Viessmann FDVS-4 User manual

Safety and Installation Requirements
Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the
instructions listed below can cause product/property damage,severe personal injury, and/or loss of life.
Working on the equipment
The installation, adjustment, service,
and maintenance of this product 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 user serviceable parts on
the boiler, burner, or control.
Ensure main power supply to
equipment, the heatin system, and all
external controls has been deactivated.
Close main oil supply valve. Take
precautions in both instances to avoid
accidental activation of power durin
service work.
Ensure that the installation
literature of other applicable
components is referenced.
General nformation
Standard installation
Boiler
Model
VR1 -22 -27 -33
Rear
Sides
Flue
inches
mm
inches
mm
inches
mm
6
150
0
0
1
25
6
150
0
0
1
25
6
150
0
0
1
25
Floor Combustibles
Alcove installation
Boiler
Model
VR1 -22 -27 -33
Rear
Sides
Flue
Top*
inches
mm
inches
mm
inches
mm
inches
mm
6
150
0
0
1
25
6
150
6
150
0
0
1
25
6
150
6
150
0
0
1
25
6
150
Floor Combustibles
* 24” with Vitotronic control.
The insulated oil direct vent system is
rated for a 1” clearance to
combustibles.
Advise owner to keep direct vent
termination and air intake free of
debris, snow and ice.
NOTE: Surface discoloration on the
outside of the buildin may occur if the
burner is not properly adjusted.
Viessmann will not accept any
responsibility for such discoloration.
NOTE: Direct Vent exhaust system
operates under a positive pressure
developed by the burner. Make sure all
vent connections and observation port
on the boiler are sealed air-ti ht by
ti htenin screws and usin hi h
temperature silicone sealant if
necessary.
NOTE: The vent components must be
supplied without any alteration except
for the len th of the flex pipe to be cut
to the desired len th.
Please file in Service Binder
5351 050 v2.5 09/2012
Installation Instructions
Supplement
for use by heating contractor
Direct Vent Systems, Part No. Z005 875 (FDVS-4)
for Vitorond 100 boilers
MPORTANT
Viessmann will not assume any
responsibility for possible effects of
an obstructed air intake or exhaust
termination.
WARN NG

Installation
2
nstallation of nsulated Stainless Steel Flexible Oil Vent
In addition to the following
instructions, also consult
Field Controls Direct Vent
ystem manual for detailed
instructions on how to install
the venting system.
Use a 4” to 3” reducer (not supplied)
to connect an intake pipe to the Riello
burner.
If no air intake is required a=0 then
provide combustion air supply to
mechanical room where the burner is
installed. The burner requires fresh air
for safe operation and must be installed
in a mechanical room where there are
provisions for adequate combustion
and ventilation air.
Refer to Vitorond 100
Installation and ervice
Instructions.
Avoid dips in the ventin system when
usin the flexible insulated stainless
steel oil vent.
The direct vent kit includes a VRV-4
vacuum relief valve which must be
installed in the air intake pipe as close
as possible to the burner when usin a
Beckett burner (see Fi . 1).
*The direct vent kit includes a
Viessmann-specific stainless steel
boiler-to-vent transition adaptor.
Do not install the regular galvanized
vent pipe adaptor shipped with the
boiler. This galvanized vent pipe
adaptor is intended for chimney venting
application and therefore must be
discarded in a direct vent application.
5351 050 v2.5
*Boiler-to-vent
transition adaptor
(stainless steel)
Supports
Smoke test port
Exhaust
12” min. above
anticipated snow line
VRV-4
Vacuum
Relief
Valve
b=15’
a=20’
(max. 2 x 90°elbows)
Each 90° elbow = 3’ e.q.L.
R
1
=min. wall clearance 28”
(for min. bend radius of
flexible vent pipe)
Ø4”
max. 3’
b
Air intake
R
1
Fig. 1
a
MPORTANT

