Installation and Service Instructions - Yaun Cobe taken when handling these materials: Precautionary measures-Avoid breathing fiberglass dust and contact with skin and eyes. - Use

Read and save these instructionsfor future reference.

IMPORTANT

VITOROND 100

Installation andService Instructionsfor use by heating contractor

Vitorond 100VR1 SeriesOil-Fired Boiler

Heating input 91 to 140 MBH27 to 41 kW

5285 705 v1.2 10/2004

Safety, Installation and Warranty Requirements

2


Please ensure that this manual is read and understood before commencing installation. Failure to comply with the issueslisted 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).

H Licensed professional heatingcontractorThe installation, adjustment, service,and maintenance of this equipmentmust be performed by a licensedprofessional heating contractor.

" Please see sectionentitled “ImportantRegulatory andInstallationRequirements.”

H Product documentationRead all applicable documentationbefore commencing installation. Storedocumentation near boiler in a readilyaccessible location for reference inthe future by service personnel.

" For a listing ofapplicable literature,please see sectionentitled “ImportantRegulatory andInstallation Requirements.”

HAdvice to ownerOnce the installation work iscomplete, the heating contractor mustfamiliarize the systemoperator/ultimate owner with allequipment, as well as safetyprecautions/requirements, shut-downprocedure, and the need forprofessional service annually beforethe heating season begins.

HContaminated airAir contaminated by chemicals cancause by-products in the combustionprocess which are poisonous toinhabitants and destructive toViessmann equipment.

" For a listing ofchemicals which cannotbe stored in or near theboiler room, please seesection entitled“Combustion Air Supply.”

HCarbon monoxideImproper installation, adjustment,service and/or maintenance can causeflue products to flow into living space.Flue products contain poisonouscarbon monoxide gas.

" For informationpertaining to the properinstallation, adjustment,service and maintenanceof this equipment toavoid formation of carbon monoxide,please see sections entitled“Combustion Air Supply” and “VentingConnection.”

H Fresh airThis equipment requires fresh air forsafe operation and must be installedensuring provisions for adequatecombustion and ventilation air exist.

" For informationpertaining to the freshair requirements of thisproduct, please seesection entitled“Combustion Air Supply.”

H Equipment ventingNever operate boiler without aninstalled venting system. An improperventing system can cause carbonmonoxide poisoning.

" For informationpertaining to ventingand chimneyrequirements, pleasesee section entitled “VentingConnection.” All products ofcombustion must be safely vented tothe outdoors.

HWarrantyInformation contained inthis and related productdocumentation must beread and followed. Failureto do so renders warrantynull and void.

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Installers must follow localregulations with respect toinstallation of carbon monoxidedetectors. Follow manufacturer’smaintenance schedule of boiler.

WARNING


3

Safety, Installation and Warranty Requirements (continued)

Please ensure that this manual is read and understood before commencing installation. Failure to comply with the issueslisted 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).

H Fiberglass wool and ceramic fibermaterials

The state of California has listed theairborne fibers of these materials as apossible cancer hazard throughinhalation. When handling thesematerials, special care must be applied.

Suppliers of ceramic fiber productsrecommend the following first aidmeasures:- Respiratory tract (nose and throat)irritationIf respiratory tract irritation develops,move the person to a dust freelocation.

- Eye irritationIf eyes become irritated, flushimmediately with large amounts oflukewarm water for at least 15minutes. Eyelids should be held awayfrom the eyeball to ensure thoroughrinsing. Do not rub eyes.

- Skin irritationIf skin becomes irritated, removesoiled clothing. Do not rub or scratchexposed skin. Wash area of contactthoroughly with soap and water.Using a skin cream or lotion afterwashing may be helpful.

- Gastrointestinal irritationIf gastrointestinal tract irritationdevelops, move the person to a dustfree environment.

Suppliers of fiberglass wool productsrecommend the following precautionsbe taken when handling these materials:

Precautionary measures- Avoid breathing fiberglass dust andcontact with skin and eyes.

- Use NIOSH approved dust/mistrespirator.

- Wear long-sleeved, loose fittingclothing, gloves and eye protection.

- Wash work clothes separately fromother clothing. Rinse washerthoroughly.

- Operations such as sawing, blowing,tearout and spraying may generateairborne fiber concentration requiringadditional protection.

First aid measures- If eye contact occurs, flush eyes withwater to remove dust. If symptomspersist, seek medical attention.

- If skin contact occurs, wash affectedareas gently with soap and warmwater after handling.

HHazardous materials

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Inhalation of fiberglass wool and/orceramic fiber materials is a possiblecancer hazard. These materials canalso cause respiratory, skin and eyeirritation.

WARNING Appliance materials of construction,products of combustion and the fuelcontain alumina, silica, heavy metals,carbon monoxide, nitrogen oxides,aldehydes and/or other toxic orharmful substances which can causeserious injury or loss of life and whichare known to the State of Californiato cause cancer, birth defects andother reproductive harm. Always useproper safety clothing, respirators andequipment when servicing or workingnearby 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 MinimumClearances for Service 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimum Clearances to Combustibles 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boiler Set-up and Location 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections Venting Connection 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Side Connections 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Connections andPressure Testing 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install safety devices on boiler 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Perform pressure test on boiler 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Burner Burner Installation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Burner Information 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Burner Set-up 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Burner mounting 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical connections 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil piping 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagram 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Examples Installation Examples 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Applications 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boiler in heating/cooling application 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low water cut-off 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5

Page

Initial Start-up and Service Initial Start-up 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Burner calibration 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Barometric draft regulator 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Procedure Overview 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Necessary Tools 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Procedure 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional Information Technical Data 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts List 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Record 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Safety

6

Important Regulatory and Installation Requirements

Take note of all symbols and notations intended to draw attention to potential hazards or important productinformation. These include ”WARNING,” ”CAUTION,” and ”IMPORTANT.” See page 7 for details.

CodesThe installation of this unit shall be inaccordance with local codes. In theabsence of local codes, use:HCSA B-139 for oil installations inCanada

HNFPA 31 Standard for the Installationof Oil Burning Equipment in the US

Always use latest editions of codes.

