Viessmann Vitogas 050 ECD Series Supplement

Warning: 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.
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
●Do not try to light any appliances.
●Do not touch any electrical switches, 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.
Installation and service must be performed by a
qualified installer, service agency or the gas supplier.
WARNING
Should overheating occur or the gas supply fail to shut
off, do not disconnect the electrical supply to the
pump. Instead, shut off the gas supply at a location
external to the appliance.
Contents: Page:
Technical Data..........................................................................3
Boiler handling – location..........................................................3
Flushing of existing piping ........................................................4
Vent damper installation ...........................................................4
Closet installation......................................................................5
Combustion air supply ..............................................................6
Installation on combustible floor ...............................................8
Boiler water piping ....................................................................8
Honeywell adjustable high limit aquastat..................................9
Circulating pump.......................................................................9
Initial system fill.......................................................................10
Boiler venting ..........................................................................11
Gas piping...............................................................................12
Gas pressure – orifice sizes ...................................................12
Main burner.............................................................................13
Blocked vent and flame roll-out switch ...................................14
Wiring......................................................................................14
Electronic thermostat ..............................................................15
System start-up.......................................................................15
Maintenance ...........................................................................15
Troubleshooting ......................................................................17
Lighting instructions ................................................................18
Wiring diagrams................................................................19, 20
Parts list ................................................................21, 22, 23, 24
Maintenance record ................................................................25
Installation / Service Manual
for use by heating contractor
Vitogas 050, ECD Series
Gas-fired, atmospheric cast iron boiler
65 to 200 MBH / 19 to 59 kW
IMPORTANT: READ AND SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE
5167 445 v1.1 03/2007

This “Attention” symbol is located beside all
important safety recommendations. Please follow
the instructions in detail to avoid property damage,
severe personal injury, or loss of life.
Warning:
Shut off all electrical power and turn off gas or oil supply
to boiler before performing any service or maintenance
on the boiler, burner, or control. Failure to heed this
warning could result in electrical shock, serious
personal injury or loss of life.
Warning:
Never operate the boiler without an adequate supply of
fresh combustion air. This boiler needs fresh air for safe
operation and must be installed so there are provisions
for adequate combustion and ventilation air. All
combustion and ventilation air must be supplied from
the outside. Failure to heed this warning can cause
severe personal injury or loss of life.
Warning:
Never operate the boiler without an installed venting
system which safely vents all products of combustion to
the outdoors. The vent system must comply with all
applicable local and/or national codes.
Improper, incomplete, obstructed, or deteriorated vent
systems can present a serious risk of flue gases leaking
into living space which could cause carbon monoxide
poisoning. Failure to heed this warning can cause
severe personal injury or loss of life.
Warning:
Before each heating season begins, have the following
service and maintenance done by a professional service
technician:
1) Boiler heat exchanger inspected and cleaned.
2) Vent system inspected for deterioration, leaks,
corrosion, proper draft, and proper operation. Check
vent system for compliance with local and national
code requirements. Repair or replace as required.
3) Burner inspected and if necessary cleaned to
ensure proper combustion and operation. Check for
adequate supply of fresh outside combustion and
ventilation air.
Neglecting to perform necessary maintenance can cause
unsafe operation.
Do not store chemicals containing chlorine or other
corrosive materials near the boiler, such as bleach,
cleaning solvents, detergents, acids, hair spray, spray
cans, paint thinners, paint, water softener salt,
refrigerants.
Warning:
Installers must follow local regulations with respect to
installation of carbon monoxide detectors. Follow
manufacturer’s maintenance schedule of boiler. Attention:
The preferred and safest location for the ECD Series
boiler is in a dedicated mechanical room with fresh
combustion air intake and ventilation openings made
directly to the outside.
Do not use this boiler if any part has been under water.
Immediately call a qualified service technician to inspect
the boiler and to replace any part of the control system
and any gas control which has been under water.
Warning:
Improper installation, adjustment, service, or
maintenance can cause flue products to flow into living
space. Flue products contain poisonous carbon
monoxide gas which can cause nausea or asphyxiation
resulting in severe personal injury or loss of life.
