Vesta VRC-100 Installation Manual Download | Manualshive

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Installation Checklist

Installation Checklist

After the boiler installation, examine the following checklist. If you are not able to answer "Yes" to all of the items in the checklist, review the

appropriate sections. To troubleshoot any operational problems, refer to "Troubleshooting" in the User's Manual.

If there are additional questions or if you need assistance, contact technical support at 1-800-761-0053.

Installing the boiler

Check

Have you maintained the required clearances from building openings and intake air vents?

Have you minimized the distance between the boiler and the vent termination?

Have you minimized the distance between the boiler and major fixtures?

Have you maintained the proper service and maintance clearances?

Is the make-up air supply sufficient for proper operation?

Is the make-up air supply free from dust, dirt, corrosive elements, and flammable vapors?

Is the boiler and vent piping clear of combustible materials, including clothing, cleaning materials, and rags?

Connecting the Gas Supply

Check

Does the gas supply match the type specified on the boiler’s rating plate?

Is the gas line at least 1/2 or 3/4 in ID (Inner Diameter)?

Is the gas supply line sufficient in length and diameter to deliver the required BTUs?

Have you measured the pressure of the gas supply line?

Is the gas supply pressure within the recommended ranges specified in this manual?

Is the gas supply line equipped with a manual shut-off valve?

Have you tested the gas line pressure and all fittings for leaks?

Has the gas company inspected the installation, if required?

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Summary of Contents for VRC-100

Page 1: ...e or explosion may result causing property damage personal injury or death Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance What to do if you smell gas Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas su...

Page 2: ...he same room or area as the boiler Vapors from flammable liquids can explode and or catch fire causing death or severe burns Keep flammable products far away from the boiler and store them in approved containers Keep the containers tightly closed and out of the reach of children The boiler has a main burner flame that can come on at any time and will ignite flammable vapors Vapors cannot be seen a...

Page 3: ...ff valve Caution Do not use the boiler for anything other than its intended purpose as described in this manual Failure to do so may result in property damage personal injury or death Do not turn on the boiler unless the water and gas supplies are fully opened Failure to do so may damage the boiler Do not use unapproved replacement or accessory parts Failure to do so may result in improper or dang...

Page 4: ...operty owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requi...

Page 5: ... Pipe Sizing Tables 25 Gas Piping 26 Inlet Gas Pressure 27 Installing a Vent 29 Vent Type 29 Vent Pipe Materials 33 Vent Length 33 Connecting the Vent Clip 34 Vent Termination 34 Setting the DIP Switches 37 Connecting the Power Supply 38 Installation Checklist 39 Operating the Boiler 42 Turning the Boiler On or Off 42 Setting the Space Heating Temperature 42 Setting the DHW Domestic Hot Water Temp...

Page 6: ... manual Vent clip Gas conversion kit Spare parts Outdoor temperature sensor with cable Pressure Relief Valve Notice If there is a missing item please contact Technical Support at 1 800 761 0053 Optional Accessories The following optional accessories are not included with the boiler but may be necessary for the installation Check the need for any of the following optional accessories before install...

Page 7: ...x H 18 1 x 27 6 x 11 6 460 mm x 700 mm x 295 mm Installation Type Indoor wall hung Venting Type Forced draft direct vent Ignition Electronic ignition Water Pressure Hydronic DHW 12 30psi 15 150 psi Supply Pressure Natural Gas 3 5 10 5 WC Propane 8 13 WC Minimum Flow Rate DHW 0 5GPM 2 0LPM Temperature Range Space Heating 80 F 180 F 27 C 82 C DHW 86 F 140 F 30 C 60 C Connection Sizes CH Supply Retur...

Page 8: ... check the rating plate located on the side of the boiler to ensure that the boiler matches the gas type gas pressure water pressure and electrical supply available in the installation location If the boiler does not match each of these ratings do not install the boiler If the gas conversion is required the included gas conversion kit must be used VRC۱٤۰ ۱٤۰ ۰۰۰ ۱۹۹ ۰۰۰ ۱۹ ۹۰۰ ۱۹ ۹۰۰ Natural Gas ۱...