All electrical wiring is to be done inaccordance with the latest edition ofCSA C22.1 Part 1 and/or local codes. Inthe U.S. use the National ElectricalCode ANSI/NFPA 70. The heatingcontractor must also conform to theStandard for Controls and SafetyDevices for Automatically Fired Boilers,ANSI/ASME CSD-1 where required bythe authority having jurisdiction.

Mechanical roomEnsure the mechanical room complieswith the requirements listed in thismanual. See section entitled MechanicalRoom on page 9.

Please carefully read this manual priorto attempting installation. Anywarranty is null and void if theseinstructions are not followed.

For information regarding otherViessmann System Technologycomponentry, please referencedocumentation of the respectiveproduct.

We offer frequent installation andservice seminars to familiarize ourpartners with our products. Pleaseinquire.

Working on the equipmentThe installation, adjustment, service,and maintenance of this boiler must bedone by a licensed professional heatingcontractor who is qualified andexperienced in the installation, service,and maintenance of hot water boilers.There are no end user serviceable partson the boiler, burner, or control.

Ensure main power supply toequipment, the heating system, and allexternal controls has been deactivated.Close main oil supply valve. Takeprecautions in both instances to avoidaccidental activation of power duringservice work.

The completeness and functionality offield supplied electrical controls andcomponents must be verified by theheating contractor. These includelow-water cut-offs, flow switches (ifused), staging controls, pumps,motorized valves, air vents,thermostats, etc.

Technical literatureLiterature applicable to all aspects ofthe Vitorond 100:- Installation, Service and OperatingInstructions

- Installation codes mentionedin this manual

Leave all literature at the installationsite and advise the systemoperator/ultimate owner where theliterature can be found. ContactViessmann for additional copies.

This product comes with severalsafety instruction labels attached.Do not remove!Contact Viessmann immediately ifreplacement labels are required.

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General Information

7

About these Installation Instructions

The following symbols and flag words are utilized in theseInstallation Instructions:

Indicates an imminently hazardoussituation which, if not avoided, couldresult in death, serious injury orsubstantial product/property damage.

Indicates an imminently hazardoussituation which, if not avoided, mayresult in minor injury orproduct/property damage.

Helpful hints for installation, operationor maintenance which pertain to theproduct.

Helpful hints for installation, operationor maintenance which pertain to theproduct.

This symbol indicates that additionalinformation is written in column 3.

This symbol indicates that otherinstructions must be referenced.

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Warnings draw your attention to thepresence of potential hazards orimportant product information.

WARNING

Cautions draw your attention to thepresence of potential hazards orimportant 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. Thisboiler does not require a flow switch.

The boiler model size selected should be based on an accurate heat loss calculationof the building. The boiler selected must be compatible with the connectedradiation.

Maximum adjustable high limit setting: 240°F / 110°C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum allowable working pressure*1: 45 psig / 3 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel: #2 fuel oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*1 Cast iron sections are ASME stamped for 58 psig / 4 bar and maximum allowabletemperature of 248°F / 120°C.

Supply/return bypass for large water content systems

For boilers connected to large water content systems (typically systems withvolume > 1 USG / 3.8 ltr for every 13000 Btu/h of boiler input), such as a previousgravity system with large free-standing radiators, a bypass line from the supply pipeto the return pipe must be used to avoid flue gas condensation in the heatexchanger and the vent system. A bypass can be installed on any system as apreventative measure. Viessmann strongly recommends installing a bypass pipe onall cast iron boilers.

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General Information

9

Mechanical Room

During the early stages of new home design, we recommend that properconsideration be given to constructing a separate mechanical room dedicated to gasor 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 closeas 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 theburner is raised at least 18” / 457 mm above the floor to avoid contact withflammable 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 freshair directly to the boiler area. In addition, do not use exhaust fans in the boiler roomand do not install the boiler in rooms with refrigeration equipment. This equipmentrequires uncontaminated outside air for safe operation - do not install wherechemicals 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 withwater. Ensure that the boiler location does not interfere with the proper circulationof combustion and ventilation air within the mechanical room.

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Fresh Air

10

Combustion Air Supply

CodesProvisions for combustion andventilation air must be made inaccordance with applicable local codes.In the absence of local codes, use:HCSA B-139 for oil installations inCanada, or

HNFPA 31, Standard for the Installationof Oil Burning Equipment in the U.S.

Always use latest editions of codes.

GeneralThis equipment requires fresh air forsafe operation and must be installedensuring provisions for adequatecombustion and ventilation air exist.

Whenever possible, install boiler near anoutside wall so that it is easy to ductfresh air directly to the boiler area.

The boiler location must never be undernegative pressure. Exhaust fans, atticfans, or dryer fans may cause air to beexhausted at a rate higher than air canenter the structure for safe combustion.

The heating contractor shall ensure allof the following requirements are met:HAn adequate supply of combustion airmust be available to ensure propercombustion.

HAmbient air temperatures must bemaintained within safe operatinglimits.

HWhen a damper is provided in anyopening intended to admit combustionair into the room within which theappliance is installed, the damper shallbe interlocked to prevent any burnerfrom starting before the damper isfully open.

H Each duct used to convey air from theoutdoors shall have:1. A cross-sectional area throughout

its length at least equal to the freearea of the inlet and outletopenings which it connects,

2. A minimum dimension of3” / 76 mm at any cross-section,

3. When making provision for outsidecombustion air, the intake shall notbe less than 1 ft / 0.3 m above theanticipated snow level for thelocation.

H The heating contractor must checkwith local authorities (municipalbuilding department, gas utility) forcombustion air requirements particularto the area.

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Failure to provide an adequate supplyof fresh combustion air can causepoisonous flue gases to enter livingspace. Flue gases entering livingspace can cause carbon monoxidepoisoning which can result in severepersonal injury or loss of life.

WARNING

Never cover the boiler or store debrisor other materials near the boiler, orin any way block the flow ofadequate fresh air to the boiler. Nevercover the combustion air opening.Advise system operator/ultimateowner accordingly.

WARNING

The boiler must not be located inareas or rooms where chemicals arestored, or aggressive vapors (i.e.bleach, hair spray, methyl chloride,carbon tetrachloride orperchloroethylene) or high dust levelsor humidity levels are present. Heatexchanger corrosion might occur andreduce the lifetime of the boilersignificantly. If above criteria are notproperly observed and boiler damageresults, any warranty on the completeboiler and related components will benull and void.

