Viessmann FDVS-4, Vitorond VR1-22, Vitorond VR1-27, VitorondVR1-33, Z005 875 Installation Instructions Manual

Installation Instructions Supplement

for use by heating contractor

Direct Vent Systems,

for Vitorond 100 boilers

Part No. Z005 875 (FDVS-4)

Safety and Installation Requirements

Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions listed below can cause product/property damage, severe personal injury, and/or loss of life.

Working on the equipment

The installation, adjustment, service, and maintenance of this product must

Please file in Service Binder

be done by a licensed professional heating contractor who is qualified and

experienced in the installation, service, and maintenance of hot water boilers. There are no user serviceable parts on the boiler, burner, or control.

Ensure main power supply to equipment, the heating system, and all external controls has been deactivated. Close main oil supply valve. Take precautions in both instances to avoid accidental activation of power during service work.

Ensure that the installation literature of other applicable components is referenced.

General Information

Standard installation

Boiler Model

Rear

Sides

Flue

Floor Combustibles

Alcove installation

Boiler Model

Rear

Sides

Flue

Top*

Floor Combustibles

VR1 -22 -27 -33

inches mm inches mm inches mm

VR1 -22 -27 -33

inches mm inches mm inches mm inches mm

150

25

150

25

150

6

150 0 0 1

6

0 0 1

6

25

150

25

150

IMPORTANT

Advise owner to keep direct vent

6

150 0 0 1

6

150 0 0 1

6

150

termination and air intake free of

6

debris, snow and ice.

0 0 1

25

6

0 0 1

25

6

WARNING

Viessmann will not assume any responsibility for possible effects of an obstructed air intake or exhaust termination.

NOTE: Surface discoloration on the outside of the building may occur if the burner is not properly adjusted. Viessmann will not accept any responsibility for such discoloration.

NOTE: Direct Vent exhaust system operates under a positive pressure developed by the burner. Make sure all vent connections and observation port on the boiler are sealed air-tight by tightening screws and using high temperature silicone sealant if necessary.

NOTE: The vent components must be supplied without any alteration except for the length of the flex pipe to be cut to the desired length.

* 24” with Vitotronic control.

The insulated oil direct vent system is rated for a 1” clearance to combustibles.

5351 050 v2.5 09/2012

Installation

Installation of Insulated Stainless Steel Flexible Oil Vent

In addition to the following instructions, also consult Field Controls Direct Vent System manual for detailed instructions on how to install the venting system.

Ø4”

a

*Boiler-to-vent

transition adaptor (stainless steel)

Refer to Vitorond 100 Installation and Service Instructions.

Supports max. 3’

b

Air intake

Exhaust 12” min. above anticipated snow line

VRV-4 Vacuum Relief Valve

Fig. 1

Use a 4” to 3” reducer (not supplied) to connect an intake pipe to the Riello burner. If no air intake is required a=0 then provide combustion air supply to mechanical room where the burner is installed. The burner requires fresh air for safe operation and must be installed in a mechanical room where there are provisions for adequate combustion and ventilation air.

Smoke test port

R

1

Avoid dips in the venting system when using the flexible insulated stainless steel oil vent.

The direct vent kit includes a VRV-4 vacuum relief valve which must be installed in the air intake pipe as close as possible to the burner when using a Beckett burner (see Fig. 1).

*The direct vent kit includes a Viessmann-specific stainless steel boiler-to-vent transition adaptor.

b=15’ a=20’

(max. 2 x 90°elbows) Each 90° elbow = 3’ e.q.L.

R1=min. wall clearance 28”

(for min. bend radius of flexible vent pipe)

IMPORTANT

Do not install the regular galvanized vent pipe adaptor shipped with the boiler. This galvanized vent pipe adaptor is intended for chimney venting application and therefore must be discarded in a direct vent application.

2

5351 050 v2.5

Burner Set-up (Beckett)

Electrical connections (with Aquastat control)

Burner - Beckett

Installations must follow these codes

WARNING

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.

"

All field supplied nominal 120 VAC voltage wiring must be sheathed in a flexible metal conduit.

