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Viessmann VITOROND 100 VR1 Series, Installation And Service Instructions Manual, Page: 60 / 76

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Viessmann VITOROND 100 VR1 Series Installation And Service Instructions Manual Download Page 60

Initial Start-up

60

Initial Start-Up

(continued)

Riello burner calibration

*1

Boiler model

Model No.

VR1-40

VR1-50

VR1-63

Burner model

Riello 40
Series

F5

F5

F10

Fuel type

oil

No. 2 fuel oil

Pump pressure

psig

175

175

175

Oil nozzle

Danfoss

0.85x60°xAH

*3

1.10x60°xAH

1.35x60°xAH

*2

Oil nozzle

Delavan

0.85x60°xA

0.85x60°xW

1.10x60°xA

*3

1.35x60°xA

1.35x60°xW

Hago

0.85x60°xH

1.10x60°xH

1.10x60°xSS

1.35x45°xSS

Oil nozzle flow rate

GPH@psig

1.15@175

1.40@175

1.75@175

Air tube length

inches
mm

6

5

/

16

160

6

5

/

16

160

7

178

Air tube insertion

inches
mm

4¼

108

4¼

108

4¾

121

Turbulator setting

1.0

3.0

2.0

Air gate setting

3.5

3.6

2.8

*1

For VR1-40 and -50 boilers, replace installed nozzle in VR1-33 Riello burner with the appropriate nozzle packaged with
burner.

*2

Factory-installed nozzle.

*3

Nozzles must be installed by installer.

Note:

The Riello burner for the VR1-33 boiler is shipped with factory setting and oil nozzle installed, and should require only
minor adjustments. For VR1-40, and -50 boilers, replace installed nozzle with nozzle packaged with burner.

Barometric draft regulator

When a barometric draft regulator is
used, adjust the barometric draft
regulator such that the over-fire draft is
0.00 to +0.01 “w.c., while the breech
draft is approximately -0.02 “w.c.

During operation of the burner, the
barometric draft regulator installed in
the vent system must move freely.

5

6

7

1

0

4

4

v

1

.0

IMPORTANT

Summary of Contents for VITOROND 100 VR1 Series

Page 1: ...tructions for future reference IMPORTANT VITOROND 100 Installation and Service Instructions for use by heating contractor Vitorond 100 VR1 Series Oil Fired Boiler Heating input 161 to 245 MBH 47 to 72 kW 5671 044 v1 0 08 2012 ...

Page 2: ...icals can cause by products in the combustion process which are poisonous to inhabitants and destructive to Viessmann equipment For a listing of chemicals which cannot be stored in or near the boiler room please see section entitled Combustion Air Supply H Carbon monoxide Improper installation adjustment service and or maintenance can cause flue products to flow into living space Flue products con...

Page 3: ...ollowing precautions be taken when handling these materials Precautionary measures Avoid breathing fiberglass dust and contact with skin and eyes Use NIOSH approved dust mist respirator Wear long sleeved loose fitting clothing gloves and eye protection Wash work clothes separately from other clothing Rinse washer thoroughly Operations such as sawing blowing tearout and spraying may generate airbor...

Page 4: ...mbustibles 14 Recommended Minimum Clearances for Service 15 Boiler Set up and Location 15 Insulation Installation 16 Combustion Chamber Insert 19 Connections Venting Connection 20 Water Side Connections with Aquastat Control 22 Safety Connections with Aquastat Control 23 Install safety devices on boiler 23 Water Side Connections with Vitotronic Control 25 Safety Connections with Vitotronic Control...

Page 5: ...er coding card 39 Pump junction box with Vitotronic Control 40 Wiring diagram with Vitotronic Control 42 Wiring diagram Vitorond 100 with Beckett burner GeniSys control and Vitotronic Control 43 Burner Riello Burner Installation 44 Burner Information 44 Burner Set up Riello 45 Burner mounting 45 Oil piping 46 Electrical connections with Aquastat Control 47 Wiring harness connection to Honeywell hi...