Warning:
If flame roll-out or blocked vent switch trips during start-
up or normal operation, it indicates a hazardous
condition to be corrected immediately. Do not attempt to
put boiler in operation. Immediately contact a qualified
service professional to locate source of problem and
correct. Failure to heed this warning could result in
property damage, severe personal injury, or loss of life.
Warning:
The installation, adjustment, service, and maintenance
of this boiler must be done by a licensed professional
service technician who is qualified and experienced in
the installation, service, and maintenance of gas-fired
hot water boilers. There are no user serviceable parts on
the boiler, burner, or control. Failure to heed this
warning can cause property damage, severe personal
injury, or loss of life.
2

Before operating this boiler/burner unit, make sure you fully
understand its method of operation. Your heating contractor
should always perform the initial start-up and explain the
system and the need for regular inspection and maintenance.
The installation must conform to the requirements of the
authority having jurisdiction or, in the absence of such
requirements, to the National Fuel Gas Code, ANSI Z223.1
(latest edition). In Canada follow CAN/CSA–B149.1 or .2
Installation Codes (latest edition).
These instructions must be placed in an envelope and affixed
to the boiler.
Boiler handling
The boiler is shipped on a wooden pallet in a cardboard crate.
Crate and wooden pallet must be removed. Vent damper is
shipped separately.
Boiler location – Minimum clearances to combustibles
(all measurements from boiler enclosure)
Left side: 150 mm (6˝)
Right side: 25 mm (1˝)
Front: 150 mm (6˝)
Top: 450 mm (18˝)
Rear: 25 mm (1˝)
Floor: Non-combustible
Flue: 150 mm (6˝).
Above clearances apply to all ECD boilers. 3
* With vent damper and intermittent pilot ignition All sizes available with propane gas. Electrical requirement
kW figures are approximate For net IBR rating divide output by 1.15. 120V, 60Hz, less than 12A
Model CSA input DOE heating Width Vent Gas Water Cast Burners Water Weight AFUE* Steady
capacity “A”Conn. Conn. Conn. Iron Content State
CGA output “BØ” Sections Efficiency
ECD-65 65,000 Btu/h 53,950 Btu/h 350 mm 5˝1⁄2˝11⁄4˝3 2 9.9 ltr 106 kg 83.7% 83%
19 kW 16 kW 14˝2.6 USG 233lbs
ECD-80 80,000 Btu/h 66,400 Btu/h 350 mm 5˝1⁄2˝11⁄4˝3 2 9.9 ltr 106 kg 83.5% 83%
23 kW 19 kW 14˝2.6 USG 233 lbs
ECD-100 100,000 Btu/h 83,000 Btu/h 450 mm 6˝1⁄2˝11⁄4˝4 3 13.2 ltr 130 kg 83.5% 83%
29 kW 24 kW 173⁄4˝3.5 USG 285 lbs
ECD-115 115,000 Btu/h 95,450 Btu/h 450 mm 6˝1⁄2˝11⁄4˝4 3 13.2 ltr 130 kg 83.5% 83%
34 kW 28 kW 173⁄4˝3.5 USG 285 lbs
ECD-140 140,000 Btu/h 116,200 Btu/h 550 mm 7˝1⁄2˝11⁄4˝5 4 16.5 ltr 157 kg 83.5% 83%
41 kW 34 kW 213⁄4˝4.3 USG 345 lbs
ECD-155 155,000 Btu/h 128,500 Btu/h 550 mm 7˝1⁄2˝11⁄4˝5 4 16.5 ltr 157 kg 83.4% 83%
45 kW 38 kW 213⁄4˝4.3 USG 345 lbs
ECD-180 180,000 Btu/h 149,400 Btu/h 654 mm 7˝1⁄2˝11⁄4˝6 5 26.8 ltr 192 kg 83.2% 83%
52 kW 44 kW 253⁄4˝7.1 USG 423 lbs
ECD-200 200,000 Btu/h 166,000 Btu/h 654 mm 7˝1⁄2˝11⁄4˝6 5 26.8 ltr 192 kg 83.0% 83%
58 kW 48 kW 253⁄4˝7.1 USG 423 lbs
Vitogas 050, ECD Series Technical Data
Cut-away view
(left side) Left view Front view
A
Draft hood
Boiler well for
capillaries
Transformer
Ignition control
24V gas valve
Burner manifold
Vent
connection
Boiler supply
water 11⁄4˝
(water flows out)
120V power in
120V 4A max.
