Viessmann VITOROND 100 VR1 Series Instruction manual

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Hot water heating boiler
91 to 245 MBH / 27 to 72 kW
5285 767 v2.2 07/2013
Te hni al Data Manual
Model Nos. and pricing: see Price List

Vitorond 100
VR1 Series
Oil-Fired Boiler
of ast iron se tional onstru tion
for hydroni heating systems
with modulating boiler water temperatures
Heating input: 91 to 245 MBH
27 to 72 kW

Produ t Information
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A genuine triple-pass boiler of ast iron
se tional design. The high-quality
onstru tion and innovative oil heating
te hnology of this boiler provide a high level
of operational reliability, high-effi ien y
operation and redu ed emissions.
The bene its at a glance:
HGet the most out o your uel dollar!
Maximum heat extra tion with triple-pass
design. A.F.U.E.: up to 86.9%.
HExtremely durable ast iron heat
ex hanger for maximum reliability and
service li e.
HClean combustion with Be kett or Riello
burner.
HIntegrated stainless steel ombustion
hamber insert for clean and e icient
combustion.
HThi k 3½” insulation for extremely low
standby losses and uel savings.
HEasy access
Full-swing left- or right-hinged ombustion
hamber door.
HLow maintenance cost with
servi e-friendly burner and easy-to- lean
flue gas passageways.
HSpa ious, wet-base water walls prevent
deposits, redu e stress and increase boiler
li e.
HDirect vent option (up to VR1-33)
eliminates the need for a himney and
ombustion air supply opening.
HMultiple control options:
Choose from a standard 24 VAC room
thermostat or Vitotroni ontrol options
for additional energy savings.
HAdditional energy savings and reduced
emissions with modulating boiler water
temperatures when using Vitotroni ontrol
options.
HBoiler return inje tor available with
Vitotroni ontrols prote ts against
formation of ondensation and enables
safe lower-temperature operation for
increased e iciency.
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Produ t Information
Cut-Away Se tion
Boiler/burner and controls combination may not be exactly as illustrated.
*1
Stainless steel combustion chamber insert not shown.
Special return water
flow control injector
Eutectoplex heat
exchanger surface of
special homogeneous
gray cast iron
Vitotronic 100 -
indoor/outdoor
digital boiler and
heating system
control
Oil burner
Third pass
Combustion chamber*
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Te hni al Data
4
Technical data
Boiler Model Model No. VR1-22 VR1-27 VR1-33 VR1-40 VR1-50 VR1-63
CSA input
*1
MBH
kW
GPH
91
27
0.65
105
31
0.75
140
41
1.0
161
47
1.15
196
57
1.4
245
72
1.75
CSA output MBH
kW
80
23
92
27
122
36
140
41
172
50
215
63
Net I=B=R rating MBH
kW
70
21
80
23
106
31
122
36
150
44
187
55
A.F.U.E. % 86.8 86.8 86.8 86.9 86.9 86.9
Heat exchanger sur ace area ft
2
(m
2
)
15.71
1.47
21.31
1.98
21.31
1.98
23.29
2.16
32.29
3.0
41.11
3.82
Boiler dimensions
Depth (without burner)
Width
Height
Overall dimensions (with ja ket)
Total depth (in ludes burner)
Total width
Total height (without Vitotroni )
- Height 1 ( ontrol unit in
position for operation and
programming)
- Height 2 ( ontrol unit in
position for servi ing)
Height of boiler stand
in hes
mm
in hes
mm
in hes
mm
in hes
mm
in hes
mm
in hes
mm
in hes
mm
in hes
mm
in hes
mm
25½
650
15½
391
30½
775
38½
976
19¾
500
33
840
43
7
/
8
1115
52¾
1340
9¾
250
31
790
15½
391
30½
775
44
1116
19¾
500
33
840
43
7
/
8
1115
52¾
1340
9¾
250
31
790
15½
391
30½
775
44
1116
19¾
500
33
840
43
7
/
8
1115
52¾
1340
9¾
250
24½
583
20
512
37
935
36
914
22¼
565
39¾
1010
50½
1285
59½
1510
9¾