Page 6: ...tion Examples Aquastat 62 Special Applications Aquastat 63 Boiler in heating cooling application 63 Low water cut off 63 Installation Examples Vitotronic 64 Special Applications Vitotronic 66 Boiler in heating cooling application 66 Low water cut off 66 Service Service Procedure Overview 67 Necessary Tools 68 Service Procedure 68 Additional Information Parts List 73 Maintenance Record NO TAG 5671 ...

Page 7: ...umentation of the respective product We offer frequent installation and service seminars to familiarize our partners with our products Please inquire Working on the equipment The installation adjustment service and maintenance of this boiler must be done by a licensed professional heating contractor who is qualified and experienced in the installation service and maintenance of hot water boilers T...

Page 8: ...pertain to the product Helpful hints for installation operation or maintenance which pertain to the product This symbol indicates that additional information is written in column 3 This symbol indicates that other instructions must be referenced Please note Viessmann Manufacturing Company Inc reserves the right to make product changes or updates without notice and will not be held liable for typog...

Page 9: ...ge free standing radiators a bypass line from the supply pipe to the return pipe must be used to avoid flue gas condensation in the heat exchanger and the vent system A bypass can be installed on any system as a preventative measure Viessmann strongly recommends installing a bypass pipe on all cast iron boilers IMPORTANT This boiler is equipped with an outdoor reset module that saves energy by red...

Page 10: ...act with flammable vapors and fumes Viessmann strongly recommends installing the boiler on a concrete foundation Whenever possible install boiler near an outside wall so that it is easy to duct fresh air directly to the boiler area In addition do not use exhaust fans in the boiler room and do not install the boiler in rooms with refrigeration equipment This equipment requires uncontaminated outsid...

Page 11: ...y air from the outdoors shall have 1 A cross sectional area throughout its length at least equal to the free area of the inlet and outlet openings which it connects 2 A minimum dimension of 3 76 mm at any cross section 3 When making provision for outside combustion air the intake shall not be less than 1 ft 0 3 m above the anticipated snow level for the location H The heating contractor must check...

Page 12: ...l communicate directly or by means of ducts with the outdoors or to such spaces such as a crawl space that freely communicate with the outdoors and shall be sized in accordance with the following methods H Vertical duct s with a free area of not less than 1 in2 4000 Btu h or 5 5 cm2 kWh of the total input rating of all appliances in the enclosure H Horizontal duct s with an equivalent length of le...

Page 13: ...nes Legend Casting 1 pipe x2 Rear wooden block Front wooden block If carrying handles are not available follow the steps below 1 Remove top and sides of crate To avoid damage during lifting carefully remove front panel by lifting panel up and out 2 Place wooden block 12 from rear of skid 3 Insert 1 Ø Schedule 40 pipes through openings in casting legs Ends of pipes should be centered on wooden bloc...

Page 14: ...Sides Flue inches mm inches mm inches mm 6 150 0 0 9 230 6 150 0 0 9 230 6 150 0 0 9 230 Floor Combustibles Alcove installation Boiler Model VR1 40 50 63 Rear Sides Flue Top inches mm inches mm inches mm inches mm 6 150 0 0 9 230 6 150 6 150 0 0 9 230 6 150 6 150 0 0 9 230 6 150 Floor Combustibles 1 Clearance of 24 610 mm required for burner service 5671 044 v1 0 min 6 150 mm min 9 230 mm min 0 0 ...

Page 15: ...echanical Room on page 10 The boiler should be located as close to the chimney as possible Set up locate boiler with slight incline towards the rear of the boiler using levelling bolts 5671 044 v1 0 20 508 mm 4 100 mm 33 850 mm 1 2 1 1 Fig 7 IMPORTANT 5671 044 v1 0 Boiler must be installed in such a way that oil ignition system components are protected from water spraying splashing etc during boil...

Page 16: ...ssary to install the insulation are shipped with the carton containing the insulation 1 Wrap insulation blanket around cast iron block with the cutout facing to the front 2 Secure insulation blanket with supplied spring clips 5671 044 v1 0 2 1 Fig 8 ...

Page 17: ...n behind the front panel of the boiler and out through the bottom 4 Install support brackets 5 Position left side panel onto support brackets 6 Line up bottom tab of side panel with notch in casting leg of rear section 7 Once side panel is in place bend down tab using pliers as shown 5671 044 v1 0 A 41 2x M10 SW15 5 3 6 7 4 Fig 9 ...

