Viessmann VITOROND 100 Installation And Service Instructions Manual
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Viessmann VITOROND 100 Installation And Service Instructions Manual

Viessmann VITOROND 100 Installation And Service Instructions Manual

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See also: Technical Manual , Instruction and Installation Manual
Installation and
Service Instructions
for use by heating contractor
Vitorond 100
VR1 Series
Oil-Fired Boiler
Heating input 161 to 245 MBH
47 to 72 kW
VITOROND 100
5671 044 v1.0 08/2012
IMPORTANT
Read and save these instructions
for future reference.

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Summary of Contents for Viessmann VITOROND 100

  • Page 1 Installation and Service Instructions for use by heating contractor Vitorond 100 VR1 Series Oil-Fired Boiler Heating input 161 to 245 MBH 47 to 72 kW VITOROND 100 IMPORTANT Read and save these instructions for future reference. 5671 044 v1.0 08/2012...
  • Page 2 Viessmann equipment. " Please see section " For a listing of entitled “Important chemicals which cannot "...
  • Page 3 Safety, Installation and Warranty Requirements Safety, Installation and Warranty Requirements (continued) H Fiberglass wool and ceramic fiber H Hazardous materials materials WARNING Suppliers of fiberglass wool products WARNING recommend the following precautions Appliance materials of construction, be taken when handling these materials: products of combustion and the fuel Inhalation of fiberglass wool and/or contain alumina, silica, heavy metals,...

  • Page 4: Table Of Contents

    Contents Page Important Regulatory, Installation Requirements Safety ... General Information About these Instructions ............Product Information .
  • Page 5 ........Wiring diagram (Vitorond 100, VR1-40, -50 and -63...
  • Page 6 Contents Page Initial Start-up Initial Start-up ................Burner calibration .
  • Page 7 Technical literature Leave all literature at the installation 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 8: About These Instructions

    This symbol indicates that other instructions must be referenced. Please note Viessmann Manufacturing Company Inc. reserves the right to make product changes or updates without notice and will not be held liable for typographical errors or omissions in the product literature.

  • 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.

  • Page 10: 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 11: 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 12: Fresh Air

    Fresh Air Combustion Air Supply (continued) Unconfined spaces Confined spaces Louvers 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 obtains all of its air for consideration shall be given to the insufficient infiltration, additional air for...

  • Page 13: Product Delivery

    Fig. 1 Unpacking Instructions To avoid injury and to facilitate boiler manoeuvering, it is strongly recommended that Viessmann carrying handles (Part No. 7189 602) 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 14: Minimum Clearances To Combustibles

    Set-up Minimum Clearances to Combustibles For typical installations, Viessmann recommends installing the boiler with clearances as published on page 15 under Recommended Minimum Clearances for Service. The following are clearances to min. 6” / 150 mm combustibles: min. 0” / 0 mm Standard installation min.

  • Page 15: Recommended Minimum Clearances For Service

    Set-up Set-up Recommended Minimum Clearances for Service 20” / 508 mm 33½” / 850 mm 4” / 100 mm Boiler Fig. 6 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 16: Insulation Installation

    Set-up Insulation Installation All parts necessary to install the insulation are shipped with the carton containing the insulation. 1. Wrap insulation blanket around cast iron block with the cutout facing to the front. 2. Secure insulation blanket with supplied spring clips. Fig.
  • Page 17 Set-up Insulation Installation 3. If installing Vitotronic control: Run the plug-in connector cable of the Vitotronic control down behind the front panel of the boiler and out through the bottom. 4. Install support brackets 5. Position left side panel onto support brackets 6.
  • Page 18 Set-up Insulation Installation (continued) 8. Install rear insulation blanket to cast iron block, black side facing outward. 3,9 x 9,5 9. Install rear panel. Fig. 10 10. Install right side panel on support brackets. Ensure top of side panel fits over top of rear panel. 11.

  • Page 19: Combustion Chamber Insert

    Set-up Insulation Installation (continued) 3.9 x 9.5 IMPORTANT If installing a Vitotronic control: Before installing the top front and rear panels, see sections covering Vitotronic control. 13. Slide the top front panel locking notches into the side panel holes. 14. Install the top rear panel by sliding it into the notches.

  • Page 20: 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 21 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.
  • Page 22 Connections Water Side Connections (Aquastat 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). CAUTION Failure to flush the heating system could cause system sludge to settle Fig.

