Viessmann Vitorond 100 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 91 to 140 MBH
27 to 41 kW
3 1 290 v2.2 01/2011

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.
3 1 290 v2.2
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 1
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
3 1 290 v2.2
Inhalation of fiberglass wool and/or
ceramic fiber materials is a possible
cancer hazard. These materials can
also cause respiratory, skin and eye
irritation.
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 and Installation Requirements 6....
General Information About these Instructions 7.......................................................
Product Information 8................................................................
Mechanical Room 9....................................................................
Fresh Air Combustion Air Supply 10. . ........................................................
Set-up Product Delivery 12.......................................................................
Unpacking Instructions 12..........................................................
Minimum Clearances to Combustibles 13..............................
Recommended Minimum Clearances for Service 14...........
Boiler Set-up and Location 14....................................................
Combustion Chamber Insert 1..................................................
Connections Venting Connection 16................................................................
ater Side Connections (with Aquastat Control) 18..........
Safety Connections (with Aquastat Control) 19...................
Install safety devices on boiler 19.............................................
ater Side Connections (with Vitotronic Control) 21.........
Safety Connections (with Vitotronic Control) 22..................
Install safety devices on boiler 22.............................................
Pressure Testing 24......................................................................
Burner (Beckett) Burner Installation 2....................................................................
Burner Information 2...................................................................
Burner mounting 26........................................................................
Oil piping 27.....................................................................................
Electrical connections (with Aquastat control) 28................
Wiring diagram (with Aquastat control) 30.............................
Wiring diagram (Vitorond 100 with Beckett burner and
Honeywell Aquastat) 31...............................................................
Burner Set-up (Beckett) 32..........................................................
Electrical connections (with Vitotronic control) 32..............
Installation of Vitotronic control 33..........................................
Boiler coding card 3.....................................................................
Electrical connections (with Vitotronic control) 36..............
Wiring diagram (with Vitotronic control) 38...........................
Wiring diagram (Vitorond 100 with Beckett burner,
GeniSys control and Vitotronic control) 39.............................
3 1 290 v2.23 1 290 v2.2

Contents
5
Burner (Riello) Burner Installation 40....................................................................
Burner Information 40...................................................................
Burner Set-up (Riello) 41...............................................................
Burner mounting 41........................................................................
Oil piping 42.....................................................................................
Electrical connections (with Aquastat control) 43................
Wiring harness connection to Honeywell high limit
and Riello burner sub-base (with Aquastat control) 44.......
Wiring diagram (with Aquastat control) 4.............................
Installation of Vitotronic control 46..........................................
Electrical connections (with Vitotronic control) 48..............
Wiring diagram (with Vitotronic control) 1...........................
Boiler coding card 2.....................................................................
Initial Start-up Initial Start-up 3...........................................................................
Burner calibration 4......................................................................
Beckett burner calibration ......................................................
Riello burner calibration 6..........................................................
Barometric draft regulator 6......................................................
Examples Installation Examples 7..............................................................
Installation Examples - Aquastat 8.........................................
Special Applications - Aquastat 9..........................................
Boiler in heating/cooling application 9....................................
Low water cut-off 9....................................................................
Installation Examples - Vitotronic 60.......................................
Special Applications - Vitotronic 62.........................................
Boiler in heating/cooling application 62....................................
Low water cut-off 62....................................................................
Service Service Procedure Overview 63................................................
Necessary Tools 64.......................................................................
Service Procedure 64.....................................................................
Additional Information
Parts List 69....................................................................................
Maintenance Record 71...............................................................
3 1 290 v2.2

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 ” ARNING,” ”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 10.
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 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.
Safety
3 1 290 v2.2

General Information
7
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.
3 1 290 v2.2
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
3 1 290 v2.2

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 (Aquastat): 240°F / 110°C.......................
Maximum allowable working pressure
*1
: 4 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 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.
3 1 290 v2.2

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 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” / 4 7 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.
3 1 290 v2.2

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
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.
3 1 290 v2.2
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.
ARNING
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.
ARNING
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.
ARNING