Viessmann ECV Series Quick guide

VITOGAS 050
Installation and
Service Instructions
Vitogas 050
ECV Series
Natural gas-/Propane-fired
atmospheric cast iron boiler
Rated input: 65 to 200 MBH
19 to 59 kW
Read and save these instructions
for future reference.
IMPORTANT
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
WARNING
Do not store or use gasoline or other flammable
liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
JDo not try to light any appliances.
JDo not touch any electrical switches, do not
use any phone in your building.
JImmediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
JIf you cannot reach your gas supplier, call the
fire department.
Installation and service must be performed by a
qualified installer, service agency or the gas
supplier.
Improper installation, adjustment, and/or operation
could cause carbon monoxide poisoning resulting in
injury or loss of life.
This product must be installed and serviced by a
professional service technician who is experienced
and qualified in hot water boiler installation and gas
combustion.
WARNING
5167 450 v1.4 07/2006
Please file in Service Binder

Safety, Installation and Warranty Requirements
2
Safety, Installation and Warranty Requirements
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the
instructions 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).
JLicensed 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”.
JProduct 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”.
JAdvice 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.
JContaminated 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 Supply”.
JCarbon 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 Supply” and “Venting
Connection”.
JFresh 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 Supply”.
JEquipment venting
Never operate boiler without an
installed venting system.Animproper
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.
JWarranty
Information contained in
this and related product
documentation must be
read and followed. Failure
to do so renders warranty
null and void.
Warning
This boiler requires fresh air for safe operation and must be installed with provisions for adequate combustion and ventilation
air (in accordance with local codes and regulations of authorities having jurisdiction).
Do not operate this boiler in areas with contaminated combustion air. High levels of contaminants such as dust, lint or
chemicals can be found at construction sites, home renovations, in garages, workshops, in dry cleaning/laundry facilities,
near swimming pools and in manufacturing facilities.
Contaminated combustion air will damage the boiler and may lead to substantial property damage, severe personal injury
and/or loss of life. Ensure boiler/burner is inspected and serviced by a qualified heating contractor at least once a year in
accordance with the Start-up/Service Instructions of the boiler.
5167 450 v1.4
Installers must follow local
regulations with respect to
installation of carbon monoxide
detectors. Follow manufacturer’s
maintenance schedule of boiler.
WARNING

Safety, Installation and Warranty Requirements
3
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/orloss of life.
Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
JFiberglass 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,
movethepersontoadustfree
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.
-Skin 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.
JHazardous materials
5167 450 v1.4
Inhalation of fiberglass wool and/or
ceramic fiber materials is a possible
cancer hazard. These materials can
also cause respiratory, skin and eye
irritation.
WARNING 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.
WARNING

Contents
4
Page
Safety Important Regulatory and Installation Requirements 7....
General Information About these Installation Instructions 8.................................
Product Information 9................................................................
Excerpt from our Warranty Terms 9......................................
Mechanical Room 10....................................................................
Set-up Standard Equipment 10.................................................................
Before Set-up 11............................................................................
Installation on Combustible Floor 11........................................
Combustion Air Supply 12..........................................................
Minimum Clearances 14..............................................................
Recommended minimum clearances for service 14............
Recommended minimum clearances to combustibles 14...
Closet and alcove installation 15...............................................
Flushing of Existing Piping 16.....................................................
Removal of Existing Boiler 17....................................................
Boiler Piping in a Heating/Cooling Application 17.................
Connections Venting Connection 18.................................................................
Installing Z-FLEX AL-29-4C special stainless
steel venting system 18
...............................................................
Maximum vent length 19.............................................................
Installing Z-FLEX pipe and fittings 20.......................................
Vent terminal connection 21.......................................................
Riser box 22.....................................................................................
Installation Checklist 23...............................................................
Low Water Cut-Off 24..................................................................
Initial System Fill 25.....................................................................
Pressure Relief Valve 25...............................................................
Gas Piping 26..................................................................................
Testing - Gas Pipe 26....................................................................
Gas pressure - Orifice Sizes 27..................................................
Manifold orifices - natural gas (1,000 Btu/cu. ft.) 27..........
Manifold orifices - propane (2,500 Btu/cu. ft.) 27................
Gas Burner Removal 28................................................................
Gas Input 29.....................................................................................
Main Burner 30................................................................................
Gas Burner Positioning 30............................................................
Electrical Connections 32.............................................................
Electronic Thermostat Connection 33......................................
5167 450 v1.4

