchor rodsA.
5862915GB
A4x
2.
4x
1.
1.

18
Boiler section assembly (cont.)
5862915GB
1.

19
Water pressure test
If the boiler is supplied in sections
The water pressure test is not required if the boiler is supplied as a
factory−tested block.
Never fit any pressure, control or safety equipment during the water pressure
or leak tests.
Test the water pressure in accordance with TRD702 or local regulations. Test
the pressure with a pressure gauge class1.0.
Test pressure: 4bar
AManual air vent valve (on site)
BCap (on site)
CDummy plugs
DSensor well
EReturn injector nozzle
5862915GB
B
B
A
C
C
D
2.
6.
1.
4.
5.
3.
E

20
Fitting the turbulators, the boiler door and possibly the flue
pipe adaptor
If the boiler is supplied in sections
Note
In the delivered condition, the boiler door opens to the l.h. side.
Reposition the hinges, if required.
ASecondpass at the bottom*1
BSecondpass at the top*1
CThirdpass*1
DFlue pipe adaptor (for 80 and
100kW). Seal in the cast−on flue
outlet adaptor with Dirko sealant.
*1For insertion of the respective turbulators, see parts list in the service instructions.
Continue on page30.
5862915GB
2.
3.
D
1.