Burner - Beckett
Fig. 2
3
Burner Set-up (Beckett)
Electrical connections (with Aquastat control)
Installations must follow these codes
and requirements:
- National Electrical Code, ANSI/NFPA
70, latest edition and any addtional
national, state or local codes.
- In Canada, CSA C22.1 Canadian
Electrical Code Part 1 and any local
codes.
- Wirin must be N.E.C. Class 1. If
ori inal wire as supplied with boiler
must be replaced, type 105°C wire
or equivalent must be used. Supply
wirin to boiler and additional control
wirin must be 14 a. or heavier.
- Provide electrical round at boiler as
required by codes.
" All field supplied nominal 120 VAC voltage wiring must be sheathed in a flexible metal conduit.
" Disconnect means, overload protection and low water cut-off must be provided as required by local codes.
" Connect incoming line voltage HOT (L1) wire to terminal L1, and N to terminal L2 of the Honeywell high limit control (see
wiring diagram on page 5.
Legend
Cable strap (supplied)
Honeywell hi h limit control
Burner wirin harness (supplied)
Burner wiring
The R7184 or GeniSys 7505P primary
control with valve-on delay (pre-purge)
and burner motor-off delay (post-purge
- factory default settings can be field
adjusted), requires a constant 120
VAC power source supplied to the
BLACK wire on the control (see wiring
diagram on following page).
1. The cover mountin plate is not a
conduit connection point. Pass
conduit and attached connector
throu h the front openin in the
mountin plate or throu h one of the
knockouts on either side of the cover
and attach it directly to the
burner-mounted 4x4 electrical
junction box.
Room thermostat wiring
1. Install thermostat on inside wall
away from influences of drafts, hot
or cold water pipes, li htin fixtures,
television, sun rays or fireplaces.
2. Follow instructions supplied with
room thermostat. If it has a heat
anticipator, set heat anticipator in
thermostat to match power
requirements of equipment
connected to it. Boiler wirin
dia rams ive settin for standard
equipment.
5351 050 v2.5
Electric shock hazard. Can cause
severe personal injury or loss of life if
power source, including service
switch on boiler, is not disconnected
before installing or servicing.
WARN NG
Ensure that burner wiring harness is
properly attached and secured to the
boiler side panel using the supplied
cable straps as depicted above. The
cable strap must be coiled on the
boiler side panel so that no slack is
left, allowing the burner/boiler door
to be swung open without
disconnecting the burner wiring
harness from the burner. Failure to
heed this warning may result in
personal injury.
WARN NG
MPORTANT

Burner - Beckett
4
Burner Set-up (Beckett) (continued)
Electrical connections (with Aquastat control) (continued)
Installations must follow these codes
and requirements:
- National Electrical Code, ANSI/NFPA
70, latest edition and any addtional
national, state or local codes.
- In Canada, CSA C22.1 Canadian
Electrical Code Part 1 and any local
codes.
- Wirin must be N.E.C. Class 1. If
ori inal wire as supplied with boiler
must be replaced, type 105°C wire
or equivalent must be used. Supply
wirin to boiler and additional control
wirin must be 14 a. or heavier.
- Provide electrical round at boiler as
required by codes.
Burner wiring harness (supplied)
Fig. 3
5351 050 v2.5
Electric shock hazard. Can cause
severe personal injury or loss of life if
power source, including service
switch on boiler, is not disconnected
before installing or servicing.
WARN NG
white
black
red
15” *
1/4 quick
connect
insulated
fla
white black
red
round
round

Burner - Beckett
5
Burner Set-up (Beckett) (continued)
Wiring diagram (with Aquastat control) with outdoor reset module
Installations must follow these codes
and requirements:
- National Electrical Code, ANSI/NFPA
70, latest edition and any additional
national, state or local codes.
- In Canada, CSA C22.1 Canadian
Electrical Code Part 1 and any local
codes.
- Wirin must be N.E.C. Class 1. If
ori inal wire as supplied with boiler
must be replaced, type 105°C wire
or equivalent must be used. Supply
wirin to boiler and additional control
wirin must be 14 a. or heavier.
- Provide electrical round at boiler as
required by codes.
" All field supplied nominal 120 VAC voltage wiring must be sheathed in a flexible metal conduit.
" Disconnect means, overload protection and low water cut-off must be provided as required by local codes.
" Connect incoming line voltage HOT (L1) wire to terminal L1, and N to terminal L2 of the Honeywell high limit control (see
wiring diagram below).
Fig. 4
Legend
Oil solenoid valve
I nition transformer
Burner motor
CAD cell flame detector
Burner roundin screw
R7184 Series primary control
with post-pur e (factory default
settin : 30 sec. - can be field
adjusted; see Beckett burner
manual)
Factory-installed jumper
5351 050 v2.5
Electric shock hazard. Can cause
severe personal injury or loss of life if
power source, including service
switch on boiler, is not disconnected
before installing or servicing.
WARN NG
Ensure that the burner cycles ON and
OFF on proper call for heat before
leaving the job site. Failure to do so
may lead to boiler runaway situation,
which may lead to property damage,
personal injury or death.
WARN NG
A field supplied manual reset high
limit control must be installed at the
outlet pipe of the boiler to interrupt
burner operation should the factory
supplied high limit control fail. This
field supplied high limit control must
be set 20°F above the setting of the
factory supplied high limit control.
The setting of this field supplied high
limit control must never be greater
than 220°F.
CAUT ON