  • Page 23: Install Safety Devices On Boiler

    Connections Safety Connections (Aquastat Control) Install safety devices on boiler 1. Install pressure relief valve. Pipe Pressure relief valve IMPORTANT pressure relief valve as illustrated and connect to boiler water supply Install the (approved) factory supplied connection. pressure relief valve. Instructions supplied with Removal of air from the system must pressure relief valve.
  • Page 24 Connections Safety Connections (Aquastat 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 ” drill bit. To reinstall the top panel, drill a new ”...
  • Page 25 Connections 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). CAUTION Failure to flush the heating system could cause system sludge to settle in the boiler, causing overheating and Fig.

  • Page 26: Install Safety Devices On Boiler

    Connections Safety Connections (Vitotronic Control) Install safety devices on boiler Pressure relief valve IMPORTANT 1. Install pressure relief valve. Pipe pressure relief valve as illustrated Install the (approved) factory supplied and connect to boiler water supply pressure relief valve. connection. Removal of air from the system must Instructions supplied with occur via use of air vent(s) in the...
  • Page 27 Connections 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 ” drill bit. To reinstall the top panel, drill a new ”...

  • Page 28: Pressure Testing

    Connections 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 times the maximum operating pressure of the boiler.

  • Page 29: Burner (Beckett)

    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 30: Burner Set-Up (Beckett)

    Burner - Beckett Burner Set-up (Beckett) 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 31: Oil Piping

    Burner - Beckett Burner Set-up (Beckett) (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 32: Electrical Connections (With Aquastat Control)

    Burner - Beckett Burner Set-up (Beckett control) Electrical connections (with Aquastat control) - Wiring must be N.E.C. Class 1. If Installations must follow these codes WARNING original wire as supplied with boiler and requirements: - National Electrical Code, ANSI/NFPA must be replaced, type 105°C wire or Electric shock hazard.
  • Page 33 Burner - Beckett Burner Set-up (Beckett control) (continued) Electrical connections (with Aquastat control) (continued) - Wiring must be N.E.C. Class 1. If Installations must follow these codes WARNING original wire as supplied with boiler and requirements: - National Electrical Code, ANSI/NFPA must be replaced, type 105°C wire Electric shock hazard.

  • Page 34: Wiring Diagram (With Aquastat Control For Nx Burner For Vitorond 100, Vr1-40)

    Burner - Beckett Burner Set-up (Beckett) (continued) Wiring diagram (with Aquastat control for NX burner for Vitorond 100, VR1-40) - Wiring must be N.E.C. Class 1. If Installations must follow these codes WARNING original wire as supplied with boiler and requirements: - National Electrical Code, ANSI/NFPA must be replaced, type 105°C wire or...

  • Page 35: With Beckett Burner, Genisys Control And Honeywell Aquastat)

    Burner - Beckett Burner Set-up (Beckett burner with GeniSys primary control) (continued) Wiring diagram (Vitorond 100 with Beckett burner, GeniSys control and Honeywell Aquastat) with outdoor reset module - Wiring must be N.E.C. Class 1. If Installations must follow these codes...

  • Page 36: Electrical Connections (With Vitotronic Control)

    Burner - Beckett Burner Set-up (Beckett control) (continued) Electrical connections (with Vitotronic control) - Wiring must be N.E.C. Class 1. If Installations must follow these codes WARNING original wire as supplied with boiler and requirements: - National Electrical Code, ANSI/NFPA must be replaced, type 105°C wire or Electric shock hazard.

  • Page 37: Installation Of Vitotronic Control

    Connections Burner Set-up (Beckett) (continued) Electrical connections (with Vitotronic control) (continued) Room thermostat wiring 1. Install thermostat on inside wall away from influences of drafts, hot or cold water pipes, lighting fixtures, television, sun rays or fireplaces. 2. Follow instructions supplied with room thermostat.
  • Page 38 Connections Burner Set-up (Beckett control) (continued) Installation of Vitotronic control (continued) 6. Channel power supply cable or Power/Pump Module cable (for Vitotronic 200) and all other 120 VAC cabling through back opening toward boiler control. 7. Channel low voltage cables (i.e. sensor cables) through cable opening toward boiler control.

  • Page 39: Boiler Coding Card

    Connections Burner Set-up (Beckett control) (continued) 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 this, pre-drill the panels with an ”...

