Viessmann VR1 22 Installation And Service Instructions Manual
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Viessmann VR1 22 Installation And Service Instructions Manual

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Installation and
Service Instructions
for use by heating contractor
Vitorond 100, VR1
Models 22 to 33, 91 to 140
Oil-Fired Boiler
Heating input 91 to 140 MBH
27 to 41 kW
VITOROND
H
5583 571 - 05
10/2017
100
r
Product may not be exactly as shown
IMPORTANT
Read and save these instructions
for future reference.
Please file in Service Binder

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  • Page 1 Installation and Service Instructions for use by heating contractor Vitorond 100, VR1 Models 22 to 33, 91 to 140 Oil-Fired Boiler Heating input 91 to 140 MBH 27 to 41 kW VITOROND Product may not be exactly as shown IMPORTANT Read and save these instructions for future reference.

  • Page 2: Important Safety, Installation, Regulatory And Warranty Requirements

    Safety Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Important Safety, Installation, Regulatory and Warranty Requirements Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life.
  • Page 3 Safety Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Important Safety, Installation, Regulatory and Warranty Requirements (continued) H Fiberglass wool and ceramic fiber materials Suppliers of fiberglass wool products recommend the WARNING following precautions be taken when handling these...
  • Page 4 Safety Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Important Safety, Installation, Regulatory and Warranty Requirements (continued) For installations on the Commonwealth of Massachusetts, the following modifications to NFPA-54 chapter 10 apply: Excerpt from 248 CMR 5-08:...
  • Page 5 Safety Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Important Safety, Installation, Regulatory and Warranty Requirements (continued) Codes Mechanical room The installation of this unit shall be in accordance with Ensure the mechanical room complies with the local codes.

  • Page 6: Table Of Contents

    Table of Contents Vitorond 100, VR1-22 to -33 Installation and Service Page Safety Important Safety, Installation, Regulatory and Warranty Requirements..........2 General Information About these Instructions..........7 Product Information.............8 Mechanical Room............9 Combustion Air Supply..........9 Set-up Product Delivery............11 Unpacking Instructions..........11 Minimum Clearances to Combustibles......12 Recommended Minimum Clearances for Service...12 Boiler Set-up and Location ........13 Combustion Chamber Insert........13...

  • Page 7: About These Instructions

    General Information Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service About these Instructions Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below.

  • Page 8: Product Information

    General Information Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Product Information Sectional gray cast-iron boiler with triple-pass design. For operation in closed loop, forced circulation hot water heating systems. This boiler does not require a flow switch.

  • Page 9: Mechanical Room

    General Information Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Mechanical Room During the early stages of new home design, we Whenever possible install boiler near an outside wall so recommend that proper consideration be given to that it is easy to duct fresh air directly to the boiler area.
  • Page 10 General Information Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Combustion Air Supply (continued) Codes Installation Provisions for combustion and ventilation air must be Install a combustion air opening. Round duct diameters made in accordance with applicable local codes.

  • Page 11: Product Delivery

    Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Product Delivery Vitorond boilers size VR1 22 to 33, 91 to 140 are shipped in a crate with separate boiler jacketry. Product delivery Ensure each of the following has been...

  • Page 12: Minimum Clearances To Combustibles

    Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Minimum Clearances to Combustibles For typical installations, Viessmann recommends installing the boiler with clearances as shown in Recommended Minimum Clearances for Service. The following are clearances to combustibles:...

  • Page 13: Boiler Set-Up And Location

    Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Boiler Set-up and Location IMPORTANT For important information concerning boiler placement and set-up, refer to the section entitled “Mechanical Room” on page 9. The boiler should be located as close to the chimney as possible.

  • Page 14: Venting Connection

    Connections Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Venting Connection General Vitorond 100 The heating contractor shall ensure all of the following The vent system must comply with all applicable local requirements are met: and/or national codes.
  • Page 15 Connections Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Venting Connection (continued) When installing piping or venting, or while insulating overhead pipes, do not stand on top panel of boiler. Advise other trades accordingly! Installation Use approved vent material only.

  • Page 16: Water Side Connections (With Hydrostat 3250-Plus Control)

    Connections Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Water Side Connections (with Hydrostat 3250-Plus Control) IMPORTANT This boiler is designed for closed loop, forced circulation heating systems only. 1. Flush heating system thoroughly (particularly with existing systems which have been in operation for years).

