Viessmann VITOROND 100 VR1 Series Quick guide

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IMPORTANT
VITOROND 100
Installation and
Service Instructions
for use by heating contractor
Vitorond 100
VR1 Series
Oil-Fired Boiler
Heating input 161 to 245 MBH
47 to 72 kW
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Safety, Installation and Warranty Requirements
2
Safety, Installation and arranty Requirements
Please ensure that this manual is read and understood before commencing installation. Failure to comply with the issues
listed below and details printed in this manual can cause product/property damage,severe personal injury, and/or loss of life.
Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
HLicensed professional heating
contractor
The installation, adjustment, service,
and maintenance of this equipment
must be performed by a licensed
professional heating contractor.
"
Please see section
entitled “Important
Regulatory and
Installation
Requirements.”
HProduct documentation
Read all applicable documentation
before commencing installation. Store
documentation near boiler in a readily
accessible location for reference in
the future by service personnel.
"
For a listing of
applicable literature,
please see section
entitled “Important
Regulatory and
Installation Requirements.”
HAdvice to owner
Once the installation work is
complete, the heating contractor must
familiarize the system
operator/ultimate owner with all
equipment, as well as safety
precautions/requirements, shut-down
procedure, and the need for
professional service annually before
the heating season begins.
HContaminated air
Air contaminated by chemicals can
cause by-products in the combustion
process which are poisonous to
inhabitants and destructive to
Viessmann equipment.
"
For a listing of
chemicals which cannot
be stored in or near the
boiler room, please see
section entitled
“Combustion Air upply.”
HCarbon monoxide
Improper installation, adjustment,
service and/or maintenance can cause
flue products to flow into living space.
Flue products contain poisonous
carbon monoxide gas.
"
For information
pertaining to the proper
installation, adjustment,
service and maintenance
of this equipment to
avoid formation of carbon monoxide,
please see sections entitled
“Combustion Air upply” and “Venting
Connection.”
HFresh air
This equipment requires fresh air for
safe operation and must be installed
ensuring provisions for adequate
combustion and ventilation air exist.
"
For information
pertaining to the fresh
air requirements of this
product, please see
section entitled
“Combustion Air upply.”
HEquipment venting
Never operate boiler without an
installed venting system. An improper
venting system can cause carbon
monoxide poisoning.
"
For information
pertaining to venting
and chimney
requirements, please
see section entitled “Venting
Connection.” All products of
combustion must be safely vented to
the outdoors.
Harranty
Information contained in
this and related product
documentation must be
read and followed. Failure
to do so renders warranty
null and void.
5671 44 v1.
Installers must follow local
regulations with respect to
installation of carbon monoxide
detectors. Follow manufacturer’s
maintenance schedule of boiler.
ARNING

Safety, Installation and Warranty Requirements
3
Safety, Installation and arranty Requirements (continued)
HFiberglass wool and ceramic fiber
materials
The state of California has listed the
airborne fibers of these materials as a
possible cancer hazard through
inhalation. When handling these
materials, special care must be applied.
Suppliers of ceramic fiber products
recommend the following first aid
measures:
-Respiratory tract (nose and throat)
irritation
If respiratory tract irritation develops,
move the person to a dust free
location.
-Eye irritation
If eyes become irritated, flush
immediately with large amounts of
lukewarm water for at least 15
minutes. Eyelids should be held away
from the eyeball to ensure thorough
rinsing. Do not rub eyes.
-kin irritation
If skin becomes irritated, remove
soiled clothing. Do not rub or scratch
exposed skin. Wash area of contact
thoroughly with soap and water.
Using a skin cream or lotion after
washing may be helpful.
-Gastrointestinal irritation
If gastrointestinal tract irritation
develops, move the person to a dust
free environment.
Suppliers of fiberglass wool products
recommend the following precautions
be taken when handling these materials:
Precautionary measures
-Avoid breathing fiberglass dust and
contact with skin and eyes.
- Use NIOSH approved dust/mist
respirator.
- Wear long-sleeved, loose fitting
clothing, gloves and eye protection.
- Wash work clothes separately from
other clothing. Rinse washer
thoroughly.
- Operations such as sawing, blowing,
tearout and spraying may generate
airborne fiber concentration requiring
additional protection.
First aid measures
-If eye contact occurs, flush eyes with
water to remove dust. If symptoms
persist, seek medical attention.
- If skin contact occurs, wash affected
areas gently with soap and warm
water after handling.
HHazardous materials
5671 44 v1.
Inhalation of fiberglass wool and/or
ceramic fiber materials is a possible
cancer hazard. These materials can
also cause respiratory, skin and eye
irritation.
