Viessmann ECV Series Guide rapide

VITOGAS 050

Installation and

Service Instructions

Vitogas 050

ECV Series

Natural gas-/Propane-fired

atmospheric cast iron boiler

Rated input: 65 to 200 MBH

19 to 59 kW

Read and save these instructions

for future reference.

IMPORTANT

If the information in this manual is not followed

exactly, a fire or explosion may result causing

property damage, personal injury or loss of life.

WARNING

Do not store or use gasoline or other flammable

liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

JDo not try to light any appliances.

JDo not touch any electrical switches, do not

use any phone in your building.

JImmediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

JIf you cannot reach your gas supplier, call the

fire department.

Installation and service must be performed by a

qualified installer, service agency or the gas

supplier.

Improper installation, adjustment, and/or operation

could cause carbon monoxide poisoning resulting in

injury or loss of life.

This product must be installed and serviced by a

professional service technician who is experienced

and qualified in hot water boiler installation and gas

combustion.

WARNING

5167 450 v1.4 07/2006

Please file in Service Binder

Safety, Installation and Warranty Requirements

Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the

instructions listed 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).

JLicensed professional heating

contractor

The installation, adjustment, service,

and maintenance of this equipment

must be performed by a licensed

professional heating contractor.

"Please see section

entitled “Important

Regulatory and

Installation

Requirements”.

JProduct documentation

Read all applicable documentation

before commencing installation. Store

documentation near boiler in a readily

accessible location for reference in

the future by service personnel.

"For a listing of

applicable literature,

please see section

entitled “Important

Regulatory and

Installation Requirements”.

JAdvice to owner

Once the installation work is

complete, the heating contractor must

familiarize the system

operator/ultimate owner with all

equipment, as well as safety

precautions/requirements, shut-down

procedure, and the need for

professional service annually before

the heating season begins.

JContaminated air

Air contaminated by chemicals 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”.

JCarbon monoxide

Improper installation, adjustment,

service and/or maintenance can cause

flue products to flow into living space.

Flue products contain poisonous

carbon monoxide gas.

"For information

pertaining to the proper

installation, adjustment,

service and maintenance

of this equipment to

avoid formation of carbon monoxide,

please see sections entitled

“Combustion Air Supply” and “Venting

Connection”.

JFresh air

This equipment requires fresh air for

safe operation and must be installed

ensuring provisions for adequate

combustion and ventilation air exist.

"For information

pertaining to the fresh

air requirements of this

product, please see

section entitled

“Combustion Air Supply”.

JEquipment venting

Never operate boiler without an

installed venting system.Animproper

venting system can cause carbon

monoxide poisoning.

"For information

pertaining to venting

and chimney

requirements, please

see section entitled “Venting

Connection”. All products of

combustion must be safely vented to

the outdoors.

JWarranty

Information contained in

this and related product

documentation must be

read and followed. Failure

to do so renders warranty

null and void.

Warning

This boiler requires fresh air for safe operation and must be installed with provisions for adequate combustion and ventilation

air (in accordance with local codes and regulations of authorities having jurisdiction).

Do not operate this boiler in areas with contaminated combustion air. High levels of contaminants such as dust, lint or

chemicals can be found at construction sites, home renovations, in garages, workshops, in dry cleaning/laundry facilities,

near swimming pools and in manufacturing facilities.

Contaminated combustion air will damage the boiler and may lead to substantial property damage, severe personal injury

and/or loss of life. Ensure boiler/burner is inspected and serviced by a qualified heating contractor at least once a year in

accordance with the Start-up/Service Instructions of the boiler.

5167 450 v1.4

Installers must follow local

regulations with respect to

installation of carbon monoxide

detectors. Follow manufacturer’s

maintenance schedule of boiler.

WARNING

Safety, Installation and Warranty Requirements

Safety, Installation and Warranty Requirements (continued)

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

listed below and details printed in this manual can cause product/property damage,severe personal injury,and/orloss of life.

Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).

JFiberglass wool and ceramic fiber

materials

The state of California has listed the

airborne fibers of these materials as a

possible cancer hazard through

inhalation. When handling these

materials, special care must be applied.

Suppliers of ceramic fiber products

recommend the following first aid

measures:

-Respiratory tract (nose and throat)

irritation

If respiratory tract irritation develops,

movethepersontoadustfree

location.

-Eye irritation

If eyes become irritated, flush

immediately with large amounts of

lukewarm water for at least 15

minutes. Eyelids should be held away

from the eyeball to ensure thorough

rinsing. Do not rub eyes.

-Skin irritation

If skin becomes irritated, remove

soiled clothing. Do not rub or scratch

exposed skin. Wash area of contact

thoroughly with soap and water.

Using a skin cream or lotion after

washing may be helpful.

-Gastrointestinal irritation

If gastrointestinal tract irritation

develops, move the person to a dust

free environment.

Suppliers of fiberglass wool products

recommend the following 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

airborne fiber concentration requiring

additional protection.

First aid measures

-If eye contact occurs, flush eyes with

water to remove dust. If symptoms

persist, seek medical attention.

- If skin contact occurs, wash affected

areas gently with soap and warm

water after handling.

JHazardous materials

5167 450 v1.4

Inhalation of fiberglass wool and/or

ceramic fiber materials is a possible

cancer hazard. These materials can

also cause respiratory, skin and eye

irritation.

WARNING Appliance materials of construction,

products of combustion and the fuel

contain alumina, silica, heavy metals,

carbon monoxide, nitrogen oxides,

aldehydes and/or other toxic or

harmful substances which can cause

serious injury or loss of life and which

are known to the State of California

to cause cancer, birth defects and

other reproductive harm. Always use

proper safety clothing, respirators and

equipment when servicing or working

nearby the appliance.

