Viessmann Vitorond 100 Quick guide

Read and save these instructions
for future reference.
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
5285 706 v1.2 10/2004

Safety, Installation and Warranty Requirements
2
Safety, Installation and Warranty 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/orloss 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 Supply.”
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 Supply” 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 Supply.”
HEquipment venting
Never operate boiler without an
installed venting system.Animproper
venting system can cause carbon
monoxide poisoning.
"For information
pertaining to venting
and chimney
requirements, please
see section entitled “Venting
Connection.” All products of
combustion must be safely vented to
the outdoors.
HWarranty
Information contained in
this and related product
documentation must be
read and followed. Failure
to do so renders warranty
null and void.
5285 706 v1.2
Installers must follow local
regulations with respect to
installation of carbon monoxide
detectors. Follow manufacturer’s
maintenance schedule of boiler.
WARNING

Safety, Installation and Warranty Requirements
3
Safety, Installation and Warranty Requirements (continued)
Please ensure that this manual is read and understood before commencing installation. Failure to comply with the issues
listed below and details printed in this manual can cause product/property damage,severe personal injury,and/orloss of life.
Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
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,
movethepersontoadustfree
location.
-Eye irritation
If eyes become irritated, flush
immediately with large amounts of
lukewarm water for at least 15
minutes. Eyelids should be held away
from the eyeball to ensure thorough
rinsing. Do not rub eyes.
-Skin irritation
If skin becomes irritated, remove
soiled clothing. Do not rub or scratch
exposed skin. Wash area of contact
thoroughly with soap and water.
Using a skin cream or lotion after
washing may be helpful.
-Gastrointestinal irritation
If gastrointestinal tract irritation
develops, move the person to a dust
free environment.
Suppliers of fiberglass wool products
recommend the following precautions
be taken when handling these materials:
Precautionary measures
-Avoid breathing fiberglass dust and
contact with skin and eyes.
- Use NIOSH approved dust/mist
respirator.
- Wear long-sleeved, loose fitting
clothing, gloves and eye protection.
- Wash work clothes separately from
other clothing. Rinse washer
thoroughly.
- Operations such as sawing, blowing,
tearout and spraying may generate
airborne fiber concentration requiring
additional protection.
First aid measures
-If eye contact occurs, flush eyes with
water to remove dust. If symptoms
persist, seek medical attention.
- If skin contact occurs, wash affected
areas gently with soap and warm
water after handling.
HHazardous materials
5285 706 v1.2
Inhalation of fiberglass wool and/or
ceramic fiber materials is a possible
cancer hazard. These materials can
also cause respiratory, skin and eye
irritation.
WARNING Appliance materials of construction,
products of combustion and the fuel
contain alumina, silica, heavy metals,
carbon monoxide, nitrogen oxides,
aldehydes and/or other toxic or
harmful substances which can cause
serious injury or loss of life and which
are known to the State of California
to cause cancer, birth defects and
other reproductive harm. Always use
proper safety clothing, respirators and
equipment when servicing or working
nearby the appliance.
WARNING

Contents
4
Page
Safety Important Regulatory and Installation Requirements 6....
General Information About these Installation Instructions 7.................................
Product Information 8................................................................
Mechanical Room 9....................................................................
Fresh Air Combustion Air Supply 10..........................................................
Set-up Product Delivery 12.......................................................................
Recommended Minimum
Clearances for Service 12
...........................................................
Minimum Clearances to Combustibles 13..............................
Boiler Set-up and Location 14....................................................
Connections Venting Connection 20................................................................
Water Side Connections 22........................................................
Safety Connections and
Pressure Testing 23
......................................................................
Install safety devices on boiler 23.............................................
Perform pressure test on boiler 24............................................
Burner Burner Installation 25....................................................................
Burner Information 25...................................................................
Burner Set-up 26.............................................................................
Burner mounting 26........................................................................
Electrical connections 27..............................................................
Oil piping 28.....................................................................................
Wiring Diagram (for Vitorond 100, VR1-40) 29....................
Wiring Diagram (for Vitorond 100, VR1-50, 63) 30.............
Examples Installation Examples 31..............................................................
Special Applications 33................................................................
Boiler in heating/cooling application 33....................................
Low water cut-off 33....................................................................
5285 706 v1.2