  • Page 40: Pump Junction Box (With Vitotronic Control)

    Connections Burner Set-up (Beckett control) (continued) Pump junction box (with Vitotronic control) The pump junction box supplies power to field supplied pumps. It is shipped with the boiler and must be installed whenever each of the boilers is installed in conjunction with the following controls: - Vitotronic 100, KK10 - Vitotronic 100, KW10...
  • Page 41 RED wire is live (120VAC) at all times. Do not remove or cut its closed end connector unless it is necessary to do so. Failure to heed the above Viessmann #41-plug instructions may cause severe personal injury or control connection loss of life.

  • Page 42: Wiring Diagram (With Vitotronic Control)

    Connections Burner Set-up (Beckett) (continued) Wiring diagram (with Vitotronic control) - Wiring must be N.E.C. Class 1. If Installations must follow these codes WARNING original wire as supplied with boiler and requirements: - National Electrical Code, ANSI/NFPA must be replaced, type 105°C wire Electric shock hazard.

  • Page 43: Wiring Diagram (Vitorond 100,With Beckett Burner, Genisys Control And Vitotronic Control)

    Connections Burner Set-up (Beckett burner with GeniSys primary control)) (continued) Wiring diagram (Vitorond 100 with Beckett burner, GeniSys control and Vitotronic control) - Wiring must be N.E.C. Class 1. If Installations must follow these codes WARNING original wire as supplied with boiler...

  • Page 44: Burner (Riello)

    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 45: Burner Set-Up (Riello)

    Burner Burner Set-up (Riello) 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 46: Oil Piping

    Burner Burner Set-up (Riello) (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 47: Electrical Connections (With Aquastat Control)

    Burner Burner Set-up (Riello) Electrical connections (with Aquastat control) - Wiring must be N.E.C. Class 1. If Installations must follow these codes WARNING original wire as supplied with boiler and requirements: - National Electrical Code, ANSI/NFPA must be replaced, type 105°C wire or Electric shock hazard.

  • Page 48: Wiring Harness Connection To Honeywell High Limit And Riello Burner Subbase (With Aquastat Control)

    Burner Burner Set-up (Riello) (continued) Wiring harness connection to Honeywell high limit and Riello burner subbase (with Aquastat control) - Wiring must be N.E.C. Class 1. If Installations must follow these codes WARNING original wire as supplied with boiler and requirements: - National Electrical Code, ANSI/NFPA must be replaced, type 105°C wire or Electric shock hazard.

  • Page 49: Wiring Diagram (With Aquastat Control)

    Burner Burner Set-up (Riello) (continued) Wiring diagram (with Aquastat control) with outdoor reset module - Wiring must be N.E.C. Class 1. If Installations must follow these codes WARNING original wire as supplied with boiler and requirements: - National Electrical Code, ANSI/NFPA must be replaced, type 105°C wire or Electric shock hazard.

  • Page 50: Installation Of Vitotronic Control

    Connections Burner Set-up (Riello) Installation of Vitotronic control 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. Remove top back panel. 3.
  • Page 51 Connections Burner Set-up (Riello) (continued) Installation of Vitotronic control (continued) 6. Channel power supply cable or Power/Pump Module cable (for Vitotronic 200) and all other 7. Channel low voltage cables (i.e. 120 VAC cabling through back sensor cables) through cable opening toward boiler control.

  • Page 52: Electrical Connections (With Vitotronic Control)

    Burner Burner Set-up (Riello) (continued) Electrical connections (with Vitotronic control) - Wiring must be N.E.C. Class 1. If Installations must follow these codes WARNING original wire as supplied with boiler and requirements: - National Electrical Code, ANSI/NFPA must be replaced, type 105°C wire or Electric shock hazard.
  • Page 53 Connections Burner Set-up (Riello) (continued) Electrical connections (with Vitotronic control) (continued) The pump junction box supplies power to field supplied pumps. It is shipped with the boiler and must be installed whenever each of the boilers is installed in conjunction with the following controls: - Vitotronic 100, KK10 - Vitotronic 100, KW10...
  • Page 54 RED wire is live (120VAC) at all times. Do not remove or cut its closed end connector unless it is necessary to do so. Failure to heed the above Viessmann #41-plug instructions may cause severe personal injury or control connection loss of life.

  • Page 55: Wiring Diagram (With Vitotronic Control)

    Burner Burner Set-up (Riello) (continued) Wiring diagram (with Vitotronic control) - Wiring must be N.E.C. Class 1. If Installations must follow these codes WARNING original wire as supplied with boiler and requirements: - National Electrical Code, ANSI/NFPA must be replaced, type 105°C wire Electric shock hazard.