Contents (continued)
5
Page
Initial Start-up and Service Initial Start-up 34............................................................................
Also pay attention to the following... 34.................................
Annual shut-down 35....................................................................
Advise the owner/operator 35....................................................
Service Schedule 36......................................................................
Service Procedure Overview 37.................................................
Service Procedure 38.....................................................................
Troubleshooting Guide 42...........................................................
Additional Information Technical Data 45..........................................................................
Wiring Diagrams 46.......................................................................
Parts List 48....................................................................................
Maintenance Record 50...............................................................
Lighting and Operating Instructions 51...................................
5167 450 v1.4

Safety
6
Important Regulatory and Installation Requirements
Codes
The installation of this unit shall be in
accordance with local codes or, in the
absence of local codes, use
CAN/CSA-B149.1 or .2 Installation
Codes for Gas Burning Appliances for
Canada. For U.S. installations use the
National Fuel Gas Code ANSI Z223.1.
Always use latest editions of codes.
In Canada 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 70.
The heating contractor must also
comply with the Standard for Controls
and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD-1 where
required by the authority having
jurisdiction.
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 System 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.
For installations in the Commonwealth of Massachusetts, the following local
requirements apply in addition to all other applicable NFPA requirements:
1) For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the
vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied.
1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector
and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply
with NFPA 720 (2005 Edition).
2. A carbon monoxide detector shall be located in the room that houses the appliance or equipment and shall:
a. Be powered by the same electrical circuit as the appliance or equipment such that only one service switch
services both the appliance and the carbon monoxide detector;
b. Have battery back-up power;
c. Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005 Edition); and
d. Have been approved and listed by a Nationally Recognized Testing Laboratory as recognized under 527
CMR.
3. A Product-approved vent terminal must be used, and if applicable, a Product-approved air intake must be used.
Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation
instructions shall remain with the appliance or equipment at the completion of the installation.
4. A metal or plastic identification plate shall be mounted at the exterior of the building, four feet directly above the
location of vent terminal. The plate shall be of sufficient size to be easily read from a distance of eight feet away,
and read ”Gas Vent Directly Below”.
Continued on following page.
5167 450 v1.4

Safety
7
Important Regulatory and Installation Requirements (continued)
For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment where the bottom of the
vent terminal and the air intake is installed above four feet above grade the following requirements must be satisfied:
1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector
and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply
with NFPA 720 (2005 Edition).
2. A carbon monoxide detector shall:
a. Be located in the room that houses the appliance or equipment;
b. Be either hard-wired or battery powered or both; and
c. Shall comply with NFPA 720 (2005 Edition).
3. A Product-approved vent terminal must be used, and if applicable, a Product-approved air intake must be used.
Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation
instructions shall remain with the appliance or equipment at the completion of the installation.
Mechanical room
Ensure the mechanical room complies
with the requirements of the Technical
Data Manual. In addition, see section
entitled Mechanical Room in this
manual.
Workingontheequipment
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 user serviceable parts on
the boiler, burners, or control.
Ensure main power supply to
equipment, the heating system, and all
external controls has been deactivated.
Close main gas supply valve. Take
precautions in all instances to avoid
accidental activation of power during
service work.
Technical literature
Literature for the Vitogas boiler:
- Technical Data Manual
- Installation and Service Instructions
- Operating Instructions
and User’s Information Manual
- Instructions of other Viessmann
products utilized and installed on the
Vitogas 050, ECV boiler
- Installation codes mentioned
in this manual
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.
This product comes with several
safety instruction labels attached.
Do not remove!
Contact Viessmann immediately if
replacement labels are required.
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.
5167 450 v1.4