Page 18: ...cing outward 9 Install rear panel 10 Install right side panel on support brackets Ensure top of side panel fits over top of rear panel 11 Line up bottom tab of side panel with notch in casting leg 12 Once side panel is in place bend down tab as shown 5671 044 v1 0 A 41 8 9 3 9 x 9 5 Fig 10 2x Fig 11 12 10 10 11 ...

Page 19: ...he front panel in place by attaching it to the side panels as shown and securing with screws Combustion Chamber Insert For optimum environmentally sound operation Vitorond boilers are equipped with a high grade corrosion resistant stainless steel combustion chamber insert Ensure the bolts of the combustion chamber door are tightened before installing the burner Combustion chamber insert sizes Boil...

Page 20: ...etermine if operation of exhaust devices could lead to levels of depressurization of the house that would adversely affect the operation of the oil burning appliance and its venting system If such is the case the building owner shall be informed of the situation in writing H The chimney shall be inspected to ensure that the material construction condition and size are suitable for the application ...

Page 21: ... runs must be supported by appropriate means to prevent sagging Avoid long horizontal runs of vent pipe Horizontal runs should have not less than rise per ft from the boiler to the vent terminal Metal strapping must be used to support horizontal runs every 4 ft 3 Connect factory supplied vent pipe adaptor to flue gas collar Fasten using either three equally spaced corrosion resistant self tapping ...

Page 22: ...system during summer months 2 Remove screw Q Remove top back panel before starting to connect pipe fittings to boiler water supply connection 3 Connect system supply to using NPT fittings as shown in Fig 16 Connect the system return to using NPT fittings as shown in Fig 16 See installation examples in the following section starting on page 60 4 Install temperature and pressure gage O with brass ex...

Page 23: ... a flow switch Install the approved factory supplied pressure relief valve Removal of air from the system must occur via use of air vent s in the system supply To ensure the boiler can be purged of all air ensure supply return water lines do not contain restrictive piping where air could be trapped 1 Install supplied high limit control as shown in Fig 18 Maximum allowable temperature setting is 24...

Page 24: ...el we recommend moving the top panel screw approximately 3 to the left or right To do so pre drill the panel with an 1 8 drill bit To reinstall the top panel drill a new 1 8 pilot hole through the top back panel and into the back panel Reinstall the screw P into this new mounting hole P Fig 19 5671 044 v1 0 ...

Page 25: ... 2 Remove screw P Remove top back panel before starting to connect pipe fittings to boiler water supply connection 3 Connect system supply to using NPT fittings Fig 21 Connect the system return to using NPT fittings pictured below See installation examples 4 Install temperature and pressure gage with brass extension coupling M in opening as shown in the illustration Fig 21 Use thread sealing compo...

Page 26: ...ischarge pipe 3 4 Piping to precharged expansion tank VR1 40 to VR1 63 3 4 This boiler does not require a flow switch Install the approved factory supplied pressure relief valve Removal of air from the system must occur via use of air vent s in the system supply To ensure the boiler can be purged of all air ensure supply return water lines do not contain restrictive piping where air could be trapp...

Page 27: ...nel we recommend moving the top panel screw approximately 3 to the left or right To do so pre drill the panel with an 1 8 drill bit To reinstall the top panel drill a new 1 8 pilot hole through the top back panel and into the back panel Reinstall the screw P into this new mounting hole P Fig 23 5671 044 v1 0 ...

Page 28: ...e for 15 minutes During time of pressure testing do not leave boiler unattended 5 Inspect all pipe joint connections the safety devices Safety Header if applicable and boiler base with flashlight for leaks 6 After 15 minutes release water pressure from boiler by opening boiler drain valve slowly remove caps from supply and return connections as well as cap from safety nipple and install pressure r...

Page 29: ...urner specifications see table on page 59 Burner calibration Ensure that the combustion results of the oil fired burner mounted on this boiler are verified after start up If adjustments are necessary always verify results with a calibrated flue gas analyzer For Beckett burner specifications see table on page 59 This burner is shipped with the oil pump set to operate on a single line system To oper...

