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Installation and
Service Instructions
Vitogas 050
ECV Series
Natural gas-/Propane-fired
atmospheric cast iron boiler
Rated input:
65 to 200 MBH
19 to 59 kW
VITOGAS 050
IMPORTANT
Read and save these instructions
for future reference.
5167 450 v1.4 07/2006
WARNING
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable
liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliances.
J
Do not touch any electrical switches, do not
J
use any phone in your building.
Immediately call your gas supplier from a
J
neighbor's phone. Follow the gas supplier's
instructions.
If you cannot reach your gas supplier, call the
J
fire department.
Installation and service must be performed by a
qualified installer, service agency or the gas
supplier.
WARNING
Improper installation, adjustment, and/or operation
could cause carbon monoxide poisoning resulting in
injury or loss of life.
This product must be installed and serviced by a
professional service technician who is experienced
and qualified in hot water boiler installation and gas
combustion.
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Table of Contents
Related Manuals for Viessmann ECV Series
Summary of Contents for Viessmann ECV Series
- Page 1 Installation and Service Instructions Vitogas 050 ECV Series Natural gas-/Propane-fired atmospheric cast iron boiler Rated input: 65 to 200 MBH 19 to 59 kW VITOGAS 050 WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
- Page 2 Viessmann equipment. Please see section For a listing of For information " "...
- Page 3 Safety, Installation and Warranty Requirements Safety, Installation and Warranty Requirements (continued) Please ensure that this manual is read and understood before commencing installation. Failure to comply with the issues listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
- Page 4 Contents Page Safety Important Regulatory and Installation Requirements ..General Information About these Installation Instructions ....... . . Product Information .
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Page 5: Table Of Contents
Contents (continued) Page Initial Start-up and Service Initial Start-up ................Also pay attention to the following... - Page 6 CAN/CSA-B149.1 or .2 Installation Codes for Gas Burning Appliances for For information regarding other Canada. For U.S. installations use the Viessmann System Technology National Fuel Gas Code ANSI Z223.1. componentry, please reference Always use latest editions of codes. documentation of the respective product.
- Page 7 - Installation and Service Instructions replacement labels are required. - Operating Instructions and User’s Information Manual - Instructions of other Viessmann Leave all literature at the installation products utilized and installed on the site and advise the system Vitogas 050, ECV boiler...
- Page 8 General Information About these Installation 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. Warnings draw your attention to the WARNING presence of potential hazards or important product information.
- Page 9 Such systems must have the non-oxygen diffusion barrier tubing separated from the boiler with a heat exchanger. Viessmann recommends the use of underfloor plastic tubing with an oxygen diffusion barrier.
- Page 10 Set-up Mechanical Room During the early stages of new home design, we recommend that proper consideration be given to constructing a separate mechanical room dedicated to gas- or oil-fired equipment including domestic hot water storage tanks. The boiler must be located in a heated indoor space, near a floor drain, and as close as possible to the vertical chimney or vent.
- Page 11 Please reference the Viessmann Price List. 1. Verify that base size and material are in conformity with local codes. 2. Locate the base so that the minimum clearances of boiler to combustible materials are maintained.
- Page 12 Set-up Combustion Air Supply Whenever possible, install boiler near an CAUTION outside wall so that it is easy to duct fresh air directly to the boiler area. See Follow local regulations with respect example in Fig. 2. Refer to national to CO detectors.
- Page 13 Set-up Combustion Air Supply (continued) If boiler is installed in a confined space CAUTION (a space with a volume of less than 50 cubic feet per 1000 Btu/h of gas input Do not store chemicals containing for all fuel burning equipment) or chlorine or other corrosive chemicals building construction is unusually tight, near the boiler, such as bleach,...
- Page 14 Set-up Minimum Clearances Recommended minimum service clearances Side inches Rear: Top: Right side: Left side: Front: 1220 All clearances are measured from boiler enclosure. Minimum clearances to combustibles Side inches Rear: Top: Right side: Left side: Front: Floor: non combustible Above clearances apply to all ECV boilers.
- Page 15 Set-up Minimum Clearances (continued) Closet and alcove installation Vitogas 050, ECV-65 to 155 boilers are approved for closet installation. 18” / Vitogas 050, ECV-180, -200 boilers are 457 mm approved for alcove installations. Do not use models ECV-180, -200 for closet installations.
- Page 16 Set-up Flushing of Existing Piping Before boiler is connected to a piping/heating system which has previously been in service (the ECV is a replacement boiler), the piping system should be flushed thoroughly with water in order to remove sludge or other contaminants, especially in large piping systems such as old gravity pipe systems.
- Page 17 Set-up Removal of Existing Boiler When an existing boiler is removed from WARNING a common venting system, the common venting is likely to be too large for The Vitogas 050, ECV boiler has a proper venting of the appliances positive vent pressure when vented remaining connected to it and may horizontally with 3”...