General Information
8
About these Installation 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 potential hazards or
important product information.
Cautions draw your attention to the
presence of potential hazards or
important product information.
Helpful hints for installation, operation
or maintenance which pertain to the
product.
This symbol indicates that additional,
pertinent information is to be found in
column three.
This symbol indicates that other
instructions must be referenced.
5167 450 v1.4
Indicates an imminently hazardous
situation which, if not avoided, could
result in substantial product/property
damage, serious injury or loss of life.
WARNING
Indicates an imminently hazardous
situation which, if not avoided, may
result in product/property damage or
minor injury.
CAUTION
IMPORTANT

General Information
9
Product Information
The Vitogas 050, ECV boiler is for use in closed-loop forced circulation hot water
heating systems only. Boiler operation is limited by ASME Code to maximum water
pressure of 50 psig and maximum water temperature of 248°F/120°C. The vast
majority of applications operate below 30 psig and below 194°F/90°C.
The boiler model selected should be based on an accurate heat loss calculation of
the building.
Necessary permits from local authorities must be obtained before installing boiler.
Installation must be made in accordance with local ordinances which may differ
from the instructions in this manual.
Excerpt from our Warranty Terms
The Vitogas 050, ECV boiler is not
covered under any warranty terms for
damages resulting from the following:
Improper application and installation,
installation by unqualified personnel,
ignorance of instructions, improper
service and maintenance work,
incorrect replacement component
selection or application, incorrect field
wiring. Full warranty applies only when
boiler is installed and operated
according to instructions and used only
with the proper gas and the applicable
gas pressures.
Please read boiler warranty card.
Installation, service and maintenance
work must be done by qualified and
experienced technicians only.
Improper installation, service or
maintenance could create a hazard,
which could result in property
damage, severe personal injury and/or
loss of life.
WARNING
5167 450 v1.4
This boiler is not for use in systems
where water is constantly or
frequently replenished. Minerals such
as calcium in make-up water can
deposit on heat exchanger causing
overheating and eventual boiler
leakage. This type of failure is not
covered by warranty. Water must not
be drained from system for use by
cleaning personnel. Do not draw
water from boiler for any purpose.
CAUTION
The boiler warranty does not cover
leaks resulting from corrosion caused
by the use of underfloor plastic tubing
without an oxygen diffusion barrier.
Such systems must have the
non-oxygen diffusion barrier tubing
separated from the boiler with a heat
exchanger. Viessmann recommends
the use of underfloor plastic tubing
with an oxygen diffusion barrier.
CAUTION

Set-up
10
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 must be located in a heated indoor space, near a floor drain, and as close
as possible to the vertical chimney or vent.
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” starting on page 12 for further details regarding the
above.
Locate boiler on flooring capable of supporting the weight of the boiler filled with
water. Pour a concrete pad if necessary. Ensure that the boiler location does not
interfere with the proper circulation of combustion and ventilation air within the
mechanical room.
The maximum room temperature of the mechanical room where the boiler is located
must not exceed 104°F/40°C.
Standard Equipment
HWet base sectional cast iron heat
exchanger with stainless steel burners
HInduced draft blower and pressure
switch
HElectronic ignition
H24 VAC redundant seat gas valve
HBoiler fully insulated with 1½”/38 mm
fiberglass wrap-around blanket
HBoiler control panel with adjustable
operating limit (122°F - 194°F), fixed
high limit (248°F) and temperature
gage
HPump aquastat to turn pump on at
104°F / 40°C and off at 91°F / 33°.
HOne 120/24 VAC transformer
H30 psig pressure relief valve, pressure
gage and fittings
HOne cleaning brush
Boiler comes standard equipped with
30 psig ASME-rated pressure relief
valve. This 30 psig pressure relief valve
may be exchanged at the job site with a
50 psig ASME-rated pressure relief
valveonlybystrictlyobservingthe
minimum relief valve capacity in lb/h
marked on the nameplate. The
maximum allowable working pressure is
50 psig.
Be aware that best overall performance
is achieved when all components are
properly sized. Sizing of the required
circulation pump according to the pipe
layout and calculation of a proper
volume expansion tank is vital to obtain
the system’s peak performance.
5167 450 v1.4