5
Page
Initial Start-up and Service Initial Start-up 34...........................................................................
Burner calibration 35......................................................................
Barometric draft regulator 36......................................................
Service Procedure Overview 37................................................
Necessary Tools 38.......................................................................
Service Procedure 38.....................................................................
Additional Information Technical Data 43..........................................................................
Parts List 44....................................................................................
Maintenance Record 47...............................................................
5285 706 v1.2

Safety
6
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 ”WARNING,” ”CAUTION,” and ”IMPORTANT.” See page 7 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 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.
Mechanical room
Ensure the mechanical room complies
with the requirements listed in this
manual. See section entitled Mechanical
Room on page 9.
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.
Working 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 100:
- 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.
5285 706 v1.2

General Information
7
About these Installation 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
informationiswrittenincolumn3.
This symbol indicates that other
instructions must be referenced.
5285 706 v1.2
Warnings draw your attention to the
presence of potential hazards or
important product information.
WARNING
Cautions draw your attention to the
presence of potential hazards or
important product information.
CAUTION
IMPORTANT

General Information
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: 240°F / 110°C
............................................
Maximum allowable working pressure*1: 45psig/3bar........................................
Fuel: #2 fuel oil.............................................................................................................
*1 Cast iron sections are ASME stamped for 58 psig / 4 bar and maximum allowable
temperature of 248°F / 120°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 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.
5285 706 v1.2

General Information
9
Mechanical Room
During the early stages of new home design, we recommend that proper
consideration be given to constructing a separate mechanical room dedicated to gas
or oil fired equipment including domestic hot water storage tanks.
The boiler must be located in a heated indoor space, near a floor drain, and as close
as possible to the vertical chimney or vent.
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.
5285 706 v1.2

Fresh Air
10
Combustion Air Supply
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
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” / 76 mm at any cross-section,
3. When making provision for outside
combustion air, the intake shall not
belessthan1ft/0.3mabovethe
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.
5285 706 v1.2
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
Nevercovertheboilerorstoredebris
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.
WARNING

Fresh Air
11
Combustion Air Supply (continued)
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.
Confined spaces
If the boiler is located in a confined
space and that 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.
Eachopeningshallhaveafreeareaof
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
lengthoflessthan50ft/15m,
havingafreeareaofnotlessthan
1in
2/2000 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
1in
2/4000 Btu/h or 5.5 cm2/kWh of
the total input rating of all appliances
in the enclosure.
Louvres and grilles
In calculating free area as specified
above, consideration shall be given to
the blocking effect of louvers, grilles, or
screens that protect openings. Screens
used shall be not smaller than
¼” / 6 mm mesh and shall be readily
accessible for cleaning. If the free area
through a design of louvre 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.
Installation
Install a combustion air opening. Round
duct diameters are as follows:
Boiler Model Model No. VR1-40 VR1-50 VR1-63
Round duct for combustion air supply *1 Ø” 6 6 7
*1Round duct diameter given is a minimum.
Ensure that all code requirements are met.
5285 706 v1.2

Set-up
12
Product Delivery
Vitorond boilers size VR1-40 to VR1-63 are shipped in a crate with separate boiler
jacketry.
Product delivery
Ensure each of the following has been
delivered:
HCrate with boiler casting
HCrate with insulation jacket
HCarton with burner (shipped
separately)
HCarton with standard installation
equipment
Recommended Minimum Clearances for Service
Boiler
*1 Minimum access for cleaning and
service.
5285 706 v1.2
20” / 508 mm
4” / 100 mm
33½” / 850 mm*1

