Viessmann Vitorond 100 User manual

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Hot water heating boiler
91 to 245 MBH / 27 to 72 kW
5285 767 v2.1 09/2012
Technical ata Manual
Model Nos. and pricing: see Price List

Vitorond 100
VR1 Series
Oil-Fired Boiler
of cast iron sectional construction
for hydronic heating systems
with modulating boiler water temperatures
Heating input: 91 to 245 MBH
27 to 72 kW

Product Information
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A genuine triple-pass boiler of cast iron
sectional design. The high-quality
construction and innovative oil heating
technology of this boiler provide a high level
of operational reliability, high-efficiency
operation and reduced emissions.
The bene its at a glance:
HGet the most out o your uel dollar!
Maximum heat extraction with triple-pass
design. A.F.U.E.: up to 86.9%.
HExtremely durable cast iron heat
exchanger for maximum reliability and
service li e.
HClean combustion with Beckett or Riello
burner.
HIntegrated stainless steel combustion
chamber insert for clean and e icient
combustion.
HThick 3½” insulation for extremely low
standby losses and uel savings.
HEasy access
Full-swing left- or right-hinged combustion
chamber door.
HLow maintenance cost with
service-friendly burner and easy-to-clean
flue gas passageways.
HSpacious, wet-base water walls prevent
deposits, reduce stress and increase boiler
li e.
HDirect vent option (up to VR1-33)
eliminates the need for a chimney and
combustion air supply opening.
HMultiple control options:
Choose from a standard 24 VAC room
thermostat or Vitotronic control options
for additional energy savings.
HAdditional energy savings and reduced
emissions with modulating boiler water
temperatures when using Vitotronic control
options.
HBoiler return injector available with
Vitotronic controls protects against
formation of condensation and enables
safe lower-temperature operation for
increased e iciency.
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Product Information
Cut-Away Section
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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Technical ata
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
Boiler dimensions
epth (without burner)
Width
Height
Overall dimensions (with jacket)
Total depth (includes burner)
Total width
Total height (without Vitotronic)
- Height 1 (control unit in
position for operation and
programming)
- Height 2 (control unit in
position for servicing)
Height of boiler stand
inches
mm
inches
mm
inches
mm
inches
mm
inches
mm
inches
mm
inches
mm
inches
mm
inches
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 block
Total weight, boiler with insulation,
burner and boiler control
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
rain valve
inches
inches
inches
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 ∅inches 5 5 5 6 6 6
Required lue dra t “w.c. -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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Technical ata
5
Vitorond 100 with Aquastat
e
f
g
h
d
a
BNR,B
FGC
BHL
BWS,SS
Width
VITOROND 100
5” / 130 m m
9 ¾” / 250 mm
Total width
Fig. 1
B
A
Legend
B Boiler rain
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
Beckett or Riello Burner
Vitorond 100 with Vitotronic Control
e
k
f
g
h
d
9 ¾” / 250 mm
c b epth
a
B
SR,B
FGC
BHL
BWS,SS
A
Width
BTS
VITOROND 100
Total height
Height 2
VIESMANN
Total depth
Total width
Fig. 2
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Technical ata
6
Dimensions
Boiler Model VR1 -22 -27 -33 -40 -50 -63
a
b
c
d
e
f
g
h
k
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
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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Technical ata
7
Minimun Clearances to Combustibles
Standard installation
Boiler
Burner - Riello or Beckett
Boiler
Model
VR1 -22 -27 -33 -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
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
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
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” Vitotronic
installation
min. 6” Aquastat
installation
Fig. 4 Side view
6½”
a
6”
b
All models
Fig. 5

Technical ata
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 Beckett 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 anfoss n.a. 0.60x60°AS n.a. 0.85x60°AH n.a. n.a.
O
i
l
n
o
z
z
l
e
elavan 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 inches
mm
7
178
7
178
7
178
7
178
9
230
9
230
Air tube insertion inches
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 anfoss 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
elavan 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 inches
mm
7
178
7
178
6
5
/
16
160
6
5
/
16
160
6
5
/
16
160
7
178
Air tube insertion inches
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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Technical ata /
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 anfoss n.a. n.a. n.a.
Oil nozzle elavan 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 inches
mm
7
178
7
178
6
5
/
16
160
Air tube insertion inches
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 rain valve
The Boiler Stand must be ordered separately.
H Installation fittings
H Tridicator
H Honeywell aquastat
(with outdoor reset module)
H Beckett burner c/w Viessmann specified
oil nozzle
HRiello burner c/w Viessmann specified
oil nozzle
Boiler Control Alternatives
Honeywell Aquastat Control
High Limit
Model L7248C1006
(with outdoor reset module)
Vitotronic 100, KW10B
enhanced boiler control for modulating
temperature heating systems with
indoor/outdoor system control
Vitotronic 200, KW2
for multiple temperature heating systems
with or without a mixing valve
with indoor/outdoor digital boiler and heating
system control
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IMPORTANT

