Viessmann Vitorond 100 VR1 Series Installation And Service Instructions Manual
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Viessmann Vitorond 100 VR1 Series Installation And Service Instructions Manual

Viessmann Vitorond 100 VR1 Series Installation And Service Instructions Manual

Oil-fired boiler heating input 91 to 140 mbh 27 to 41 kw
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See also: Technical Data Manual , Installation and Service Instructions Manual
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
H
5583 571 - 01 01/2014
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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Summary of Contents for Viessmann Vitorond 100 VR1 Series

  • Page 1 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 Product may not be exactly as shown IMPORTANT Read and save these instructions for future reference. 5583 571 - 01 01/2014 Please file in Service Binder...

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

    Installers must follow local regulations with respect to installation of carbon monoxide detectors. Follow the Viessmann maintenance schedule of the Warranty boiler in the “Service Instructions” manual. Information contained in this and related product documentation must be read and followed.
  • Page 3 Safety Vitorond 100, VR1-22 to -33 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 materials: Inhaling of fiberglass wool and/or ceramic fiber Precautionary measures materials is a possible cancer hazard.

  • Page 4: 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..........8 Product Information.............9 Mechanical Room.............10 Combustion Air Supply..........10 Set-up Product Delivery............12 Unpacking Instructions..........12 Minimum Clearances to Combustibles......13 Recommended Minimum Clearances for Service...13 Boiler Set-up and Location ........14 Combustion Chamber Insert........14...
  • Page 5 Table of Contents Vitorond 100, VR1-22 to -33 Installation and Service Page Start-up Initial Start-up............45 Burner Calibration.............46 Beckett Burner Calibration ........47 Riello Burner Calibration..........48 Barometric Draft Regulator.........49 Waterside Flow............49 Connections Installation Examples - Hydrostat 3250-Plus....50 Installation Examples - Vitotronic........51 Service Necessary Tools............54 Service Procedure.............54 Shut-down heating system........54...
  • Page 6 Safety Vitorond 100, VR1-22 to -33 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: 2(a) For all side-wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side-wall exhaust vent termination is less than (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:...
  • Page 7 - Service Instructions For information regarding other Viessmann System - Operating Instructions and User’s Information Manual Technology componentry, please reference - Instructions of other Viessmann products utilized with documentation of the respective product. this installation We offer frequent installation and service seminars - Hydrostat 3250-Plus instructions to familiarize our partners with our products.

  • Page 8: About These Instructions

    General Information Vitorond 100, VR1-22 to -33 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. Warnings draw your attention to the presence of WARNING potential hazards or important product information.

  • Page 9: 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. Hydrostat thermal targeting...

  • Page 10: Mechanical Room

    18 in. room. (457 mm) above the floor to avoid contact with flammable vapors and fumes). Viessmann strongly recommends installing the boiler on a concrete foundation. Combustion Air Supply General This equipment requires fresh air for safe operation and...
  • Page 11 General Information Vitorond 100, VR1-22 to -33 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. are as follows: In the absence of local codes, use: H CSA B-139.00 for oil installations in Canada, or Boiler Model No.

  • Page 12: Product Delivery

    WARNING To avoid injury and to facilitate boiler maneuvering, Do not lift or position boiler alone. it is strongly recommended that Viessmann carrying Do not lift by or push against panels. handles (Part No. 7189 602) be used. The carrying Do not bump boiler panels against floor.

  • Page 13: Minimum Clearances To Combustibles

    Set-up Vitorond 100, VR1-22 to -33 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: Standard installation Boiler model VR1...

  • Page 14: Boiler Set-Up And Location

    Set-up Vitorond 100, VR1-22 to -33 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 10. The boiler should be located as close to the chimney as possible.

  • Page 15: Venting Connection

    Connections Vitorond 100, VR1-22 to -33 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. The vent system shall ensure that no hazard is created If installing boiler with a side wall vent system, ensure by the products of combustion.
  • Page 16 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. For direct vent application, refer to the Direct...

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

    Connections Vitorond 100, VR1-22 to -33 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). WARNING Failure to flush the heating system could cause system sludge to settle in the boiler, causing overheating and...

  • Page 18: Safety Connections (With Hydrostat 3250-Plus Control)

    Connections Vitorond 100, VR1-22 to -33 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. Refer to instructions supplied with the pressure relief valve.
  • Page 19 Connections Vitorond 100, VR1-22 to -33 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 20: Water Side Connections (With Vitotronic Control)

    Connections Vitorond 100, VR1-22 to -33 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 21: Safety Connections (With Vitotronic Control)

    Connections Vitorond 100, VR1-22 to -33 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. 2.
  • Page 22 Connections Vitorond 100, VR1-22 to -33 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 23: Pressure Testing

    Connections Vitorond 100, VR1-22 to -33 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 24: Burner Installation

    Observe all instructions supplied with the burner. Burner Information Fuel This boiler is for use with the Beckett #2 fuel oil burner supplied by Viessmann only. Use only the fuel stated on the rating plate of the burner. WARNING DO NOT USE GASOLINE CRANKCASE DRAININGS OR ANY OIL CONTAINING GASOLINE.