Page 30: ...the factory 2 Mount four M8 spacer bolts in threaded holes of combustion chamber door 3 Slide burner gasket over spacer bolts 4 Mount burner as shown For proper insertion lengths see table on page 59 5 Secure burner with M8 nuts and washers provided 5671 044 v1 0 Burner mounting Fig 24 Burner air tube insertion VR1 40 Fig 25 Burner air tube insertion VR1 50 63 Fig 26 ...

Page 31: ...und oil line piping must be encased to prevent oil leaking into ground Check local codes for information If any part of fuel oil tank is above burner level an anti siphon device must be used to prevent flow of oil in case of oil line break Make tank connections with swing joints or copper tubing to prevent breaking in case the tank settles Make swing joints so they will tighten as tank settles Non...

Page 32: ...usted requires a constant 120 VAC power source supplied to the BLACK wire on the control see wiring diagram on pages 35 and 35 1 The cover mounting plate is not a conduit connection point Pass conduit and attached connector through the front opening in the mounting plate or through one of the knockouts on either side of the cover and attach it directly to the burner mounted 4x4 electrical junction...

Page 33: ...al codes In Canada CSA C22 1 Canadian Electrical Code Part 1 and any local codes Wiring must be N E C Class 1 If original wire as supplied with boiler must be replaced type 105 C wire or equivalent must be used Supply wiring to boiler and additional control wiring must be 14 ga or heavier Provide electrical ground at boiler as required by codes 5671 044 v1 0 Electric shock hazard Can cause severe ...

Page 34: ... first 5671 044 v1 0 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 WARNING ground black white red black ground red white POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED CONTROL CASE MUST BE CONNECTED TO EARTH GROUND USE GROUNDING SCREW PROVIDED B1...

Page 35: ...ed 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 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 WARNING If burner lock ou...

Page 36: ... 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 41 1 The cover mounting plate is not a conduit connection point Pass conduit and attached connector through the front opening in the mounting plate or through one of the knockouts on either side of the cover ...

Page 37: ...l Installation Instructions Boiler Control for all connections to control base The power supply cable is shipped with the boiler control 1 Loosen two screws and remove cover plate 2 Remove top back panel 3 Remove front panel 4 Place control console on boiler and fasten with two screws removed in step 1 Boiler temperature sensor is shipped with the boiler control not applicable to Vitotronic 100 KK...

Page 38: ...ling through back opening toward boiler control 7 Channel low voltage cables i e sensor cables through cable opening toward boiler control 8 Coil excess cabling and tuck between side panel and insulation 9 Tighten strain reliefs 5671 044 v1 0 6 Fig 34 Always route all cables and capillaries between nylon backed insulation and metal enclosure panels never directly on cast iron heat exchanger WARNIN...

Page 39: ...ough the top back panel and into the back panel Reinstall the screw P into this new mounting hole Boiler coding card Only the boiler coding card supplied with the standard equipment of the boiler may be used The coding card is enclosed in the accessory pack of the boiler 1 Push boiler coding card through recess in the cover and insert it into plug in location X7 If the boiler coding card is not in...

Page 40: ...nect the RAST 5 plug in connector of the Pump Junction Box to the main circuit board of the control See Fig 38 3 Feed the power supply cabling of the system pump through the opening at the back of the boiler and connect to terminals in pump junction box See Fig 38 Run BX armoured cable or any other approved wire required by local authority having jurisdiction from junction box terminal to heating ...

Page 41: ...al control wiring must be 14 ga or heavier Provide electrical ground at boiler as required by codes 5671 044 v1 0 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 WARNING Jumper RED Viessmann 41 plug control connection BL O BK W G R B4 S3 T2 T1 N G L1 18 Blue Closed end conne...

Page 42: ...life if power source including service switch on boiler is not disconnected before installing or servicing WARNING BK W G R Y Y O BL W V BK R O BL O T T Block vent safety switch Canada Only Factory installed Jumper 41 Vitotronic Control Refer to corresponding Vitotronic Control manual 1 2 Refer to Vitotronic 200 300 KW2 KW3 for alternate connection location of LWCO 41 1 2 2 Control case must be co...