"

Disconnect means, overload protection and low water cut-off must be provided as required by local codes.

"

Connect incoming line voltage HOT (L1) wire to terminal L1, and N to terminal L2 of the Honeywell high limit control (see wiring diagram on page 5.

and requirements:

- National Electrical Code, ANSI/NFPA 70, latest edition and any addtional national, state or local codes.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

- 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.

Burner wiring

IMPORTANT

The R7184 or GeniSys 7505P primary control with valve-on delay (pre-purge) and burner motor-off delay (post-purge

- factory default settings can be field

adjusted), requires a constant 120 VAC power source supplied to the BLACK wire on the control (see wiring diagram on following page).

Fig. 2

Legend

Cable strap (supplied) Honeywell high limit control Burner wiring harness (supplied)

5351 050 v2.5

WARNING

Ensure that burner wiring harness is properly attached and secured to the boiler side panel using the supplied cable straps as depicted above. The cable strap must be coiled on the boiler side panel so that no slack is left, allowing the burner/boiler door to be swung open without disconnecting the burner wiring harness from the burner. Failure to heed this warning may result in personal injury.

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 box.

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 anticipator, set heat anticipator in thermostat to match power requirements of equipment connected to it. Boiler wiring diagrams give setting for standard equipment.

3

Burner - Beckett

Burner Set-up (Beckett)

(continued)

Electrical connections (with Aquastat control) (continued)

Installations must follow these codes

WARNING

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.

and requirements:

- National Electrical Code, ANSI/NFPA 70, latest edition and any addtional national, state or local codes.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

Burner wiring harness (supplied)

white

black

ground

red

15” *

- 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.

ground

1/4 quick connect insulated flag

red

Fig. 3

white

black

4

5351 050 v2.5

Burner - Beckett

Burner Set-up (Beckett)

Wiring diagram (with Aquastat control) with outdoor reset module

WARNING

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.

"

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).

(continued)

Installations must follow these codes and requirements:

- National Electrical Code, ANSI/NFPA 70, latest edition and any additional national, state or local codes.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

- 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.

Fig. 4

Legend

Oil solenoid valve Ignition transformer Burner motor CAD cell flame detector Burner grounding screw R7184 Series primary control with post-purge (factory default setting: 30 sec. - can be field adjusted; see Beckett burner manual) Factory-installed jumper

5351 050 v2.5

WARNING

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.

CAUTION

A field supplied manual reset high limit control must be installed at the outlet pipe of the boiler to interrupt burner operation should the factory supplied high limit control fail. This field supplied high limit control must be set 20°F above the setting of the factory supplied high limit control. The setting of this field supplied high limit control must never be greater than 220°F.

5

Burner - Beckett

Burner Set-up (Beckett burner with GeniSys primary control)

Wiring diagram (Vitorond 100 with Beckett (NX) burner and Honeywell Aquastat)

Installations must follow these codes

WARNING

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.

"

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).

and requirements:

- National Electrical Code, ANSI/NFPA 70, latest edition and any additional national, state or local codes.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

- 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.

(continued)

Fig. 5

6

WARNING

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.

CAUTION

A field supplied manual reset high limit control must be installed at the outlet pipe of the boiler to interrupt burner operation should the factory supplied high limit control fail. This field supplied high limit control must be set 20°F above the setting of the factory supplied high limit control. The setting of this field supplied high limit control must never be greater than 220°F.

5351 050 v2.5

Burner - Beckett

Burner Set-up (Beckett)

Electrical connections (with Vitotronic control)

WARNING

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.

(continued)

Installations must follow these codes and requirements:

- National Electrical Code, ANSI/NFPA 70, latest edition and any addtional national, state or local codes.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

41

#41 plug-in connector

- 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.

Burner wiring

IMPORTANT

The R7184 primary control with valve-on delay (pre-purge) and burner motor-off delay (post-purge - factory default settings can be field adjusted), requires a constant 120 VAC power source supplied to the BLACK wire on the control (see wiring diagram on page 9).

Fig. 6

1.

2.