250
29½
710
20
512
37
935
37½
956
22¼
565
39¾
1010
50½
1285
59½
1510
9¾
250
34½
837
20
512
37
935
42½
1081
22¼
565
39¾
1010
50½
1285
59½
1510
9¾
250
Weight boiler blo k
Total weight, boiler with insulation,
burner and boiler ontrol
lbs
kg
lbs
kg
280
127
442
200
353
160
508
230
353
160
508
230
414
188
564
256
527
239
694
315
639
290
822
373
Boiler water content USG (ltrs) 9.2 (35) 11.6 (44) 11.6 (44) 12.7 (48) 16.1 (61) 19.3 (73)
Max. operating pressure
*2
psig (kPa) 30 (207) 30 (207) 30 (207) 30 (207) 30 (207) 30 (207)
Boiler water connections
Supply and return
Safety supply
Drain valve
in hes
in hes
in hes
1½
1½
1½
1½
1½
1½
1½
1½
1½
2
2
2
2
2
2
2
2
2
Gross lue gas temperature
*3
at
- 104°F / 40°C boiler water
temperature
- 167°F / 75°C boiler water
temperature
°F
°C
°F
°C
311
155
356
180
311
155
356
180
311
155
356
180
311
155
356
180
311
155
356
180
311
155
356
180
Boiler vent connection
*4
outer ∅in hes 5 5 5 6 6 6
Required lue dra t “w. . -0.02 -0.02 -0.02 -0.02 -0.02 -0.02
*1
Combustion results are based on 11.0% to 13.5% C
2
with fuel oil #2 and a hot water heating system supply temperature of
167°F / 75°C, return 140°F / 60°C.
*2
Max. operating pressure is 45 psig / 310 kPa in all Canadian provinces where a CRN is not required, and in the U.S.A.
*3
Measured flue gas temperature with combustion air temperature of 68°F / 20°C.
*4
A 5” vent pipe adaptor is shipped with models VR1-22 to VR1-33. The vent pipe adaptor is not supplied with boiler models VR1-40 to
VR1-63.
"
For information regarding direct vent applications, please refer to Direct Vent Systems Installation Instruction Supplement.
"
For information regarding other Viessmann System Technology componentry, please reference documentation of the respective product.
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Te hni al Data
5
Vitorond 100 with Aquastat
e
f
g
h
d
a
BNR,BD
FGC
BHL
BWS,SS
Width
VITOROND 100
5” / 130 m m
9 ¾” / 250 mm
Total width
Fig. 1
B
A
Legend
BD Boiler Drain
BTS Boiler Temperature Sensor
BWR Boiler Water Return
BWS Boiler Water Supply
FGC Flue Gas Collar
SR Safety Return
SS Safety Supply
BHL Boiler High Limit (with outdoor reset module)
Boiler Stand
Be kett or Riello Burner
Vitorond 100 with Vitotronic Control
e
k
f
g
h
d
9 ¾” / 250 mm
b Depth
a
B
SR,BD
FGC
BHL
BWS,SS
A
Width
BTS
VITOROND 100
Total height
Height 2
VIESMANN
Total depth
Total width
Fig. 2
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Te hni al Data
6
Dimensions
Boiler Model VR1 -22 -27 -33 -40 -50 -63
a
b
d
e
f
g
h
k
in h
mm
in h
mm
in h
mm
in h
mm
in h
mm
in h
mm
in h
mm
in h
mm
in h
mm
13¼
338
3
75
12½
312
5½
137
23
585
26¼
667
28½
726
33
840
5½
138
13¼
338
3
75
12½
312
5½
137
23
585
26¼
667
28½
726
33
840
5½
138
13¼
338
3
75
12½
312
5½
137
23
585
26¼
667
28½
726
33
840
5½
138
13¾
347
3
75
12½
312
4¼
107
27¾
702
32¼
822
34¾
882
39¾
1010
6½
166
13¾
347
3
75
9½
247
4¼
107
27¾
702
32¼
822
34¾
882
39¾
1010
6½
166
13¾
347
3
75
9½
247
4¼
107
27¾
702
32¼
822
34¾
882
39¾
1010
6½
166
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Te hni al Data
7
Minimun Clearances to Combustibles
Standard installation
Boiler
Burner - Riello or Be kett
Boiler
Model
VR1 -22 -27 -33 -40 -50 -63
Rear
Sides
Flue
in hes
mm
in hes
mm
in hes
mm
6
150
0
0
9
230
6
150
0
0
9
230
6
150
0
0
9
230
6
150
0
0
9
230
6
150
0
0
9
230
6
150
0
0
9
230
Floor Combustibles
Alcove installation
Boiler
Model
VR1 -22 -27 -33 -40 -50 -63
Rear
Sides
Flue
Top*
2
in hes
mm
in hes
mm
in hes
mm
in hes
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
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
*
1
Front service clearance.
