VST VRC-80 Installation Manual
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VST VRC-80 Installation Manual

Revolution condensing combi-boilers
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For Your Safety
WARNING: If the information in these instructions are not followed exactly, a fire or explosion may result
causing property damage, personal injury or death.
- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
- WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury (exposure
to hazardous materials)* or loss of life. Refer to the user's information manual provided with this boiler. Installation and service
must be performed by a qualified installer, service agency or the gas supplier (who must read and follow the supplied instruc-
tions before installing, servicing, or removing this boiler. This boiler contains materials that have been identified as carcino-
genic, or possibly carcinogenic, to humans).
This boiler must be installed in accordance with local codes. In the absence of local codes, it must be installed in compliance
with The Federal Manufactured Home Construction and Safety Stand Title 24 CRF, part 3280 or CAN/CSA Z240 MH series,
mobile home. In the absence of such standard, The Standard for mobile Homes (ANSI/NFPA No. 601B-1977).
The installation must conform with local codes or, in the absence of local codes, the National Fuel Gas Code, AN-
SIZ223.1/NFPA 54 and/or CSA B149.1, Natural Gas and Propane Installation Code.
REVOLUTION CONDENSING
COMBI-BOILERS
Installation
Manual
Model
VRC-80 VRC-100
VRC-120 VRC-140
Keep this manual near this boiler for future reference
whenever maintance or service is required.
WARNING

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  • Page 1 REVOLUTION CONDENSING COMBI-BOILERS Installation Manual Model VRC-80 VRC-100 VRC-120 VRC-140 Keep this manual near this boiler for future reference whenever maintance or service is required. For Your Safety WARNING: If the information in these instructions are not followed exactly, a fire or explosion may result causing property damage, personal injury or death.

  • Page 2: Safety Information

    Safety Information The following safety symbols are used in this manual for user's safety. Read this manual carefully and follow all instructions to avoid property damage, fire, explosion, personal injury, or death. Danger Indicates an imminently hazardous situation which, if not avoided, will result in severe injury or death. Warning Indicates a potentially hazardous situation which, if not avoided, will result in injury or death.
  • Page 3 Warning • Do not store combustibles, such as papers or laundry, near the boiler or venting system. Failure to do so may result in fire or explosion. • Do not store or use gasoline or other flammable liquids near this boiler. Failure to do so may result in fire or explosion.

  • Page 4: Important Note For The State Of Massachusetts

    Important Note for the State of Massachusetts NOTICE BEFORE INSTALLATION This appliance must be installed by a licensed plumber or gas fitter in accordance with the Massachusetts Plumbing and Fuel Gas Code 248 CMR Sections 4.00 and 5.00. IMPORTANT: In the State of Massachusetts (248 CMR 4.00 & 5.00) 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 seven (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 5: Table Of Contents

    Table of Contents Safety Information ........2 Installing a Vent ........29 Vent Type ................29 Important Note for the State of Vent Pipe Materials ............33 Massachusetts ........... 4 Vent Length ...............33 Connecting the Vent Clip ..........34 General Information ........6 Vent Termination .............34 Included Items ..............

  • Page 6: General Information

    General Information Included Items Optional Accessories The following items are included with the boiler. Check each of the The following optional accessories are not included with the boiler, following items before installation. but may be necessary for the installation. Check the need for any of the following optional accessories before installation.

  • Page 7: Specifications

    Specifications The following table shows the specifications for the boiler. Additional specifications about water, gas, electric, and air supplies (venting) appear in each installation section. MODEL VRC-80 VRC-100 VRC-120 VRC-140 Space Heating 19,900–80,000 BTU/H 19,900–100,000 BTU/H 19,900–120,000 BTU/H 19,900–140,000 BTU/H...

  • Page 8: Rating Plate

    Rating Plate The gas type and electricity voltage must match the rating plate. Using a different gas type and electricity voltage will cause the boiler to malfunction. Danger Before the installation, check the rating plate located on the side of the boiler to ensure that the boiler matches the gas type, gas pressure, water pressure, and electrical supply available in the installation location.