output to pump
24V vent damper
Gas connection
Boiler return
water 11⁄4˝
(water flows in)
24V thermostat
19.75˝(502)
17.50˝(445)
11.00˝(279)
12.25˝(310)
26.00˝(660)
ECD-180/200 45.75˝(1160mm)
ECD-65 to 155 41.75˝(1060mm)
2.82˝(72)
B
Boiler electrical requirements are 120V, 60 Hz, less than 12A
Max. pump amperage is 4A. Use field supplied relay for pumps over 4A.
2.5˝(64)

Recommended minimum service clearances:
Left side: 610 mm (24˝)
Right side: 610 mm (24˝)
Front: 1220 mm (48˝)
Top: 610 mm (24˝)
Rear: 610 mm (24˝)
Recommendation
If boiler is located in a confined space, install main gas shut-off
valve (gas cock) and main power supply switch in easily
accessible location outside the confined space.
The boiler model selected should be based on an accurate
heat loss calculation of the building.
General information
Please read and observe the following instructions carefully before
installing the boiler. Install boiler according to these instructions.
Installation, service and maintenance work must be done by
qualified and experienced technicians only. Improper installation,
service or maintenance could create a hazard, resulting in
property damage, severe personal injury, or loss of life.
The ECD Series 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. The vast majority
of applications operate below 30 psig and below 194°F.
Standard equipment on the ECD boiler includes a 30 psig
relief valve and adjustable aquastat with maximum setting of
194°F. An alternate construction is available for operation
between 194°F and 248°F. Consult a Viessmann
representative for alternate construction before ordering boiler.
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.
Flushing of existing piping
Before boiler is connected to a piping/heating system which has
previously been in service (the ECD is a replacement boiler),
the piping system should be flushed thoroughly with water in
order to remove sludge or other contaminants, especially in
large piping systems such as old gravity pipe systems. Flush
from the top of the system with city water pressure. Failure to
flush out system can lead to deposits in boiler resulting in boiler
failure. This type of failure is not covered under warranty.
Boiler foundation
Provide a solid, level foundation, capable of supporting the weight
of the boiler filled with water, and extending at least 1˝past the
jacket on all sides. Pour a concrete foundation if necessary. The
boiler must be installed in an indoor heated space.
The boiler should be located near a floor drain.
Do not install boilers on carpeting. Install on non-combustible floor.
If the boiler is to be installed on combustible floors or on a
mezzanine, it should be equipped with a special base pan.
Please reference the Viessmann Price List.
Typical boiler piping is shown in Fig. A.
Vent damper installation
Boilers are sold with a vent damper, packaged separately. The
vent damper must be installed on the boiler to meet minimum
federal efficiency standards. If possible, install vent damper at
the top of the draft hood. Otherwise install vent damper as
close to the boiler as possible.
The vent damper must be field installed on the boiler. Read the
vent damper manufacturer’s instructions before installing the
vent damper. Vent damper must be installed as close as
possible to the boiler flue outlet.
The closing and opening action of the vent damper is driven by
a motor. Spring action is not used to move the vent damper
blade. Do not force vent damper blade by hand. Forcing the
vent damper blade by hand will damage the motor. To observe
the vent damper blade move, turn thermostat up and down
after the vent damper has been installed. Vent damper blade
must be in open position when burner is firing.
The vent damper must be installed according to Fig. B. The
vent damper may be placed directly on top of the ECD boiler.
Ensure that damper blade rotates freely and is not obstructed
in any way. Read and save the vent damper manufacturer’s
instructions packaged with the vent damper.
After vent damper has been installed on boiler connect the
vent damper cable using the following instructions.
