Viessmann Vitorond 100, Installation Instructions Manual

Page 1: ...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 ...

Page 2: ...st only be carried out by a qualified electrician Regulations Observe the following when working on this system H all legal instructions regarding the prevention of accidents H all legal instructions regarding environmental protection H regulations issued by professional bodies H all current safety regulations as defined by DIN EN DVGW TRGI TRF VDE and all locally applicable standards Working on t...

Page 3: ...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 H the boiler lying down 24 H the 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 co...

Page 4: ...r 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 A Boiler door B Front section C Centre section D Back section with cast on flue outlet A Flue pipe adaptor for 80 and 100 kW Rated output ...

Page 5: ...tions A Clean the sealing faces hub grooves and tongues with solvent B Fill the sealing grooves with sealant C Apply additional Dirko sealant in the marked area For all sections D Clean the nipples with solvent and apply the enclosed linseed oil graphite 5862 915 GB 1 2 B A C D 3 ...

Page 6: ...6 Boiler section assembly cont 5862 915 GB 2 1 3 ...

Page 7: ...on 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 ...

Page 8: ...8 Boiler section assembly cont 5862 915 GB 1 2 ...

Page 9: ...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 ...

Page 10: ...10 Boiler section assembly cont Continue on page 19 5862 915 GB 1 2 ...

Page 11: ...11 Boiler section assembly cont Assembly with the boiler standing up 5862 915 GB M 12 1 2 ...

Page 12: ...ction assembly cont For all sections A Clean the sealing faces hub grooves and tongues with solvent B Fill the sealing grooves with sealant C Apply additional Dirko sealant in the marked area 5862 915 GB 1 A B 2 C ...

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

Page 14: ...14 Boiler section assembly cont 5862 915 GB 2 1 ...

Page 15: ...ion 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 ...

Page 16: ...16 Boiler section assembly cont 5862 915 GB 2 1 ...

Page 17: ...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 ...

Page 18: ...18 Boiler section assembly cont 5862 915 GB 1 ...

Page 19: ...it 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 A Manual air vent valve on site B Cap on site C Dummy plugs D Sensor well E Return injector nozzle 5862 915 GB B B A C C D 2 6 1 4 5 3 E ...

Page 20: ...r door opens to the l h side Reposition the hinges if required A Second pass at the bottom 1 B Second pass at the top 1 C Third pass 1 D Flue 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 ...

Page 21: ...If the boiler is supplied as an assembled block Dismantling Danger Tipping the boiler block can lead to injuries and equipment damage Remove the boiler door before splitting the block Note Remove the turbulators before splitting the boiler block A Protective caps 5862 915 GB 1 A ...

Page 22: ...22 Splitting the boiler block for easier transport into the boiler room cont 5862 915 GB 1 2 ...

Page 23: ...ler room cont Please note To prevent damaging the cast iron sections drive the wedges in only at the designated points where the boiler body is thicker and not anywhere near the hubs For the assembly of the boiler standing up continue on page 27 5862 915 GB 3x 1 2 ...

Page 24: ... down Note Always use new nipples during assembly A Clean the sealing faces hub grooves and tongues with solvent B Fill the sealing grooves with sealant C Apply additional Dirko sealant in the marked area D Clean the nipples with solvent and apply the enclosed linseed oil graphite 5862 915 GB B A D C 2 1 3 ...

Page 25: ...m cont Please note Only release the compression tool when the sections have been joined with anchor rods A Notes 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 2 3 1 A A ...

Page 26: ...er room cont Notes In the delivered condition the boiler door opens to the l h side Reposition the hinges if required Carry out a water pressure test see page 19 Insert the turbulators see page 20 A Sensor well B Dummy plugs C Locking cap 5862 915 GB A B B C C 3 1 2 ...