10
System esign Considerations
System Design Considerations
Chimney
For proper operation of the Vitorond boiler,
all products of combustion must be safely
vented to the outdoors, while ensuring that
flue gases do not cool prematurely.
It is critical that the chimney system be
properly designed to handle the flue gas
temperatures which the Vitorond boiler
produces.
Flue gases which cool too quickly and
produce condensation lead to damages if
the chimney diameter is too large and the
chimney system is not well insulated.
If a calculated chimney diameter lies
between two values, the larger diameter
should be selected.
Intermediate section
The intermediate (vertical and horizontal)
section of venting between the boiler vent
pipe collar and the chimney must be of the
identical diameter as the vent connection of
the boiler. Use the shortest possible path
between the boiler and the chimney. A
maximum of two elbows may be installed in
the intermediate section. Avoid the use of
two level 90° elbows.
The intermediate section must be sealed
pressure tight at the boiler vent pipe collar
and at the chimney connection. Ensure any
test port for combustion values is sealed as
well.
The chimney connection length between the
boiler vent pipe collar and the chimney may
be installed with insulation. We recommend
consulting a reputable chimney installer for
advice in project-specific circumstances.
Barometric damper must be used!
NOTE: irect Vent exhaust system operates
under a positive pressure developed by the
burner. Make sure all vent connections and
observation ports on the boiler are sealed air
tight by tightening screws and using high
temperature silicone sealant if necessary.
The vent components must be supplied
without any alteration except for the length
of the flex pipe which can be cut to the
desired length.
Warranty
Our warranty does not cover damages
resulting from the following:
– installation or service by unqualified and
not licensed personnel
– corrosion caused by flue gas condensation
due to low boiler water and/or return
water temperatures
– operation with contaminated fill and
supplementary feed water
For detailed warranty information, please
read warranty sheet supplied with product.
Combustion air supply
The boiler must not be located in areas or
rooms where chemicals containing chlorine,
bromine, fluorine, or other corrosive
chemicals are stored. Examples include
refrigerants, bleach, paint, paint thinner, hair
spray, cleaning solvents, water softener
salt, etc. The combustion air must not be
contaminated with the above mentioned, or
other aggressive or corrosive chemicals.
Boiler should never be installed in areas
where excessive dust, high humidity, or risk
of frost exist. Ensure adequate ventilation
and supply of fresh combustion air.
Consult Viessmann with uncertainties in
regard to a suitable boiler installation
location.
This boiler/burner unit needs clean fresh air
for safe operation and must be installed so
that there are provisions for adequate
combustion 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 local codes.
The sizing methods outlined in the above
codes should be used when installing a
round duct to supply combustion air from
the outside. Observe local jurisdictional
requirements.
System layout
The boiler water temperature limit is factory
set to 167°F / 75°C (Vitotronic only).
The boiler water temperature limit can be
increased by altering the adjustable high
limit to increase the supply water
temperature.
To minimize piping losses of the system
however, we recommend that the radiation
and domestic hot water production 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
considered in areas of known problems,
such as where a high mineral content and
hardness exist. In areas where freezing
might occur, an antifreeze may be added to
the system water to protect the system.
Please adhere to the specifications given by
the antifreeze manufacturer. o not use
automotive silicate based antifreeze. Please
observe that an antifreeze/water mixture
may require a backflow preventer within the
automatic water feed and influence
components such as diaphragm expansion
tanks, radiation, etc. A 40% antifreeze
content will provide freeze-up protection to
-10°F / -23°C. o not use antifreeze other
than specifically made for hot water heating
systems. System also may contain
components which might be negatively
affected by antifreeze. Check total system
frequently when filled with antifreeze.
Advise system operator/ultimate owner that
system is filled with a glycol mix.
The heating contractor must provide an
MS S (Material Safety ata Sheet) for the
antifreeze used to the system
operator/ultimate owner.
Oxygen di usion barrier
under loor tubing
The boiler warranty does not cover leaks
resulting from corrosion caused by the use
of underfloor plastic tubing without an
oxygen diffusion barrier. Such systems must
have the non-oxygen diffusion barrier tubing
separated from the boiler with a heat
exchanger. Viessmann recommends the use
of underfloor plastic tubing with an oxygen
diffusion barrier.
Low water cut-o
A low water cut-off may be required by local
codes. If boiler is installed above the
radiation level, a low water cut-off device of
approved type must be installed in all
instances. An approved type low water
cut-off device must be provided by the
heating contractor. o not install an
isolation valve between the boiler and the
low water cut-off.
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11
Installation Examples
General
The schematics on the following pages are
to be seen as guidelines only. They further
do not display all system varieties, safety
devices, or concepts possible. Specific
system layouts may be further discussed
with the local Viessmann sales
representative office.
Clearances
A minimum of 2” circumferential clearance
from non-insulated hot water pipes to
combustible construction must be
maintained. In cases where the pipes are
insulated with pipe insulation of appropriate
and sufficient thickness and insulation
values, the above clearance may be reduced
to 0”.
Waterside low
VR1-22 to -33
VR1-40 to -63
Flow rates
The relationship between boiler flow rate and temperature rise is according
to the formula:
Boiler output (Btu/h) = 500 x flow (USGPM) x Rise (°F)
The following chart lists typical 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 v2.1
P
r
e
s
s
u
r
e
d
r
o
p
m
3
/h
GPM
5
22
20 50
“w.c
.
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

