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

Viessmann vitorond 100 vr1 series oil-fired boiler
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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
5285 706 v1.2 10/2004
IMPORTANT
Read and save these instructions
for future reference.

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  • 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. 5285 706 v1.2 10/2004...
  • 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).

  • Page 4: Table Of Contents

    ....Wiring Diagram (for Vitorond 100, VR1-50, 63) ... . .
  • Page 5 Page Initial Start-up and Service Initial Start-up ................Burner calibration .

  • 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...

  • Page 12: Product Delivery

    Set-up Product Delivery Vitorond boilers size VR1-40 to VR1-63 are shipped in a crate with separate boiler jacketry. Product delivery Ensure each of the following has been delivered: H Crate with boiler casting H Crate with insulation jacket H Carton with burner (shipped separately) H Carton with standard installation equipment...

  • 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: Boiler Set-Up And Location

    Set-up Boiler Set-up and Location IMPORTANT For important information concerning boiler placement and set-up, refer to the section entitled “Mechanical Room” on page 9. The boiler should be located as close to the chimney as possible. Set-up/locate boiler with slight incline towards the rear of the boiler using leveling bolts CAUTION...

  • Page 15: Insulation Installation

    Set-up Insulation Installation All parts necessary to install the insulation are shipped with the carton containing the insulation. 1. Install support brackets as shown. 2. Wrap insulation blanket around cast iron block. 3. Secure insulation blanket with supplied spring clips. Cutout facing to the front...
  • Page 16 Set-up Insulation Installation (continued) 4. Position left side panel onto support brackets. 5. Line up bottom bracket of side panel with notch in casting leg. 6. Once side panel is in place, bend down one part of bracket using pliers, as shown.
  • Page 17 Set-up Insulation Installation (continued) 7. Install rear insulation blanket to cast iron block. 8. Install rear panel. Black side facing outward...
  • Page 18 Set-up Insulation Installation (continued) 9. Install right side panel to support brackets. Ensure top of side panel fits over top of rear panel. 10. Line up bottom bracket of side panel with notch in casting leg. 11. Once side panel is in place, bend down one part of bracket using pliers, as shown.
  • Page 19 Set-up Insulation Installation (continued) 12. Install top panel onto support 3.9 x 9.5 brackets. 13. Secure top panel with sheet metal screws. 14. Install front panel to front of boiler. 15. Secure front panel in place by attaching it to side panels as shown.

  • 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 Connections Venting Connection (continued) Installation IMPORTANT Use approved vent material only. When installing piping or venting, or 1. Install the venting so as to achieve while insulating overhead pipes, do not the shortest possible way with stand on top panel of boiler. Advise minimum elbows.

  • Page 22: 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 23: 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 24: 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 25: 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 26: 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 27: 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 29 or 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 28: 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-BurningEquipment.

  • Page 29: Wiring Diagram (For Vitorond 100, Vr1-40)

    Burner Wiring Diagram (for NX Burner for Vitorond 100, VR1-40) 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 30: Wiring Diagram (For Vitorond 100, Vr1-50, 63)

    Burner Wiring Diagram (for AFG Burner for Vitorond 100, VR1-50, -60) 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: 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 32 Connections Installation Examples (continued) Heating circuit Spring-loaded flow check valve Circulation pump Automatic air vent Pressure relief valve High limit control Expansion tank...

  • Page 33: 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 34: Initial Start-Up

    Initial Start-up and Service 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 35: Burner Calibration

    Initial Start-up and Service Initial Start-Up (continued) Burner calibration Instructions supplied with Beckett 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 36: Barometric Draft Regulator

    Initial Start-up and Service Initial Start-Up (continued) Burner calibration (continued) Boiler model Model No. VR1-40 VR1-50 VR1-63 Burner model Beckett NX-VI 102 AFG-VI 201 AFG-VI 201 Fuel type No. 2 fuel oil Pump pressure psig 1344 1207 1207 Danfoss n.a. 1.10x60°AS n.a.

  • Page 37: Service Procedure Overview

    Initial Start-up and Service Service Procedure Overview Service steps 1. Shut down heating system Page 38 ..........................2.

  • Page 38: Shut Down Heating System

    Initial Start-up and 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 39: Clean Heat Exchanger And Flue Pipe

    Initial Start-up and Service Service Procedure (continued) 3. 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 40: Close Combustion Chamber Door

    Initial Start-up and Service Service Procedure (continued) 5. Close combustion chamber door 1. Reinsert flue gas turbulators 2. 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 41: Ensure Proper Operation Of Expansion Tank, Low Water Cut-Off (If Applicable) And Pumps

    Initial Start-up and 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.

  • Page 42: Calibrate The Burner

    Initial Start-up and Service Service Procedure (continued) 11. Calibrate the burner For burner technical information see technical data table on page 36. " Instructions supplied with Beckett 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 43: Technical Data

    Aditional Information Technical Data Boiler model Model No. VR1-40 VR1-50 VR1-63 CSA input CSA output Net I=B=R rating A.F.U.E. 86.9 86.9 86.9 Overall dimensions (incl. burner) Total depth inches 1092 1219 Total width inches Total height inches 1016 1016 1016 Total weight (boiler with insulation and burner) Vent pipe diameter...

  • 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

    Additional Information Parts List (continued) Other parts (not illustrated) Parts List 023 Combustion chamber door 062 Temperature and pressure gage 019 Touch-up spray paint Vitotec silver refractory 101 Aquastat, L8148a1124 020 Touch-up paint stick Vitotec silver 024 Combustion chamber door 102 Sensor well 041 Cleaning brush handle 800 mm, 025 Hinge bracket...
  • Page 46 Additional Information Notes...

  • 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.

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