Viessmann VITOROND 100 Installation And Service Instructions Manual
Oil-fired boiler heating input 91 to 140 mbh 27 to 41 kw
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Summary of Contents for Viessmann VITOROND 100
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Page 1: Service Instructions
Installation and Service Instructions for use by heating contractor Vitorond 100 VR1 Series Oil-Fired Boiler Heating input 91 to 140 MBH 27 to 41 kW VITOROND 100 IMPORTANT Read and save these instructions for future reference. 5346 537 v1.0 10/2006... - Page 2 Viessmann equipment. Please see section For a listing of " " entitled “Important...
- 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).
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Page 4: Table Of Contents
Contents Page Safety Important Regulatory and Installation Requirements ..General Information About these Installation Instructions ....... . . Product Information . - Page 5 Page Burner (Riello) Burner Installation ..............Burner Information .
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Page 6: Safety
Leave all literature at the installation Technical literature Literature applicable to all aspects of site and advise the system the Vitorond 100: operator/ultimate owner where the - Installation, Service and Operating literature can be found. Contact Instructions Viessmann for additional copies. -
Page 7: General Information
General Information About these Installation Instructions The following symbols and flag words are utilized in these Installation Instructions: Indicates an imminently hazardous WARNING situation which, if not avoided, could result in death, serious injury or Warnings draw your attention to the substantial product/property damage. -
Page 8: Product Information
A bypass can be installed on any system as a preventative measure. Viessmann strongly recommends installing a bypass pipe on all cast iron boilers. -
Page 9: Mechanical Room
18” / 457 mm above the floor to avoid contact with flammable vapors and fumes). Viessmann strongly recommends installing the boiler on a concrete foundation. Whenever possible install boiler near an outside wall so that it is easy to duct fresh air directly to the boiler area. -
Page 10: Combustion Air Supply
Fresh Air Combustion Air Supply Codes General Provisions for combustion and This equipment requires fresh air for ventilation air must be made in safe operation and must be installed accordance with applicable local codes. ensuring provisions for adequate In the absence of local codes, use: combustion and ventilation air exist. - Page 11 Fresh Air Combustion Air Supply (continued) Unconfined spaces Confined spaces Louvres and grilles Where the boiler is located in an If the boiler is located in a confined In calculating free area as specified unconfined space in a building having space and that obtains all of its air for above, consideration shall be given to insufficient infiltration, additional air for...
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Page 12: Product Delivery
Unpacking Instructions To avoid injury and to facilitate boiler manoeuvering, it is strongly recommended that Viessmann carrying handles (Part No.: 7189602) be used. The carrying handles allow easy removal of boiler from skid and enables easy transportation to permanent location, while reducing the risk of boiler panel damage due to improper lifting or manoeuvering techniques. -
Page 13: Minimum Clearances To Combustibles
Set-up Minimum Clearances to Combustibles For typical installations, Viessmann recommends installing the boiler with clearances as published on page 10 under Recommended Minimum Clearances for Service. The following are clearances to combustibles: min. 6” / 150 mm Standard installation Boiler min. -
Page 14: Recommended Minimum Clearances For Service
Set-up Set-up Recommended Minimum Clearances for Service 20” / 508 mm 33½” / 850 mm 4” / 100 mm Boiler Minimum access for cleaning and service. Boiler Set-up and Location IMPORTANT For important information concerning boiler placement and set-up, refer to the section entitled “Mechanical Room”... -
Page 15: Combustion Chamber Insert
Set-up Combustion Chamber Insert For optimum, environmentally sound operation, Vitorond boilers are equipped with a high-grade, corrosion resistant, stainless steel combustion chamber insert. Ensure the bolts of the combustion chamber door are tightened before installing the burner Combustion chamber insert sizes Boiler Model inches... -
Page 16: Venting Connection
Connections Venting Connection Vitorond 100 General The vent system must comply with all The heating contractor shall ensure all H A chimney flue shall extend at least 3 applicable local and/or national codes. of the following requirements are met: ft / 1 m above the highest point at... - Page 17 6. Seal all flue pipe joints. 7. Viessmann recommends that any non-insulated vent pipe is insulated to reduce cooling of flue gas and velocity noises.