Page 9: ...utlet 3 4 NPT E CH Supply 1 NPT F Gas Inlet 3 4 NPT G Exhaust Vent 2 H Air inlet 2 27 56 700 mm 31 87 809 5 mm 2 80 71 1 mm 0 36 9 2 mm 18 11 460 mm 5 57 141 5 mm 5 26 133 5 mm 11 61 295 mm G H 4 0 101 6 mm 3 6 91 4 mm 2 7 68 6 mm 1 6 40 6 mm 6 1 154 9 mm 2 8 71 1 mm 3 4 86 4 mm 4 7 119 4 mm 2 2 55 9 mm 8 0 203 2 mm A B C D E F 1 8 45 7 mm ...

Page 10: ...ector Air intake connector Gas connector Gas valve 3 way valve Pressure sensor Space heating supply Gas inlet Hot water outlet Burner hood Deco cover Pump Air vent Condensate drain Space heating return Cold water inlet Exhaust temperature sensor ...

Page 11: ...11 General Information Ignition transformer PCB assembly Front panel Secondary heat exchanger Primary heat exchanger Flow sensor Air Pressure Sensor TDR damper Pressure sensor Turbo fan assembly ...

Page 12: ...re protected from water dripping spraying rain etc during operation and service Drainage A signifcant amount of condensate is produced during the boiler operation Install the boiler near a suitable drain and where damage from a possible leak will be minimal Installing the boiler without a drain will void the warranty For more information about condensate drainage refer to Connection the Condensate...

Page 13: ...can be contaminated Do not install the boiler in areas with greasy fumes or heavy amounts of steam if necessary take measures to prevent fumes and steam from entering the boiler Chemicals that are corrosive in nature should not be stored or used near the boiler Position Caution Do not mount the boiler to unsubstantial fooring or unreinforced dry wall The boiler can be mounted to the wall For easy ...

Page 14: ...acket and hang the boiler from the bracket Warning The boiler is heavy Always lift the unit with assitance Be careful not to drop the bolier while lifting or handling it to avoid bodily injury or damage to the unit Do not rest the bolier on the bottom end after removing it from the shiping carton Doing so may result in excessive pressure on protruding pipes and cause product damage If you must put...

Page 15: ... protection for the space heating system Freeze protection products may be used to prevent the space heating system from becoming frozen A specially manufactured glycol is necessary for preventing a new or existing piping system from becoming frozen This glycol should include inhibitors not harmful to metallic system components Before using freeze protection products it is necessary to check if th...

Page 16: ...most cases an additional water fill connection is not necessary If an additional water fill connection is necessary for special use install the water fill connection at the same location as the expansion tank s connection to the system When replacing the expansion tank refer to the literature of the expansion tank manufacturer for selecting the proper size When installing the diaphragm expansion t...

Page 17: ... avoid damage After installing the boiler check if the space heating water flows smoothly and if there is a water leak Inform the boiler owner of the fact that the strainer should be cleaned periodically to maintain the smooth flow of space heating water The strainer is located on the side of the space heating return Installing a Domestic Hot Water DHW System VESTA DS VRC boiler can supply domesti...

Page 18: ... scaling The installer or the user should take appropriate measures in order to avoid any problem related to the quality of water Freeze Protection VESTA DS recommends to insulate the DHW pipes The pipes can be covered using heat insulating materials Freeze damage voids the warranty Essential Elements in a DHW System DHW Heat Exchanger The DHW heat exchanger installed on the VRC boiler is designed...

Page 19: ...When installing the discharge piping line do not install a coupling whose internal diameter decreases or has other restrictions If the pressure relief valve discharges hot water periodically it may be caused by thermal expansion of the closed water system Contact the water supplier or a local plumbing inspector in order to such a problem Do not plug the pressure relief valve DHW System Piping Caut...

Page 20: ...in To a drain via a neutralizer To a laundry tub To a laundry tub via a condensate pump a From the boiler directly into an external drain b From the boiler through a neutralizing agent and then into an external drain Notice If you choose this option the neutralizing agent must be replaced periodically Depletion of the neutralizing agent will vary based on the usage rate of the boiler During the fi...