WARNING

Fresh Air

11

Combustion Air Supply (continued)

Unconfined spacesWhere the boiler is located in anunconfined space in a building havinginsufficient infiltration, additional air forcombustion and ventilation shall beobtained from outdoors or from spacesfreely communicating with theoutdoors. Under these conditions,permanent opening(s) shall be providedso that the total air received throughthese openings will be at least as muchas would be admitted by openingshaving a total free area of 1 in2/5000Btu/h or 4.5 cm2/kWh of the total inputrating of all oil-fired appliances.

Confined spacesIf the boiler is located in a confinedspace and that obtains all of its air forcombustion and ventilation from withinthe conditioned space, the building shallbe provided with two permanentopenings, one near the top of theenclosure and another near the bottom.Each opening shall have a free area ofnot less than 1 in2/1000 Btu/h or19.5 cm2/kWh of the total input ratingof all appliances in the enclosure, freelycommunicating with interior areas thathave in turn adequate infiltration fromthe outside.

If the boiler is located in a confinedspace and that obtains all of its air forcombustion and ventilation fromoutside, the building shall be providedwith two permanent openings, one nearthe top of the enclosure and anothernear the bottom. Each opening shallcommunicate directly or by means ofducts with the outdoors or to suchspaces (such as a crawl space) thatfreely communicate with the outdoors,and shall be sized in accordance withthe following methods:HVertical duct(s) with a free area of notless than 1 in2/4000 Btu/h or5.5 cm2/kWh of the total input ratingof all appliances in the enclosure,

HHorizontal duct(s) with an equivalentlength of less than 50 ft / 15 m,having a free area of not less than1 in2/2000 Btu/h or 11 cm2/kWh ofthe total input of all appliances in theenclosure,

HAir openings that communicatedirectly with the outdoors, having afree area of not less than1 in2/4000 Btu/h or 5.5 cm2/kWh ofthe total input rating of all appliancesin the enclosure.

Louvres and grillesIn calculating free area as specifiedabove, consideration shall be given tothe blocking effect of louvers, grilles, orscreens that protect openings. Screensused shall be not smaller than¼” / 6 mm mesh and shall be readilyaccessible for cleaning. If the free areathrough a design of louvre or grille isknown, it shall be used in calculatingthe size of opening required to providethe free area specified. If the designand free area are not known, it shall beassumed that wood louvres have20-25% free area and metal louvresand grills have 60-75% free area.

InstallationInstall a combustion air opening. Roundduct diameters are as follows:

Boiler Model Model No. VR1-22 VR1-27 VR1-33

Round duct for combustion air supply *1 Ø” 5 5 6*1Round duct diameter given is a minimum.

Ensure that all code requirements are met.

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Set-up

12

Product Delivery

Vitorond boilers up to size VR1-33 are shipped in a crate with the combustionchamber door and boiler jacketry already mounted.

Product deliveryEnsure each of the following has beendelivered:HCrate with boilerHCarton with standard installationequipment

HCarton with burner (shippedseparately)

Recommended Minimum Clearances for Service

Boiler

*1 Minimum access for cleaning andservice.

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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 withclearances as published on page 10 under Recommended Minimum Clearances forService.

LegendBoilerBurner

*1 Clearance of 24” / 610 mm requiredfor burner service.

The following are clearances tocombustibles:

Standard installation

BoilerModel

VR1 -22 -27 -33

Rear

Sides

Flue

inchesmminchesmminchesmm

6150

009

230

6150

009

230

6150

009

230

Floor Combustibles

Alcove installation

BoilerModel

VR1 -22 -27 -33

Rear

Sides

Flue

Top

inchesmminchesmminchesmminchesmm

6150

009

2306

150

6150

009

2306

150

6150

009

2306

150

Floor Combustibles

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min. 6” / 150 mm

min.9”/230mm

min. 0” / 0 mm

min.24”610 mm *1

min. 6” / 150 mm

min.9”/230mm

min.24”610 mm *1

Set-up

14

Boiler Set-up and Location

For important information concerningboiler placement and set-up, refer to thesection entitled “Mechanical Room” onpage 9.

The boiler should be located as close tothe chimney as possible.

Set-up/locate boiler with slight inclinetowards the rear of the boiler usingleveling bolts .

IMPORTANT

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1.

1.

2.

Boiler must be installed in such a waythat oil ignition system componentsare protected from water (spraying,splashing, etc) during boiler systemoperation and service.

CAUTION

Connections

15

Venting Connection

Vitorond 100The vent system must comply with allapplicable local and/or national codes.

If installing boiler with a side wall ventsystem, ensure all manufacturer’srequirements are met.

Venting codesFor oil-fired boilers install ventingsystem in accordance with all applicablelocal codes:. In the absence of localcodes, follow national codesH Local codes or CSA B139-00 inCanada, or

HNFPA-31 in the U.S.

Building codesMasonry or concrete or metal chimneys(smokestacks) shall be constructedaccording to the requirements of theprovince/state building code or, in theabsence of such regulations, inaccordance with:HCSA Standard CAN/CSA-A405(National Building Code of Canada) inCanada, or

HNFPA 211 (Standard for Chimneys,Fireplaces, Vents, and SolidFuel-Burning Appliances) in the US.Metal chimneys also shall meet therequirements of Chapter 4 ofNFPA 211.

In Canada, factory built chimneys shall:HConform to ULC StandardsCAN/ULC-S629 for 1202°F / 650°C,CAN/ULC-S604 for Type A, orCAN/ULC-S609 for Type L chimneys,

H Be certified and installed inaccordance with the manufacturer’scertified instructions, and

H Be provided with a clean-out openingthat is equipped with a tight-fittingremovable cap, and constructed sothat no air can enter the clean-outfacility when the cap is in place.

In the U.S., factory built chimneys shall:HMeet the requirements of NFPA, andH Be listed, installed and used inaccordance with their listings andmanufacturer’s instructions.

GeneralThe heating contractor shall ensure allof the following requirements are met:H The vent system shall ensure that nohazard is created by the products ofcombustion.

H Provision shall be made to vent theproducts of combustion safely tooutside the building, and such ventingshall not pass through or be installedin return air, supply air, ventilating, orcombustion air ducts or shafts.

