Viessmann VITOROND 100 VR1 40 Quick guide

Please file in Service Binder
5583 572 - 07 01/2024
Installation and
Service Instructions
for use by heating contractor
VITOROND
r
100
Vitorond 100, VR1
Models 40 to 63, 161 to 245
Oil-Fired Boiler
Heating input 161 to 245 MBH
47 to 72 kW
H
Read and save these instructions
for future reference.
Product may not be exactly as shown
IMPORTANT

Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
5583 572 - 07
2
Important Safety, Installation, Regulatory and Warranty Requirements
Safety
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).
WARNING
Installers must follow local regulations with respect
to installation of carbon monoxide detectors.
Follow the Viessmann maintenance schedule of the
boiler in the “Service Instructions” manual.
gCarbon monoxide
Improper installation, adjustment, service and/or
maintenance can cause flue products to flow into
living space. Flue products contain poisonous carbon
monoxide gas.
uFor information pertaining to the
proper installation, adjustment, service
and maintenance of this equipment to
avoid formation of carbon monoxide,
please see section entitled “Combustion
air supply” and “Venting information”
in this manual.
gFresh air
This equipment requires fresh air for
safe operation and must be installed
ensuring provisions for adequate
combustion and ventilation air exist.
uFor information pertaining to the
fresh air requirements of this product,
please see subsection entitled
“Mechanical Room” in this manual.
gEquipment venting
Never operate boiler without an installed venting
system. An improper venting system can cause
carbon monoxide poisoning.
uFor information pertaining to
venting and chimney requirements,
please see section entitled “Venting
Information” in this manual. All
products of combustion must be
safely vented to the outdoors.
gProduct 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.
uFor a listing of applicable literature,
please see section entitled “Important
Regulatory and Safety Requirements”.
gLicensed professional heating contractor
The installation, adjustment, service and maintenance
of this equipment must be performed by a licensed
professional heating contractor.
uPlease see section entitled
“Important Regulatory and Installation
Requirements”.
gContaminated air
Air contaminated by chemicals can cause by-products
in the combustion process, which are poisonous to
inhabitants and destructive to
Viessmann equipment.
uFor a listing of chemicals which
cannot be stored in or near the
boiler room, please see section
entitled “Mechanical Room”.
in this manual.
gAdvice 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, shutdown procedure, and
the need for professional service annually before the
heating season begins.
gWarranty
Information contained in this and
related product documentation must
be read and followed. Failure to do
so renders the warranty null and void.

3
5583 572 - 07
Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service Safety
Important Safety, Installation, Regulatory and Warranty Requirements (continued)
WARNING
Inhaling of fiberglass wool and/or ceramic fiber
materials is a possible cancer hazard. These materials
can also cause respiratory, skin and eye irritation.
HFiberglass wool and ceramic fiber materials
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.
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 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, tear-out 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
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.
- 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.

Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
5583 572 - 07
4
Safety
Important Safety, Installation, Regulatory and Warranty Requirements (continued)
For installations on the Commonwealth of Massachusetts, the following modifications to NFPA-54 chapter 10 apply:
Excerpt from 248 CMR 5-08:
2(a) 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 (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:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side-wall
horizontal vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired
carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas
equipment is to be installed. In addition, the installing plumber or gas fitter shall observe that a battery
operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the
dwelling, building or structure served by the side-wall horizontal vented gas fueled equipment. It shall be
the responsibility of the property owner to secure the services of qualified licensed professional for the
installation of hard-wired carbon monoxide detectors.
a. In the event that the side-wall horizontally vented gas fueled equipment is installed in a crawl space or
an attic, the hard-wired carbon monoxide detector with alarm and battery back-up may be installed on
the next adjacent floor level.
b. In the event that the requirements of this subdivision can not be met at the time of completion of
installation, the owner shall have a period of thirty (30) days to comply with the above requirements;
provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector
with an alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance
with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the
building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal
for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no
less than one-half (b) inch in size, "GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS".
4. INSPECTION. The state or local gas inspector of the side-wall horizontally vented gas fueled equipment
shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide
detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:
1. The equipment listed in Chapter 10 entitled "Equipment Not Required To Be Vented" in the most current
edition of NFPA 54 as adopted by the Board; and
2. Product Approved side-wall horizontally vented gas fueled equipment installed in a room or structure
separate from the dwelling, building or structure used in whole or in part for residential purposes.

