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Installation / Service Manual
for Vitogas 050, RS Series
Gas-fired, atmospheric cast iron boiler
550 to 1050 MBH / 161 to 308 kW
IMPORTANT: READ AND SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE
These instructions cover the installation, operation and
servicing of the Viessmann Vitogas 50, RS series of cast-iron
sectional atmospheric gas-fired hot water boilers. These
instructions must be read thoroughly prior to installation.
These instructions must be saved and made available to
service technicians when required. Install boiler according to
these instructions.
The installation of this unit shall be in accordance with local
codes or, in the absence of local codes, use CSA-B149.1 or .2
Installation Codes for Gas Burning Appliances for Canada. For
U.S. installations use ANSI Z223.1. Always use latest editions
of codes.
Where required by the authority having jurisdiction, the
installation must conform to the Standard for Controls and
Safety Devices for Automatically Fired Boilers, ANSI/ASME
CSD-1.
These instructions must be placed in an envelope and affixed
to the boiler.
5167 456 v1.2 03/2007
Contents:
Technical Data ..........................................................................3
Boiler Features .........................................................................4
Installation.................................................................................4
Gas Connections ......................................................................7
Water Connections ...................................................................8
Vent Connections ...................................................................10
Accessories ............................................................................10
Start-up and Operating Instructions ........................................11
Maintenance ...........................................................................13
Troubleshooting ......................................................................17
Piping Layouts ........................................................................18
Wiring Diagrams .....................................................................22
Installation Checklist ...............................................................24
Replacement Parts List...........................................................25
Assembly of cast-iron block using draw tool ...........................30
®
Viessmann Manufacturing Company Inc.
750 McMurray Road
•
Waterloo, Ontario
N2V 2G5
•
Tel. (519) 885-6300
Fax (519) 885-0887
•
www.viessmann.ca
mail@viessmann.ca
Viessmann Manufacturing Company (U.S.) Inc.
45 Access Road
•
•
Warwick, RI
02886
U.S.A.
Tel.: (401) 732-0667 Fax: (401) 732-0590
•
www.viessmann-us.com
mail@viessmann-us.com
Page:
•
Canada
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Table of Contents
Related Manuals for Viessmann Vitogas 050 Rs Series
Summary of Contents for Viessmann Vitogas 050 Rs Series
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Page 1: Table Of Contents
IMPORTANT: READ AND SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE Contents: Page: These instructions cover the installation, operation and servicing of the Viessmann Vitogas 50, RS series of cast-iron Technical Data ................3 sectional atmospheric gas-fired hot water boilers. These Boiler Features .................4 instructions must be read thoroughly prior to installation. - Page 2 This “Attention” symbol is located beside all Warning: important safety recommendations. Please follow the instructions in detail to avoid property damage, Before each heating season begins, have the following severe personal injury, or loss of life. service and maintenance done by a professional service technician: Boiler heat exchanger inspected and cleaned.
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Page 3: Technical Data
*4 If the gas supply pressure is higher than the maximum permissible value, a separate field supplied gas regulator must be installed upstream of the boiler gas train. For for information regarding other Viessmann System Technology componentry, please reference documentation of the respective product. -
Page 4: Boiler Features
2.2. Also see Fig. 23 on Assembly of split cast-iron heat exchanger requires the page 18. use of a Viessmann draw tool, which must be specified at time of ordering. See page 30 for use of draw tool. Installation with piping on left side... - Page 5 switching from right to left, rotate the tube 90° clockwise to align the holes with the water passages in the casting (see Fig. 3). Remount the flanges and gaskets. Draft hood Remove the 5-point well from the right tapping and the plug or well from the left.
- Page 6 Provisions for combustion and ventilation air must be 2.4.1 Assembly (see Figs. 6, 7, 11, 23, 26) made in accordance with section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas These instructions cover the assembly of the standard Code, ANSI Z223.1, or applicable provisions of the local boiler with right hand water and left hand gas codes.
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Page 7: 2.4.5 Gas Connections
2.4.4 Gas controls (see Figs. 9, 11, 22, 23, 25) Draft hood assembly Refer to Fig. 9, Gas controls, and Wiring diagram. Connect gas train to the burner manifold using the union provided. Align gas train with manifold and tighten union. Connect pilot gas tubing to the fitting downstream of the pilot gas valve. -
Page 8: Water Connections
Adjustable high limit sensor bulb ⁄ ˝ flexible Leak test Manual reset high limit sensor bulb tubing supply Test valve Manual Redundant Combination ⁄ ˝ aluminum gas shut- automatic regulator and or copper off valve gas valve automatic gas tubing Thermometer valve ⁄... - Page 9 Initial system fill Flow direction must be as shown Treatment for boiler feed water should be considered in pipe areas of known problems, such as high mineral content Return Supply and hardness. In areas where freezing might occur, an Sensing well Power for aquastat 120V...
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Page 10: Vent Connections
(atmospheric-fired) gas water heater. installation instructions. Consult Viessmann technical Observe national codes, local rules and regulations. sales representative for ordering. Removal of existing boiler... -
Page 11: Start-Up And Operating Instructions
See wiring diagram in rear of manual and wiring label should extend to the floor drain and end approximately on boiler. Viessmann reserves the right to substitute 6˝ above drain. Do not install a shut-off valve in electrical components as necessary. The boiler wiring discharge piping. - Page 12 piping system at test pressures equal to or less than 14˝ Cooling season starts: Close valve V1 and open w.c. (3.5 kPa). valve V2. Heating season starts: Close valve V2 and open Unions and manifold have been factory-tested. Leak valve V1. test must be repeated during initial trial operation of A metal tag should be attached to these valves as to burner by mechanical contractor.