HSufficient air for combustion of the oiland ventilation of the appliance shallbe supplied to the space wherein theappliance is located (see sectionentitled Combustion Air Supply).

H The house and its mechanicalsystems shall be inspected todetermine if operation of exhaustdevices could lead to levels ofdepressurization of the house thatwould adversely affect the operationof the oil-burning appliance and itsventing system. If such is the case,the building owner shall be informedof the situation in writing.

H The chimney shall be inspected toensure that the material construction,condition, and size are suitable for theapplication.

H This boiler/burner combination shallnot be connected to an unlinedchimney. Such chimneys shall be linedin accordance with the applicablecodes and standards.

H The chimney shall be capable ofexhausting the products ofcombustion and of producing a draftnot less than that recommended bythe manufacturer of the applianceconnected thereto, during the mildestweather conditions under which theappliance is expected to operate.During cold weather testing, excessflow performance shall bedemonstrated to ensure that flow isadequate in warmer weather.

HAn oil burning appliance that dependson natural chimney draft shall beconnected to an individual chimneyvent used for no other appliance,except as permitted by the applicablecodes and standards.

H The vent connector of this boiler mustnot be connected into any portion ofmechanical draft systems operatingunder positive pressure.

HA chimney flue shall extend at least 3ft / 1 m above the highest point atwhich the chimney comes in contactwith the roof, and not less than 2 ft /0.6 m above the highest roof surfaceor structure within 10 ft. / 3 m of thechimney on a horizontal planeperpendicular to the chimney. Notmore than 8” / 200 mm of chimneyflue above the top of the chimney capshall be considered in computingheight.

HDown draft and condensationproblems must be corrected.

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Improper sizing, maintenance,termination of vent or chimney cancause flue gases to enter livingspace. Any blockage of vent orchimney by birds’ nests, ice, snow,debris, or other materials can causeflue gases to enter living space. Fluegases entering living space can causecarbon monoxide poisoning which canresult in severe personal injury or lossof life.

WARNING

Never operate the boiler/burnerwithout an installed venting systemwhich safely vents all products ofcombustion to the outdoors. The ventsystem must comply with allapplicable local and/or national codes.

WARNING

Connections

16

Venting Connection (continued)

When installing piping or venting, orwhile insulating overhead pipes, do notstand on top panel of boiler. Adviseother trades accordingly!

LegendVitorond boiler with burnerOutside rain capVent, use approved single wallgalvanized steel vent, 24/26 ga.or betterM-Barometric damper(field supplied) for oil*1

Vent pipe adaptor (factory supplied)

*1 Install in accordance with the draftcontrol manufacturer’s instructions.

InstallationUse approved vent material only.

1. Install the venting so as to achievethe shortest possible way withminimum elbows. If necessary,rearrange existing water piping toachieve closest chimney connection.

2. Horizontal runs must be supported byappropriate means to preventsagging. Avoid long horizontal runs ofvent pipe. Horizontal runs shouldhave not less than ¼” rise per ft.from the boiler to the vent terminal.Metal strapping must be used tosupport horizontal runs every 4 ft.

3. Connect factory supplied vent pipeadaptor to flue gas collar. Fastenusing either three equally spaced,corrosion resistant, self-tappingscrews and high temperaturesilicone, or equivalent means.

4. Connect chimney via a field supplied,slightly inclined intermediate sectionof venting. Flue pipe outside ∅: 5”.

5. Drill a ½” opening on the side of thevent pipe approximately three timesthe vent pipe diameter away from theflue gas collar of the boiler for fluegas analysis equipment.

6. Seal all flue pipe joints.

7. Ensure any non-insulated vent pipe isinsulated to reduce cooling of fluegas and velocity noises.

IMPORTANT

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Ø ½” / 10 mm

Connections

17

Water Side Connections

LegendHoneywell high limit controlImmersion wellHex bushing, 1¼” x ¾”Tee, 1½” x 1½” x ¾”Nipple, ¾” x 3¾”

Pressure relief valveFlue gas adaptor, Ø 5”Tee, 1½” x 1½” x ¾”Drain valve (sediment faucet), ¾”

This boiler is designed for closed loop,forced circulation heating systems only.

1. Flush heating system thoroughly(particularly with existing systemswhich have been in operation foryears).

2. Connect system supply to usingNPT fittings pictured below.

Connect the system return tousing NPT fittings pictured below.See installation examples in followingsection.

We recommend the installation of aspring-loaded flow-check valve inheating circuits without mixing valves.This serves to avoid uncontrolledgravity circulation of heat into theheating system during summer months.

Boiler water supply connection, pressure relief valve 1½” NPT. . . . . . . . . . . . . . . . . . . . . . .

High limit control location 1¼” NPTF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boiler water return, drain and automatic feed 1½” NPT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Legend

IMPORTANT

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CAUTIONFailure to flush the heating systemcould cause system sludge to settlein the boiler, causing overheating andfailure. This type of failure is notcovered under warranty.

IMPORTANT

Connections

18

Safety Connections and Pressure Testing

Install safety devices on boiler

H Pressure relief valve

H Boiler control

1. Install pressure relief valve. Pipepressure relief valve as illustratedand connect to boiler water supplyconnection.

Instructions supplied withpressure relief valve.

LegendPressure relief valveNipple, ¾” x 3¾”Tee, 1½” x 1½” x ¾”

2. Install discharge pipe on pressurerelief valve. The discharge pipeshould terminate approximately6” / 150 mm above a floor drain. Theend of the pipe must not bethreaded.

Minimum connection diameters:Pressure relief valve 3/4“. . . . . . . . . . . . . . . . . . . . . . . . . .

Discharge pipe 3/4“. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piping to prechargedexpansion tankVR1-22 to VR1-33 3/4“. . . . . . . . . . . . . . . . . . . . . . . . . . . .

This boiler does not require a flowswitch.

Install the (approved) factory suppliedpressure relief valve.

Removal of air from the system mustoccur via use of air vent(s) in thesystem supply. To ensure the boiler canbe purged of all air, ensuresupply/return water lines do not containrestrictive piping where air could betrapped.

1. Install supplied high limit control (seeillustration).

Maximum allowable temperaturesetting is 240°F / 110°C.

LegendHoneywell high limit control,L8148AImmersion wellHex bushing

Instructions supplied withHoneywell aquastat.