  • Page 25: Burner Mounting

    Beckett Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Burner Mounting Refer to instructions supplied with the Beckett burner. 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 26: Oil Piping Connection

    Beckett Burner Set-up Vitorond 100, VR1-22 to -33 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. - In Canada, CSA B139.00, Installation of Oil-Burning Equipment.

  • Page 27: Electrical Connections (With Hydrostat 3250-Plus Control)

    Beckett Burner Set-up Vitorond 100, VR1-22 to -33 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. Electric shock hazard.
  • Page 28 Beckett Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Electrical Connections (with Hydrostat 3250-Plus control) (continued) Installations must follow these codes and requirements: WARNING - National Electrical Code, ANSI/NFPA 70, latest edition and any addtional national, state or local codes. Electric shock hazard.
  • Page 29 Beckett Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Electrical Connections (with Hydrostat 3250-Plus control) (continued) Legend A Power supply, provide disconnect means and overload protection as required. B Control case must be connected to earth ground. Use grounding provided. C B1 is a in.

  • Page 30: Electrical Connections (With Vitotronic Control)

    Beckett Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Electrical Connections (with Vitotronic control) Installations must follow these codes and requirements: WARNING - National Electrical Code, ANSI/NFPA 70, latest edition and any addtional national, state or local codes. Electric shock hazard.
  • Page 31 Beckett Burner Set-up Vitorond 100, VR1-22 to -33 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. Installations must follow these codes and requirements: - National Electrical Code, ANSI/NFPA 70, latest edition and any addtional national, state or local codes.

  • Page 32: Installation Of Vitotronic Control

    Beckett Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Installation of Vitotronic Control Refer to Installation Instructions Boiler Control (for all connections to control base) IMPORTANT The power supply cable is shipped with the boiler control. 1. Loosen two screws, remove cover plate and discard. 2.

  • Page 33: Boiler Coding Card

    Beckett Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Installation of 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 1/8”...

  • Page 34: Electrical Connections (With Genisys Primary Control)

    Beckett Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Electrical Connections (with GeniSys primary control) 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 Installation

    Burner Information Fuel This boiler is for use with the Riello #2 fuel oil burner supplied by Viessmann only. Use only the fuel stated on the rating plate of the burner. Oil nozzle The Riello burner for the VR1-33 boiler is shipped with factory setting and oil nozzle installed, and should require only minor adjustments.

  • Page 36: Burner Mounting

    Riello Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Burner Mounting Refer to the 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 A in threaded holes of combustion chamber door.

  • Page 37: Oil Piping Connection

    Riello Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Oil Piping Connection General oil piping requirements Refer to the Instructions supplied Location and installation of oil tanks, oil piping and with Riello burner burners must follow: - Local codes and regulations. - Information provided with burner and fuel pump.
  • Page 38 Riello Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Electrical Connections (with Hydrostat 3250-Plus control) All field supplied nominal 120 VAC voltage wiring WARNING must be sheathed in a flexible metal conduit. Disconnect means, overload protection and low water Electric shock hazard.

  • Page 39: Electrical Connections (With Hydrostat 3250-Plus Control)

    Riello Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Electrical Connections (with Hydrostat 3250-Plus control) Legend A Power supply, provide disconnect means and overload protection as required. B Control case must be connected to earth ground. Use grounding provided. C B1 is a in.

  • Page 40: Electrical Connections (With Vitotronic Control)

    Riello Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Electrical Connections (with Vitotronic control) 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. Installations must follow these codes and requirements: - National Electrical Code, ANSI/NFPA 70, latest edition...
  • Page 41 Riello Burner Set-up Vitorond 100, VR1-22 to -33 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. Installations must follow these codes and requirements: - National Electrical Code, ANSI/NFPA 70, latest edition and any addtional national, state or local codes.
  • Page 42 Riello Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Electrical Connections (with Vitotronic control) (continued) Installations must follow these codes and requirements: WARNING - National Electrical Code, ANSI/NFPA 70, latest edition and any addtional national, state or local codes. Electric shock hazard.

  • Page 43: Installation Of Vitotronic Control

    Riello Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Installation of Vitotronic Control Refer to Installation Instructions Boiler Control (for all connections to control base) IMPORTANT The power supply cable is shipped with the boiler control. 1. Loosen two screws and remove cover plate. 2.

  • Page 44: Boiler Coding Card

    Riello Burner Set-up Vitorond 100, VR1-22 to -33 Installation and Service Installation of Vitotronic Control Installation of 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 1/8”...