Page 21: ...and DHW pipes are connected The procedure is as follows When you turn the makeup water feeding valve shown in the figure below counterclockwise the space heating system will be filed with water When filling with water after installing it for the first time it may operate and stop repeatedly due to the presence of air Allow sufficient time to remove air from the pipes completely After filling with ...

Page 22: ...le are provided to suggest basic guidelines when you install the boiler system However the actual installation may vary depending on the circumstances local building codes or state regulations Check the local building codes and state regulations thoroughly before installation and comply with them fully External Water Fill Connection Read and follow the guidelines below for system piping of the VES...

Page 23: ...g so will guarantee the lowest pressure in the system will be at least equal to the tank and make up water pressure Ensure the expansion tank cannot become isolated from the boiler anytime the system is operating Failure to follow these instructions may lead to discharge form the pressure relief valve which may result in property damage or injury System Application Zone System with Zone Valves Zon...

Page 24: ...24 Installation Manual System Application Zone System with Circulators Check Valve Zone 1 Zone 2 Zone 3 System pump Air Separator Expansion tank Not exceed Max 12 in ...

Page 25: ...50 60 70 80 90 100 125 150 200 3 4 372 255 205 175 156 142 130 121 114 107 95 86 74 1 702 482 387 331 293 266 245 228 213 202 179 162 139 1 1 4 1441 990 795 680 603 546 503 468 439 415 367 332 285 1 1 2 2158 1483 1191 1019 903 819 753 701 658 621 550 499 427 2 4155 2856 2293 1963 1740 1576 1450 1349 1266 1195 1060 960 822 Liquid propane gas Maximum Capacity of propane LP Gas Based on 11 WC supply ...

Page 26: ...or local installation codes To ensure a sufficient gas supply it is recommended that the boiler be the first appliance to be connected to the gas supply line To connect the gas supply 1 Determine the gas type and pressure by referring to the rating plate 2 Perform a pressure test on the main gas supply line 3 Purge the gas line of any debris 4 Determine the proper type and size for the gas line Re...

Page 27: ...iler must be isolated from the gas supply piping system during any pressure testing of that system at test pressures equal to or more than 0 5 psig If overpressure has occurred through improper testing of the gas lines or malfunction of the supply system the gas valve must be checked for safe operation The inlet gas pressure must be maintained between 3 5 and 10 5 WC for natural gas and between 8 ...

Page 28: ...gas shut off valve and check for leaks 7 Open multiple fixtures that have high flow rates such as bathtub and shower faucets to ramp up the boiler to its maximum firing rate 8 When the boiler reaches its maximum firing rate check the inlet gas pressure reading on the manometer The gas pressure must fall within the ranges specifed in Specifications on page 7 9 Tighten the inlet gas pressure screw 1...

Page 29: ...known to accumulate protect the vent termination from blockage Ensure that the vent termination is at least 12 305mm above ground or as required by local codes Support the vent pipe with hangers at regular intervals or as required by local codes Exhaust and intake air pipes must be supported at least every 4 feet 1 2m The vent for this appliance shall not terminate over public walkways or near sof...

Page 30: ...al air supply inlet to building or the combustion air inlet to any other application 36 in 91 cm 12 in 30 cm K Clearance to mechanical air supply inlet 72 in 182 cm 36 in 91 cm above if within 10 feet horizontally L Clearance above paved sidewalk or paved driveway located on public property 84 in 236 cm 3 M Clearance under veranda porch deck or balcony 12 in 30 cm 4 1 In accordance with the curren...

Page 31: ...ctured home mobile home all combustion air must be supplied from the outdoors as described on page 27 When using non direct venting maintain non direct vent clearances shown on page 29 as required by ANSI Z21 10 3 and the National Fuel Gas Code ANSI Z223 1 NFPA 54 and CAN CSA B149 1 Natural Gas and Propane Installation Code To use non direct venting for the boiler Insert the elbow into the intake ...