Page 27: ...g up Note Always use new nipples during assembly A Clean the sealing faces hub grooves and tongues with solvent B Fill the sealing grooves with sealant C Apply additional Dirko sealant in the marked area D Clean the nipples with solvent and apply the enclosed linseed oil graphite 5862 915 GB D A 3 3x 2 1 C B ...

Page 28: ...ont Please note Only release the compression tool when the sections have been joined with anchor rods A Notes 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 A4x 3 2 1 4x 3x ...

Page 29: ...o the boiler room cont Notes In the delivered condition the boiler door opens to the l h side Reposition the hinges if required Carry out a water pressure test see page 19 Insert the turbulators see page 20 A Sensor well B Dummy plugs 5862 915 GB A B B 2 1 ...

Page 30: ... length of the Vitoair c mm 100 2 1Necessary clearance for cleaning purposes 2Maintain a minimum distance of 500 mm for adjustments and maintenance work on that side of the boiler where the gas combination valve is to be fitted if the boiler is to be equipped with a Vitoflame 200 gas burner 5862 915 GB A a b c ...

Page 31: ...and keep save the bag containing the boiler type plate The type plate is later affixed to the front panel Positioning on a plinth up to 63 kW Installation instructions on the plinth packaging Positioning without a plinth see page 32 5862 915 GB 2 1 1 ...

Page 32: ...32 Fitting the thermal insulation Note All components required for the assembly of the thermal insulation are included in the insulation carton A Notch forward 5862 915 GB A 1 2 ...

Page 33: ...ermal insulation cont Note Burner cable fA supplied in the thermal insulation pack From 80 kW Install the extension for two stage modulating burner operation A Return edge forward 5862 915 GB A 41 2x M10 SW15 3 1 4 5 2 ...

Page 34: ...34 Fitting the thermal insulation cont A Black side out 5862 915 GB A 41 1 2 3 9 x 9 5 ...

Page 35: ...35 Fitting the thermal insulation cont 5862 915 GB 1 4 3 2x 2 ...

Page 36: ...36 Fitting the thermal insulation cont 5862 915 GB 2 3 9 x 9 5 3 9 x 9 5 3 9 x 9 5 1 3 ...

Page 37: ...te Damaged capillaries result in incorrect sensor functions Never kink the capillary tubes Note The boiler water temperature sensor is included in the control unit pack Insert the sensor and the boiler water temperature sensor fully into the sensor well The power supply plug fÖ is supplied in the control unit pack 5862 915 GB 3 41 41 5 2 4 3 1 6 7 45 ...

Page 38: ...nd 100 kW 180 mm 2 Create test port A 3 Seal in and insulate the flue pipe Note Joints must be sound Primary connections A Boiler return G 2 B Drain and diaphragm expansion vessel G 2 C Boiler flow safety connection safety valve and air vent valve G 2 Installation instructions Divicon heating circuit distributor Divicon adaptor Note Install the return injector nozzle into the boiler return see pag...

Page 39: ... expansion vessel DN 20 R Permiss operating pressure 3 bar Test pressure 4 bar Low water indicator Tests have verified that the requirements to EN 12828 have been met This makes an additional low water indicator unnecessary Note Equip boilers with a safety valve which is type tested and meets the requirements of TRD 721 or local regulations Safety valves must be marked subject to the respective sy...

Page 40: ...al insulation Note Secure the 230 V cables and the LV leads cables with cable ties C supplied Bundle and route 230 V cables A and LV leads cables B separately D Boiler type plate 5862 915 GB A B C 1 2 D 5 3 4 7 6 3 9 x 9 5 M4 x 28 8 ...

Page 41: ...tion Install and adjust the burner Separate burner documentation Important information on commissioning For commissioning and adjustments see the service instructions for boiler burner and boiler control unit 5862 915 GB ...

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Page 44: ...52 70 27 80 www viessmann de Viessmann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Tel 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com 44 Printed on environmentally friendly chlorine free bleached paper 5862 915 GB Subject to technical modifications ...