*
2
24” with Vitotronic control.
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min. 6” / 150 mm
min. 9” / 230 mm
min. 0” / 0 mm
min.
24”
610 mm
*1
Fig. 3 Top view
min. 9” / 230 mm
min.
24”
610 mm
*1
min. 24” Vitotroni
installation
min. 6” Aquastat
installation
Fig. 4 Side view
6½”
a
6”
b
All models
Fig. 5

Te hni al Data
8
Beckett burner (chimney and direct vent*
1
application)
Boiler Model Model No. VR1-22* VR1-27* VR1-33* VR1-40 VR1-50 VR1-63
Burner model Be kett NX-VI 501 NX-VI 502 NX-VI 503 NX-VI 504 AFG-VI 601 AFG-VI 601
Fuel type oil No. 2 fuel oil
Pump pressure psig
kPa
190
1207
175
1207
175
1207
175
1207
175
1207
175
1207
Oil nozzle Danfoss n.a. 0.60x60°AS n.a. 0.85x60°AH n.a. n.a.
O
i
l
n
o
z
z
l
e
Delavan 0.50x60°B n.a. 0.75x60°A/W 0.85x60°A 1.10x45°W 1.35x60°W
Hago 0.50x60°B 0.60x60°B n.a n.a. 1.10x45°W 1.35x60°B
Oil nozzle low rate GPH@psig 0.65@175 0.75@175 1.00@175 1.15@175 1.40@175 1.75@175
Air tube length in hes
mm
7
178
7
178
7
178
7
178
9
230
9
230
Air tube insertion in hes
mm
3¼
83
3¼
83
3
5
/
8
92
4
7
/
8
124
7¼
184
7¼
184
*
1
Direct vent burners available only for sizes VR1-22, -27, -33
"
For information regarding direct vent applications, please refer to Direct Vent Systems Installation Instruction Supplement.
Riello burner (chimney vent application)
Boiler Model Model No. VR1-22 VR1-27 VR1-33 VR1-40 VR1-50 VR1-63
Burner model Riello 40
Series
F3 F3 F5 F5 F5 F10
Fuel type oil No. 2 fuel oil
Pump pressure psig
kPa
175
1207
175
1207
175
1207
175
1207
175
1207
175
1207
Oil nozzle Danfoss 0.50x60°AS 0.60x60°AS 0.75x60°AS 0.85x60°AH 1.10x60°AH 1.35x60°AH
O
i
l
n
o
z
z
l
e
Delavan 0.50x60°SS 0.60x60°W 0.75x60°A
0.75x60°W
0.85x60°A
0.85x60°W
1.10x60°A 1.35x60°A
1.35x60°W
Hago 0.50x60°SS 0.60x60°ES n.a. 0.85x60°H 1.10x60°H
1.10x60°SS
1.35x45°SS
Oil nozzle low rate GPH@psig 0.65@175 0.75@175 1.00@175 1.15@175 1.40@175 1.75@175
Air tube length in hes
mm
7
178
7
178
6
5
/
16
160
6
5
/
16
160
6
5
/
16
160
7
178
Air tube insertion in hes
mm
4
5
/
8
118
4
5
/
8
118
4¼
108
4¼
108
4¼
108
4¾
121
Turbulator setting 0.0 2.0 0.8 1.0 3.0 2.0
Air gate setting 3.1 3.4 2.9 3.5 3.6 2.8
"
Boiler standard working pressure: 30 psig; maximum working pressure: 45 psig.