- Page 18 Connections Venting Connection The Vitogas 050, ECV boiler must be This boiler model was certified by an located so that the vent length is as independent testing agency to short and direct as possible. The withstand 40 mph winds. Areas with minimum equivalent length is 10 ft.
- Page 19 Connections Venting Connection (continued) Maximum vent length Example of maximum vent length IMPORTANT calculation: Equivalent length Maximum equivalent vent length (all 12 ft. of pipe length 12 ft. models) is 20 ft. for 3” of pipe. 3” dia. Maximum equivalent vent length (all models) is 30 ft.
- Page 20 Connections Venting Connection (continued) Installing Z-FLEX pipe and fittings 45° Use a hacksaw or sheet metal snips to IMPORTANT cut the pipe to size. Use a file to smooth rough edges. Pipe must be Fan outlet Use liberal beads of silicone to seal round and not bent into an oval shape.
- Page 21 Connections Venting Connection (continued) Vent terminal connection The vent must be installed observing 8. underneath a veranda, porch or deck; local regulations in addition to National Codes, CAN/CSA-B149.1 or 2, or ANSI 9. within 6 ft. (1.8 m) of an inside Z223.1.
- Page 22 Flex-L Star-34 vent. If using this vent model, please contact The vent pipe enclosed in the riser box Viessmann for the corresponding must be insulated to resist condensate installation instructions. freeze-up. The riser box must be sealed...
- Page 23 Connections Installation Checklist Prior to and after the installation, use the following check list to ensure proper installation. Improper installation could create a hazard, resulting in property damage, severe personal injury, or loss of life. The correct answer is “yes” to all of the following questions.
- Page 24 Connections Low Water Cut-off Air vent (field supplied) If the ECV boiler is installed above radiation level, a low water cut-off Flow direction device must be installed. See Figs. 9 and 10 for location of low water cut-off device. Note: Flow direction must be as Supply shown in Fig.
- Page 25 Connections Initial System Fill Treatment for boiler feed water should Please observe that an antifreeze/water be considered in areas of known mixture may require a backflow problems, such as high mineral content preventer within the automatic water and hardness. In areas where freezing feed and influence components such as might occur, an antifreeze may be diaphragm expansion tanks, radiation...
- Page 26 Connections Gas Piping Before connecting gas boiler to gas line, install main gas shut-off valve, union, and capped drip leg (see Fig. 11 below). Size gas supply piping to boiler according to local utility requirements. Identify the main shut-off valve as such with a tag and familiarize owner of boiler with this valve.
- Page 27 Connections Gas Pressure - Orifice Sizes Natural Gas PILOT PRESSURE FOR Q3451A PILOT Minimum gas valve Natural Gas 5 - 7 ”w.c. inlet pressure 4½ ”w.c......Maximum gas valve Propane Gas 8 - 10 ”w.c.
- Page 28 Connections Gas Burner Removal The main gas burner manifold with the individual stainless steel burners mounted may be easily removed from the boiler. 1. Close the main gas shut-off valve external to boiler. 2. Disconnect all power to boiler. 3. Remove front cover panel from boiler.
- Page 29 Connections Gas Input Main flame cone CAUTION Do not exceed input rating stamped on rating plate of boiler. 1. Close main gas shut-off valve. 2. Disconnect main power supply to boiler. Light blue 3. Remove plug “ NPT on manifold. Blue Install test plug and connect U-tube Inner flame...
- Page 30 Connections Main Burner Proper flame: Upper main flame cone with light orange coloring, sharply defined individual flames. See Fig. 13 on previous page. Underfired: Lazy-burning main flame cone, mushy flame appearance throughout, smaller flame sizes than in Fig. 13. Overfired: Increased burner noise, larger flame sizes than in Fig.
- Page 31 Connections Gas Burner Positioningg (continued) Every ECV boiler will have a flame Left Right roll-out switch (set at 200 °F / 93 °C) located in the burner area (see Fig.12 on page 28). WARNING If a flame roll-out switch trips during start-up operation, it indicates a hazardous condition to be corrected immediately.
- Page 32 Electrical Connections Refer to wiring diagrams on pages 46 Terminal strip Separate breaker and 47. All wiring must be properly 120V power Transformer/relay grounded! Before attempting to wire input (field supplied) unit, disconnect power supply at main service panel first. For pumps exceeding 4 A, refer to Fig.
- Page 33 Connections Electrical Connections (continued) Pumps under 4 Amp. can be connected directly to boiler terminal strip. Pumps over 4 Amp. must be switched by an external relay or transformer/relay to prevent failure of the pump aquastat See Fig. 16 on previous page. Pump will not activate until boiler water temperature reaches 116°F.