5
5583 572 - 07
Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service Safety
Important Safety, Installation, Regulatory and Warranty Requirements (continued)
Working on the equipment
The installation, adjustment, service, and maintenance
of this boiler must be performed 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.
Note: The completeness and functionality of field supplied
electrical controls and components must be verified
by the heating contractor. This includes low water
cut-offs, flow switches (if used), staging controls,
pumps, motorized valves, air vents, thermostats, etc.
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.
Codes
The installation of this unit shall be in accordance with
local codes. In the absence of local codes, use:
CAN/CSA-B139.00 for oil installations in Canada
Note: 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.
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 conform to the Standard
for Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1 where required by the
authority having jurisdiction.
Technical literature
Literature for the Vitorond 100 boiler:
- Technical Data Manual
- Installation Instructions
- Service Instructions
- Operating Instructions and User’s Information Manual
- Instructions of other Viessmann products utilized with
this installation
- Hydrostat 3250-Plus instructions
Note: 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.
Mechanical room
Ensure the mechanical room complies with the
requirements of the System Design Guidelines and/or
Technical Data Manual. In addition, see section entitled
“Mechanical Room” on page 9 in this manual.

6
Page
Table of Contents
5583 572 - 07
Vitorond 100, VR1-40 to -63 Installation and Service
Safety
General Information
Set-up
Connections
Burner Set-up
Start-up
Connections
Service
Additional Information
Important Safety, Installation, Regulatory and
Warranty Requirements.................................................2
About these Instructions..............................................7
Product Information.....................................................8
Mechanical Room.......................................................9
Combustion Air Supply...............................................9
ProductDelivery........................................................11
Unpacking Instructions..............................................11
Minimum Clearances to Combustibles..........................12
Recommended Minimum Clearances for Service...........12
Boiler Set-up and Location ........................................13
Insulation Installation.................................................13
Combustion Chamber Insert.......................................16
Venting Connection...................................................16
Water Side Connections
(with Hydrostat 3250-Plus Control).............................19
Safety Connections
(with Hydrostat 3250-Plus Control).............................20
Water Side Connections (with Vitotronic Control).........22
Safety Connections (with Vitotronic Control)...............23
Pressure Testing.......................................................25
Burner Installation.....................................................26
Burner Information....................................................26
Burner Mounting.......................................................27
Oil Piping Connection.................................................28
Electrical Connections
(with Hydrostat 3250-Plus Control).............................29
Electrical Connections (with Vitotronic Control)............33
Initial Start-up..........................................................39
Burner Calibration.....................................................40
Barometric Draft Regulator.........................................43
Waterside Flow........................................................43
Installation Examples - Hydrostat 3250-Plus.................44
Installation Examples - Vitotronic................................45
Necessary Tools.......................................................48
Service Procedure.....................................................48
Shut-down heating system....................................48
Open combustion chamber door............................48
Clean heat exchanger and flue pipe........................49
Check all gaskets and insulation.............................49
Close combustion chamber door............................49
Check heating system and
domestic hot water connections.............................50
Ensure proper operation of all safety devices...........50
Ensure proper operation of expansion tank,
low water cut-off (if applicable) and pumps.............50
Ensure that an adequate combustion air
supply exists in the boiler room.............................50
Ensure functionality of the barometric
draft regulator of the burner..................................50
Calibrate the Burner..............................................51
Parts List.................................................................52
Maintenance Record..................................................55

7
5583 572 - 07
Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service General Information
About these 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.
u
IMPORTANT
uWarnings draw your attention to the presence of
potential hazards or important product information.
uCautions draw your attention to the presence of
potential hazards or important product information.
uHelpful hints for installation, operation or maintenance
which pertain to the product.
uThis symbol indicates that additional, pertinent
information is to be found.
uThis symbol indicates that other instructions must
be referenced.
WARNING
Indicates an imminently hazardous situation which,
if not avoided, could result in loss of life, serious
injury or substantial product/property damage.
CAUTION
Indicates an imminently hazardous situation which,
if not avoided, may result in minor injury or product/
property damage.

Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
5583 572 - 07
8
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
(Hydrostat 3250-Plus):...........................190°F (88°C)
Fixed High limit Vitotronic 100 or 200
(factory set):..........................................230°F (110°C)
Adjustable High limit Vitotronic 100 or 200
(factory set):..........................................167°F (75°C)
Maximum allowable working pressure*1: ..45 psig (3 bar)
Fuel:.....................................................#2 fuel oil
*1 Cast iron sections are ASME 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 L) for every
13000 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.
Hydrostat thermal targeting
Thermal Targeting technology analyzes thermostat activity
and continually evaluates how much heat the house
requires. When it is very cold outside, the heat demand is
high and the Fuel Smart HydroStat will raise the boiler’s
Target temperature to provide needed heat to the home.
When the outside temperature is milder, the heat demand
is lower. During these periods, the Fuel Smart HydroStat
will lower the boiler’s Target temperature – saving fuel –
while continuing to provide comfort to the house.
This boiler control maybe equipped with an outdoor reset
module (field supplied) 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 FOLLOWING 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.
IMPORTANT
General Information

9
5583 572 - 07
Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
Mechanical Room
General Information
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.
WARNING
Failure to provide an adequate supply of fresh
combustion air can cause poisonous flue gases
to enter living space. Flue gases entering living
space can cause carbon monoxide poisoning which
can result in severe personal injury or loss of life.
WARNING
Never cover the boiler or store debris or other
materials near the boiler, or in any way block the
flow of adequate fresh air to the boiler. Never
cover the combustion air opening.
Advise system operator/ultimate owner accordingly.
WARNING
The boiler must not be located in areas or rooms
where chemicals are stored, or aggressive
vapors (i.e. bleach, hair spray, methyl chloride,
carbon tetrachloride or perchloroethylene) or high
dust levels or humidity levels are present. Heat
exchanger corrosion might occur and reduce the
lifetime of the boiler significantly. If above criteria
are not properly observed and boiler damage
results, any warranty on the complete boiler and
related components will be null and void.
General
This equipment requires fresh air for safe operation and
must be installed ensuring provisions for adequate
combustion and ventilation air exist.
Whenever possible, install boiler near an outside wall so
that it is easy to duct fresh air directly to the boiler area.
The boiler location must never be under negative pressure.
Exhaust fans, attic fans, or dryer fans may cause air to be
exhausted at a rate higher than air can enter the structure
for safe combustion.
The heating contractor shall ensure all of the following
requirements are met:
HAn adequate supply of combustion air must be available
to ensure proper combustion.
HAmbient air temperatures must be maintained within
safe operating limits.
HWhen a damper is provided in any opening intended to
admit combustion air into the room within which the
appliance is installed, the damper shall be interlocked to
prevent any burner from starting before the damper is
fully open.
HEach duct used to convey air from the outdoors shall
have:
1. A cross-sectional area throughout its length at least
equal to the free area of the inlet and outlet
openings which it connects,
2. A minimum dimension of 3 in. (76 mm) at any
cross-section,
3. When making provision for outside combustion air,
the intake shall not be less than 1 ft. (0.3 m) above
the anticipated snow level for the location.
HThe heating contractor must check with local
authorities (municipal building department, gas utility)
for combustion air requirements particular
to the area.
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 in.
(457 mm) above the floor to avoid contact with
flammable vapors and fumes).
Viessmann strongly recommends installing the boiler on
a concrete foundation.
Combustion Air Supply

Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
5583 572 - 07
10
Combustion Air Supply (continued)
Codes
Provisions for combustion and ventilation air must be
made in accordance with applicable local codes.
In the absence of local codes, use:
HCSA B-139 for oil installations in Canada, or
HNFPA 31, Standard for the Installation of Oil Burning
Equipment in the U.S. Always use latest editions of
codes.
General Information
Unconfined spaces
Where the boiler is located in an unconfined space in a
building having insufficient infiltration, additional air for
combustion and ventilation shall be obtained from
outdoors or from spaces freely communicating with the
outdoors. Under these conditions, permanent opening(s)
shall be provided so that the total air received through
these openings will be at least as much as would be
admitted by openings having a total free area of
1 in2/5000 Btu/h or 4.5 cm2/kWh of the total input
rating of all oil-fired appliances
Louvers and grilles
In calculating free area as specified, consideration shall be
given to the blocking effect of louvers, grilles, or screens
that protect openings. Screens used shall be no smaller
than ¼ in. (6 mm) mesh and shall be readily accessible
for cleaning. If the free area through a design of louver or
grille is known, it shall be used in calculating the size of
opening required to provide the free area specified. If the
design and free area are not known, it shall be assumed
that wood louvres have 20-25% free area and metal
louvres and grills have 60-75% free area.
Confined spaces
If the boiler is located in a confined space and obtains all
of its air for combustion and ventilation from within the
conditioned space, the building shall be provided with
two permanent openings, one near the top of the
enclosure and another near the bottom. Each opening
shall have a free area of not less than 1 in2/1000 Btu/h
or 19.5 cm2/kWh of the total input rating of all appliances
in the enclosure, freely communicating with interior areas
that have in turn adequate infiltration from the outside.
If the boiler is located in a confined space and that obtains
all of its air for combustion and ventilation from outside,
the building shall be provided with two permanent
openings, one near the top of the enclosure and another
near the bottom. Each opening shall communicate directly
or by means of ducts with the outdoors or to such
spaces (such as a crawl space) that freely communicate
with the outdoors, and shall be sized in accordance with
the following methods:
HVertical duct(s) with a free area of not less than
1 in2/4000 Btu/h or 5.5 cm2/kWh of the total input
rating of all appliances in the enclosure,
HHorizontal duct(s) with an equivalent length of less
than 50 ft (15 m), having a free area of not less than
1 in2/2000 Btu/h or 11 cm2/kWh of the total input of
all appliances in the enclosure,
HAir openings that communicate directly with the
outdoors, having a free area of not less than 1 in2/4000
Btu/h or 5.5 cm2/kWh of the total input rating of all
appliances in the enclosure.
Boiler Model No. VR1
40, 161
VR1
50, 196
VR1
63, 245
Round duct
for combustion
air supply *1
Ø” 6 6 7
Installation
Install a combustion air opening. Round duct diameters
are as follows:

11
5583 572 - 07
Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service Set-up
Product Delivery
CAUTION
Do not lift or position boiler alone.
Do not lift by or push against panels.
Do not bump boiler panels against floor.
Do not drop boiler.
Unpacking Instructions
Vitorond boilers size VR1 40 to 63, 161 to 245 are
shipped in
a crate with separate boiler jacketry.
Product delivery
Ensure each of the following has been
delivered:
HCrate with boiler casting A
HCrate with insulation jacket B
HCarton with burner (shipped separately)
HCarton with standard installation equipment
WARNING
To avoid injury and to facilitate boiler maneuvering,
it is strongly recommended that Viessmann carrying
handles (Part No. 7189 602) be used. The carrying
handles allow easy removal of boiler from skid and
enables easy transportation to permanent location,
while reducing the risk of boiler panel damage due to
improper lifting or maneuvering techniques. The
carrying handles are designed to prevent boiler
slippage onto hand when carrying up/down inclines.
CAUTION
To avoid injury to hands, place wooden block under
pipes in front of skid.
Legend
ACasting
B1” pipe, x2
C Rear wooden block
D Front wooden block
If carrying handles are not available, follow the steps
below.
1. Remove top and sides of crate.
To avoid damage during lifting, carefully remove front
panel by lifting panel up and out.
2. Place wooden block 12” from rear of skid.
3. Insert 1” Ø Schedule 40 pipes through openings in
casting legs. Ends of pipes should be centered on
wooden block behind skid.
4. Lift boiler using pipes until clear from skid. Remove
skid
from beneath boiler.
5. Lower boiler until pipes rest on front block.
6. To remove rear block, lift (by casting - not jacket) to
tilt unit forward.
To remove front block, lift (by casting - not jacket) to
tilt unit backward.
7. Remove pipes. Reinstall front boiler panel once boiler
is in final position.

Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
5583 572 - 07
12
Set-up
Minimum Clearances to Combustibles
Legend
ABoiler
BBurner
For typical installations, Viessmann recommends installing
the boiler with clearances under Recommended Minimum
Clearances for Service.
The following are clearances to combustibles:
Standard installation
Boiler model VR1 VR1
40, 161
VR1
50, 196
VR1
63, 245
Rear
Sides
Flue
in.
(mm)
in.
(mm)
in.
(mm)
6
(150)
0
0
9
(230)
6
(150)
0
0
9
(230)
6
(150)
0
0
9
(230)
Floor Combustibles
Boiler model VR1 VR1
40, 161
VR1
50, 196
VR1
63, 245
Rear
Sides
Flue
Top
in.
(mm)
in.
(mm)
in.
(mm)
in.
(mm)
6
(150)
0
0
9
(230)
6
(150)
6
(150)
0
0
9
(230)
6
(150)
6
(150)
0
0
9
(230)
6
(150)
Floor Combustibles
Alcove installation
*1 Clearance of 24” (610 mm) required . for burner service.
Recommended Minimum Clearances for Service
Legend
ABoiler
*1 Minimum access for cleaning and service.

13
5583 572 - 07
Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
Boiler Set-up and Location
CAUTION
Boiler must be installed in such a way that oil ignition
system components are protected from water (spraying,
splashing, etc) during boiler system operation and service.
IMPORTANT
Insulation Installation
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 levelling bolts A.
All parts necessary to install the insulation are shipped
with the carton containing the insulation.
1. Wrap insulation blanket A around cast iron block
with the cutout facing to the front.
2. Secure insulation blanket with supplied spring clips.
Set-up

Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
5583 572 - 07
14
Insulation Installation (continued)
3. If installing Vitotronic control:
Run the fA plug-in connector cable of the Vitotronic
control down behind the front panel of the boiler
and out through the bottom.
4. Install support brackets A.
5. Position left side panel onto support brackets A.
6. Line up bottom tab of side panel with notch in
casting leg of rear section.
7. Once side panel is in place, bend down tab using
pliers as shown.
Set-up
8. Install rear insulation blanket to cast iron block,
black side facing outward.
9. Install rear panel.

15
5583 572 - 07
Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
Insulation Installation (continued)
10. Install right side panel on support brackets.
Ensure top of side panel fits over top of rear panel.
11. Line up bottom tab of side panel with notch in
casting leg.
12. Once side panel is in place, bend down tab as shown.
IMPORTANT
Set-up
If installing a Vitotronic control:
Before installing the top front and rear panels, see
sections covering Vitotronic control.
13. Slide the top front panel locking notches into the
side panel holes.
14. Install the top rear panel by sliding it into the notches.
15. Secure top rear panel with sheet metal screws
(see also page 15).
16. Mount the front panel in place by attaching it to the
side panels as shown and securing with screws.

Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
5583 572 - 07
16
Set-up/Connections
Combustion Chamber Insert
For optimum, environmentally sound operation, Vitorond
boilers are equipped with a high-grade, corrosion resistant,
stainless steel combustion chamber insert.
Ensure the bolts of the combustion chamber door are
tightened before installing the burner.
Combustion chamber insert sizes
Venting Connection
Boiler model No. VR1
40, 161
VR1
50, 196
VR1
63, 245
a
b
in.
(mm)
in.
(mm)
9f
(244)
11b
(294)
9f
(244)
11b
(294)
9f
(244)
11b
(294)
Vitorond 100
The vent system must comply with all applicable local
and/or national codes.
If installing boiler with a side wall vent system, ensure
all manufacturer’s requirements are met.
Venting codes
For oil-fired boilers install venting system in accordance
with all applicable local codes:. In the absence of local
codes, follow national codes
gLocal codes or CSA B139-00 in Canada
or
gNFPA-31 in the U.S.
Building codes
Masonry or concrete or metal chimneys (smokestacks)
shall be constructed according to the requirements of
the province/state building code or, in the absence of
such regulations, in accordance with:
gCSA Standard CAN/CSA-A405
(National Building Code of Canada) in Canada, or
gNFPA 211 (Standard for Chimneys, Fireplaces, Vents,
and Solid Fuel-Burning Appliances) in the US. Metal
chimneys also shall meet the requirements of Chapter
4 of NFPA 211.
In Canada, factory built chimneys shall:
gConform to ULC Standards
CAN/ULC-S629 for 1202°F (650°C),
CAN/ULC-S604 for Type A, or
CAN/ULC-S609 for Type L chimneys,
gBe certified and installed in accordance with the
manufacturer’s certified instructions, and
gBe provided with a clean-out opening that is equipped
with a tight-fitting removable cap, and constructed so
that no air can enter the clean-out facility when the cap
is in place.
In the U.S., factory built chimneys shall:
gMeet the requirements of NFPA, and
gBe listed, installed and used in accordance with their
listings and manufacturer’s instructions.