  • Page 45: Initial Start-Up

    Start-up Vitorond 100, VR1-22 to -33 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. Verify completeness of all discussion points on the 2.

  • Page 46: Burner Calibration

    Start-up Vitorond 100, VR1-22 to -33 Installation and Service Burner Calibration Refer to the Instructions supplied with the WARNING Beckett or Riello burner. DO NOT USE GASOLINE, CRANKCASE DRAININGS OR ANY OIL CONTAINING GASOLINE. Combustion analysis This oil burner requires combustion measurements performed at the final installation site, using calibrated WARNING combustion equipment, to verify factory settings, or to...

  • Page 47: Beckett Burner Calibration

    Start-up Vitorond 100, VR1-22 to -33 Installation and Service Beckett Burner Calibration Boiler Model No. VR1-22 VR1-27 VR1-33 Beckett NX-VI 701 NX-VI 702 NX-VI 703 Burner model No. 2 fuel oil No. 2 fuel oil No. 2 fuel oil Fuel type psig Pump pressure Danfoss...

  • Page 48: Riello Burner Calibration

    Start-up Vitorond 100, VR1-22 to -33 Installation and Service Riello Burner Calibration Boiler Model No. VR1-22 VR1-27 VR1-33 Riello 40 Series F3*1 Burner model No. 2 fuel oil No. 2 fuel oil No. 2 fuel oil Fuel type psig Pump pressure Danfoss 0.50x60°xAS 0.60x60°xAS*3...

  • Page 49: Barometric Draft Regulator

    They further do not display all system varieties, safety devices, or concepts possible. Specific system layouts may be further discussed with the local Viessmann sales representative office. Clearances A minimum of 2” circumferential clearance from non- insulated hot water pipes to combustible construction must be maintained.

  • Page 50: Installation Examples - Hydrostat 3250-Plus

    Connections Vitorond 100, VR1-22 to -33 Installation and Service Installation Examples - Hydrostat 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 Legend IMPORTANT A Heating/Cooling unit B Spring-loaded flow check valve We strongly suggest that the valves be labelled “v1”...

  • Page 51: Installation Examples - Vitotronic

    Connections Vitorond 100, VR1-22 to -33 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 valve, and temperature pressure gage E Expansion tank F Low water cut-off (if required)
  • Page 52 Connections Vitorond 100, VR1-22 to -33 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 one mixing valve actuator accessory kit Legend A Heating circuit B Spring-loaded flow check valve...
  • Page 53 Connections Vitorond 100, VR1-22 to -33 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 one mixing valve actuator accessory kit Legend A Heating circuit...

  • Page 54: Necessary Tools

    Service Vitorond 100, VR1-22 to -33 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. Testing/analysis equipment H Calibrated flue gas analyzer WARNING Cleaning supplies...

  • Page 55: Clean Heat Exchanger And Flue Pipe

    Service Vitorond 100, VR1-22 to -33 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 56: Check Heating System And Domestic Hot Water Connections

    Service Vitorond 100, VR1-22 to -33 Installation and Service Service Procedure (continued) Check heating system and domestic hot water connections Ensure all connections are pressure tight. Ensure proper operation of all safety devices Check pressure gage, air vent and pressure relief valve. Ensure pressure relief valve does not leak.

  • Page 57: Calibrate The Burner

    Service Vitorond 100, VR1-22 to -33 Installation and Service Service Procedure (continued) Calibrate the burner WARNING Refer to the Instructions supplied with the DO NOT USE GASOLINE, CRANKCASE DRAININGS OR Beckett or Riello burner. ANY OIL CONTAINING GASOLINE. Note: For burner technical information refer to table on page 47 or page 48.

  • Page 58: Parts List

    VR1-33 Boiler 7249050 Ordering Replacement Parts: Please provide boiler Model and Serial Number from rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor. Parts 202 Top panel, front 203 Side panel, left 204 Insulation blanket 205 Back panel...
  • Page 59 Additional Information Vitorond 100, VR1-22 to -33 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 006 Glass-fiber gasket, 3x116 mm*1 008 Observation port cover 011 Turbulator insert, x2 2nd pass, VR1-22 *2 012 Turbulator insert, x2, VR1-33 *3...
  • Page 60 Additional Information Vitorond 100, VR1-22 to -33 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” x 1½” x ½” 0706 Nipple, 1½”...

  • Page 61: Maintenance Record

    Additional Information Vitorond 100, VR1-22 to -33 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 62 Vitorond 100, VR1-22 to -33 Installation and Service...
  • Page 63 Vitorond 100, VR1-22 to -33 Installation and Service...
  • Page 64 5583 571 - 01 Technical information subject to change without notice. Printed on environmentally friendly (recycled and recyclable) paper.

This manual is also suitable for:

Vitorond 100 vr1-22Vitorond 100 vr1-27Vitorond 100 vr1-33

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