Burner - Beckett
6
Burner Set-up (Beckett burner with GeniSys primary control) (continued)
Wiring diagram (Vitorond 100 with Beckett (NX) burner and Honeywell Aquastat)
Installations must follow these codes
and requirements:
- National Electrical Code, ANSI/NFPA
70, latest edition and any additional
national, state or local codes.
- In Canada, CSA C22.1 Canadian
Electrical Code Part 1 and any local
codes.
- Wirin must be N.E.C. Class 1. If
ori inal wire as supplied with boiler
must be replaced, type 105°C wire
or equivalent must be used. Supply
wirin to boiler and additional control
wirin must be 14 a. or heavier.
- Provide electrical round at boiler as
required by codes.
" All field supplied nominal 120 VAC voltage wiring must be sheathed in a flexible metal conduit.
" Disconnect means, overload protection and low water cut-off must be provided as required by local codes.
" Connect incoming line voltage HOT (L1) wire to terminal L1, and N to terminal L2 of the Honeywell high limit control (see
wiring diagram below).
Fig. 5
5351 050 v2.5
Electric shock hazard. Can cause
severe personal injury or loss of life
if power source, including service
switch on boiler, is not disconnected
before installing or servicing.
WARN NG
Ensure that the burner cycles ON and
OFF on proper call for heat before
leaving the job site. Failure to do so
may lead to boiler runaway situation,
which may lead to property damage,
personal injury or death.
WARN NG
A field supplied manual reset high
limit control must be installed at the
outlet pipe of the boiler to interrupt
burner operation should the factory
supplied high limit control fail. This
field supplied high limit control must
be set 20°F above the setting of the
factory supplied high limit control.
The setting of this field supplied high
limit control must never be greater
than 220°F.
CAUT ON

Burner - Beckett
1.
2.
Fig. 6
41
#41 plu -in connector
7
Burner Set-up (Beckett) (continued)
Electrical connections (with Vitotronic control)
Installations must follow these codes
and requirements:
- National Electrical Code, ANSI/NFPA
70, latest edition and any addtional
national, state or local codes.
- In Canada, CSA C22.1 Canadian
Electrical Code Part 1 and any local
codes.
- Wirin must be N.E.C. Class 1. If
ori inal wire as supplied with boiler
must be replaced, type 105°C wire
or equivalent must be used. Supply
wirin to boiler and additional control
wirin must be 14 a. or heavier.
- Provide electrical round at boiler as
required by codes.
Burner wiring
The R7184 primary control with
valve-on delay (pre-purge) and burner
motor-off delay (post-purge - factory
default settings can be field
adjusted), requires a constant 120
VAC power source supplied to the
BLACK wire on the control (see
wiring diagram on page 9).
1. The cover mountin plate is not a
conduit connection point. Pass
conduit and attached connector
throu h the front openin in the
mountin plate or throu h one of the
knockouts on either side of the cover
and attach it directly to the
burner-mounted 4x4 electrical
junction box.
Electrical connections
1.Run the plu -in connector cable of
the Vitotronic control down behind
the front panel of the boiler and out
throu h the bottom. (Fi . 5)
2.Connect the female plu of the
burner to the male plu of the
Vitotronic control. (Fi . 5)
5351 050 v2.5
Electric shock hazard. Can cause
severe personal injury or loss of life if
power source, including service
switch on boiler, is not disconnected
before installing or servicing.
WARN NG
MPORTANT

Connections
8
Burner Set-up (Beckett) (continued)
Electrical connections (with Vitotronic control) (continued)
Room thermostat wiring
1. Install thermostat on inside wall
away from influences of drafts, hot
or cold water pipes, li htin fixtures,
television, sun rays or fireplaces.
2. Follow instructions supplied with
room thermostat. If it has a heat
anticipator, set heat anticipator in
thermostat to match power
requirements of equipment
connected to it. Boiler wirin
dia rams ive settin for standard
equipment.
5351 050 v2.5