  • Page 17: Safety Connections (With Hydrostat 3250-Plus Control)

    Connections Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Safety Connections (with Hydrostat 3250-Plus Control) Pressure relief valve 1. Install pressure relief valve. Pipe pressure relief valve as illustrated and connect to boiler water supply connection.
  • Page 18 Connections Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Safety Connections (with Hydrostat 3250-Plus Control) (continued) 1. To avoid problems with removing the top panel, we recommend moving the top panel screw approximately 3” to the left or right. To do so, pre-drill the panel with an ”...

  • Page 19: Water Side Connections (With Vitotronic Control)

    Connections Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Water Side Connections (Vitotronic Control) IMPORTANT This boiler is designed for closed loop, forced circulation heating systems only. 1. Flush heating system thoroughly (particularly with existing systems which have been in operation for years).

  • Page 20: Safety Connections (With Vitotronic Control)

    Connections Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Safety Connections (Vitotronic Control) Pressure relief valve 1. Install pressure relief valve. Pipe pressure relief valve as illustrated and connect to boiler water supply connection. Refer to instructions supplied with the pressure relief valve.
  • Page 21 Connections Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Safety Connections (Vitotronic Control) (continued) 1. To avoid problems with removing the top panel, we recommend moving the top panel screw approximately 3” to the left or right. To do so, pre-drill the panel with an ”...

  • Page 22: Pressure Testing

    Connections Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Pressure Testing Perform pressure test on boiler The boiler must be leak tested before being placed in operation. Before boiler is connected to piping or electrical power supply, it must be hydrostatically pressure tested with a maximum of 1½...

  • Page 23: Burner Installation

    Burner Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Burner Installation Refer to instructions supplied with the burner. Observe all instructions supplied with the burner. Burner Information Fuel This boiler is for use with the #2 fuel oil burner supplied by Viessmann only.

  • Page 24: Burner Mounting

    Burner Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Burner Mounting 1. Remove burner from carton. The mounting flange has been installed at the factory. 2. Mount four M8 spacer bolts A in threaded holes of combustion chamber door.

  • Page 25: Oil Piping Connection

    Burner Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Oil Piping Connection General Oil piping requirements Location and installation of oil tanks, oil piping and burners must follow: - Local codes and regulations. - Information provided with burner and fuel pump.

  • Page 26: Electrical Connections (With Hydrostat 3250-Plus Control)

    Burner Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Electrical Connections (with Hydrostat 3250-Plus control) Installations must follow these codes and requirements: WARNING - National Electrical Code, ANSI/NFPA 70, latest edition and any additional national, state or local codes.
  • Page 27 Burner Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Electrical Connections (with Hydrostat 3250-Plus control) (continued) WARNING Electric shock hazard. Can cause severe personal injury or loss of life if power source, including service switch on boiler, is not disconnected before installing or servicing.
  • Page 28 Burner Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Electrical Connections (with Hydrostat 3250-Plus control) (continued) Note: Used with standard venting and direct vent systems. WARNING Installations must follow these codes and requirements: National Electrical Code, ANSI/NFPA 70, latest edition Ensure that the burner cycles ON and OFF on proper and any additional national, state or local codes.

  • Page 29: Electrical Connections (With Vitotronic Control)

    Burner Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Electrical Connections (with Hydrostat 3250-Plus control) (continued) Riello burner Legend IMPORTANT A Power supply, provide disconnect means and overload protection as required. B Control case must be connected to earth ground.
  • Page 30 Burner Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Electrical Connections (with Vitotronic control) Installations must follow these codes WARNING and requirements: - National Electrical Code, ANSI/NFPA 70, latest edition Electric shock hazard. Can cause severe personal injury and any addtional national, state or local codes.
  • Page 31 Burner Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Electrical Connections (with Vitotronic control) (continued) Refer to Installation Instructions Boiler Control (for all connections to control base) IMPORTANT The power supply cable is shipped with the boiler control.
  • Page 32 Burner Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Electrical Connections (with Vitotronic control) (continued) Removing and installing top panel 1. To avoid problems with removing the top panel, we recommend moving the top panel screw approximately 3”...
  • Page 33 Burner Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Electrical Connections (with Vitotronic Control) (continued) WARNING Electric shock hazard. Can cause severe personal injury or loss of life if power source, including service switch on boiler, is not disconnected before installing or servicing.
  • Page 34 Burner Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Electrical Connections (with Vitotronic Control) (continued) WARNING WARNING Electric shock hazard. Can cause severe personal injury Ensure that the burner cycles ON and OFF on proper call or loss of life if power source, including service switch for heat before leaving the job site.
  • Page 35 Burner Set-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Electrical Connections (with Vitotronic Control) (continued) Riello burner Legend BL Blue OG Orange BK Black W White Green/Ground Yellow Violet BR Brown GY Gray Carlin burner...