  • Page 9: Dimensions

    Dimensions Description Diameter Space heating Return 1" NPT Cold water inlet 3/4" NPT Condensate Outlet 1/2" NPT Hot water Outlet 3/4" NPT Space heating Supply 1" NPT Gas Inlet 3/4" NPT Exhaust Vent 2" Air inlet 2" 5.57" 5.26" 1.8" (141.5 mm) (133.5 mm) (45.7 mm)

  • Page 10: Components

    Components Flue connector Air intake connector Exhaust temperature sensor Burner hood Gas connector Heat Exchanger Cover Gas valve Pressure sensor Air vent Pump 3-way valve Condensate drain Space heating supply Gas inlet Space heating return Cold water inlet Hot water outlet Installation Manual...
  • Page 11 Turbo fan assembly Ignition transformer Primary heat TDR damper exchanger Secondary heat exchanger Water Pressure Sensor Air Pressure Sensor PCB assembly Flow sensor Front panel General Information...

  • Page 12: Installing The Boiler

    Installing the Boiler Installer Qualifications Access to utilities • Electricity – Close to where the electrical supply enters the building A licensed professional must install and inspect the appliance. A • Water – Close to where the domestic water supply enters the licensed professional is a person who is licensed for the following: building •...
  • Page 13 Clearances Clean, debris and chemical-free combustion The boiler should be installed in an area that allows for service and maintenance access to utility connections, piping, filters, and traps. • Do not install the boiler in areas where dust and debris may Ensure the following clearances are maintained: accumulate or where combustion air can be contaminated.
  • Page 14 Mounting to the wall • The boiler is heavy. Always lift the unit with assistance. Be careful not to drop the boiler while lifting or handling it to To mount the boiler to the wall: avoid bodily injury or damage to the unit. Warning •...

  • Page 15: Installing The System Piping

    When installing the VST boiler and keeping the existing pipes, all pipes including the radiator should be cleaned. • VST VRC boiler is intended solely for use in a pressurized closed loop heating system operating with 7-30psi water pressure If you fail to remove the above-mentioned contaminants at the boiler outlet.
  • Page 16 When replacing the expansion tank, refer to the literature of the Internal LWCO expansion tank manufacturer for selecting the proper size. The VST VRC boiler is equipped with a factory-installed, pressure- • When installing the diaphragm expansion tank, always install sensing type low water cutoff (LWCO) device.

  • Page 17: Installing A Domestic Hot Water(Dhw) System

    Guidelines for a DHW System water, domestic hot water may scatter or splash onto other equipment around. Connect the pressure relief valve to the VST VRC boiler is designed to use space heating and domestic hot outlet pipe. water. •...
  • Page 18 Copper 1.0 mg/l DHW Filter Iron 0.3 mg/l VST VRC boiler has a filter on its cold water inlet nipple. Clean the Manganese 0.05 mg/l filter periodically to prevent the interruption of water flow by foreign matters. 6.5 – 8.5...
  • Page 19 If the pressure relief valve discharges hot water periodically, it • VST recommends the use of unions and manual shut-off valves may be caused by thermal expansion of the closed water system. for the cold water inlet and DHW outlet.

  • Page 20: Connection The Condensate Drain

    Connection the Condensate Drain Notice • If you choose this option, the neutralizing agent must be replaced • All condensate must drain and be disposed of according to periodically. Depletion of the neutralizing agent will vary, based on local codes. the usage rate of the boiler.

  • Page 21: System Filling

    Built-in water filling unless filled with water prior to operation. Pour more than 0.1 gallon VST VRC boiler is designed to fill the system with water. Therefore, (400 ml) of water into the exhaust duct. Deflate air sufficiently or additional water fill connection is not necessary in most cases.