17
5583 572 - 07
Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
Venting Connection (continued)
Connections
WARNING
Never operate the boiler/burner 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.
General
The heating contractor shall ensure all of the following
requirements are met:
gThe vent system shall ensure that no hazard is created
by the products of combustion.
gProvision shall be made to vent the products of
combustion safely to outside the building, and
such venting shall not pass through or be installed
in return air, supply air, ventilating, or combustion air
ducts or shafts.
gSufficient air for combustion of the oil and ventilation
of the appliance shall be supplied to the space wherein
the appliance is located (see section entitled
Combustion Air Supply).
gThe house and its mechanical systems shall be
inspected to determine if operation of exhaust devices
could lead to levels of depressurization of the house
that would adversely affect the operation of the oil-
burning appliance and its venting system. If such is the
case, the building owner shall be informed of the
situation in writing.
gThe chimney shall be inspected to ensure that the
material construction, condition, and size are suitable
for the application.
gThis boiler/burner combination shall not be connected
to an unlined chimney. Such chimneys shall be lined
in accordance with the applicable codes and standards.
gThe chimney shall be capable of exhausting the
products of combustion and of producing a draft
not less than that recommended by the manufacturer
of the appliance connected thereto, during the mildest
weather conditions under which the appliance is
expected to operate.
During cold weather testing, excess flow performance
shall be demonstrated to ensure that flow is adequate
in warmer weather.
gAn oil burning appliance that depends on natural
chimney draft shall be connected to an individual
chimney vent used for no other appliance, except
as permitted by the applicable codes and standards.
gThe vent connector of this boiler must not be
connected into any portion of mechanical draft
systems operating under positive pressure.
gA chimney flue shall extend at least 3 ft (1 m) above
the highest point at which the chimney comes in
contact with the roof, and not less than 2 ft (0.6 m)
above the highest roof surface or structure within
10 ft. (3 m) of the chimney on a horizontal plane
perpendicular to the chimney. Not more than 8”
(200 mm) of chimney flue above the top of the
chimney cap shall be considered in computing height.
gDown draft and condensation problems must be
corrected.
WARNING
Improper sizing, maintenance, termination of vent or
chimney can cause flue gases to enter living space.
Any blockage of vent or chimney by birds’ nests, ice,
snow, debris, or other materials can cause flue gases
to enter living space. Flue gases entering living space
can cause carbon monoxide poisoning which can
result in severe personal injury or loss of life.

Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
5583 572 - 07
18
Venting Connection (continued)
Connections
Legend
AVitorond boiler with burner
BOutside rain cap
C Vent, use approved vent material
D M-Barometric damper (field supplied) for oil *1
E Vent pipe adaptor (factory supplied)
F For Canada: Blocked vent safety switch
*1 Install in accordance with the draft control
manufacturer’s instructions.
When installing piping or venting, or while insulating
overhead pipes, do not stand on top panel of boiler.
Advise other trades accordingly!
Installation
Use approved vent material only.
1. Install the venting so as to achieve the shortest
possible way with minimum elbows. If necessary,
rearrange existing water piping to achieve closest
chimney connection.
2. Horizontal runs must be supported by appropriate
means to prevent sagging. Avoid long horizontal runs
of vent pipe. Horizontal runs should have not less
than ¼” rise per ft. from the boiler to the vent
terminal. Metal strapping must be used to support
horizontal runs every 4 ft. (1.2 m).
3. Connect factory supplied vent pipe adaptor to flue
gas collar. Fasten using either three equally spaced,
corrosion resistant, self-tapping screws and high
temperature silicone, or equivalent means.
4. Connect chimney via a 18” (457 mm) long field
supplied, slightly inclined intermediate section of
venting. Flue pipe outside Ø: 6”.
5. Drill a ½” opening on the side of the vent pipe
approximately three times the vent pipe diameter
away from the flue gas collar of the boiler for flue
gas analysis equipment.
6. Seal all flue pipe joints.
7. Viessmann recommends that any non-insulated vent
pipe is insulated to reduce cooling of flue gas and
velocity noises.
Installation Instructions
Blocked Vent Safety Switch