ARNING Appliance materials of construction,
products of combustion and the fuel
contain alumina, silica, heavy metals,
carbon monoxide, nitrogen oxides,
aldehydes and/or other toxic or
harmful substances which can cause
serious injury or loss of life and which
are known to the State of California
to cause cancer, birth defects and
other reproductive harm. Always use
proper safety clothing, respirators and
equipment when servicing or working
nearby the appliance.
ARNING

Contents
4
Page
Safety Important Regulatory, Installation Requirements 7...........
General Information About these Instructions 8.......................................................
Product Information 9................................................................
Mechanical Room 1....................................................................
Fresh Air Combustion Air Supply 11..........................................................
Set-up Product Delivery 13.......................................................................
Unpacking Instructions 13..........................................................
Minimum Clearances to Combustibles 14..............................
Recommended Minimum
Clearances for Service 15...........................................................
Boiler Set-up and Location 15....................................................
Insulation Installation 16...............................................................
Combustion Chamber Insert 19..................................................
Connections Venting Connection 2................................................................
ater Side Connections (with Aquastat Control) 22..........
Safety Connections (with Aquastat Control) 23...................
Install safety devices on boiler 23.............................................
ater Side Connections (with Vitotronic Control) 25........
Safety Connections (with Vitotronic Control) 26..................
Install safety devices on boiler 26.............................................
Pressure Testing 28......................................................................
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Contents (continued)
5
Burner (Beckett) Burner Installation 29....................................................................
Burner Information 29...................................................................
Burner Set-up (Beckett) 3..........................................................
Burner mounting 3........................................................................
Oil piping 31.....................................................................................
Electrical connections (with Aquastat Control) 32...............
Wiring diagram (with Aquastat Control for NX
burner for Vitorond 1 , VR1-4 ) 34.......................................
Wiring diagram (Vitorond 1 , VR1-4 , -5 and -63
with Beckett burner, GeniSys control and
Honeywell Aquastat) 35...............................................................
Electrical connections (with Vitotronic Control) 36..............
Installation of Vitotronic control 37..........................................
Boiler coding card 39.....................................................................
Pump junction box (with Vitotronic Control) 4....................
Wiring diagram (with Vitotronic Control) 42...........................
Wiring diagram (Vitorond 1 ,with Beckett burner,
GeniSys control and Vitotronic Control) 43............................
Burner (Riello) Burner Installation 44....................................................................
Burner Information 44...................................................................
Burner Set-up (Riello) 45...............................................................
Burner mounting 45........................................................................
Oil piping 46.....................................................................................
Electrical connections (with Aquastat Control) 47...............
Wiring harness connection to Honeywell high limit
and Riello burner sub-base (with Aquastat Control) 48.......
Wiring diagram (with Aquastat Control) 49............................
Installation of Vitotronic control 5..........................................
Electrical connections (with Vitotronic Control) 52..............
Wiring diagram (with Vitotronic Control) 55...........................
Boiler coding card 55.....................................................................
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Contents
6
Page
Initial Start-up Initial Start-up 57...........................................................................
Burner calibration 58......................................................................
Beckett burner calibration 59......................................................
Riello burner calibration 6..........................................................
Barometric draft regulator 6......................................................
Examples Installation Examples 61..............................................................
Installation Examples (Aquastat) 62.........................................
Special Applications (Aquastat) 63..........................................
Boiler in heating/cooling application 63....................................
Low water cut-off 63....................................................................
Installation Examples (Vitotronic) 64.......................................
Special Applications (Vitotronic) 66.........................................
Boiler in heating/cooling application 66....................................
Low water cut-off 66....................................................................
Service Service Procedure Overview 67................................................
Necessary Tools 68.......................................................................
Service Procedure 68.....................................................................
Additional Information Parts List 73....................................................................................
Maintenance Record ...............................................................
NO TAG
5671 44 v1.

Safety
7
Important Regulatory and Installation Requirements
Take note of all symbols and notations intended to draw attention to potential hazards or important product
information. These include ” ARNING,” ”CAUTION,” and ”IMPORTANT.” See page 8 for details.
Codes
The installation of this unit shall be in
accordance with local codes. In the
absence of local codes, use:
HCSA B-139 for oil installations in
Canada
HNFPA 31 Standard for the Installation
of Oil Burning Equipment in the US
Always use latest editions of codes.
All electrical wiring is to be done in
accordance with the latest edition of
CSA C22.1 Part 1 and/or local codes. In
the U.S. use the National Electrical
Code ANSI/NFPA 7 . The heating
contractor must also conform to the
Standard for Controls and Safety
Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1 where required by
the authority having jurisdiction.
Mechanical room
Ensure the mechanical room complies
with the requirements listed in this
manual. See section entitled Mechanical
Room on page 1 .
Please carefully read this manual prior
to attempting installation. Any
warranty is null and void if these
instructions are not followed.
For information regarding other
Viessmann ystem Technology
componentry, please reference
documentation of the respective
product.