  • Page 22: Test The Water System

    Notice VST VRC boiler has an air vent inside the product in order to purge air in the system. Installation Manual...
  • Page 23 Expansion Tank The size of expansion tank should be decided according to the boiler capacity and the amount of water in the system. It is important to locate the expansion tank, and make-up water fill, on the inlet side of any circulator in the system, as doing so will guarantee the lowest pressure in the system will be at least equal to the tank and make-up water pressure.
  • Page 24 System Application – Zone System with Circulators Zone 1 Zone 2 Zone 3 Check Valve System pump Air Separator Not to exceed 4 pipe Dia or Max. 12 in Expansion tank Installation Manual...

  • Page 25: Connecting The Gas Supply

    Connecting the Gas Supply Gas Pipe Sizing Tables Gas pipe sizing is based on the gas type, supplied gas pressure, pressure drop in the system, and gas line type. The tables below are for reference only (when the gas supply is piping straight to the boiler with no connections to any other gas appliances). For gas pipe sizing, refer to the latest National Fuel Gas code, NFPA 54 and consult the gas pipe manufacturer for actual gas pipe capacities.

  • Page 26: Gas Piping

    • Leak test the appliance and its gas connection before operating the boiler. • Do not attempt a field conversion without a VST conversion kit. Use the VST conversion kit to convert from natural gas to propane or vice versa. Failure to do so may result in Check for gas leaks at all joints.

  • Page 27: Inlet Gas Pressure

    Inlet Gas Pressure • The following is a LP gas piping example for the single regulator system Inlet gas pressure should be measured by a licensed professional only. The boiler cannot function properly without Warning sufficient inlet gas pressure. • The boiler must be isolated from the gas supply piping system during any pressure testing of that system at test pressures equal to or more than 0.5 psig.
  • Page 28 Remove the boiler front cover by loosening the 2 Phillips When the boiler reaches its maximum firing rate, check the screws securing it to the case. inlet gas pressure reading on the manometer. The gas pressure must fall within the ranges specified in "Specifications" on page Tighten the inlet gas pressure screw.

  • Page 29: Installing A Vent

    CAN/CGA B149.1 Natural Gas and Propane avoid back drafting cold air through the boiler. VST recommends Installation Code in Canada, as well as all applicable local direct air vent installations when installing the boiler in your attic to building codes and regulations.
  • Page 30 IN S ID E D E T A IL C O R N E R F IX E D C L O S E D O P E R A B F IX E D C L O S E D O P E R A B VENT TERMINAL AIR SUPPLY INLET...
  • Page 31 VST warranty. If there is any question about the possibility of back-drafting in the installation location, use a direct venting system for the boiler.
  • Page 32 IN S ID E D E T A IL C O R N E R F IX E D C L O S E D O P E R A B F IX E D C L O S E D O P E R A B VENT TERMINAL AIR SUPPLY INLET...

  • Page 33: Vent Pipe Materials

    • Each 45° elbow equates • This boiler has a built-in control to limit the exhaust to 3 linear feet (0.9 m) temperature to 149°F (65°C). As a result, the VST boiler can of vent be vented with Schedule 40 PVC.

  • Page 34: Connecting The Vent Clip

    Connecting the Vent Clip Vent Termination • Air intake must be protected from any debris. To connect the exhaust vent firmly, must use the vent clip • When connecting to the air intake connector and exhaust included with boiler. Caution Caution flue connector, all connecting parts must be installed properly.
  • Page 35 Two-pipe sidewall venting Snorkel flue Internal view 10" (254 mm) min. Exhaust gas Intake air Schedule 40 PVC pipe 12" (300 mm) min. 10" min. External view • Maintain 12" (300 mm) min. (18" (450 mm) min. for Canada) clearance above highest-anticipated snow level. Maximum 12"...
  • Page 36 Non-concentric sidewall venting Two-pipe vertical venting 36" (900 mm) min. Exhaust gas Intake air 12" (300 mm) min. From any obstruction 10" (254 mm) min. (above, below, left, or right) • Maintain 12" (300 mm) min. (18" (450 mm) min. for Canada) •...