19
5583 572 - 07
Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
Water Side Connections (with Hydrostat 3250-Plus Control)
Legend
A Boiler water supply connection,
pressure relief valve:................................... 2” NPT
B High limit control location:........................1½” NPTF
C Boiler water return, drain and automatic feed:..2” NPT
Legend
DHydrostat 3250-Plus control
EElectro-well
F Hex bushing, 1½” x ¾”
GNipple, 2” x 5”
HPressure relief valve
ITee, 2” x 2” x ¾”
JDrain valve (sediment faucet), ¾”
We recommend the installation of a spring-loaded flow-
check valve in heating circuits without mixing valves.
This serves to avoid uncontrolled gravity circulation of
heat into the heating system during summer months.
2. Remove screw Q. Remove top back panel before
starting to connect pipe fittings to boiler water supply
connection.
3. Connect system supply A to using NPT fittings,
as shown in the illustration. Connect the system
return C to using NPT fittings, as shown in the
illustration. See installation examples in the following
section starting on page 44.
4. Install temperature and pressure gage Owith brass
extension coupling in ½” opening as shown in the
illustration. Use thread sealing compound such as
Loctite or Teflon tape.
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).
Connections
WARNING
Failure to flush the heating system could cause system
sludge to settle in the boiler, causing overheating and
failure. This type of failure is not covered under
warranty.
IMPORTANT
IMPORTANT
Hydrostat control is equipped with a remote mounting
kit (c/w a 48’ sensor cable) for easy installation of the
control in a convenient location.
KReducing tee/elbow, 2” x ¾” x 2”
LStreet elbow, ¾”
MNipple, ¾” x 3½”
NReducing tee, 2” x 2” x ½”
OTemperature and pressure gage
PFlue gas adaptor, Ø 6”

Vitorond 100, VR1 40 to 63, 161 to 245 Installation and Service
5583 572 - 07
20
Connections
Safety Connections (with Hydrostat 3250-Plus Control)
Pressure relief valve
1. Install pressure relief valve. Pipe pressure relief valve
as illustrated and connect to boiler water supply
connection.
2. Install discharge pipe on pressure relief valve.
The discharge pipe should terminate approximately
6” (150 mm) above a floor drain.
The end of the pipe must not be threaded.
Minimum connection diameters:
Pressure relief valve...............................................¾”
Discharge pipe.......................................................¾”
Piping to precharged expansion tank VR1 40 to 63,
161 to 245 ..........................................................¾”
This boiler does not require a flow switch.
Install the (approved) factory supplied pressure relief valve.
Removal of air from the system must occur via use of air
vent(s) in the system supply. To ensure the boiler can be
purged of all air, ensure supply/return water lines do not
contain restrictive piping where air could be trapped.
WARNING
Do not install an isolation valve between boiler and
pressure relief valve.
The discharge pipe for the pressure relief valve must be
oriented to prevent scalding of attendants. Pipe pressure
relief valve discharge pipe close to floor drain. Never pipe
discharge pipe to the outdoors.
IMPORTANT
Refer to instructions supplied with
the pressure relief valve.
Boiler control
1. Install supplied high limit control as shown.
Maximum allowable temperature setting is 240°F (110°C).
Refer to instructions supplied with
the Hydrostat 3250-Plus control.
Legend
A Pressure relief valve
B Nipple, ¾” x 3½”
CTee, 1½” x ¾” x 1½”
Legend
AHydrostat 3250-Plus high limit control
BElectro-well
CHex bushing