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IMPORTANT

Do not install an isolation valvebetween boiler and pressure reliefvalve.The discharge pipe for the pressurerelief valve must be oriented toprevent scalding of attendants.Pipe pressure relief valve dischargepipe close to floor drain. Never pipedischarge pipe to the outdoors.

WARNING

Connections

19

Safety Connections and Pressure Testing (continued)

Perform pressure test on boiler

The boiler must be leak tested beforebeing placed in operation. Before boileris connected to piping or electricalpower supply, it must be hydrostaticallypressure tested with a maximum of 1½times the maximum operating pressureof the boiler.

1. After installing safety devices(above), install temporary cap on ¾”nipple extension (nipple for pressurerelief valve mounting).

2. Cap supply and return connections.

3. Connect ½” garden hose to boilerdrain valve and fill boiler slowly untilpressure gage indicates max. 68 psi /465 kPa.

4.Maintain pressure for 15 minutes.During time of pressure testing, donot leave boiler unattended.

5. Inspect all pipe joint connections, thesafety devices (Safety Header, ifapplicable), and boiler base withflashlight for leaks.

6. After 15 minutes, release waterpressure from boiler by opening boilerdrain valve slowly, remove caps fromsupply and return connections aswell as ¾” cap from safety nipple,and install pressure relief valveimmediately instead of ¾” cap.

After boiler has passed pressure test,proceed with installation.

Max. allowable operating pressure45 psig / 310 kPa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Max. allowable testing pressure68 psig / 465 kPa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Max. allowable boiler temperature248°F / 120°C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Exposing the boiler to pressures andtemperatures in excess of those listedwill result in damages, and will renderwarranty null and void.

WARNING

Burner

20

Burner Installation

Instructions suppliedwith Beckett burner

Observe all instructions supplied withthe burner.

Burner Information

FuelThis boiler is for use with the Beckett#2 fuel oil burner supplied byViessmann only. Use only the fuelstated on the rating plate of the burner.

Oil nozzleThe Beckett burner for the VR1-33boiler is shipped with factory settingand oil nozzle installed. For VR1-27boiler, replace installed nozzle withnozzle packaged with burner.

Burner calibrationEnsure that the combustion results of theoil-fired burner mounted on this boiler areverified after start-up.

If adjustments are necessary, alwaysverify results with a calibrated flue gasanalyzer.

For burner specifications see table onpage 30.

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DO NOT USE GASOLINECRANKCASE DRAININGS OR ANYOIL CONTAINING GASOLINE.

WARNING

Burner

21

Burner Set-up

Burner mounting

Instructions supplied withBeckett burner.

1. Remove burner from carton. Themounting flange has been installed atthe factory.

2.Mount four M8 spacer bolts inthreaded holes of combustionchamber door.

3. Slide burner gasket over spacerbolts.

4.Mount burner as shown.(For proper insertion lengths seeTechnical Data table on page 37).

5. Secure burner with M8 nuts andwashers provided.

Burner mounting diagram

Burner air tube insertionVR1-22, -27, -33

Burner

22

Burner Set-up (continued)

Electrical connections

Installations must follow these codesand requirements:- National Electric Code, ANSI/NFPA70, latest edition and any addtionalnational, state or local codes.

- In Canada, CSA C22.1 CanadianElectrical Code Part 1 and any localcodes.

- Wiring must be N.E.C. Class 1. Iforiginal wire as supplied with boilermust be replaced, type 105°C wire orequivalent must be used. Supplywiring to boiler and additional controlwiring must be 14 ga. or heavier.

- Provide electrical ground at boiler asrequired 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 24.

LegendBurner harness (see wiring diagramon page 24)Control harness (see wiring diagramon page 24.Cable strapHoneywell high limit control(factory pre-wired for connection toburner)

Burner wiring

1. Burner harness incorporates afemale Viessmann 3-poledisconnect plug, providing aconvenient way to disconnect wiringwhen burner mounting door isopened.

2. Secure control harness using 2supplied cable straps . Controlharness incorporates the countermale Viessmann 3-pole plug.

3. Connect quick connect plugs and.

Room thermostat wiring

1. Install thermostat on inside wallaway from influences of drafts, hotor cold water pipes, lighting fixtures,television, sun rays or fireplaces.

2. Follow instructions supplied withroom thermostat. If it has a heatanticipator, set heat anticipator inthermostat to match powerrequirements of equipment connectedto it. Boiler wiring diagrams givesetting for standard equipment.

Electric shock hazard. Can causesevere personal injury or loss of life ifpower source, including serviceswitch on boiler, is not disconnectedbefore installing or servicing.

WARNING

Burner wiring

Burner

23

Burner Set-up (continued)

Oil piping

LegendOil line (see local codes forappropriate arrangement and pipingof filter control valves, etc., backto oil tank)Flare fitting

General oil piping requirements

Location and installation of oil tanks, oilpiping and burners must follow:- Local codes and regulations.- Information provided with burner andfuel pump.

- In Canada, CSA B139, Installation ofOil-BurningEquipment.

- In USA, NFPA 31, Standard for theInstallation of Oil-Burning Equipment.

Underground oil line piping must beencased to prevent oil leaking intogound. Check local codes forinformation.

If any part of fuel oil tank is aboveburner level, an anti-siphon device mustbe used to prevent flow of oil in case ofoil line break.

Make tank connections with swingjoints or copper tubing to preventbreaking in case the tank settles. Makeswing joints so they will tighten as tanksettles. Non-hardening pipe jointcompounds should be used on allthreads.

Support oil lines as required by codes.

Oil piping connection at burner

See illustration above for recommendedconnection at burner, allowing burnermounting door to swing opencompletely for servicing.

Oil pipig connection

Do not use Teflon tape as an oil pipesealant. It can cause valves to fail,crreating hazards. Do not usecompression fittings.

WARNING

The oil supply inlet pressure to thefuel unit cannot exceed 3 psig. Installa pressure-limiting device inaccordance with the above mentionedcodes.

WARNING

Burner

24

Wiring Diagram

Installations must follow these codesand requirements:- National Electric Code, ANSI/NFPA70, latest edition and any addtionalnational, state or local codes.

- In Canada, CSA C22.1 CanadianElectrical Code Part 1 and any localcodes.