"
Wherever possible, vertically vent the boiler with a properly sized chimney which meets all local and national codes.
"
Draft at the breech is typically -0.02 to -0.08 “w.c.
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Te hni al Data /
Boiler Control Alternatives
9
Riello burner (direct vent application)
Boiler model Model No. VR1-22 VR1-27
*1
VR1-33
Burner model Riello 40
Series
BF3 BF3
*1
BF5
Fuel type oil No. 2 fuel oil
Pump pressure psig 175 175 140
Oil nozzle Danfoss n.a. n.a. n.a.
Oil nozzle Delavan 0.5x60°SS 0.6x60°W
*3
0.85x60°W
*2
Oil nozzle Hago n.a. n.a. n.a.
Oil nozzle low rate GPH@psig 0.65@175 0.75@175 1.00@140
Air tube length in hes
mm
7
178
7
178
6
5
/
16
160
Air tube insertion in hes
mm
4
5
/
8
118
4
5
/
8
118
4¼
108
Turbulator setting 0.0 1.0 1.0
Air gate setting 3.7 5.0 4.0
*1
For VR1-27 boiler, replace installed nozzle with nozzle packaged with Riello burner. Riello oil burners are factory set for Vitorond 100,
VR1-22, and -33 boilers and should only require minor adjustments. Install appropriate nozzle and set the burner for model VR1-27.
*2
Factory-installed nozzle.
*3
Nozzles must be installed by installer.
Standard Boiler Equipment
Note:
Boiler with controls and burners are
purchased separately. Please see Price List
for details.
H Boiler shell (insulation preinstalled up to
size VR1-33)
H 30 psig pressure relief valve
H Drain valve
The Boiler Stand must be ordered separately.
H Installation fittings
H Tridi ator
H Honeywell aquastat
(with outdoor reset module)
H Be kett burner /w Viessmann spe ified
oil nozzle
HRiello burner /w Viessmann spe ified
oil nozzle
Boiler Control Alternatives
Honeywell Aquastat Control
High Limit
Model L7248C1006
(with outdoor reset module)
Vitotronic 100, KW10B
enhan ed boiler ontrol for modulating
temperature heating systems with
indoor/outdoor system ontrol
Vitotronic 200, KW2
for multiple temperature heating systems
with or without a mixing valve
with indoor/outdoor digital boiler and heating
system ontrol
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IMPORTANT

10
System Design Considerations
System Design Considerations
Chimney
For proper operation of the Vitorond boiler,
all produ ts of ombustion must be safely
vented to the outdoors, while ensuring that
flue gases do not ool prematurely.
It is riti al that the himney system be
properly designed to handle the flue gas
temperatures whi h the Vitorond boiler
produ es.
Flue gases whi h ool too qui kly and
produ e ondensation lead to damages if
the himney diameter is too large and the
himney system is not well insulated.
If a al ulated himney diameter lies
between two values, the larger diameter
should be sele ted.
Intermediate section
The intermediate (verti al and horizontal)
se tion of venting between the boiler vent
pipe ollar and the himney must be of the
identi al diameter as the vent onne tion of
the boiler. Use the shortest possible path
between the boiler and the himney. A
maximum of two elbows may be installed in
the intermediate se tion. Avoid the use of
two level 90° elbows.
The intermediate se tion must be sealed
pressure tight at the boiler vent pipe ollar
and at the himney onne tion. Ensure any
test port for ombustion values is sealed as
well.
The himney onne tion length between the
boiler vent pipe ollar and the himney may
be installed with insulation. We re ommend
onsulting a reputable himney installer for
advi e in proje t-spe ifi ir umstan es.
Barometri damper must be used!
NOTE: Dire t Vent exhaust system operates
under a positive pressure developed by the
burner. Make sure all vent onne tions and
observation ports on the boiler are sealed air
tight by tightening s rews and using high
temperature sili one sealant if ne essary.