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Page 13: Maintenance
If the heat exchanger is to be cleaned, replace burner tubes only after cleaning is completed. For combination space heating and domestic hot water consult Viessmann sales representative for control Table 1: GAS ORIFICES options and piping diagrams. Altitude above Natural Gas L.P. -
Page 14: For Your Safety Read Before Operating
Lighting instructions – intermittent pilot ignition system: FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Boiler and piping system must be filled with water and purged of all air before operating boiler. - Page 15 Diagonal passes with brush Boiler casting Gas orifice Locating hole Support pin Burner Guide Burner manifold tube Fig. 18 Installing burner tubes – side view Second passes with brush Fig. 20 Boiler casting Cleaning heat exchanger Burner screw Remove the front inspection and cleaning cover to get access to the heat exchanger.
- Page 16 Ionization Ignition electrode electrode Ionization 44±2 electrode Pilot burner Ignition electrode (always on bottom) 2-3mm Note: Pilot is shown 16mm on left side. Standard gas train Ground screw requires pilot to be mounted on right side. See Fig. 11 and Fig.
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Page 17: Troubleshooting
Troubleshooting – spark ignition system TROUBLE CAUSE REMEDY Pilot burner will No call for heat Check that contacts on thermostat not light or operating control are closed. Boiler temperature Allow boiler to cool and ensure too high that limit controls are reset. No power Check for 120 VAC power to transformer. -
Page 18: Piping Layouts
10.0 Piping layouts Single boiler installation – piping arrangements Fig. A Note: Gas train connection to manifold must be on the same side as pilot assembly RS boiler with right hand water piping – left hand gas piping Sensing well for aquastat Return Supply... - Page 19 Multiple boiler installation – layouts 4´ 8˝ (1590mm) RS-50 RS-50 RS-50 4´ 3´ 10 ⁄ ˝ (1220mm) (1190mm) 11´ 9˝ (3580mm) RS-50 Back to back lay-out Front to front lay-out L-shape lay-out RS-50 RS-50 2´ (610mm) 12´ 4˝ (3760mm) Fig. 24 Lay-outs Vitogas RS-50 gas boilers –...
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Page 22: Wiring Diagrams
Vitotronic Contol – Operating limit adjustable aquastat Refer to wiring label affixed to boiler access panel, Viessmann reserves the right to substitute components or Do not operate burner without boiler control wiring methods. Boiler wiring label takes precedence. Never bypass safety high limit aquastats... - Page 23 Vitogas 050, RS 2-stage with Vitotronic control (Natural Gas) R e f e r t o i n t e r n a l w i r i n g d i a g r a m s u p p l i e d w i t h t h e V i t o t r o n i c c o n t r o l T o # 1 9 1 T o # 4 1...
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Page 24: Installation Checklist
Such systems must have water temperature can cause damage to concrete slabs. 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 25: Replacement Parts List
Fig. 26... - Page 26 Atola-RS Parts List Pos. Description and Model Boiler Left hand end section Intermediate section with drilling ⁄ ˝ NPSC Intermediate section RS-8 Intermediate section RS-11 Intermediate section RS-14 Right hand end section Push nipple 2 ⁄ ˝ RS-8 Push nipple 2 ⁄...
- Page 27 Pos. Description and Model Boiler Nozzle Ø 4,30 – M14x1 RS-8-NG Nozzle Ø 4,30 – M14x1 RS-11-NG Nozzle Ø 4,30 – M14x1 RS-14-NG Burner RS-8 Burner RS-11 Burner RS-14 Screw TCB M5x8 ZnCr RS-8 Screw TCB M5x8 ZnCr RS-11 Screw TCB M5x8 ZnCr RS-14 Screw Hex.H.
- Page 28 Vitogas 050, RS controls and accessories Vitotronic Boiler Control Please refer to the corresponding Vitotronic control manual shipped with the boiler 2-stage module 41-plug #41 plug Honeywell S8600B 4˝ x 4˝ 4˝ x 4˝ PV PV GND 24V M & O L &...
- Page 29 ⁄ ˝ nat. gas, 24V *Obtain replacement parts from your Viessmann dealer. Installation of incorrect replacement parts can cause unsafe operation. *Refer to the corresponding Vitotronic boiler control manual for details. *Refer to the corresponding wiring diagram shipped with the boiler (affixed to the inside of the front access panel).
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Page 30: Assembly Of Cast-Iron Block Using Draw Tool
12.0 Assembly of split cast-iron block using Viessmann draw tool 12.1 Section block assembly (see Figs. 10, 27, 28, 29, 30) Depending on the boiler size, the cast-iron section assembly is shipped in pre-assembled blocks of two or more. Site assembly of the blocks is required and the following procedure must be strictly adhered to. - Page 31 Attention: Use plenty of oil between hexagon brass nuts and steel pressure plates as well as on assembly tool threads! Important: Use only a Viessmann assembly tool for this procedure. Start to draw by tightening the two hexagon brass nuts equally with the two hexagon keys supplied.