Page 43: ...laced type 105 C wire or equivalent must be used Supply wiring to boiler and additional control wiring must be 14 ga or heavier Provide electrical ground at boiler as required by codes If burner lock out occurs verify blocked vent safety switch operation first 5671 044 v1 0 Electric shock hazard Can cause severe personal injury or loss of life if power source including service switch on boiler is ...

Page 44: ...burner For Riello burner specifications see table on page 60 Burner calibration Ensure that the combustion results of the oil fired burner mounted on this boiler are verified after start up If adjustments are necessary always verify results with a calibrated flue gas analyzer For Riello burner specifications see table on page 60 This burner is shipped with the oil pump set to operate on a single l...

Page 45: ...has been installed at the factory 2 Mount four M8 spacer bolts in threaded holes of combustion chamber door 3 Slide burner gasket over spacer bolts 4 Mount burner as shown For proper insertion lengths see table on page 60 5 Secure burner with M8 nuts and washers provided 5671 044 v1 0 Fig 42 Burner air tube insertion VR1 40 50 63 Fig 43 ...

Page 46: ...il line piping must be encased to prevent oil leaking into ground Check local codes for information If any part of fuel oil tank is above burner level an anti siphon device must be used to prevent flow of oil in case of oil line break Make tank connections with swing joints or copper tubing to prevent breaking in case the tank settles Make swing joints so they will tighten as tank settles Non hard...

Page 47: ...s see wiring diagram on pages 48 and 49 Cable strap supplied Honeywell high limit control Burner wiring 1 Secure control harness using 2 supplied cable straps Room thermostat wiring 1 Install thermostat on inside wall away from influences of drafts hot or cold water pipes lighting fixtures television sun rays or fireplaces 2 Follow instructions supplied with room thermostat If it has a heat antici...

Page 48: ...d with boiler must be replaced type 105 C wire or equivalent must be used Supply wiring to boiler and additional control wiring must be 14 ga or heavier Provide electrical ground at boiler as required by codes IMPORTANT Red wire not used in this application Use wire nuts to cap both ends inside high limit control and Riello burner sub base 5671 044 v1 0 Electric shock hazard Can cause severe perso...

Page 49: ... to terminal L1 and N to terminal L2 of the Honeywell high limit control see wiring diagram below Red wire not used in this application Use wire nuts to cap both ends inside high limit control and Riello burner sub base 5671 044 v1 0 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 ser...

Page 50: ...on boiler and fasten with two screws removed in step 1 Boiler temperature sensor number is shipped with the boiler control does not apply to Vitotronic 100 KK10 5 Carefully push high limits thermometer sensor and boiler temperature sensor behind front panel and into sensor wells as far as possible Lay excess sensor cabling and capillary tubing on insulation 5671 044 v1 0 2 3 4 Fig 48 1 1 3 5 4 2 I...

Page 51: ...le or Power Pump Module cable for Vitotronic 200 and all other 120 VAC cabling through back opening toward boiler control 7 Channel low voltage cables i e sensor cables through cable opening toward boiler control 8 Coil excess cabling and tuck between side panel and insulation 9 Tighten strain reliefs 5671 044 v1 0 6 Fig 49 Always route all cables and capillaries between nylon backed insulation an...

Page 52: ...ostat wiring 1 Install thermostat on inside wall away from influences of drafts hot or cold water pipes lighting 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 wiring diagrams give setting for standard equipment Electrical c...

Page 53: ...Connect the RAST 5 plug in connector of the Pump Junction Box to the main circuit board of the control as shown in Fig 51 3 Feed the power supply cabling of the system pump through the opening at the back of the boiler and connect to terminals in pump junction box See Fig 51 Run BX armoured cable or any other approved wire required by local authority having jurisdiction from junction box terminal ...

Page 54: ...oiler as required by codes 5671 044 v1 0 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 WARNING Jumper RED Viessmann 41 plug 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...

Page 55: ...W B BK WH R G L1 R G T1 T2 WH N BK S3 B4 BL OG G L1 T1 T2 N S3 B4 41 6 G OG BL B Capacitor 41 Factory installed jumper Vitotronic Control Refer to corresponding Vitotronic Control manual 1 2 2 A Motor 120 VAC receptacle field supplied 120 VAC power supply to boiler Low water cut off if required field supplied VIESMANN Main ON OFF switch field supplied 120 VAC Power supply Installer must provide 15...