  • Page 37: Setting The Dip Switches

    Setting the DIP Switches The boiler has a DIP switch on the main circuit board(PCB) Set the DIP switch appropriately, depending on the installation environment. Switch Function ON: No temperature limit for exhaust gas Temperature limit switch for exhaust gas OFF: Temperature limit for exhaust gas ON: Enable EEP ROM data change EEP ROM data change switch...

  • Page 38: Connecting The Power Supply

    Connecting the Power Supply When connecting the power supply, follow these guidelines: Improperly connecting the power supply can result in electrical shock and electrocution. Follow all applicable • Do not connect the electric supply until all plumbing and gas electrical codes of the local authority having jurisdiction. In Warning piping is complete and the boiler has been filled with water.

  • Page 39: Installation Checklist

    Installation Checklist After the boiler installation, examine the following checklist. If you are not able to answer "Yes" to all of the items in the checklist, review the appropriate sections. To troubleshoot any operational problems, refer to "Troubleshooting" in the User's Manual. If there are additional questions or if you need assistance, contact technical support at 1-800-761-0053.
  • Page 40 Connecting the Domestic Water Supply Check Is the water supply pressure sufficient (greater than 40 psi)? Have you installed shut off valves on the inlet and outlet to facilitate cleaning of the inlet water filter? Have you bled the air out at each fixture? Have you checked each fixture to ensure hot water is being supplied? Have you cleaned the inlet water filter? If you installed a recirculation line, have you insulated the hot water pipes and the return line?
  • Page 41 Connecting the Condensate Drain Check Have you installed a condensate drain line from the boiler to a drain or laundry tub? Venting the boiler Check Have you vented the boiler with 2/3 in PVC, CPVC, Polypropylene, Type BH Special Gas Vent (ULC-S636) for Category IV boilers (Canada), or in accordance with all local codes and the guidelines in this manual? Have you ensured that ABS or PVC cellular core pipe has not been used as venting for the boiler? Is the vent sloped upward toward the vent termination at a rate of 1/4 in per foot (2% grade)?

  • Page 42: Operating The Boiler

    Operating the Boiler Turning the Boiler On or Off Setting the Space Heating Temperature To turn the Boiler on or off, press the button. If your household includes children, or elderly or disabled individuals, consider using a lower temperature setting. Danger To set the space heating water temperature.

  • Page 43: Setting The Dhw(Domestic Hot Water) Temperature

    Setting the DHW(Domestic Hot Viewing Basic Information Water) Temperature To turn the boiler on, press the button. Water above 120°F (50°C) can cause instant scalding, severe burns, or death. Caution To adjust the water temperature: Press the Mode button until the icon turns on.
  • Page 44 • • This is the mode for checking the previous error. This is the mode for checking the current error. • • H0 and the previous error (example: A6) will be displayed H2 and the current error (Example : A3) will be displayed repeatedly on the screen.
  • Page 45 • This is the mode for checking the current number of revolutions • This is the mode for checking the current exhaust gas of the fan. temperature. • H4 and the current number of revolutions of the fan (Example : •...
  • Page 46 • • This is the mode for checking the current ambient temperature. This is the mode for checking the hot water and heating modes. • • H8 and the current ambient temperature (example: 25) will be HA and the heating mode or the hot water mode (example: FF displayed repeatedly on the screen.

  • Page 47: Setting The Heat Load For The Outdoor Reset Control Mode

    Setting the Heat Load for The • When you set ON for C7 and press the MODE button, C8 and “1” will be displayed repeatedly. Outdoor Reset Control Mode • You can set a value from 0 to 6 using the buttons.
  • Page 48 • When “6”(custom mode) is set for C8, the user can set the temperature. • By pressing the MODE button, the user can enter modes such as C9, CA, Cb, and CC, and can set the temperature. • The content of each mode is as follows. •...