Page 32: ... supply inlet to building or the combustion air inlet to any other application 36 in 91 cm 4 feet below or to side of opening 1 foot above opening K Clearance to mechanical air supply inlet 72 in 182 cm 36 in 91 cm above if within 10 feet horizontally L Clearance above paved sidewalk or paved driveway located on public property 84 in 236 cm 3 84 in 236 cm M Clearance under veranda porch deck or ba...

Page 33: ...ture to 158 F 70 C As a result the VESTA DS boiler can be vented with Schedule 40 PVC In high temperature applications the exhaust temperature can exceed 149 F 65 C In that case you must use Schedule 40 or 80 CPVC or Approved Polypropylene in the USA or Type BH Special Gas Vent Class IIB CPVC or Class IC Polypropylene that conforms to ULC S636 in Canada Generally the boiler limits the flue gas to ...

Page 34: ...ce above highest anticipated snow level Maximum of 24 600 mm above roof Install a bird screen at the end of the intake air pipe and exhaust pipe Determine what type of vent termination is appropriate for the installation location and situation before installing the boiler The following subsections describe some venting configurations but do not include all possible options Single pipe sidewall ven...

Page 35: ... mm above roof Install a bird screen at the end of the intake air pipe and exhaust pipe Notice It is recommended to install the intake air vent terminal as far from the exhaust gas vent terminal as possible Snorkel flue 10 254 mm min 12 300 mm min 12 300 mm min Schedule 40 PVC pipe Caution Maintain 12 300 mm min 18 450 mm min for Canada clearance above highest anticipated snow level Maximum of 24 ...

Page 36: ...n Maintain 12 300 mm min 18 450 mm min for Canada clearance above highest anticipated snow level Maximum of 24 600 mm above roof Two pipe vertical venting 36 900 mm min Exhaust gas 12 300 mm min From any obstruction above below left or right Intake air 12 300 mm min Caution Maintain 12 300 mm min 18 450 mm min for Canada clearance above highest anticipated snow level Maximum of 24 600 mm above roo...

Page 37: ...ta change switch ON Enable EEP ROM data change OFF Disable EEP ROM data change Long flue Length 1 DIP S W 3 DIP S W 4 FLUE LENGTH 2 PVC 3 PVC OFF OFF Up to 15 Up to 150 OFF ON Up to 30 N A ON OFF Up to 45 ON ON Up to 60 Long flue Length 2 Cascade operation ON Cascade operation OFF No cascade operation Minimum heat capacity operation ON Minimum operation OFF Normal operation Maximum heat capacity o...

Page 38: ...er If local codes require the boiler to be wired directly remove and discard the factory installed plug Install a power switch between the breaker and the boiler to facilitate end user maintenance and servicing Connect the boiler to a 110 120V AC at 60 Hz with a maximum of 5A rating electrical supply The boiler must be electrically grounded If using the power plug ensure that the electrical outlet...

Page 39: ... maintained the proper service and maintance clearances Is the make up air supply sufficient for proper operation Is the make up air supply free from dust dirt corrosive elements and flammable vapors Is the boiler and vent piping clear of combustible materials including clothing cleaning materials and rags Connecting the Gas Supply Check Does the gas supply match the type specified on the boiler s...

Page 40: ... the proper system pressure If antifreeze has been used is it the proper type and is the concentration appropriate Connecting a Pressure Relief Valve Check Have you installed an approved pressure relief valve on the boiler Does the rating of the pressure relief valve match or exceed the maximum BTU rating of the boiler Is the pressure relief valve 3 4 in on the hot water outlet and 3 4 in at the p...

Page 41: ...ported the vent termination Have you properly sealed all air intake and exhaust joints from the flue collar to the vent termination Have you installed end caps on the exhaust and intake pipes Have you checked the venting for leaks Is the vent termination at least 12 in 300mm above the exterior grade Have you ensured that sufficient make up air is available Is the total vent length within the maxim...

Page 42: ...e Heating Temperature Danger If your household includes children or elderly or disabled individuals consider using a lower temperature setting To set the space heating water temperature 1 Press the MODE button until the icon turns on 2 Press the or buttons until the desired temperature appears on the digital display Temperature range Adjusting the water temperature 80 180 F Fahrenheit mode 27 82 C...