We offer frequent installation and
service seminars to familiarize our
partners with our products. Please
inquire.
orking on the equipment
The installation, adjustment, service,
and maintenance of this boiler must be
done by a licensed professional heating
contractor who is qualified and
experienced in the installation, service,
and maintenance of hot water boilers.
There are no end user serviceable parts
on the boiler, burner, or control.
Ensure main power supply to
equipment, the heating system, and all
external controls has been deactivated.
Close main oil supply valve. Take
precautions in both instances to avoid
accidental activation of power during
service work.
The completeness and functionality of
field supplied electrical controls and
components must be verified by the
heating contractor. These include
low-water cut-offs, flow switches (if
used), staging controls, pumps,
motorized valves, air vents,
thermostats, etc.
Technical literature
Literature applicable to all aspects of
the Vitorond 1 :
- Installation, Service and Operating
Instructions
- Installation codes mentioned
in this manual
Leave all literature at the installation
site and advise the system
operator/ultimate owner where the
literature can be found. Contact
Viessmann for additional copies.
This product comes with several
safety instruction labels attached.
Do not remove!
Contact Viessmann immediately if
replacement labels are required.
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General Information
8
About these Instructions
Symbols and flag words used in these instructions
The following symbols and flag words are utilized in these
Installation Instructions:
Indicates an imminently hazardous
situation which, if not avoided, could
result in death, serious injury or
substantial product/property damage.
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or
product/property damage.
Helpful hints for installation, operation
or maintenance which pertain to the
product.
Helpful hints for installation, operation
or maintenance which pertain to the
product.
This symbol indicates that additional
information is written in column 3.
This symbol indicates that other
instructions must be referenced.
Please note
Viessmann Manufacturing Company Inc. reserves the right to make product
changes or updates without notice and will not be held liable for typographical
errors or omissions in the product literature.
5671 44 v1.
arnings draw your attention to the
presence of potential hazards or
important product information.
ARNING
Cautions draw your attention to the
presence of potential hazards or
important product information.
CAUTION
IMPORTANT
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General Information
9
Product Information
Sectional gray cast-iron boiler with triple-pass design.
For operation in closed loop, forced circulation hot water heating systems. This
boiler does not require a flow switch.
The boiler model size selected should be based on an accurate heat loss calculation
of the building. The boiler selected must be compatible with the connected
radiation.
Maximum adjustable high limit setting (Aquastat): 24 °F / 11 °C
.......................
Maximum allowable working pressure
*1
: 45 psig / 3 bar........................................
Fuel: #2 fuel oil.............................................................................................................
*1
Cast iron sections are A ME stamped for 58 psig / 4 bar and maximum allowable
temperature of 250°F / 121°C.
Supply/return bypass for large water content systems
For boilers connected to large water content systems (typically systems with
volume > 1 USG / 3.8 ltr for every 13 Btu/h of boiler input), such as a previous
gravity system with large free-standing radiators, a bypass line from the supply pipe
to the return pipe must be used to avoid flue gas condensation in the heat
exchanger and the vent system. A bypass can be installed on any system as a
preventative measure. Viessmann strongly recommends installing a bypass pipe on
all cast iron boilers.
IMPORTANT
This boiler is equipped with an outdoor reset module that saves energy by reducing
the boiler water temperature as the heating load decreases. This feature is equipped
with an override which is provided primarily to permit the use of an external energy
management system that serves the same function.
THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE
FOLLO ING CONDITIONS IS TRUE:
- an external energy management system is installed that reduces the boiler water
temperature as the heating load decreases.
- This boiler is not used for any space heating.
- This boiler is part of a modular or multiple boiler system having a total input of
300,000 BTU/hr or greater.
- This boiler is equipped with a tankless coil.
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General Information
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 should be located in a heated indoor space, near a floor drain, and as
close as possible to the vertical chimney or vent.
Install the boiler on a concrete foundation if:
- the floor may be flooded,
- the floor is not level,
- the boiler will be installed in a residential garage (in this case ensure that the
burner is raised at least 18” / 457 mm above the floor to avoid contact with
flammable vapors and fumes).
Viessmann strongly recommends installing the boiler on a concrete foundation.
Whenever possible install boiler near an outside wall so that it is easy to duct fresh
air directly to the boiler area. In addition, do not use exhaust fans in the boiler room
and do not install the boiler in rooms with refrigeration equipment. This equipment
requires uncontaminated outside air for safe operation - do not install where
chemicals are stored or in a room with negative pressure. See section entitled
“Combustion Air Supply” for further details regarding the above.
Locate boiler on flooring capable of supporting the weight of the boiler filled with
water. Ensure that the boiler location does not interfere with the proper circulation
of combustion and ventilation air within the mechanical room.
5671 44 v1.