Viessmann Vitorond 100 User manual

VITOROND 100
Installation instructions
for contractors
Vitorond100
TypeVR2E
Rated output 58 to 146kW
49 880 to 125 560 kcal/h
Oil/gas fired boiler
5592971GB9/2007 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,
Hall regulations 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
main 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.
5592971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, boiler door and flue adaptor (option)
(if the boiler is supplied in sections) 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Splitting the boiler block for easier handling
(if the boiler is supplied as a 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 connection38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections on the heating water side 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety connections and testing for leaks39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DHW connections39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing additional thermal insulation40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner installation41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important information on commissioning41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5592971GB

4
Boiler section assembly
For delivery in sections (for delivery as block, see page 21)
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 heating water 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 heating water side; these are
pressed into the sections.
ABoiler door
BFront section
CCentre section
DBack section with cast−on flue
outlet
AFlue pipe adaptor
Rated output kW 58 72 90 116 146
Boiler sections as block in individual
sections
Number of centre
sections
1 2 3 4 5
5592971GB
AB C D E

5
Boiler section assembly (cont.)
Assembly with the boiler lying down
For all sections:
1. Clean the sealing faces (hubs,
grooves and tongues) with
solvent.
2. Fill the sealing grooves with
sealant.
3. Apply additional Dirko sealant in
the marked area.
5592971GB
1.
3. 2.

6
Boiler section assembly (cont.)
For all sections:
1. Clean the nipples with solvent and
apply the linseed oil graphite
supplied.
5592971GB
2. 1.
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
lubricant supplied.
During compression, maintain the same distance at the top and bottom
between the individual sections. Never secure the sections out of true.
5592971GB
5. 6.
2.
4.
3.
1.

8
Boiler section assembly (cont.)
5592971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.
5592971GB
M 12
A
2.
1.
A
A
3.

10
Boiler section assembly (cont.)
Continue on page19.
5592971GB
1.
2.

11
Boiler section assembly (cont.)
Assembly with the boiler standing up
5592971GB
M 12
1.
2.

12
Boiler section assembly (cont.)
For all sections:
1. Clean the sealing faces (hubs,
grooves and tongues) with
solvent.
2. Fill the sealing grooves with
sealant.
3. Apply additional Dirko sealant in
the marked area.
5592971GB
1.
2.
3.

13
Boiler section assembly (cont.)
For all sections:
1. Clean the nipples with solvent and
apply the linseed oil graphite
supplied.
5592971GB
2.
1.

14
Boiler section assembly (cont.)
5592971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
lubricant supplied.
During compression, maintain the same distance at the top and bottom
between the individual sections. Never secure the sections out of true.
5592971GB
1.
2.
5.
3. 4.
6.

16
Boiler section assembly (cont.)
5592971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.
5592971GB
A4x
2.
4x
1.
1.

18
Boiler section assembly (cont.)
5592971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: 5.2bar
AManual air vent valve (on site)
BCap (on site)
CDummy plugs
DSensor well
EReturn injector nozzle
5592971GB
B
B
A
C
C
D
2.
6.
1.
4.
5.
3.
E

20
Fitting the turbulators, boiler door and flue adaptor (option)
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.
1. Insert the turbulators:
See the parts list in the service
instructions.
2. Fit the boiler door.
3. Flue adaptor (for 116 and 146kW).
Seal in the cast−on flue adaptor
with Dirko sealant.
Continue on page30.
5592971GB
2.
3.
1.