- Wiring must be N.E.C. Class 1. Iforiginal wire as supplied with boilermust be replaced, type 105°C wire orequivalent must be used. Supplywiring to boiler and additional controlwiring must be 14 ga. or heavier.

- Provide electrical ground at boiler asrequired 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).

LegendOil solenoid valveIgnition transformerBurner motorCAD cell flame detectorBurner grounding screwR7184 Series primary control (postpurge feature of the R7184 primarycontrol not used in this application)

Factory-installed jumper BK BlackBL BlueGRN GreenOG OrangeRD RedVT VioletWH WhiteYE Yellow

Electric shock hazard. Can causesevere personal injury or loss of life ifpower source, including serviceswitch on boiler, is not disconnectedbefore installing or servicing.

WARNING

BKGRN

GRN

WH

RDBK

WH

BK

WH

VT

BL

OG

YE

YE

Burner disconnect Burner disconnect

Burner junction box Burner primary control

120 VAC field wiring

24 VAC field wiring

Low voltage factory wiring

120 VAC factory wiring

POWER SUPPLY. PROVIDE DISCONNECTMEANS, OVERLOAD PROTECTION ANDLOW WATER FUEL CUT-OFF AS REQUIRED

CONTROL CASE MUST BE CONNECTEDTO EARTH GROUND. USE GROUNDINGSCREW PROVIDED

B1 IS 1/4 IN. TAB TERMINAL

Female 3-pole plug Male 3-pole plug

Room thermostat

Circulator

120 VAC

Burner harness

Honeywell limitcontrol harness

Additional temperature

Factory-installed

limit control (when

jumper

required by localjurisdiction

Hon

eywellhigh

limit

L8148A

Connections

25

Installation Examples

GeneralThe schematics on the following pagesare to be seen as guidelines only. Theyfurther do not display all systemvarieties, safety devices, or conceptspossible. Specific system layouts maybe further discussed with the localViessmann sales representative office.

ClearancesA minimum of 2” circumferentialclearance from non-insulated hot waterpipes to combustible construction mustbe maintained. In cases where the pipesare insulated with pipe insulation ofappropriate and sufficient thickness andinsulation values, the above clearancemay be reduced to 0”.

Waterside flow

VR1-22 to -33

Flow ratesThe relationship between boiler flow rate and temperature rise is accordingto 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

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Waterflow

Flow

restriction

m3/h

USGPM

5

22

20 50

“w.c

mba

r

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

Connections

26

Installation Examples (continued)

Heating circuitSpring-loaded flow check valveCirculation pumpAutomatic air ventPressure relief valveHigh limit controlExpansion tank

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F

Connections

27

Special Applications

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 unitSpring-loaded flow check valveCirculation pumpAutomatic air vent,Pressure relief valveHigh limit controlWater chillerExpansion tank

We strongly suggest that the valvespictured above be labelled “v1” andv2.”

Low water cut-off

A low water cut-off may be required bylocal codes. If boiler is installed aboveradiation level, a low water cut-offdevice of approved type (fieldsupplied) must be installed in allinstances. Do not install an isolationvalve between boiler and low watercut-off.

v1

v2F

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IMPORTANT

F

Initial Start-up and Service

28

Initial Start-Up

Burner instructions.

1. Ensure fresh air intake of boiler roomis open and that chimney and all fluepipes are connected, sealed andunobstructed inside.

2. Ensure proper size and operation ofexpansion tank. Undersized expansiontanks cause fresh water to be addedto the system through fill valve. Thiswill cause premature section failure,which is not covered by warranties.

3. Fill heating system with water andbleed out air completely. Ensurecomplete system is properly ventedof air.

4. Perform a pressure test of the boilerand the water piping. Pressure testmust not exceed 1½ times themaximum operating pressure (45 psi)of the boiler. Pressure relief valvemust be removed during pressuretest. Any leaks must be corrected.

H the max. operating pressure is45 psig / 310 kPa

H the max. testing pressure is68 psig / 465 kPa.

5. Ensure proper and adequate fuelsupply exists; open oil shut-off valve.

If the nitrogen pressure of theprecharged expansion tank is lessthan the static pressure of thesystem, inflate membrane pressure toslightly exceed pressure of system.The static pressure required at thetank is based upon the static heightof the system. Normal fill pressure formost residential applications is 12 to15 psig when the system is cold. Alower pressure gage reading usuallyindicates loss of water due toleakage. All leaks must be corrected.Refer to instructions packaged withautomatic fill valve. Follow localregulations with respect to backflowpreventers.

Water treatment should be consideredin areas where it is known that boilerfeed water contains a high mineralcontent and hardness. Contact localwater treatment company.

In areas where freezing might occur,an antifreeze may be added to thesystem water to protect the system.Please adhere to the specificationsgiven by the antifreeze manufacturer.Do not use automotive silicate-basedantifreeze. Ensure a copy of theMaterial Safety Data Sheet is left onsite.Please observe that anantifreeze/water mixture may requirea backflow preventer within theautomatic water feed and influencecomponents such as diaphragmexpansion tanks, radiation, etc. A40% antifreeze content will providefreeze-up protection to -10°F / -23°C.Do not use antifreeze other thanspecifically made for hot waterheating systems. System also maycontain components which might benegatively affected by antifreeze.Check total system frequently whenfilled with antifreeze. Followanti-freeze manufacturer’sinstructions. 5

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Verify completeness of all discussionpoints on the following pages beforestarting-up system.

WARNING

Manometer and temperaturegage


29

Initial Start-Up (continued)

Burner calibration


Combustion analysisThis oil burner requires combustionmeasurements performed at the finalinstallation site, using calibratedcombustion equipment, to verify factorysettings, or to be used as a guide inchanging burner settings to suite localconditions.

Examples of local conditions whichinfluence combustion results include:weather conditions, length of horizontalvent pipe, diameter and height of thechimney, side wall venting (powervent), altitude above sea level, qualityand heating value of oil used, maximumnumber of other fuel burning appliancesrunning at the same time. Theseconditions affect the burner set-up. Theburner must be adjusted for acceptablecombustion results under localconditions of the installation.

Combustion measurements (CO2, stacktemperature, draft and CO) are taken inthe flue pipe between boiler andbarometric draft regulator beforedilution air (see the installation manual).Overfire draft is measured at thecombustion chamber observation portopening. The expected CO2 averagerange for #2-oil is from 11.0% to13.0%.