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Page 18: Water Side Connections
Connections Water Side Connections 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). CAUTION Failure to flush the heating system could cause system sludge to settle in the boiler, causing overheating and failure. -
Page 19: Safety Connections And Pressure Testing
Connections Safety Connections and Pressure Testing Install safety devices on boiler Pressure relief valve IMPORTANT 1. Install pressure relief valve. Pipe Install the (approved) factory supplied pressure relief valve as illustrated pressure relief valve. and connect to boiler water supply connection. -
Page 20: Perform Pressure Test On Boiler
Connections Safety Connections and Pressure Testing (continued) 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 times the maximum operating pressure of the boiler. -
Page 21: Burner Installation
WARNING This boiler is for use with the Beckett #2 fuel oil burner supplied by DO NOT USE GASOLINE Viessmann only. Use only the fuel CRANKCASE DRAININGS OR ANY stated on the rating plate of the burner. OIL CONTAINING GASOLINE... -
Page 22: Burner Set-Up
Burner Burner Set-up Burner mounting Instructions supplied with Beckett burner. 1. Remove burner from carton. The mounting flange has been installed at the factory. 2. Mount four M8 spacer bolts threaded holes of combustion chamber door. 3. Slide burner gasket over spacer bolts. -
Page 23: Electrical Connections
Connect incoming line voltage HOT (L1) wire to terminal L1, and N to terminal L2 of the Honeywell high limit control (see " wiring diagram on page 25. Burner wiring 1. Burner harness incorporates a female Viessmann 3-pole disconnect plug, providing a convenient way to disconnect wiring when burner mounting door is opened. 2. Secure control harness... -
Page 24: Oil Piping
Burner Burner Set-up (continued) Oil piping 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. - In Canada, CSA B139, Installation of Oil-Burning Equipment. -
Page 25: Wiring Diagram
Burner Wiring Diagram (Vitorond 100 with Beckett burner) Installations must follow these codes - Wiring must be N.E.C. Class 1. If WARNING and requirements: original wire as supplied with boiler - National Electric Code, ANSI/NFPA must be replaced, type 105°C wire or Electric shock hazard. -
Page 26: Burner Calibration
Burner Information Fuel WARNING This boiler is for use with the Riello #2 fuel oil burner supplied by Viessmann DO NOT USE GASOLINE only. Use only the fuel stated on the CRANKCASE DRAININGS OR ANY rating plate of the burner. -
Page 27: Burner Mounting
Burner Burner Set-up Burner mounting Instructions supplied with Riello burner. 1. Remove burner from carton. The mounting flange has been installed at the factory. 2. Mount four M8 spacer bolts threaded holes of combustion chamber door. 3. Slide burner gasket over spacer bolts. -
Page 28: Electrical Connections
Connect incoming line voltage HOT (L1) wire to terminal L1, and N to terminal L2 of the Honeywell high limit control (see " wiring diagram on page 30. Burner wiring 1. Burner harness incorporates a female Viessmann 3-pole disconnect plug, providing a convenient way to disconnect wiring when burner mounting door is opened. 2. Secure control harness... -
Page 29: Oil Piping
Burner Burner Set-up (continued) Oil piping Riello burner instructions 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. - In Canada, CSA B139, Installation of Oil-Burning Equipment. -
Page 30: Wiring Diagram
Burner Wiring Diagram (for Riello burner) Installations must follow these codes - Wiring must be N.E.C. Class 1. If WARNING and requirements: original wire as supplied with boiler - National Electric Code, ANSI/NFPA must be replaced, type 105°C wire or Electric shock hazard. - Page 31 Initial Start-up Initial Start-Up Burner instructions. WARNING Verify completeness of all discussion points on the following pages before starting-up system. 1. Ensure fresh air intake of boiler room If the nitrogen pressure of the is open and that chimney and all flue precharged expansion tank is less pipes are connected, sealed and than the static pressure of the...
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Page 32: Barometric Draft Regulator
Initial Start-up Initial Start-Up (continued) Burner calibration Instructions supplied with Beckett or Riello burner Combustion analysis WARNING This oil burner requires combustion measurements performed at the final DO NOT USE GASOLINE installation site, using calibrated CRANKCASE DRAININGS OR ANY combustion equipment, to verify factory OIL CONTAINING GASOLINE. - Page 33 Initial Start-up Initial Start-Up (continued) Beckett burner calibration Boiler model Model No. VR1-22 VR1-27 VR1-33 Burner model Beckett NX-VI 301 NX-VI 302 NX-VI 303 Fuel type No. 2 fuel oil Pump pressure psig 1207 1207 1207 Danfoss n.a. 0.60x60°AS n.a. Oil nozzle Delavan 0.50x60°B...