Connections
9
Burner Set-up (Beckett) (continued)
Electrical connections (with Vitotronic control) (continued)
Burner wiring harness (supplied)
Fig. 7
Le end
BL Blue
O Oran e
BK Black
W White
G Green / Ground
R Red
*If Beckett burner is bein installed,
cut this len th to 6” for connection
to burner junction box (located
under the burner primary control).
Installations must follow these codes
and requirements:
- National Electrical Code, ANSI/NFPA
70, latest edition and any addtional
national, state or local codes.
- In Canada, CSA C22.1 Canadian
Electrical Code Part 1 and any local
codes.
- Wirin must be N.E.C. Class 1. If
ori inal wire as supplied with boiler
must be replaced, type 105°C wire
or equivalent must be used. Supply
wirin to boiler and additional control
wirin must be 14 a. or heavier.
- Provide electrical round at boiler as
required by codes.
5351 050 v2.5
Electric shock hazard. Can cause
severe personal injury or loss of life if
power source, including service
switch on boiler, is not disconnected
before installing or servicing.
WARN NG
Jumper
RED
Viessmann #41-plu
control connection
BL
O
BK
W
G
R
B4
S3
T2
T1
N
G
L1
18” *
Blue
Closed end connectors are factory installed on
RED, ORANGE and BLUE wires. These RED,
ORANGE and BLUE wires may or may not be
used in your burner application. See wirin
dia ram in this manual which is specific to your
burner application. Do not remove or cut any of
the closed end connectors of the RED, ORANGE
or BLUE wires, unless it is necessary to do so.
RED wire is live (120VAC) at all times. Do not
remove or cut its closed end connector unless it
is necessary to do so. Failure to heed the above
instructions may cause severe personal injury or
loss of life.

Connections
10
Burner Set-up (Beckett) (continued)
Wiring diagram (with Vitotronic control)
Installations must follow these codes
and requirements:
- National Electrical Code, ANSI/NFPA
70, latest edition and any additional
national, state or local codes.
- In Canada, CSA C22.1 Canadian
Electrical Code Part 1 and any local
codes.
- Wirin must be N.E.C. Class 1. If
ori inal wire as supplied with boiler
must be replaced, type 105°C wire
or equivalent must be used. Supply
wirin to boiler and additional control
wirin must be 14 a. or heavier.
- Provide electrical round at boiler as
required by codes.
Legend
Oil solenoid valve
I nition transformer
Burner motor
CAD cell flame detector
Burner roundin screw
R7184 Series primary control
with post-pur e (factory default
settin : 30 sec. - can be field
adjusted; see Beckett burner
manual)
Factory-installed jumper
5351 050 v2.5
Electric shock hazard. Can cause
severe personal injury or loss of life if
power source, including service
switch on boiler, is not disconnected
before installing or servicing.
WARN NG
Blue and oran e wires not used in this
application. DO NOT cut or remove closed
end connector from the wires.
120 VAC
power supply
installer must
provide 15A
overcurrent
protection
Main
ON/OFF
switch
(field supplied)
Low water
cut-off
(if required)
(field supplied)
G
L1
T1
T2
N
S3
B4
BK
W
G
R
Y
Y
O
BL
W
V
BK
R
BL
O
T
T
Factory
installed
jumper
1
41
1
2
2
Burner junction box
120 VAC receptacle
(field supplied)
120 VAC
power
supply
to boiler
Power supply. Provide disconnect
means and overload protection as
required.
Control case must be connected
to earth round.
G
L1
T1
T2
N
S3
B4
Refer to Vitotronic
200/300 (KW2/KW3)
for alternate connection
location of LWCO.
Fig. 8
O
Legend
Y Yellow
BL Blue
BK Black
O Oran e
W White
G Green / Ground
R Red
GY Gray
BR Brown
V Violet
41
O
BL
W
BK
G
R
Vitotronic Control
(Refer to correspondin Vitotronic Control manual)
2
Ensure that the burner cycles ON and
OFF on proper call for heat before
leaving the job site. Failure to do so
may lead to boiler runaway situation,
which may lead to property damage,
personal injury or death.
WARN NG