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 box.

Electrical connections

1.Run the plug-in connector cable of

the Vitotronic control down behind the front panel of the boiler and out through the bottom. (Fig. 5)

2.Connect the female plug of the

burner to the male plug of the Vitotronic control. (Fig. 5)

5351 050 v2.5

7

Connections

Burner Set-up (Beckett)

Electrical connections (with Vitotronic control) (continued)

(continued)

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 anticipator, set heat anticipator in thermostat to match power requirements of equipment connected to it. Boiler wiring diagrams give setting for standard equipment.

8

5351 050 v2.5

Connections

Burner Set-up (Beckett)

(continued)

Electrical connections (with Vitotronic control) (continued)

Installations must follow these codes

WARNING

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.

and requirements:

- National Electrical Code, ANSI/NFPA 70, latest edition and any addtional national, state or local codes.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

Burner wiring harness (supplied)

Closed end connectors are factory installed on RED, ORANGE and BLUE wires. These RED, ORANGE and BLUE wires may or may not be used in your burner application. See wiring diagram in this manual which is specific to your burner application. Do not remove or cut any of the closed end connectors of the RED, ORANGE or BLUE wires, unless it is necessary to do so. RED wire is live (120VAC) at all times. Do not remove or cut its closed end connector unless it

Viessmann #41-plug control connection

is necessary to do so. Failure to heed the above instructions may cause severe personal injury or loss of life.

B4

BL

O

S3

BK

T2

T1

W

N

G

R

L1

Jumper RED

- 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.

Blue

18” *

Fig. 7

Legend BL Blue O Orange BK Black W White G Green / Ground R Red

* If Beckett burner is being installed,

cut this length to 6” for connection to burner junction box (located under the burner primary control).

5351 050 v2.5

9

Connections

Burner Set-up (Beckett)

(continued)

Wiring diagram (with Vitotronic control)

WARNING

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.

Blue and orange wires not used in this application. DO NOT cut or remove closed end connector from the wires.

Installations must follow these codes and requirements:

- National Electrical Code, ANSI/NFPA 70, latest edition and any additional national, state or local codes.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

Burner junction box

2

G

BL

O

BK

R

W

R

BK

W

- 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.

WARNING

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.

Factory

41

N

B4

T2

S3

O

BL

BK

B4

T2

S3

G

T1

G

W

N

G

T1

installed jumper

L1

R

L1

41

Legend

Y Yellow BL Blue BK Black O Orange W White G Green / Ground R Red GY Gray BR Brown V Violet

Vitotronic Control

(Refer to corresponding Vitotronic Control manual)

Fig. 8

2

O

Refer to Vitotronic 200/300 (KW2/KW3) for alternate connection location of LWCO.

120 VAC power supply to boiler

120 VAC receptacle (field supplied)

Power supply. Provide disconnect

1

means and overload protection as required. Control case must be connected

2

to earth ground.

V

BL

T

O

T

Y

120 VAC

1

power supply installer must provide 15A overcurrent protection

Main ON/OFF switch (field supplied)

Low water cut-off (if required) (field supplied)

Legend

Oil solenoid valve Ignition transformer Burner motor CAD cell flame detector Burner grounding screw R7184 Series primary control with post-purge (factory default setting: 30 sec. - can be field adjusted; see Beckett burner manual) Factory-installed jumper

5351 050 v2.5

10

Burner Set-up (Beckett burner with GeniSys primary control)

Wiring diagram (Vitorond 100 with Beckett (NX) burner, GeniSys control and Vitotronic control)

Connections

WARNING

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.

Installations must follow these codes and requirements:

- National Electrical Code, ANSI/NFPA 70, latest edition and any additional national, state or local codes.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

- 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.

WARNING

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.

VIESMANN

Fig. 9

5351 050 v2.5

11

Burner - Riello

Burner Set-up (Riello)

Electrical connections (with Aquastat control)

Installations must follow these codes

WARNING

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.

"

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 12).

and requirements:

- National Electrical Code, ANSI/NFPA 70, latest edition and any additional national, state or local codes.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

- 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.

