Viessmann VITOROND 100 VR1 Series Kurzanleitung

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IMPORTANT

VITOROND 100

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

5671 44 v1. 8/2 12

Safety, Installation and Warranty Requirements

Safety, Installation and arranty Requirements

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).

HLicensed professional heating

contractor

The installation, adjustment, service,

and maintenance of this equipment

must be performed by a licensed

professional heating contractor.

Please see section

entitled “Important

Regulatory and

Installation

Requirements.”

HProduct documentation

Read all applicable documentation

before commencing installation. Store

documentation near boiler in a readily

accessible location for reference in

the future by service personnel.

For a listing of

applicable literature,

please see section

entitled “Important

Regulatory and

Installation Requirements.”

HAdvice to owner

Once the installation work is

complete, the heating contractor must

familiarize the system

operator/ultimate owner with all

equipment, as well as safety

precautions/requirements, shut-down

procedure, and the need for

professional service annually before

the heating season begins.

HContaminated air

Air contaminated by chemicals can

cause by-products in the combustion

process which are poisonous to

inhabitants and destructive to

Viessmann equipment.

For a listing of

chemicals which cannot

be stored in or near the

boiler room, please see

section entitled

“Combustion Air upply.”

HCarbon monoxide

Improper installation, adjustment,

service and/or maintenance can cause

flue products to flow into living space.

Flue products contain poisonous

carbon monoxide gas.

For information

pertaining to the proper

installation, adjustment,

service and maintenance

of this equipment to

avoid formation of carbon monoxide,

please see sections entitled

“Combustion Air upply” and “Venting

Connection.”

HFresh air

This equipment requires fresh air for

safe operation and must be installed

ensuring provisions for adequate

combustion and ventilation air exist.

For information

pertaining to the fresh

air requirements of this

product, please see

section entitled

“Combustion Air upply.”

HEquipment venting

Never operate boiler without an

installed venting system. An improper

venting system can cause carbon

monoxide poisoning.

For information

pertaining to venting

and chimney

requirements, please

see section entitled “Venting

Connection.” All products of

combustion must be safely vented to

the outdoors.

Harranty

Information contained in

this and related product

documentation must be

read and followed. Failure

to do so renders warranty

null and void.

5671 44 v1.

Installers must follow local

regulations with respect to

installation of carbon monoxide

detectors. Follow manufacturer’s

maintenance schedule of boiler.

ARNING

Safety, Installation and Warranty Requirements

Safety, Installation and arranty Requirements (continued)

HFiberglass wool and ceramic fiber

materials

The state of California has listed the

airborne fibers of these materials as a

possible cancer hazard through

inhalation. When handling these

materials, special care must be applied.

Suppliers of ceramic fiber products

recommend the following first aid

measures:

-Respiratory tract (nose and throat)

irritation

If respiratory tract irritation develops,

move the person to a dust free

location.

-Eye irritation

If eyes become irritated, flush

immediately with large amounts of

lukewarm water for at least 15

minutes. Eyelids should be held away

from the eyeball to ensure thorough

rinsing. Do not rub eyes.

-kin irritation

If skin becomes irritated, remove

soiled clothing. Do not rub or scratch

exposed skin. Wash area of contact

thoroughly with soap and water.

Using a skin cream or lotion after

washing may be helpful.

-Gastrointestinal irritation

If gastrointestinal tract irritation

develops, move the person to a dust

free environment.

Suppliers of fiberglass wool products

recommend the following precautions

be taken when handling these materials:

Precautionary measures

-Avoid breathing fiberglass dust and

contact with skin and eyes.

- Use NIOSH approved dust/mist

respirator.

- Wear long-sleeved, loose fitting

clothing, gloves and eye protection.

- Wash work clothes separately from

other clothing. Rinse washer

thoroughly.

- Operations such as sawing, blowing,

tearout and spraying may generate

airborne fiber concentration requiring

additional protection.

First aid measures

-If eye contact occurs, flush eyes with

water to remove dust. If symptoms

persist, seek medical attention.

- If skin contact occurs, wash affected

areas gently with soap and warm

water after handling.

HHazardous materials

5671 44 v1.

Inhalation of fiberglass wool and/or

ceramic fiber materials is a possible

cancer hazard. These materials can

also cause respiratory, skin and eye

irritation.

ARNING Appliance materials of construction,

products of combustion and the fuel

contain alumina, silica, heavy metals,

carbon monoxide, nitrogen oxides,

aldehydes and/or other toxic or

harmful substances which can cause

serious injury or loss of life and which

are known to the State of California

to cause cancer, birth defects and

other reproductive harm. Always use

proper safety clothing, respirators and

equipment when servicing or working

nearby the appliance.