  • Page 56: Boiler Coding Card

    Connections Burner Set-up (Riello) (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 this, pre-drill the panels with an ” drill bit. To reinstall the top panel, drill a new ”...

  • Page 57: Initial Start-Up

    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...

  • Page 58: Burner Calibration

    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 59: Beckett Burner Calibration

    Initial Start-up Initial Start-Up (continued) Beckett burner calibration Model No. VR1-40 VR1-50 VR1-63 Boiler model Beckett NX-VI 704 AFG-VI 801 AFG-VI 801 Burner model No. 2 fuel oil Fuel type psig Pump pressure Danfoss 0.85x60°AH n.a. n.a. Oil nozzle Oil nozzle Delavan 0.85x60°A 1.10x45°W...

  • Page 60: Riello Burner Calibration

    Initial Start-up Initial Start-Up (continued) Riello burner calibration Model No. VR1-40 VR1-50 VR1-63 Boiler model Riello 40 Burner model Series No. 2 fuel oil Fuel type psig Pump pressure Danfoss 0.85x60°xAH 1.10x60°xAH 1.35x60°xAH Oil nozzle Oil nozzle Delavan 0.85x60°xA 1.10x60°xA 1.35x60°xA 0.85x60°xW 1.35x60°xW...

  • Page 61: 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 62: Installation Examples (Aquastat)

    Connections Installation Examples - Aquastat Heating circuit Spring-loaded flow check valve Circulation pump Automatic air vent Pressure relief valve High limit control Expansion tank Fig. 58...

  • Page 63: Special Applications (Aquastat)

    Connections Special Applications - Aquastat 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...

  • Page 64: Installation Examples (Vitotronic)

    Connections Installation Examples - Vitotronic Without mixing valve e.g. with Vitotronic 100, Model KW10B Heating circuit Spring-loaded flow check valve Circulation pump Automatic air vent (field supplied), pressure relief valve, and temperature and pressure gage Expansion tank Fig. 61 Without mixing valve and with DHW e.g.
  • Page 65 Connections 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 Heating circuit Spring-loaded flow check valve Circulation pump Automatic air vent (field supplied), pressure relief valve, and...

  • Page 66: Special Applications (Vitotronic)

    Connections Special Applications - Vitotronic 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 (field supplied), pressure relief valve, and temperature and pressure gage Expansion tank...

  • Page 67: Service Procedure Overview

    Service Service Procedure Overview OverviewOverview Service steps Page 68 1. Shut down heating system ..........................Page 68 2.

  • Page 68: Necessary Tools

    Service Necessary Tools Testing/analysis equipment Use only calibrated 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 69 Service Service Procedure (continued) 2. Open combustion chamber door (continued) 4. Remove turbulators , if applicable. See page 74 for details. 5. Remove combustion chamber insert (if applicable). 3. Clean heat exchanger and flue pipe 1. Clean heat exchanger with field supplied cleaning brush and use vacuum cleaner to remove all...
  • Page 70 Service Service Procedure (continued) 5. Close combustion chamber door 1. Reinsert flue gas turbulators 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 71 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 72 Service Service Procedure (continued) 11. Calibrate the burner For burner technical information table on page 59 or page 60. " 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...

  • Page 73: Parts List

    7344557 VR1-63 7344558 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 Top panel, front Side panel, left Insulation blanket Back panel Insulation blanket, rear...

  • Page 74: Additional Information

    Additional Information Parts List (continued) Other parts (not illustrated) Wear parts (not illustrated) Parts List 5-Point sensor well Touch-up spray paint Vitotec Cleaning brush (no handle) Combustion chamber silver door refractory Touch-up paint stick Vitotec Combustion chamber door silver Hinge bracket Cleaning brush handle 800 mm, Glass-fiber gasket Glass-fiber gasket, 3x116 mm...
  • Page 75 Additional Information Parts List (continued) Parts Installation Set 7838 764 VITOROND 100 VR1 Series for use with Aquastat control only! Model No. Serial No. VR1-40 7334379 VR1-50 7334385 VR1-63 7334394 Parts Electronic aquastat Sensor well Hex bushing, 1½” x ¾”...

  • Page 76: Maintenance Record

    Maintenance Record Start-up 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 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 1.

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