Page 43: ...ss the or buttons until the desired temperature appears on the display Temperature range Adjusting the water temperature 86 140 F Fahrenheit mode 30 60 C Celsius mode 2 F or 1 C increments 130 F 140 F 55 C 60 C 5 F or 2 C increments Viewing Basic Information To turn the boiler on press the button To view information about the boiler press the MODE and buttons for 5 seconds Press the MODE button to...

Page 44: ...rror H1 and the most recent error Example A2 will be displayed repeatedly on the screen H2 This is the mode for checking the current error H2 and the current error Example A3 will be displayed repeatedly on the screen H3 This is the mode for checking the current pressure in the system H3 and the current pressure in the boiler Example 25 will be displayed repeatedly on the screen The pressure unit ...

Page 45: ...the fan H5 and the output voltage Example C5 will be displayed repeatedly on the screen H6 This is the mode for checking the current exhaust gas temperature H6 and the current exhaust gas temperature example 120 will be displayed repeatedly on the screen The unit is F H7 This is the mode for checking the current hot water temperature H7 and the hot water temperature example 100 will be displayed r...

Page 46: ... H9 and the return temperature example 120 will be displayed repeatedly on the screen The unit is F HA This is the mode for checking the hot water and heating modes HA and the heating mode or the hot water mode example FF or 00 will be displayed repeatedly on the screen FF is the current hot water mode and 00 is the heating mode HB This is the mode for checking the current PCB version example 1 0 ...

Page 47: ...will be displayed repeatedly You can set a value from 0 to 6 using the and buttons The factory default value is 1 The meaning of each number is as follows Outdoor reset heat load types 0 Finned tube heat load types 1 Fan coil 2 Cast iron baseboard 3 Low mass radiant 4 High mass radiant 5 Radiator 6 Custom The set temperature for each heat load type is as follows Heat load Minimum set point Maximum...

Page 48: ...ws custom setting the lowest space heating temperature Display Description Temperature range 82 F 28 C 118 F 48 C custom setting the highest space heating temperature Display Description Temperature range 122 F 50 C 180 F 82 C custom setting the lowest outdoor temperature Display Description Temperature range 4 F 20 C 32 F 0 C custom setting the highest outdoor temperature Display Description Temp...

Page 49: ...nstallation of this kit The installation is not proper and complete until the operation of the converted appliance is checked as specified in the manufacturer s instructions supplied with the kit A qualified service agency is any individual firm corporation or company which either in person or through a representative is engaged in and is responsible for the connection utilization repair or servic...

Page 50: ...iver and pull the gas connector away from the TDR damper 6 Once the gas orifice is exposed remove the screw that hold the gas orifice in place and remove the gas orifice from its housing Packing Orifice Gas connector 7 Replace the old orifice piece and the packing with new part for use with LP gas Ensure that the orifice is properly seated inside the port Danger Inspect the packing whenever they a...

Page 51: ...le Exhaust analyzer hole Cap Bracket 13 Insert analyzer into the exhaust analyzer hole and measure the gas air ratio using combustion analyzer is recommended Type High fire Low fire CO2 CO2 NG 9 3 0 5 9 3 0 5 LPG 10 1 0 5 11 0 0 5 14 Fully open several hot water fixtures and if the CO2 value at low fre is not within 0 5 of the value listed in the table above the gas valve set screw will need to be...

Page 52: ...P Switches on page 37 16 Fully open several hot water fixtures and if the CO2 value at high fire is not within 0 5 of the value listed in the table above do not adjust the gas valve set screw and check if the gas orifice is properly installed Danger Improper gas valve settings can cause severe injury death or property damage Notice While measuring the gas air ratio in maximum heat capacity operati...