Special Applications - Aquastat
12
Boiler in a heating/cooling application
Cooling season starts:
close valve v1 and open valve v2
Heating season starts:
close valve v2 and open valve v1
Heating/Cooling unit
Spring-loaded flow check valve
Circulation pump
Automatic air vent,
Pressure relief valve
High limit control
Water chiller
Expansion tank
We strongly suggest that the valves
pictured above be labelled “v1” and v2.”
Low water cut-o
A low water cut-off may be required by local
codes. If boiler is installed above radiation
level, a low water cut-off device of
approved type (field supplied) must be
installed in all instances. o not install an
isolation valve between boiler and low water
cut-off.
5285 767 v2.1
v1
v2
F
Fig. 7
5285 767 v2.1
IMPORTANT
5285 767 v2.1
F
Fig. 8

13
Installation Examples - Aquastat
Heating circuit
Spring-loaded flow check valve
Circulation pump
Automatic air vent
Pressure relief valve
High limit control
Expansion tank
5285 767 v2.1
F
Fig. 9

Installation Examples - Vitotronic
14
Without mixing valve
e.g. with Vitotronic 100, Model KW10B
Heating circuit
Spring-loaded flow check valve
Circulation pump
Automatic air vent (field supplied),
pressure relief valve, and
temperature pressure gage
Expansion tank
Without mixing valve and with DHW
e.g. with Vitotronic 100, KW10B
Heating circuit
Spring-loaded flow check valve
Circulation pump
Automatic air vent (field supplied),
pressure relief valve, and
temperature pressure gage
Expansion tank
omestic hot water storage tank
(indirect-fired)
5285 767 v2.1
Fig. 10
Fig. 11

15
Installation Examples - Vitotronic (continued)
With one low-temperature circuit with
4-way mixing valve,
and with domestic hot water production
e.g. with Vitotronic 200, Model KW2
combined with one Mixing Valve Actuator
Accessory Kit
Heating circuit
Spring-loaded flow check valve
Circulation pump
Automatic air vent (field supplied),
pressure relief valve, and
temperature pressure gage
Expansion tank
omestic hot water storage tank
(indirect-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 Vitotronic 200, Model KW2
combined with one Mixing Valve Actuator
Accessory Kit
Heating circuit
Spring-loaded flow check valve
Circulation pump
Automatic air vent (field supplied),
pressure relief valve, and
temperature pressure gage
Expansion tank
omestic hot water storage tank
(indirect-fired)
4-Way mixing valve
5285 767 v2.1
Fig. 12
Fig. 13

16 Special Applications - Vitotronic
Special Applications - Vitotronic
5285 767 v2.1
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