The vent omponents must be supplied
without any alteration ex ept for the length
of the flex pipe whi h an be ut to the
desired length.
Warranty
Our warranty does not over damages
resulting from the following:
– installation or servi e by unqualified and
not li ensed personnel
– orrosion aused by flue gas ondensation
due to low boiler water and/or return
water temperatures
– operation with ontaminated fill and
supplementary feed water
For detailed warranty information, please
read warranty sheet supplied with produ t.
Combustion air supply
The boiler must not be lo ated in areas or
rooms where hemi als ontaining hlorine,
bromine, fluorine, or other orrosive
hemi als are stored. Examples in lude
refrigerants, blea h, paint, paint thinner, hair
spray, leaning solvents, water softener
salt, et . The ombustion air must not be
ontaminated with the above mentioned, or
other aggressive or orrosive hemi als.
Boiler should never be installed in areas
where ex essive dust, high humidity, or risk
of frost exist. Ensure adequate ventilation
and supply of fresh ombustion air.
Consult Viessmann with un ertainties in
regard to a suitable boiler installation
lo ation.
This boiler/burner unit needs lean fresh air
for safe operation and must be installed so
that there are provisions for adequate
ombustion and ventilation air. For oil-fired
boilers, use the “Installation Code for Oil
Burning Equipment CAN/CSA-B139”
(Canada), or NFPA 31 (USA) and/or
provisions of lo al odes.
The sizing methods outlined in the above
odes should be used when installing a
round du t to supply ombustion air from
the outside. Observe lo al jurisdi tional
requirements.
System layout
The boiler water temperature limit is fa tory
set to 167°F / 75°C (Vitotroni only).
The boiler water temperature limit an be
in reased by altering the adjustable high
limit to in rease the supply water
temperature.
To minimize piping losses of the system
however, we re ommend that the radiation
and domesti hot water produ tion in the
system be designed for a 158°F / 70°C
boiler supply water temperature (new
systems).
Water quality
Treatment for boiler feed water should be
onsidered in areas of known problems,
su h as where a high mineral ontent and
hardness exist. In areas where freezing
might o ur, an antifreeze may be added to
the system water to prote t the system.
Please adhere to the spe ifi ations given by
the antifreeze manufa turer. Do not use
automotive sili ate based antifreeze. Please
observe that an antifreeze/water mixture
may require a ba kflow preventer within the
automati water feed and influen e
omponents su h as diaphragm expansion
tanks, radiation, et . A 40% antifreeze
ontent will provide freeze-up prote tion to
-10°F / -23°C. Do not use antifreeze other
than spe ifi ally made for hot water heating
systems. System also may ontain
omponents whi h might be negatively
affe ted by antifreeze. Che k total system
frequently when filled with antifreeze.
Advise system operator/ultimate owner that
system is filled with a gly ol mix.
The heating ontra tor must provide an
MSDS (Material Safety Data Sheet) for the
antifreeze used to the system
operator/ultimate owner.
Oxygen di usion barrier
under loor tubing
The boiler warranty does not over leaks
resulting from orrosion aused by the use
of underfloor plasti tubing without an
oxygen diffusion barrier. Su h systems must
have the non-oxygen diffusion barrier tubing
separated from the boiler with a heat
ex hanger. Viessmann re ommends the use
of underfloor plasti tubing with an oxygen
diffusion barrier.
Low water cut-o
A low water ut-off may be required by lo al
odes. If boiler is installed above the
radiation level, a low water ut-off devi e of
approved type must be installed in all
instan es. An approved type low water
ut-off devi e must be provided by the
heating ontra tor. Do not install an
isolation valve between the boiler and the
low water ut-off.
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11
Installation Examples
General
The s hemati s on the following pages are
to be seen as guidelines only. They further
do not display all system varieties, safety
devi es, or on epts possible. Spe ifi
system layouts may be further dis ussed
with the lo al Viessmann sales
representative offi e.
Clearances
A minimum of 2” ir umferential learan e
from non-insulated hot water pipes to
ombustible onstru tion must be
maintained. In ases where the pipes are
insulated with pipe insulation of appropriate
and suffi ient thi kness and insulation
values, the above learan e may be redu ed
to 0”.