For burner technical data see table onfollowing page.

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WARNING

Always keep the manual fuel supplyvalve shut off if the burner is shutdown for an extended period of time.

WARNING

Do not tamper with the unit orcontrols.

WARNING

DO NOT START THE BURNERUNLESS THE COMBUSTIONCHAMBER DOOR IS SECURED INPLACE.

WARNING

DO NOT ATTEMPT TO START THEBURNER WHEN EXCESS OIL HASACCUMULATED, WHEN THE UNIT ISFULL OF VAPOR, OR WHEN THECOMBUSTION CHAMBER IS VERYHOT.

WARNING

Do not fire boiler without water.

WARNING

Do not leave any tools insidecombustion chamber.

WARNING


30

Initial Start-Up (continued)

Burner calibration (continued)

Boiler model Model No. VR1-22 VR1-27 VR1-33

Burner model Beckett NX-VI 102 NX-VI 101*1 NX-VI 101

Fuel type oil No. 2 fuel oil

Pump pressure psigkPa

1751207

1751207

1751207

Oil nozzle Danfoss n.a. 0.60x60°AS n.a.

Delavan 0.50x60°B 0.60x60°B 0.75x60°B

Hago 0.50x60°B n.a. 0.75x60°B

Oil nozzle flow rate GPH@psig 0.65@175 0.75@175 1.00@175

Air tube length inchesmm

7178

7178

7178

Air tube insertion inchesmm

37/1687

35/892

35/892

Air tube combination NX70LC NX70LC NX70LC

Head type 6-slot 6-slot 6-slot

Head setting 1.50 2.50 2.75

Air setting see head setting

Static plate n.a.

Baffle 32229 32229 32229

Solenoid valve 21844 21844 21844

Flange 32073 32073 32073

*1 The Beckett burner for the VR1-33 boiler is shipped with factory setting and oil nozzle installed. For VR1-27 boiler,replace installed nozzle with nozzle packaged with burner.

Barometric draft regulator

During operation of the burner, thebarometric draft regulator installed inthe vent system must move freely.

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31

Service Procedure Overview

Service steps

S 1. Shut down heating system Page 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S 2. Open combustion chamber door Page 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S 3. Clean heat exchanger and flue pipe Page 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S 4. Check all gaskets and insulation Page 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S 5. Close combustion chamber door Page 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S 6. Check heating system and domestic hot water connections Page 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S 7. Ensure proper operation of all safety devices Page 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S 8. Ensure proper operation of expansion tank, low water cut-off (if applicable) and pumps Page 35. . . . . . . . . . . . . . . .

S 9. Ensure that an adequate supply of combustion air exists in the boiler room Page 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S 10. Ensure functionality of the barometric draft regulator of the burner Page 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S 11. Calibrate the burner Page 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5285705v1

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32

Necessary Tools

Testing/analysis equipmentCalibrated flue gas analyzer

Cleaning suppliesHand brushRagsVacuum cleaning

Possible replacement partsRope sealant for combustion chamberdoorRefractory for combustion chamberdoor

Use only calibrated equipment.

Service Procedure

1. Shut-down heating system

1. Ensure main power supply toequipment, the heating system, andall external controls has beendeactivated. Take precautions in bothinstances to avoid accidentalactivation.

2. Close main oil supply valve nearburner and near tank.

2. Open combustion chamber door

1. Disconnect 3-pole plug-inconnector from burner.

2. Remove front panel by liftingpanel up and out.

3. Remove two bolts of combustionchamber door and open.

3. Remove turbulators , if applicable.See page 39 for details.

5285705v1

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Ensure that warning concerningfiberglass wool and ceramic fibermaterials on page 3 has been readand understood before handlinginsulation.

WARNING

NEVER ADJUST BURNER BY EYE.

WARNING


WARNING

Never burn garbage or paper in theunit, and never leave combustiblematerial around it.

WARNING


33

3. Clean heat exchanger and flue pipe

1. Clean heat exchanger with cleaningbrush and use vacuum cleaner toremove all sediment.

2. Remove all sediment from flue pipeand flue gas collector using vacuumcleaner.

4. Check all gaskets and insulation

1. Check all gaskets and the sealantrope of the combustion chamber doorfor wear or damage.

2. Check the combustion chamber doorrefractory for wear or damage.

3. Replace worn or damaged parts.

Service Procedure (continued)

5285705v1

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Ensure that warning concerningfiberglass wool and ceramic fibermaterials on page 3 has been readand understood before handlinginsulation.

WARNING


34

5. Close combustion chamber door

1. Reinsert flue gas turbulators (ifapplicable).

2. Close combustion chamber doorand tighten two bolts in an evenfashion.

3. Install front panel .

4. Connect the 3-pole plug-inconnector of the burner to thecounter plug of the control harness.

5. Fasten burner hood (if applicable) andlock in place .

6. Check heating system and domestic hot water connections

Ensure all connections are pressuretight.

7. Ensure proper operation of all safety devices

Check pressure gage, air vent andpressure relief valve. Ensure pressurerelief valve does not leak. Also ensurepressure relief valve operates inaccordance with information providedby the manufacturer.


5285705v1

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Reconnect oil burner and followinstructions found in burnerinstallation/start-up manual.

WARNING

Do not leave any tools insidecombustion chamber.

WARNING


35

8. Ensure proper operation of expansion tank, low water cut-off (if applicable) and pumps

Refer to maintenance instructionssupplied with diaphragm expansiontanks, low water cut-offs, pumps, etc.

Flush float water type low watercut-offs (if used).

The usual water fill pressure is between10 and 15 psi with the system cold. Alower pressure gage reading usuallyindicates loss of water due to leakage.All leaks must be corrected. Refer toinstructions packaged with automaticfill valve. Follow local regulations withrespect to backflow preventers.

If oil-lubricated pumps are used, ensureproper lubrication.

If motorized zone valves are used, referto maintenance instructions providedwith zone valves.

If an older non-diaphragm expansiontank is used, ensure the correct waterlevel is present.

9. Ensure that an adequate combustion air supply exists in the boiler room

Ensure fresh air intake of boiler room isopen. This opening must never beblocked or partially covered.

10. Ensure functionality of the barometric draft regulator of the burner

During operation of the burner, thebarometric draft regulator installed inthe vent system must move freely.


