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Viessmann VITOROND 100 Installation Instructions Manual

Typevr2b rated output 40 to 100kw oil/gas fired boilers
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Installation instructions

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

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Summary of Contents for Viessmann VITOROND 100

  • Page 1: Installation Instructions

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

  • Page 2: Safety Instructions

    Safety instructions ¨ Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained Regulations ¨ Danger Observe the following when working This symbol warns against the on this system H all legal instructions regarding the risk of injury.

  • Page 3: Table Of Contents

    Index Page Safety instructions ....................... . . Boiler section assembly (if the boiler is supplied in sections) .

  • Page 4: Boiler Section Assembly

    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.

  • Page 5: Assembly With H The Boiler Lying Down

    Boiler section assembly (cont.) Assembly with the boiler lying down 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 For all sections: D Clean the nipples with solvent and apply the enclosed linseed oil graphite...
  • Page 6 Boiler section assembly (cont.)
  • Page 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.
  • Page 8 Boiler section assembly (cont.)
  • Page 9 Boiler section assembly (cont.) Please note Only release the compression tool when the sections have been joined with anchor rods A. M 12...
  • Page 10 Boiler section assembly (cont.) Continue on page 19.

  • Page 11: H The Boiler Standing Up

    Boiler section assembly (cont.) Assembly with the boiler standing up M 12...
  • Page 12 Boiler section 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...
  • Page 13 Boiler section assembly (cont.) For all sections: A Clean the nipples with solvent and apply the enclosed linseed oil graphite...
  • Page 14 Boiler section assembly (cont.)
  • Page 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.
  • Page 16 Boiler section assembly (cont.)
  • Page 17 Boiler section assembly (cont.) Please note Only release the compression tool when the sections have been joined with anchor rods A.
  • Page 18 Boiler section assembly (cont.)

  • Page 19: Water Pressure Test (If The Boiler Is Supplied In Sections)

    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.

  • Page 20: If The Boiler Is Supplied In Sections

    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. A Second pass at the bottom D Flue pipe adaptor (for 80 and B Second pass at the top 100 kW).

  • Page 21: If The Boiler Is Supplied As An Assembled Block

    Splitting the boiler block for easier transportation into the boiler room 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.
  • Page 22 Splitting the boiler block for easier transport into the boiler room (cont.)
  • Page 23 Splitting the boiler block for easier transport into the boiler 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.

  • Page 24: Assembly With H The Boiler Lying Down

    Splitting the boiler block for easier transport into the boiler room (cont.) Assembly of the boiler lying 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...
  • Page 25 Splitting the boiler block for easier transport into the boiler room (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.
  • Page 26 Splitting the boiler block for easier transport into 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 C Locking cap...

  • Page 27: H The Boiler Standing Up

    Splitting the boiler block for easier transport into the boiler room (cont.) Assembly of the boiler standing 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...
  • Page 28 Splitting the boiler block for easier transport into the boiler room (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.
  • Page 29 Splitting the boiler block for easier transport into 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...

  • Page 30: Clearance Dimensions

    Clearance dimensions A Boiler Rated output 1 100 1 100 Observe the length of the Vitoair Necessary clearance for cleaning purposes. Maintain 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.

  • Page 31: Boiler Positioning And Levelling

    Boiler positioning and levelling Note Remove and keep save the bag containing the boiler type plate. The type plate is later affixed to the front panel. Positioning on a plinth Positioning without a plinth (up to 63 kW) see page 32 Installation instructions on the plinth packaging...

  • Page 32: Fitting The Thermal Insulation

    Fitting the thermal insulation Note All components required for the assembly of the thermal insulation are included in the insulation carton. A Notch forward...
  • Page 33 Fitting the thermal insulation (cont.) Note Burner cable fA supplied in the thermal insulation pack. From 80 kW: Install the extension for two−stage/modulating burner operation. SW15 A Return edge forward...
  • Page 34 Fitting the thermal insulation (cont.) 3.9 x 9.5 A Black side out...
  • Page 35 Fitting the thermal insulation (cont.)
  • Page 36 Fitting the thermal insulation (cont.) 3.9 x 9.5 3.9 x 9.5 3.9 x 9.5...
  • Page 37 Fitting the thermal insulation (cont.) For opening the control unit and its connections, see the boiler control unit installation instructions Please note 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 §...

  • Page 38: Flue Gas Connections

    Flue gas connections Vitoair installation instructions 1. Connect the flue outlet with the shortest possible run to the chimney stack using a slightly inclined flue pipe. Flue pipe (internal diameter) for ∅ 150 mm 40 to 63 kW ......∅...

  • Page 39: Safety Connections And Testing For Leaks

    Safety connections and testing for leaks Installation instructions Low water indicator safety assembly block Tests have verified that the requirements to EN 12828 have been Install the safety lines. met. This makes an additional low water Min. cross−sections indicator unnecessary. H Safety valve Inlet connection Note...

  • Page 40: Installing Additional Thermal Insulation

    Installing additional thermal 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. 3.9 x 9.5 M4 x 28 D Boiler type plate...

  • Page 41: Burner Installation

    Burner installation 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.
  • Page 44 Viessmann Werke GmbH&Co KG D 35107 Allendorf Tel: +49 6452 70 0 Fax: +49 6452 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...

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