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Page 34: Initial Start-Up
Initial Start-up Initial Start-up The boiler, piping and radiation must be If the system was shut down for an full of water and purged of all air before extended period of time, have a boiler can be fired. Pressure relief valve qualified service technician restart and must be installed as described on page recondition your system. -
Page 35: Annual Shut-Down
“off” (see Figs. 11 on page 26 and the Lighting and Operating Instructions on page 51). Viessmann indirectly heated stainless steel DHW tanks may be used with the Vitogas 050, ECV boiler for domestic hot water production. Consult your Viessmann representative for assistance. -
Page 36: Service Schedule
Initial Start-up and Service Service Schedule CAUTION In order to ensure that the boiler continues to operate at its peak performance, safety and efficiency, observe and follow the recommendations for maintenance, inspection and service routine. Early detection of problems and their immediate repair will usually result in less damage, lower repair cost and continued safe operation. -
Page 37: Service Procedure Overview
Initial Start-up and Service Service Procedure Overview Service steps 1. Shut down heating system Page 38 ........................... 2. -
Page 38: Service Procedure
Initial Start-up and Service Service Procedure 1. Shut down heating system ervice ervice 1. Deactivate main power and ensure against accidental reactivation. 2. Disconnect plug. 3. Close gas supply valve. 2. Cleaning heat exchanger ervice ervice 1. Disconnect power supply to boiler and all heating related components. - Page 39 Replace parts as necessary with replacement parts obtained from a Viessmann distributor. Do not replace with non Viessmann parts. 14. Reverse steps 3 through 8 to reassemble boiler. Seal collector box to side brackets using adhesive backed ½”...
- Page 40 Initial Start-up and Service Procedure (continued) 3. Check flue pipe and vent termination ervice ervice Repair or replace as necessary. CAUTION Under certain climatic conditions, some building materials may be affected by flue products expelled in close proximity to unprotected surfaces.
- Page 41 Initial Start-up and Service Procedure (continued) 6. Check for proper combustion air supply and ventilation for the boiler ervice ervice 7. Ensure no combustible materials or chemicals are stored near the boiler ervice ervice 8. Check high limits, pumps and low water cut-off ervice ervice Operate high limits by dialing lower...
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Page 42: Troubleshooting Guide
Additional Information Troubleshooting Guide Fan does not start Remedy Thermostat not calling for heat Turn up room thermostat No 120V power Check 120V power with voltmeter Fuse or breaker blown Replace fuse or breaker Fan relay defective Replace 24V fan relay Defective 24V transformer Replace 24V transformer Thermostat defective... - Page 43 Additional Information Troubleshooting Guide (continued) Fan runs, pilot lights, burner short cycles Remedy Thermostat anticipator too low Set anticipator to 0.9A on mercury bulb thermostats No ground or weak ground connection on pilot Replace ground wire on pilot burner Pilot on wrong burner Ensure five-port burner is used (see Fig.
- Page 44 Additional Information Technical Data 12½” / 320 mm Fig. 20 Front view 2¾” / 72 mm 11” / 279 mm 17½” / 445 mm 19¾” / 502 mm Fig. 21 Legend Vent connection, Ø 3” / 76 mm 24V thermostat Boiler water supply, 1¼”...
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Page 45: Technical Data
For use with natural gas 1000 Btu/ft. . kW figures are approximate. Parts List for Honeywell Intermittent Pilot Ignition System NATURAL GAS PROPANE GAS GAS CONTROL LIST HONEYWELL PART NO. VIESSMANN PART NO. HONEYWELL PART NO. VIESSMANN PART NO. Gas Valve VR8204M1133 9543730 VR8204M1133 9543730... -
Page 46: Wiring Diagrams
Additional Information Wiring Diagram - Vitogas 050, ECV with Honeywell Intermittent Pilot... - Page 47 Note: Burner should not activate if pressure tube is disconnected from pressure FRS2 switch. Refer to wiring label affixed to boiler access HONEYWELL panel. Viessmann reserves the right to S8600(H,M) substitute components or wiring methods. PV GND Boiler wiring label takes precedence. Q3451A...
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Page 48: Parts List
Additional Information Parts List Parts 037 Gas valve 001 Left panel VR8204M 002 Right panel 039 Pilot orifice 003 Back panel NG .020” 004 Top panel LP .014” 005 Front access panel 040 Pilot bracket for 006 Front upper panel Q3451A2012 007 Mid panel 041 Pilot shield... - Page 49 Additional Information Parts List (continued)
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Page 50: Maintenance Record
Additional Information Maintenance Record Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service... -
Page 51: Lighting And Operating Instructions
Additional Information Lighting and Operating Instructions... - Page 52 Viessmann Manufacturing Company (U.S.) Inc. Viessmann Manufacturing Company Inc. 45 Access Road 750 McMurray Road Warwick, Rhode Island • 02886 • USA Waterloo, Ontario • N2V 2G5 • Canada Tel. (401) 732-0667 • Fax (401) 732-0590 Tel. (519) 885-6300 • Fax (519) 885-0887 www.viessmann-us.com •...