  • Page 49: Appendix

    Danger cause a gas leak, resulting in severe personal injury or death. This conversion kit shall be installed by a qualified service agency* in accordance with VST instructions and all applicable codes and requirements of the authority having jurisdiction. Warning...
  • Page 50 Once the front cover is removed, place it in a safe location to Once the gas orifice is exposed, remove the screw that hold prevent accidental damage. With the internal components the gas orifice in place and remove the gas orifice from its exposed, locate the gas connector and the gas valve.
  • Page 51 Replace the gas connector and the gas inlet pipe to its original Insert analyzer into the exhaust analyzer hole and measure the position and secure all connections. gas/air ratio (using combustion analyzer is recommended). High fire Low fire Turn on the gas and water supply to the boiler. Type Set the DIP switch to minimum heat capacity operation.
  • Page 52 Set the DIP switch to maximum heat capacity operation. Be sure to turn off the power before changing the DIP switch setting. Danger Notice For more information about setting the DIP switches, refer to "Setting the DIP Switches" on page 37. Fully open several hot water fixtures and if the CO value at high fire is not within 0.5% of the value listed in the table...

  • Page 53: Wiring Diagram

    Wiring Diagram 120VAC,5A White White White White Green Green Blue Blue SRW Red SRW Red Black Blue Blue Gray Gray Black Wiring Diagram...

  • Page 54: Component Assembly Diagrams And Parts Lists

    Component Assembly Diagrams and Parts Lists Case Parts (VRC) Installation Manual...
  • Page 55 PCB Fixing Bracket (VR) 3130755S Cord, Power (VRC, VRB, VH) 3080235 O-ring, Flue sealing 3040604 Filter, Air intake 2100376S Switch, Air pressure (VRC-80) 2100377S Switch, Air pressure (VRC-100) 2100363S Switch, Air pressure (S/P-199, C-120/140) 2081158S PCB, VRC-80 2081157S PCB, VRC-100...

  • Page 56: Flue Parts (Vrc)

    Flue Parts (VRC) Installation Manual...
  • Page 57 Part NO Part Name Part Name Part NO (Individual order not available) 2081069S Ignition Transformer (VR) 3100212 Ø4X12 Tapping screw 2081098S High limit switch (VR Hood) 3100053 Ø3.5X6 Tapping screw 3130834 Wire, High limit switch (VRC, VRB) 3100051 Ø4X10 Tapping screw 3080313 Cover, Spark plug (VR) 3100198...
  • Page 58 Water Parts (VRC Model) 500 501 502 512 Installation Manual...

  • Page 59: Water Parts (Vrc Model)

    Part NO Part Name Part Name Part NO (Individual order not available) 2080390S High limit switch (VR) 3080144 Back up ring (Φ18.6) 3030260S Elbow, Supply (VRC,VRB) 3080142 P16 Back Up Ring 2081174 Thermistor, Heating/Return (VRC, VRB) 3080140 P18 Back Up Ring 2091134S Pipe, HX connect (VRC, VRB) 3080141...

  • Page 60: Outdoor Temperature Sensor Installation

    Outdoor Temperature Sensor Installation Outdoor Temperature Sensor Outdoor Reset Control (Optional) (Available with Optional Outdoor Temperature Sensor) Outdoor Temperature Sensor Installation The outdoor reset control can be used in order to improve the • Separate the sensor body from the sensor cap. energy efficiency.
  • Page 61 Memo...
  • Page 62 Memo...
  • Page 63 Memo...
  • Page 64 VESTA. DS, Inc. 2711 LBJ Fwy Suite#320, Farmers branch, TX 75234 For Technical Support 1-800-761-0053 www.vestahws.com Ver. 2.0...

This manual is also suitable for:

Vrc-100Vrc-120Vrc-140

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