Burner wiring

1. Secure control harness using 2

supplied cable straps .

WARNING

Ensure that burner wiring harness is properly attached and secured to the boiler side panel using the supplied cable straps as depicted above. The cable strap must be coiled on the boiler side panel so that no slack is left, allowing the burner/boiler door to be swung open without disconnecting the burner wiring harness from the burner. Failure to heed this warning may result in personal injury.

Room thermostat wiring

Fig. 10

Legend

Burner and control harness, (see wiring diagram on page 12) Cable strap (supplied) Honeywell high limit control

12

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.

5351 050 v2.5

Burner - Riello

Burner Set-up (Riello)

(continued)

Electrical connections (with Aquastat control) (continued)

Installations must follow these codes

WARNING

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.

and requirements:

- National Electrical Code, ANSI/NFPA 70, latest edition and any addtional national, state or local codes.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

Burner wiring harness (supplied)

white

black

ground

red

15” *

- 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.

ground

1/4 quick connect insulated flag

red

Fig. 11

* If Beckett burner is being installed,

cut this length to 6” for connection to burner junction box (located under the burner primary control).

white

black

5351 050 v2.5

13

Burner - Riello

Burner Set-up (Riello)

Wiring diagram (with Aquastat control) with outdoor reset module

WARNING

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.

"

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).

(continued)

Installations must follow these codes and requirements:

- National Electrical Code, ANSI/NFPA

- In Canada, CSA C22.1 Canadian

70, latest edition and any additional national, state or local codes.

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.

Fig. 12

CAUTION

A field supplied manual reset high limit control must be installed at the outlet pipe of the boiler to interrupt burner operation should the factory supplied high limit control fail. This field supplied high limit control must be set 20°F above the setting of the factory supplied high limit control. The setting of this field supplied high limit control must never be greater than 220°F.

14

Post-purge timer setting in conjunction with Honeywell Aquastat Model L7248C1006

IMPORTANT

If “Err4” fault occurs, set post-purge timer to a maximum of 45 seconds. Exceeding 45 seconds may lead to LED error code “Err4” on the older version of the Honeywell Aquastat.

Post-purge timer

5351 050 v2.5

Burner Set-up (Riello)

Electrical connections (with Vitotronic control)

Burner - Riello

WARNING

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.

Installations must follow these codes and requirements:

- National Electrical Code, ANSI/NFPA 70, latest edition and any additional national, state or local codes.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

2.

- 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.

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 anticipator, set heat anticipator in thermostat to match power requirements of equipment connected to it. Boiler wiring diagrams give setting for standard equipment.

1.

Fig. 13

5351 050 v2.5

#41 plug-in connector

Electrical connections

1. Run the plug-in connector cable

ofthe Vitotronic control down behind

the front panel of the boiler and out through the bottom. (Fig. 11)

2. Connect the female plug of the

41

burner to the male plug of the Vitotronic control. (Fig. 11)

15

Burner - Riello

Legen

d

Burner Set-up (Riello)

(continued)

Electrical connections (with Vitotronic control) (continued)

Installations must follow these codes

WARNING

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.

and requirements:

- National Electrical Code, ANSI/NFPA 70, latest edition and any addtional national, state or local codes.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

Burner wiring harness (supplied)

Closed end connectors are factory installed on RED, ORANGE and BLUE wires. These RED, ORANGE and BLUE wires may or may not be used in your burner application. See wiring diagram in this manual which is specific to your burner application. Do not remove or cut any of the closed end connectors of the RED, ORANGE or BLUE wires, unless it is necessary to do so. RED wire is live (120VAC) at all times. Do not remove or cut its closed end connector unless it

Viessmann #41-plug control connection

is necessary to do so. Failure to heed the above instructions may cause severe personal injury or loss of life.

B4

BL

O

S3

BK

T2

T1

W

N

G

R

L1

Jumper RED

- 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.