Page 56: ... into the back panel Reinstall the screw P into this new mounting hole Boiler coding card Only the boiler coding card supplied with the standard equipment of the boiler may be used The coding card is enclosed in the accessory pack of the boiler 1 Push boiler coding card through recess in the cover and insert it into plug in location X7 If the boiler coding card is not installed the following fault...

Page 57: ...for most residential applications is 12 to 15 psig when the system is cold A lower pressure gage reading usually indicates loss of water due to leakage All leaks must be corrected Refer to instructions packaged with automatic fill valve Follow local regulations with respect to backflow preventers Water treatment should be considered in areas where it is known that boiler feed water contains a high...

Page 58: ...in the flue pipe between boiler and barometric draft regulator before dilution air see the installation manual Overfire draft is measured at the combustion chamber observation port opening Over fire draft ranges from 0 to 0 01 w c Breeching draft is approximately 0 02 w c Note This boiler is approved for operation with a breeching draft of up to 0 08 w c when used without a barometric draft regula...

Page 59: ...GPH psig 1 15 175 1 40 175 1 75 175 Air tube length inches mm 7 178 9 230 9 230 Air tube insertion inches mm 47 8 124 7 184 7 184 Air tube combination NX70LJ AFG90MDAQ AFG90MDAQ Head type 9 slot V1 V1 Head setting 3 5 1 4 Air setting see head setting 10 1 10 2 Static plate n a 2 3 4U 2 3 4U Baffle n a Fuel pump c w solenoid valve 21844 21844 21844 Flange 32073 31309 31309 1 The Beckett burner for ...

Page 60: ...0 Air gate setting 3 5 3 6 2 8 1 For VR1 40 and 50 boilers replace installed nozzle in VR1 33 Riello burner with the appropriate nozzle packaged with burner 2 Factory installed nozzle 3 Nozzles must be installed by installer Note The Riello burner for the VR1 33 boiler is shipped with factory setting and oil nozzle installed and should require only minor adjustments For VR1 40 and 50 boilers repla...

Page 61: ...ed with pipe insulation of appropriate and sufficient thickness and insulation values the above clearance may be reduced to 0 Waterside flow Fig 57 VR1 40 to 63 Flow rates The relationship between boiler flow rate and temperature rise is according to the formula Boiler output Btu h 500 x flow USGPM x Rise F The following chart lists typical flow rates for the Vitorond boiler Boiler Model VR1 40 50...

Page 62: ...s 62 Installation Examples Aquastat Heating circuit Spring loaded flow check valve Circulation pump Automatic air vent Pressure relief valve High limit control Expansion tank 5671 044 v1 0 5671 044 v1 0 F Fig 58 ...

Page 63: ... Pressure relief valve High limit control Water chiller Expansion tank We strongly suggest that the valves pictured above be labelled v1 and v2 Low water cut off A low water cut off may be required by local codes If boiler is installed above radiation level a low water cut off device of approved type field supplied must be installed in all instances Do not install an isolation valve between boiler...

Page 64: ...eld supplied pressure relief valve and temperature and pressure gage Expansion tank Without mixing valve and with DHW e g with Vitotronic 100 KW10B Heating circuit Spring loaded flow check valve Circulation pump Automatic air vent field supplied pressure relief valve and temperature and pressure gage Expansion tank Domestic hot water storage tank indirect fired 5671 044 v1 0 Fig 61 Fig 62 ...

Page 65: ... and pressure gage Expansion tank Domestic hot water storage tank indirect fired 4 Way mixing valve With one low temperature circuit with 4 way mixing valve and one high temperature circuit and with domestic hot water production e g with Vitotronic 200 Model KW2 combined with one Mixing Valve Actuator Accessory Kit Heating circuit Spring loaded flow check valve Circulation pump Automatic air vent ...

Page 66: ...ield supplied pressure relief valve and temperature and pressure gage Expansion tank Water chiller We strongly suggest that the valves pictured above be labelled v1 and v2 Low water cut off A low water cut off may be required by local codes If boiler is installed above radiation level a low water cut off device of approved type field supplied must be installed in all instances Do not install an is...