ARNING

Contents

Page

Safety Important Regulatory, Installation Requirements 7...........

General Information About these Instructions 8.......................................................

Product Information 9................................................................

Mechanical Room 1....................................................................

Fresh Air Combustion Air Supply 11..........................................................

Set-up Product Delivery 13.......................................................................

Unpacking Instructions 13..........................................................

Minimum Clearances to Combustibles 14..............................

Recommended Minimum

Clearances for Service 15...........................................................

Boiler Set-up and Location 15....................................................

Insulation Installation 16...............................................................

Combustion Chamber Insert 19..................................................

Connections Venting Connection 2................................................................

ater Side Connections (with Aquastat Control) 22..........

Safety Connections (with Aquastat Control) 23...................

Install safety devices on boiler 23.............................................

ater Side Connections (with Vitotronic Control) 25........

Safety Connections (with Vitotronic Control) 26..................

Install safety devices on boiler 26.............................................

Pressure Testing 28......................................................................

5671 44 v1.

Contents (continued)

Burner (Beckett) Burner Installation 29....................................................................

Burner Information 29...................................................................

Burner Set-up (Beckett) 3..........................................................

Burner mounting 3........................................................................

Oil piping 31.....................................................................................

Electrical connections (with Aquastat Control) 32...............

Wiring diagram (with Aquastat Control for NX

burner for Vitorond 1 , VR1-4 ) 34.......................................

Wiring diagram (Vitorond 1 , VR1-4 , -5 and -63

with Beckett burner, GeniSys control and

Honeywell Aquastat) 35...............................................................

Electrical connections (with Vitotronic Control) 36..............

Installation of Vitotronic control 37..........................................

Boiler coding card 39.....................................................................

Pump junction box (with Vitotronic Control) 4....................

Wiring diagram (with Vitotronic Control) 42...........................

Wiring diagram (Vitorond 1 ,with Beckett burner,

GeniSys control and Vitotronic Control) 43............................

Burner (Riello) Burner Installation 44....................................................................

Burner Information 44...................................................................

Burner Set-up (Riello) 45...............................................................

Burner mounting 45........................................................................

Oil piping 46.....................................................................................

Electrical connections (with Aquastat Control) 47...............

Wiring harness connection to Honeywell high limit

and Riello burner sub-base (with Aquastat Control) 48.......

Wiring diagram (with Aquastat Control) 49............................

Installation of Vitotronic control 5..........................................

Electrical connections (with Vitotronic Control) 52..............

Wiring diagram (with Vitotronic Control) 55...........................

Boiler coding card 55.....................................................................

5671 44 v1.

Contents

Page

Initial Start-up Initial Start-up 57...........................................................................

Burner calibration 58......................................................................

Beckett burner calibration 59......................................................

Riello burner calibration 6..........................................................

Barometric draft regulator 6......................................................

Examples Installation Examples 61..............................................................

Installation Examples (Aquastat) 62.........................................

Special Applications (Aquastat) 63..........................................

Boiler in heating/cooling application 63....................................

Low water cut-off 63....................................................................

Installation Examples (Vitotronic) 64.......................................

Special Applications (Vitotronic) 66.........................................

Boiler in heating/cooling application 66....................................

Low water cut-off 66....................................................................

Service Service Procedure Overview 67................................................

Necessary Tools 68.......................................................................

Service Procedure 68.....................................................................

Additional Information Parts List 73....................................................................................

Maintenance Record ...............................................................

NO TAG

5671 44 v1.

Safety

Important Regulatory and Installation Requirements

Take note of all symbols and notations intended to draw attention to potential hazards or important product

information. These include ” ARNING,” ”CAUTION,” and ”IMPORTANT.” See page 8 for details.

Codes

The installation of this unit shall be in

accordance with local codes. In the

absence of local codes, use:

HCSA B-139 for oil installations in

Canada

HNFPA 31 Standard for the Installation

of Oil Burning Equipment in the US

Always use latest editions of codes.

All electrical wiring is to be done in

accordance with the latest edition of

CSA C22.1 Part 1 and/or local codes. In

the U.S. use the National Electrical

Code ANSI/NFPA 7 . The heating

contractor must also conform to the

Standard for Controls and Safety

Devices for Automatically Fired Boilers,

ANSI/ASME CSD-1 where required by

the authority having jurisdiction.

Mechanical room

Ensure the mechanical room complies

with the requirements listed in this

manual. See section entitled Mechanical

Room on page 1 .

Please carefully read this manual prior

to attempting installation. Any

warranty is null and void if these

instructions are not followed.

For information regarding other

Viessmann ystem Technology

componentry, please reference

documentation of the respective

product.