Page 53: ...istor CIR MAX MIN HB i y CAS Ex2 Ex1 PRG RST i y i i i i i y Solenoid Valve T D R Damper Gas Valve y y Pressure Sensor y Flow Detect Switch i w Exhaust Thermistor Yellow Yellow Remote controller 3 way Valve PUMP i i n n i i zy Gy zy Gy Condensate trap Outdoor Thermistor OPTION i i n y n n i i i DHW Thermistor i OPTION External pump nuk OPTION RCOP Return Thermistor ...

Page 54: ...54 Installation Manual Component Assembly Diagrams and Parts Lists Case Parts VRC 120 111 105 117 108 116 109 105 101 103 104 106 110 119 101 102 104 107 115 112 113 105 120 120 105 114 118 ...

Page 55: ...08 PCB fixing bracket S 110 2081155 PCB assembly VRC 140 2081156 PCB assembly VRC 120 2081157 PCB assembly VRC 100 2081158 PCB assembly VRC 80 111 2100363 Air pressure switch VRC 140 VRC 120 2100377 Air pressure switch VRC 100 2100376 Air pressure switch VRC 80 112 3011632 R C support bracket 113 3011565 R C fixing bracket 114 2081154 R C assembly 115 2010619 Case assembly 116 3100044 M4 x 12 Scre...

Page 56: ...234 235 243 218 221 222 229 241 243 244 245 245 248 245 247 246 242 249 249 249 252 253 254 222 218 230 255 251 250 202 245 245 261 201 238 101 225 224 209 260 203 105 105 214 218 256 239 240 306 264 236 237 204 205 206 207 209 210 211 212 262 226 245 228 227 221 222 223 231 258 219 208 ...

Page 57: ...16 3011590 Spark plug bracket 217 3011671 Secondary heat exchager bracket 218 3100173 Ø4 x 16 Tapping screw STS 219 3080266 Primary Secondary hex packing 220 2070715 Secondary heat exchager assembly VRC VRB 221 3011604 Secondary hex fixing bracket 222 3100150 M5 x 0 8p x 11 Screw STS 223 3080267 Secondary HEX Duct housing packing 224 3100121 Ø4 x 8 Tapping screw STS 225 3040653 Flue gas limiter 22...

Page 58: ...assembly 247 3040650 Air mixer 249 3080176 Packing 3 4 NBR 250 2091076 Gas outlet pipe 251 2030291 Gas valve 252 2091075 Gas inlet pipe 253 3080115 Gas nipple O ring 254 3050092 Gas pipe 255 3100125 M4 x 14 Screw 256 3050112 Gas connector 257 3130571 Exhaust temperature sensor 258 3090384 Condensate trap gasket 259 3090372 Fan gasket 260 2081098 Overheat prevent sensor 150 C 261 3130384 Overheat p...

Page 59: ...3 308 309 319 315 315 315 339 338 316 332 222 339 336 121 340 335 319 321 337 316 319 314 302 316 315 319 339 326 325 332 332 335 302 305 105 330 328 329 105 105 341 222 319 321 334 339 318 105 333 333 333 323 339 339 322 327 331 245 307 306 303 312 317 320 304 334 334 334 302 302 303 310 312 ...

Page 60: ...e heat exchanger cilp 316 3080144 Backup Ring P18 6 317 2040124 3way motor 318 2091133 Supply Tybe2 319 3010660 Fixing clip P14 320 3030268 Hot water nipple 321 3030267 Hex Connector 322 2060229 Flow switch 323 2060409 Cold water nipple 324 2091132 Circulation tube 325 2091137 Make up water inlet 326 2091138 Make up water outlet 327 2060228 Make up water feeding valve 328 2050136 Pump 329 3030263 ...

Page 61: ...fixed firmly The sensor is a water resistant device Outdoor Reset Control Available with Optional Outdoor Temperature Sensor The outdoor reset control can be used in order to improve the energy efficiency With the Outdoor Reset Control the space heating temperature setting automatically changes according to the outdoor temperature and the current space heating system application system load Notice...

Page 62: ...Memo ...

Page 63: ...Memo ...

Page 64: ...VESTA DS Inc 2711 LBJ Fwy Suite 320 Farmers branch TX 75234 For Technical Support 1 800 761 0053 www vestahws com Ver 1 0 ...

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