- Page 34 For VR1-27 boiler, replace installed nozzle with nozzle packaged with Riello burner. Factory-installed nozzle. Nozzles must be installed by installer. Note: Riello oil burners are factory set for Vitorond 100, VR1-22, and -33 boilers and should only require minor adjustments. Install appropriate nozzle and set the burner for model VR1-27.
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Page 35: Installation Examples
20 50 possible. Specific system layouts may be further discussed with the local 16 40 Viessmann sales representative office. 12 30 Clearances A minimum of 2” circumferential 8 20 clearance from non-insulated hot water pipes to combustible construction must be maintained. - Page 36 Connections Installation Examples (continued) Heating circuit Spring-loaded flow check valve Circulation pump Automatic air vent Pressure relief valve High limit control Expansion tank...
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Page 37: Special Applications
Connections Special Applications 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 Heating/Cooling unit Spring-loaded flow check valve Circulation pump Automatic air vent, Pressure relief valve High limit control Water chiller Expansion tank... -
Page 38: Service Procedure Overview
Service Service Procedure Overview Service steps 1. Shut down heating system Page 39 ..........................2. -
Page 39: Necessary Tools
Service Necessary Tools Use only calibrated equipment. Testing/analysis equipment Calibrated flue gas analyzer WARNING Cleaning supplies Hand brush Ensure that warning concerning Rags fiberglass wool and ceramic fiber Vacuum cleaning materials on page 3 has been read and understood before handling Possible replacement parts insulation. - Page 40 Service Service Procedure (continued) 2. Open combustion chamber door (continued) 4. Disconnect 3-pole plug-in connector from burner. 5. Remove combustion chamber insert (if applicable). 3. Clean heat exchanger and flue pipe 1. Clean heat exchanger with cleaning brush and use vacuum cleaner to remove all sediment.
- Page 41 Service Service Procedure (continued) 5. Close combustion chamber door 1. Reinsert flue gas turbulators applicable). 2. Reinstall combustion chamber insert (if applicable). 3. Close combustion chamber door and tighten two bolts in an even fashion. WARNING Reconnect oil burner and follow instructions found in burner installation/start-up manual.
- Page 42 Service Service Procedure (continued) 8. Ensure proper operation of expansion tank, low water cut-off (if applicable) and pumps Refer to maintenance instructions The usual water fill pressure is between If oil-lubricated pumps are used, ensure supplied with diaphragm expansion 10 and 15 psi with the system cold. A proper lubrication.
- Page 43 Service Service Procedure (continued) 11. Calibrate the burner For burner technical information see technical data table on pages 33 and 34. " Instructions supplied with Beckett or Riello burner Combustion analysis WARNING This oil burner requires combustion measurements performed at the final DO NOT USE GASOLINE installation site, using calibrated CRANKCASE DRAININGS OR ANY...
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Page 44: Parts List
Additional Information Parts List Ordering Replacement Parts: replacement parts. Order replacement Please provide boiler Model and Serial components from your Viessmann Number from rating plate when ordering distributor. Parts 002 Top panel 003 Side panel (left/right) 004 Insulation blanket 005 Back panel... - Page 45 Additional Information Parts List (continued) Other parts (not illustrated) Parts List 016 Combustion chamber door 101 Aquastat, 7248C100B 033 Touch-up paint stick Vitotec silver refractory 102 Sensor well 034 Touch-up spray paint Vitotec silver 018 Combustion chamber door 103 Accessory pack, 037 Cleaning brush handle 800 mm, 019 Hinge bracket burner installation hardware...
- Page 46 Additional Information Notes...
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Page 47: Maintenance Record
Additional Information Maintenance Record Start-up Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Start-up Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Before each heating season begins, WARNING have the following service and maintenance done by a licensed, Neglecting to perform necessary professional heating contractor: maintenance can cause unsafe... - Page 48 +60 +140 +70 +158 +80 +176 +90 +194 +100 +212 +110 +230 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.