Page 67: ... chamber door Page 70 S 6 Check heating system and domestic hot water connections Page 70 S 7 Ensure proper operation of all safety devices Page 70 S 8 Ensure proper operation of expansion tank low water cut off if applicable and pumps Page 71 S 9 Ensure that an adequate supply of combustion air exists in the boiler room Page 71 S 10 Ensure functionality of the barometric draft regulator of the bu...

Page 68: ...ctivation 2 Close main oil supply valve near burner and near tank 2 Open combustion chamber door 1 Disconnect power supply 2 Remove front panel by lifting panel up and out 3 Remove two bolts of combustion chamber door and open Continued on following page 5671 044 v1 0 Ensure that warning concerning fiberglass wool and ceramic fiber materials on page 3 has been read and understood before handling i...

Page 69: ...2 Remove all sediment from flue pipe and flue gas collector using vacuum cleaner 4 Check all gaskets and insulation 1 Check all gaskets and the sealant rope of the combustion chamber door for wear or damage 2 Check the combustion chamber door refractory for wear or damage 3 Replace worn or damaged parts Service Procedure continued 5671 044 v1 0 Fig 68 Ensure that warning concerning fiberglass wool...

Page 70: ...ter connections Ensure all connections are pressure tight 7 Ensure proper operation of all safety devices Check pressure gage air vent and pressure relief valve Ensure pressure relief valve does not leak Also ensure pressure relief valve operates in accordance with information provided by the manufacturer Service Procedure continued 5671 044 v1 0 C A B D Fig 69 Reconnect oil burner and follow inst...

Page 71: ...local regulations with respect to backflow preventers If oil lubricated pumps are used ensure proper lubrication If motorized zone valves are used refer to maintenance instructions provided with zone valves If an older non diaphragm expansion tank is used ensure the correct water level is present 9 Ensure that an adequate combustion air supply exists in the boiler room Ensure fresh air intake of b...

Page 72: ...e draft and CO are taken in the flue pipe between boiler and barometric draft regulator before dilution air see the installation manual Overfire draft is measured at the combustion chamber observation port opening Over fire draft ranges from 0 to 0 01 w c Breeching draft is approximately 0 02 w c Note This boiler is approved for operation with a breeching draft of up to 0 08 w c when used without ...

Page 73: ...Front panel 208 Support bracket 209 Top panel rear 210 Side panel right 211 Nameplate Vitorond 100 212 Cover edgemolding 215 Cover plate 509 Vitotronic retrofit housing Other Parts not illustrated 300 Touch up spray paint Vitotec silver 301 Touch up paint stick Vitotec silver 304 Accessory pack small parts for insulation jacket 400 Installation fittings for Aquastat applications 500 Installation f...

Page 74: ...e relief valve 30 psig 503 Vent pipe adaptor 6 504 Junction box 4 505 Accessory pack burner installation hardware 506 Temperature and pressure gage 507 Control cable with 41 plug 4 508 Burner cable 41 4 509 Vitotronic retrofit housing 4 510 Return injector nozzle Wear Parts 016 Cleaning brush handle 800mm 5 017 Cleaning brush no handle 5 1 sold with adhesive 2 for VR1 40 50 63 3 for VR1 40 only 4 ...

Page 75: ...ction tee 2 x x 2 408 90º Street elbow 409 Nipple x 3 410 Pressure relief valve 30 psig 411 Reduction tee 2 x 2 x 412 Sediment faucet 413 Vent pipe adaptor 6 415 Burner cable 85 4 wire 421 Cable clamps 422 Outdoor reset kit Other Parts not illustrated 417 Accessory pack burner installation hardware 500 Installation Operation and Service Instructions 501 Installation Instructions Direct Vent 502 Wa...

Page 76: ... service and maintenance done by a licensed professional heating contractor 1 Boiler heat exchanger inspected and cleaned 2 Vent system inspected for deterioration leaks corrosion proper draft and proper operation Check vent system for compliance with local and national code requirements Repair or replace as required 3 Burner checked and if necessary adjusted for proper combustion and operation Ch...

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