Waterside low
VR1-22 to -33
VR1-40 to -63
Flow rates
The relationship between boiler flow rate and temperature rise is a ording
to the formula:
Boiler output (Btu/h) = 500 x flow (USGPM) x Rise (°F)
The following hart lists typi al flow rates for the Vitorond boiler:
Boiler Model VR1 -22 -27 -33
20°F rise
30°F rise
USGPM
USGPM
8
5.3
9.2
6.1
12.2
8.1
Boiler Model VR1 -40 -50 -63
20°F rise
30°F rise
USGPM
m
3
/h
USGPM
m
3
/h
14
3.2
9.3
2.1
17.2
3.9
11.5
2.6
21.5
4.9
14.3
3.2
5285 767 v2.2
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e
d
r
o
p
m
3
/h
GPM
5
22
20 50
“w.
.
mbar
2 5
3.2 8
4 10
8 20
12 30
16 40
0.4 1
0.8 2
1.2 3
1.6 4
0.5
2.2
1
4.4
2
9
3
13
4
18
6
26
7
31
Water flow
F
ig. 6

Spe ial Appli ations - Aquastat
12
Boiler in a heating/cooling application
Cooling season starts:
lose valve v1 and open valve v2
Heating season starts:
lose valve v2 and open valve v1
Heating/Cooling unit
Spring-loaded flow he k valve
Cir ulation pump
Automati air vent,
Pressure relief valve
High limit ontrol
Water hiller
Expansion tank
We strongly suggest that the valves
pictured above be labelled “v1” and v2.”
Low water cut-o
A low water ut-off may be required by lo al
odes. If boiler is installed above radiation
level, a low water ut-off devi e of
approved type (field supplied) must be
installed in all instan es. Do not install an
isolation valve between boiler and low water
ut-off.
5285 767 v2.2
v1
v2
F
Fig. 7
5285 767 v2.2
IMPORTANT
5285 767 v2.2
F
Fig. 8

13
Installation Examples - Aquastat
Heating ir uit
Spring-loaded flow he k valve
Cir ulation pump
Automati air vent
Pressure relief valve
High limit ontrol
Expansion tank
5285 767 v2.2
F
Fig. 9

Installation Examples - Vitotroni
14
Without mixing valve
e.g. with Vitotroni 100, Model KW10B
Heating ir uit
Spring-loaded flow he k valve
Cir ulation pump
Automati air vent (field supplied),
pressure relief valve, and
temperature pressure gage
Expansion tank
Without mixing valve and with DHW
e.g. with Vitotroni 100, KW10B
Heating ir uit
Spring-loaded flow he k valve
Cir ulation pump
Automati air vent (field supplied),
pressure relief valve, and
temperature pressure gage
Expansion tank
Domesti hot water storage tank
(indire t-fired)
5285 767 v2.2
Fig. 10
Fig. 11

15
Installation Examples - Vitotroni (continued)
With one low-temperature circuit with
4-way mixing valve,
and with domestic hot water production
e.g. with Vitotroni 200, Model KW2
ombined with one Mixing Valve A tuator
A essory Kit
Heating ir uit
Spring-loaded flow he k valve
Cir ulation pump
Automati air vent (field supplied),
pressure relief valve, and
temperature pressure gage
Expansion tank
Domesti hot water storage tank
(indire t-fired)
4-Way mixing valve
With one low-temperature circuit with
4-way mixing valve, and one high
temperature circuit,
and with domestic hot water
production
e.g. with Vitotroni 200, Model KW2
ombined with one Mixing Valve A tuator
A essory Kit
Heating ir uit
Spring-loaded flow he k valve
Cir ulation pump
Automati air vent (field supplied),
pressure relief valve, and
temperature pressure gage
Expansion tank
Domesti hot water storage tank
(indire t-fired)
4-Way mixing valve
5285 767 v2.2
Fig. 12
Fig. 13

16 Special Applications - Vitotronic
Special Applications - Vitotronic
5285 767 v2.2
T
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Printed on environmentally friendly
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