Set-up
13
Minimum Clearances to Combustibles
For typical installations, Viessmann recommends installing the boiler with
clearances as published on page 10 under Recommended Minimum Clearances for
Service.
Legend
Boiler
Burner
*1 Clearance of 24” / 610 mm required
for burner service.
The following are clearances to
combustibles:
Standard installation
Boiler
Model
VR1 -40 -50 -63
Rear
Sides
Flue
inches
mm
inches
mm
inches
mm
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 -40 -50 -63
Rear
Sides
Flue
Top
inches
mm
inches
mm
inches
mm
inches
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
5285 706 v1.2
min. 6” / 150 mm
min. 9” / 230 mm
min. 0” / 0 mm
min.
24”
610 mm *1
min. 6” / 150 mm
min. 9” / 230 mm
min.
24”
610 mm *1

Set-up
14
Boiler Set-up and Location
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
leveling bolts .
Install temperature and pressure gage
with brass extension coupling in ½”
opening as shown in the illustration on
the left.
Use thread sealing compound such as
pipe dope or Teflon tape.
IMPORTANT
5285 706 v1.2
2.
1.
1.
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.
CAUTION

Set-up
15
Insulation Installation
Cutout facing to the front
All parts necessary to install the
insulation are shipped with the carton
containing the insulation.
1. Install support brackets as shown.
2. Wrap insulation blanket around cast
iron block.
3. Secure insulation blanket with
supplied spring clips.
5285 706 v1.2
4x
M10 1.
2.
3.

Set-up
16
Insulation Installation (continued)
4. Position left side panel onto support
brackets.
5. Line up bottom bracket of side panel
with notch in casting leg.
6. Once side panel is in place, bend
down one part of bracket using
pliers, as shown.
5285 706 v1.2
4.
5.
6.

Set-up
17
Insulation Installation (continued)
Black side facing outward
7. Install rear insulation blanket to cast
iron block.
8. Install rear panel.
5285 706 v1.2
!
7.
8.

Set-up
18
Insulation Installation (continued)
9. Install right side panel to support
brackets. Ensure top of side panel
fits over top of rear panel.
10. Line up bottom bracket of side panel
with notch in casting leg.
11. Once side panel is in place, bend
down one part of bracket using
pliers, as shown.
5285 706 v1.2
!
10.
11.
9.

Set-up
19
Insulation Installation (continued)
12. Install top panel onto support
brackets.
13. Secure top panel with sheet metal
screws.
14. Install front panel to front of boiler.
15. Secure front panel in place by
attaching it to side panels as
shown.
5285 706 v1.2
3.9 x 9.5
13.
12.
15.
15.
14.

Connections
20
Venting Connection
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
HLocal codes or CSA B139-00 in
Canada, or
HNFPA-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:
HCSA Standard CAN/CSA-A405
(National Building Code of Canada) in
Canada, or
HNFPA 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:
HConform 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,
HBe certified and installed in
accordance with the manufacturer’s
certified instructions, and
HBe 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:
HMeet the requirements of NFPA, and
HBe listed, installed and used in
accordance with their listings and
manufacturer’s instructions.
General
The heating contractor shall ensure all
of the following requirements are met:
HThe vent system shall ensure that no
hazard is created by the products of
combustion.
HProvision 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.
HSufficient 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).
HThe 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.
HThe chimney shall be inspected to
ensure that the material construction,
condition, and size are suitable for the
application.
HThis boiler/burner combination shall
not be connected to an unlined
chimney. Such chimneys shall be lined
in accordance with the applicable
codes and standards.
HThe 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.
HAn 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.
HThe vent connector of this boiler must
not be connected into any portion of
mechanical draft systems operating
under positive pressure.
HA 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.
HDown draft and condensation
problems must be corrected.
5285 706 v1.2
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.
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.
WARNING