Blue

18” *

Fig. 14

BL Blue O Orange BK Black W White G Green / Ground R Red

16

5351 050 v2.5

Burner - Riello

Burner Set-up (Riello)

(continued)

Wiring diagram (with Vitotronic control) (continued)

Installations must follow these codes

WARNING

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.

and requirements:

- National Electrical Code, ANSI/NFPA 70, latest edition and any additional national, state or local codes.

- In Canada, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

2

G

Air pressure

11

Y

switch

BK

BL

WW

BL

41

Blue wire not used in this application. DO NOT cut or remove closed end connector from the wire.

Factory installed jumper

12

BL

O

BK

R

NO

10

W

M

BL

Oil valve

BRN

NC

Capacitor

W

BK

1 2 3 4 5 6 7

X

L

N

BL

W

R

O

BK

R

AL 1009 Burner Fan-Off

Timer

- 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.

WARNING

9

BR

W

BK

8

R

GY

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.

N

G

B4

BL

B4

T1

S3

T2

O

BK

T1

S3

T2

L1

R

G

W

N

G

L1

41

Legend

BL Blue BK Black O Orange W White G Green / Ground R Red GY Gray BR Brown Y Yellow

Vitotronic Control (Refer to corresponding Vitotronic Control manual)

Fig. 15

5351 050 v2.5

2

Riello burner sub-base

Power supply. Provide disconnect means

1

and overload protection as required.

Control case must be connected

2

to earth ground.

120 VAC power supply to boiler

120 VAC receptacle (field supplied)

120 VAC

1

Power supply installer must provide 15A overcurrent protection

Main ON / OFF switch (field supplied)

Low water cut-off (if required) (field supplied)

Refer to Vitotronic 200 / 300 (KW2 / KW3) manual for alternate connection location of LWCO.

17

Initial Start-up

Oilnozzle

Initial Start-Up

Beckett burner calibration

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

Burner model Beckett NX-VI 701 NX-VI 702 NX-VI 703

Fuel type oil No. 2 fuel oil

Pump pressure psig 190 175 175

Oil nozzle

Oil nozzle flow rate GPH@psig 0.65@190 0.75@175 1.00@175

Air tube length inches

Air tube insertion inches

Air tube combination NX70LP NX70LP NX70LJ

Head type 6-slot 6-slot 9-slot

Head setting 2.00 2.50 3.25

Air setting see head setting

Static plate n.a.

Baffle n.a.

Fuel pump 21844 21844 21844

Flange 32073 32073 32073

Danfoss n.a. 0.60x60°AS n.a.

Delavan 0.50x60°B n.a. 0.75x60°A/W

Hago 0.50x60°B 0.60x60°B n.a.

mm

7

178

3¼

83

178

3¼

83

7

178

35/

92

7

8

18

5351 050 v2.5

Initial Start-Up

Initial Start-up

Riello burner calibration

Boiler model Model No. VR1-22 VR1-27

Burner model Riello 40

*1

BF3 BF3

*1

VR1-33

BF5

Series

Fuel type oil No. 2 fuel oil

Pump pressure psig 175 175 140

Oil nozzle Danfoss n.a. n.a. n.a.

Oil nozzle Delavan 0.5x60°xSS 0.6x60°xW

*3

0.85x60°xW

*2

Oil nozzle Hago n.a. n.a. n.a.

Oil nozzle flow rate GPH@psig 0.65@175 0.75@175 1.00@140

Air tube length inches

mm

Air tube insertion inches

mm

178

45/

118

7

8

178

45/

118

7

65/

16

160

8

4¼

108

Turbulator setting 0.0 1.0 1.0

Air gate setting 3.7 5.0 4.0

IMPORTANT

*1

For VR1-27 boiler, replace installed nozzle with nozzle packaged with Riello burner.

*2

Factory-installed nozzle.

*3

Nozzles must be installed by installer.

Note: Riello oil burners are factory set for Vitorond 100, VR1-22, and -33 boilers and should

only require minor adjustments. Install appropriate nozzle and set the burner for model VR1-27.

5351 050 v2.5

19

20

5351 050 v2.5

Technical information subject to change without notice.

Printed on environmentally friendly (recycled and recyclable) paper.

5351 050 v2.5