  • Page 36: Initial Start-Up

    Start-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Initial Start-up Initial Start-up 1. Ensure fresh air intake of boiler room is open and that chimney and all flue pipes are connected, sealed and WARNING unobstructed inside.

  • Page 37: Burner Calibration

    Start-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Burner Calibration WARNING Refer to the Instructions supplied with the Beckett or Riello burner. DO NOT USE GASOLINE, CRANKCASE DRAININGS OR ANY OIL CONTAINING GASOLINE. Combustion analysis...
  • Page 38 Start-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Burner Calibration (continued) Boiler Model No. VR1 22, 91 VR1 27, 105 VR1 33, 140 Burner model Beckett NX-VI 701 NX-VI 702 NX-VI 703 No. 2 fuel oil No.
  • Page 39 Start-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Burner Calibration (continued) Boiler Model No. VR1 22, 91 VR1 27, 105 VR1 33, 140 Burner model Carlin EZ-LF EZ-1-HP EZ-1-HP No. 2 fuel oil No. 2 fuel oil No.

  • Page 40: Barometric Draft Regulator

    Start-up Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Barometric Draft Regulator When a barometric draft regulator is used, adjust the barometric draft regulator such that the over-fire draft is 0.00 to +0.01 “w.c., while the breech draft is approximately -0.02 “w.c.

  • Page 41: Installation Examples - Hydrostat 3250-Plus

    Connections Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Installation Examples - Hydrostat 3250-Plus Boiler in a heating/cooling application Cooling season starts: close valve v1 and open valve v2 Heating season starts: close valve v2 and open valve v1...

  • Page 42: Installation Examples - Vitotronic

    Connections Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Installation Examples - Vitotronic Without mixing valve e.g. with Vitotronic 100, Model KW10B Legend A Heating circuit B Spring-loaded flow check valve C Circulation pump D Automatic air vent, (field supplied), pressure relief...
  • Page 43 Connections Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Installation Examples - Vitotronic (continued) With one low-temperature circuit with 4-way mixing valve, and with domestic hot water production e.g. with Vitotronic 200, Model KW2 combined with...
  • Page 44 Connections Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Installation Examples - Vitotronic (continued) With one low-temperature circuit with 4-way mixing valve, one high temperature circuit, and with domestic hot water production e.g. with Vitotronic 200, Model KW2 combined with...

  • Page 45: Necessary Tools

    Service Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Necessary Tools IMPORTANT WARNING Use only calibrated equipment. Ensure that warning concerning fiberglass wool and ceramic fiber materials on page 3 has been read and understood before handling insulation.

  • Page 46: Clean Heat Exchanger And Flue Pipe

    Service Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Service Procedure (continued) Clean heat exchanger and flue pipe 1. Clean heat exchanger with field supplied cleaning brush and use vacuum cleaner to remove all sediment. 2. Remove all sediment from flue pipe and flue gas collector using vacuum cleaner.

  • Page 47: Check Heating System And Domestic Hot Water Connections

    Service Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Service Procedure (continued) Check heating system and domestic hot water connections Ensure proper operation of expansion tank, low water cut-off (if applicable) and pumps Ensure all connections are pressure tight.

  • Page 48: Parts List

    Additional Information Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Parts List Model No. Serial No. VR1 22, 91 Boiler 7249048 VR1 27, 105 Boiler 7249049 VR1 33, 140 Boiler 7249050 Ordering Replacement Parts: Please provide boiler Model and Serial Number from rating plate when ordering replacement parts.
  • Page 49 Additional Information Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Parts List (continued) Parts 001 5-Point sensor well 002 Combustion chamber door refractory 003 Combustion chamber door 004 Hinge bracket 005 Glass-fiber gasket,16 x 12 L=2000 mm...
  • Page 50 Additional Information Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Parts List (continued) Parts List 0701 Hydrostat control, 3250-Plus 0702 Electro well, extended ¾” NPT 0703 Hex bushing, 1¼” x ¾” 0704 Temperature and pressure gage 0705 Reduction tee, 1½”...

  • Page 51: Maintenance Record

    Additional Information Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service Maintenance Record WARNING Neglecting to perform necessary maintenance can cause unsafe operation. Before each heating season begins, have the following service and maintenance done by a licensed, professional heating contractor: 1.
  • Page 52 Vitorond 100, VR1 22 to 33, 91 to 140 Installation and Service...

This manual is also suitable for:

Vitorond 100Vr1 91Vr1 27Vr1 105Vr1 33Vr1 140

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