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36

11. Calibrate the burner

" For burner technical information see technical data table on page 30.


Combustion analysisThis oil burner requires combustionmeasurements performed at the finalinstallation site, using calibratedcombustion equipment, to verify factorysettings, or to be used as a guide inchanging burner settings to suite localconditions.

Examples of local conditions whichinfluence combustion results include:weather conditions, length of horizontalvent pipe, diameter and height of thechimney, side wall venting (powervent), altitude above sea level, qualityand heating value of oil used, maximumnumber of other fuel burning appliancesrunning at the same time. Theseconditions affect the burner set-up. Theburner must be adjusted for acceptablecombustion results under localconditions of the installation.

Combustion measurements (CO2, stacktemperature, draft and CO) are taken inthe flue pipe between boiler andbarometric draft regulator beforedilution air (see the installation manual).Overfire draft is measured at thecombustion chamber observation portopening. The expected CO2 averagerange for #2-oil is from 11.0% to13.0%.


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WARNING


WARNING

Do not tamper with the unit orcontrols.

WARNING

DO NOT START THE BURNERUNLESS THE COMBUSTIONCHAMBER DOOR IS SECURED INPLACE.

WARNING

DO NOT ATTEMPT TO START THEBURNER WHEN EXCESS OIL HASACCUMULATED, WHEN THE UNIT ISFULL OF VAPOR, OR WHEN THECOMBUSTION CHAMBER IS VERYHOT.

WARNING

Do not fire the boiler without water.

WARNING

Do not leave any tools inside thecombustion chamber.

WARNING

Aditional Information

37

Technical Data

Boiler model Model No. VR1-22 VR1-27 VR1-33

CSA input MBHkW

9127

10531

14041

CSA output MBHkW

8023

9227

12236

Net I=B=R rating MBHkW

7021

8023

10631

A.F.U.E. % 86.8 86.8 86.8

Overall dimensions (incl. burner)Total depth

Total width

Total height

inchesmminchesmminchesmm

41¼1048

1948333

838

471194

1948333

838

471194

1948333

838

Total weight (boiler with insulationand burner)

lbskg

312142

385175

385175

Vent pipe diameter Ø inchesØ mm

5130

5130

5130

Maximum allowable watertemperature (fixed high limit)

°F°C

248120

248120

248120

Maximum operating temperature(adjustable high limit)

°F°C

240110

240110

240110

Maximum allowable workingpressure

psigkPa

45310

45310

45310

Burner model Beckett NX-VI 102 NX-VI 101 NX-VI 101

Fuel type oil No. 2 fuel oil

Pump pressure psigkPa

1751207

1751207

1751207

Oil nozzle Danfoss n.a. 0.60x60°AS n.a.

Delavan 0.50x60°B 0.60x60°B 0.75x60°B

Hago 0.50x60°B n.a. 0.75x60°B

Oil nozzle flow rate GPH@psig 0.65@175 0.75@175 1.00@175

Air tube length inchesmm

7178

7178

7178

Air tube insertion inchesmm

37/1687

35/892

35/892

*1 The Beckett burner for the VR1-33 boiler is shipped with factory setting and oil nozzle installed. For VR1-27 boiler,replace installed nozzle with nozzle packaged with burner.

" Boiler standard working pressure: 30 psig; maximum allowable working pressure: 45 psig." Wherever possible, vertically vent the boiler with a properly sized chimney which meets all local and national codes.

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Additional Information

38

Ordering Replacement Parts:Please provide boiler Model and SerialNumber from rating plate when ordering

replacement parts. Order replacementcomponents from your Viessmanndistributor.

Parts002 Top panel003 Side panel (left/right)004 Insulation blanket005 Back panel006 Insulation blanket, rear007 Front panel011 Nameplate Viessmann063 Support bracket

Parts List

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007

002

003

005

006

004

011

003

063

063


39

Parts List016 Combustion chamber door

refractory018 Combustion chamber door019 Hinge bracket020 Packing seal, 12×16×2000 mm022 Packing seal, 3×116 mm024 Port cover042 Turbulator insert, ×2, second

pass*1

043 Turbulator insert, ×2, secondpass*2

045 Turbulator insert, ×1, third pass*2062 Temperature and pressure gage

101 Aquastat, L8148a1124102 Sensor well103 Accessory pack,

burner installation hardware104 Sediment faucet105 Pressure relief valve, ¾” 30 psig106 Vent pipe adaptor, Ø 5”

Other parts (not illustrated)033 Touch-up paint stick Vitotec silver034 Touch-up spray paint Vitotec silver037 Cleaning brush handle 800 mm,

M10100 Adhesive, 100 ml107 Installation/Service/Operating

Instructions108 Parts List

Wear parts (not illustrated)038 Cleaning brush (no handle)

*1 Only for VR1-22.*2 Only for VR1-33.

Parts List (continued)

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042 *1 043 *2

019 062

024 022

018 016 020

105

104

102101

103 045 *2

106


40

Notes

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41

Start-up Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service

on:

by:

Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service

on:

by:

Start-up Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service

on:

by:

Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service

on:

by:

Before each heating season begins,have the following service andmaintenance done by a licensed,professional heating contractor:

1. Boiler heat exchanger inspected andcleaned.

2. Vent system inspected fordeterioration, leaks, corrosion, properdraft, and proper operation. Checkvent system for compliance withlocal and national code requirements.Repair or replace as required.

3. Burner checked, and if necessary,adjusted for proper combustion andoperation. Check for adequate supplyof fresh outside combustion andventilation air.

Maintenance Record

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Neglecting to perform necessarymaintenance can cause unsafeoperation.

WARNING

42

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43

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Viessmann Manufacturing Company Inc.750 McMurray RoadWaterloo, Ontario • N2V 2G5 • CanadaTel. (519) 885-6300 • Fax (519) 885-0887www.viessmann.ca • [email protected]

Viessmann Manufacturing Company (U.S.) Inc.45 Access RoadWarwick, Rhode Island • 02886 • USATel. (401) 732-0667 • Fax (401) 732-0590www.viessmann-us.com • [email protected]

44

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Installation and Service Instructions - Yaun Cobe taken when handling these materials: Precautionary measures-Avoid breathing fiberglass dust and contact with skin and eyes. - Use