1. Remove ECD front panel.
2. Route the end of the vent damper cable with the Molex
connector through the plastic strain relief on the ECD left
side panel.
3. Attach Molex connector to vent damper motor using the
metallic strain relief on the vent damper motor to secure
the cable.
4. Unplug the two 3-pole #41 plugs inside the boiler and
attach them to the 6-pole plug from the vent damper (see
Figs. B, C and D).
Fig. A
Typical hot water piping system
Return
ECD boiler
Supply
Strainer
location
Bypass
City
water Backflow
preventer
Fill valve
Air vent
Globe
valve Valve
Circulator Air purger
Gas pipe
Ball
valve
Diaphragm
expansion
tank
Approved gas
shut-off valve
Vent
connection
Pressure
gage
Drain
valve
Floor
drain
Level
concrete
floor pad Air flow
30 psig
pressure
relief
valve
Low
water
cut-off
location

The cable must not touch the vent pipe, and any excess cable
must be suitably supported with cable clamps screwed to the
side of the boiler if required. Refer to wiring diagrams. Do not
attach vent damper cable to water or vent pipes.
Damper must be in the open position when main burners are
operating. The damper position indicator (arrow) must be in a
visible location following boiler installation.
The venting system must be arranged so that only the ECD
boiler is served by the vent damper. Maintain a minimum
clearance of 6˝between the vent damper and combustible
construction. There must be provision for service access to the
vent damper after the installation. Use sheet metal screws
(e.g. #8 x 1⁄2˝) to fasten vent damper to boiler and vent pipe.
Thermostat anticipator should be set at 0.8A.
There are no serviceable parts on the vent damper. Defective
vent dampers must be replaced.
If the side wall vent system is used, the vent damper must
not be installed. Refer to separate side wall vent system
instructions for series boiler. The side wall vent system
must be purchased separately from the ECD boiler.
Sequence of operation with vent damper:
1. Thermostat calls for heat.
2. Vent damper blade opens.
3. Pilot sparks and ignites.
4. Pilot is proven and main valve is energized.
5. Main burner and pilot will continue to operate until
thermostat is satisfied. Burner may turn off and on in
response to the adjustable high limit aquastat (SHL1)
setting during a call for heat.
If the vent damper becomes defective:
1. Follow the vent damper manufacturer’s instructions to
leave the vent damper in the “Service”or “Hold Open
Damper”(Effikal) mode by using the service switch on the
damper motor. Vent damper blade should stay open and
boiler should operate normally.
2. If the procedure in #1 does not work, remove vent
damper, install transitional piece of vent pipe and
disconnect 6-pole plug from 3-pole plugs. Connect the 3-
pole plugs together as shown in Fig. D. Refer to wiring
diagrams. Boiler will operate without vent damper.
Closet/alcove installation
Models ECD- (65-155) are approved for closet installation with
the clearances shown in Fig.1. Models ECD- (180, 200) are
approved for alcove installation with the clearances shown in
Figs. E and F. Do not use Models ECD- (180, 200) in closet
installations.
Please note that the minimum clearance to combustibles listed
will apply when the boiler is located in a room large in
comparison to the size of the equipment. Please see the
Uniform Mechanical Code for definition. If the boiler is installed
in a space that does not fit the definition of a “room large in
comparison with the size of the equipment”, then it is
considered a closet or an alcove installation and the closet or
alcove installation instructions apply.
5
Fig. B
Vent damper harness installation
Molex
connector
“A”
Effikal vent
damper only
Plastic
strain
relief
Dim “A”
ECD-65, -80 47.75˝
ECD-100, -115 48.25˝
ECD-140, -155 48.75˝
ECD-180, -200 52.75˝
Fig. C
Plug connection with vent damper (or power vent)
Fig. D
Plug connection without vent damper
3-pole
burner plug
3-pole
control plug
6-pole
vent damper
plug
41
41 41
41
41
3-pole
burner plug 3-pole control plug
Fig. E
Alcove installation for ECD- (180, 200) boiler
1˝
6˝
Top view
1˝
Top clearance
18˝