We offer frequent installation and

service seminars to familiarize our

partners with our products. Please

inquire.

orking on the equipment

The installation, adjustment, service,

and maintenance of this boiler must be

done by a licensed professional heating

contractor who is qualified and

experienced in the installation, service,

and maintenance of hot water boilers.

There are no end user serviceable parts

on the boiler, burner, or control.

Ensure main power supply to

equipment, the heating system, and all

external controls has been deactivated.

Close main oil supply valve. Take

precautions in both instances to avoid

accidental activation of power during

service work.

The completeness and functionality of

field supplied electrical controls and

components must be verified by the

heating contractor. These include

low-water cut-offs, flow switches (if

used), staging controls, pumps,

motorized valves, air vents,

thermostats, etc.

Technical literature

Literature applicable to all aspects of

the Vitorond 1 :

- Installation, Service and Operating

Instructions

- Installation codes mentioned

in this manual

Leave all literature at the installation

site and advise the system

operator/ultimate owner where the

literature can be found. Contact

Viessmann for additional copies.

This product comes with several

safety instruction labels attached.

Do not remove!

Contact Viessmann immediately if

replacement labels are required.

5671 44 v1.

General Information

About these Instructions

Symbols and flag words used in these instructions

The following symbols and flag words are utilized in these

Installation Instructions:

Indicates an imminently hazardous

situation which, if not avoided, could

result in death, serious injury or

substantial product/property damage.

Indicates an imminently hazardous

situation which, if not avoided, may

result in minor injury or

product/property damage.

Helpful hints for installation, operation

or maintenance which pertain to the

product.

Helpful hints for installation, operation

or maintenance which pertain to the

product.

This symbol indicates that additional

information is written in column 3.

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.

5671 44 v1.

arnings draw your attention to the

presence of potential hazards or

important product information.

ARNING

Cautions draw your attention to the

presence of potential hazards or

important product information.

CAUTION

IMPORTANT

5671 44 v1.

General Information

Product Information

Sectional gray cast-iron boiler with triple-pass design.

For operation in closed loop, forced circulation hot water heating systems. This

boiler does not require a flow switch.

The boiler model size selected should be based on an accurate heat loss calculation

of the building. The boiler selected must be compatible with the connected

radiation.

Maximum adjustable high limit setting (Aquastat): 24 °F / 11 °C

.......................

Maximum allowable working pressure

: 45 psig / 3 bar........................................

Fuel: #2 fuel oil.............................................................................................................

Cast iron sections are A ME stamped for 58 psig / 4 bar and maximum allowable

temperature of 250°F / 121°C.

Supply/return bypass for large water content systems

For boilers connected to large water content systems (typically systems with

volume > 1 USG / 3.8 ltr for every 13 Btu/h of boiler input), such as a previous

gravity system with large free-standing radiators, a bypass line from the supply pipe

to the return pipe must be used to avoid flue gas condensation in the heat

exchanger and the vent system. A bypass can be installed on any system as a

preventative measure. Viessmann strongly recommends installing a bypass pipe on

all cast iron boilers.

IMPORTANT

This boiler is equipped with an outdoor reset module that saves energy by reducing

the boiler water temperature as the heating load decreases. This feature is equipped

with an override which is provided primarily to permit the use of an external energy

management system that serves the same function.

THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE

FOLLO ING CONDITIONS IS TRUE:

- an external energy management system is installed that reduces the boiler water

temperature as the heating load decreases.

- This boiler is not used for any space heating.

- This boiler is part of a modular or multiple boiler system having a total input of

300,000 BTU/hr or greater.

- This boiler is equipped with a tankless coil.

5671 44 v1.

General Information

Mechanical Room

During the early stages of new home design, we recommend that proper

consideration be given to constructing a separate mechanical room dedicated to gas

or oil fired equipment including domestic hot water storage tanks.

The boiler should be located in a heated indoor space, near a floor drain, and as

close as possible to the vertical chimney or vent.

Install the boiler on a concrete foundation if:

- the floor may be flooded,

- the floor is not level,

- the boiler will be installed in a residential garage (in this case ensure that the

burner is raised at least 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. In addition, do not use exhaust fans in the boiler room

and do not install the boiler in rooms with refrigeration equipment. This equipment

requires uncontaminated outside air for safe operation - do not install where

chemicals are stored or in a room with negative pressure. See section entitled

“Combustion Air Supply” for further details regarding the above.

Locate boiler on flooring capable of supporting the weight of the boiler filled with

water. Ensure that the boiler location does not interfere with the proper circulation

of combustion and ventilation air within the mechanical room.

5671 44 v1.

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