WARNING

Contents

Page

Safety Important Regulatory and Installation Requirements 7....

General Information About these Installation Instructions 8.................................

Product Information 9................................................................

Excerpt from our Warranty Terms 9......................................

Mechanical Room 10....................................................................

Set-up Standard Equipment 10.................................................................

Before Set-up 11............................................................................

Installation on Combustible Floor 11........................................

Combustion Air Supply 12..........................................................

Minimum Clearances 14..............................................................

Recommended minimum clearances for service 14............

Recommended minimum clearances to combustibles 14...

Closet and alcove installation 15...............................................

Flushing of Existing Piping 16.....................................................

Removal of Existing Boiler 17....................................................

Boiler Piping in a Heating/Cooling Application 17.................

Connections Venting Connection 18.................................................................

Installing Z-FLEX AL-29-4C special stainless

steel venting system 18

...............................................................

Maximum vent length 19.............................................................

Installing Z-FLEX pipe and fittings 20.......................................

Vent terminal connection 21.......................................................

Riser box 22.....................................................................................

Installation Checklist 23...............................................................

Low Water Cut-Off 24..................................................................

Initial System Fill 25.....................................................................

Pressure Relief Valve 25...............................................................

Gas Piping 26..................................................................................

Testing - Gas Pipe 26....................................................................

Gas pressure - Orifice Sizes 27..................................................

Manifold orifices - natural gas (1,000 Btu/cu. ft.) 27..........

Manifold orifices - propane (2,500 Btu/cu. ft.) 27................

Gas Burner Removal 28................................................................

Gas Input 29.....................................................................................

Main Burner 30................................................................................

Gas Burner Positioning 30............................................................

Electrical Connections 32.............................................................

Electronic Thermostat Connection 33......................................

5167 450 v1.4

Contents (continued)

Page

Initial Start-up and Service Initial Start-up 34............................................................................

Also pay attention to the following... 34.................................

Annual shut-down 35....................................................................

Advise the owner/operator 35....................................................

Service Schedule 36......................................................................

Service Procedure Overview 37.................................................

Service Procedure 38.....................................................................

Troubleshooting Guide 42...........................................................

Additional Information Technical Data 45..........................................................................

Wiring Diagrams 46.......................................................................

Parts List 48....................................................................................

Maintenance Record 50...............................................................

Lighting and Operating Instructions 51...................................

5167 450 v1.4

Safety

Important Regulatory and Installation Requirements

Codes

The installation of this unit shall be in

accordance with local codes or, in the

absence of local codes, use

CAN/CSA-B149.1 or .2 Installation

Codes for Gas Burning Appliances for

Canada. For U.S. installations use the

National Fuel Gas Code ANSI Z223.1.

Always use latest editions of codes.

In Canada all electrical wiring is to be

done in accordance with the latest

edition of CSA C22.1 Part 1 and/or

local codes. In the U.S. use the National

Electrical Code ANSI/NFPA 70.

The heating contractor must also

comply with the Standard for Controls

and Safety Devices for Automatically

Fired Boilers, ANSI/ASME CSD-1 where

required by the authority having

jurisdiction.

Please carefully read this manual prior

to attempting installation. Any

warranty is null and void if these

instructions are not followed.

For information regarding other

Viessmann System Technology

componentry, please reference

documentation of the respective

product.

We offer frequent installation and

service seminars to familiarize our

partners with our products. Please

inquire.

For installations in the Commonwealth of Massachusetts, the following local

requirements apply in addition to all other applicable NFPA requirements:

1) For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the

vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied.

1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector

and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply

with NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall be located in the room that houses the appliance or equipment and shall:

a. Be powered by the same electrical circuit as the appliance or equipment such that only one service switch

services both the appliance and the carbon monoxide detector;

b. Have battery back-up power;

c. Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005 Edition); and

d. Have been approved and listed by a Nationally Recognized Testing Laboratory as recognized under 527

CMR.

3. A Product-approved vent terminal must be used, and if applicable, a Product-approved air intake must be used.

Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation

instructions shall remain with the appliance or equipment at the completion of the installation.

4. A metal or plastic identification plate shall be mounted at the exterior of the building, four feet directly above the

location of vent terminal. The plate shall be of sufficient size to be easily read from a distance of eight feet away,

and read ”Gas Vent Directly Below”.

Continued on following page.

5167 450 v1.4

Safety

Important Regulatory and Installation Requirements (continued)

For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment where the bottom of the

vent terminal and the air intake is installed above four feet above grade the following requirements must be satisfied:

1. If there is not one already present, on each floor level where there are bedroom(s), a carbon monoxide detector

and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply

with NFPA 720 (2005 Edition).

2. A carbon monoxide detector shall:

a. Be located in the room that houses the appliance or equipment;

b. Be either hard-wired or battery powered or both; and

c. Shall comply with NFPA 720 (2005 Edition).

3. A Product-approved vent terminal must be used, and if applicable, a Product-approved air intake must be used.

Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation

instructions shall remain with the appliance or equipment at the completion of the installation.

Mechanical room

Ensure the mechanical room complies

with the requirements of the Technical

Data Manual. In addition, see section

entitled Mechanical Room in this

manual.

Workingontheequipment

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.

There are no user serviceable parts on

the boiler, burners, or control.

Ensure main power supply to

equipment, the heating system, and all

external controls has been deactivated.

Close main gas supply valve. Take

precautions in all instances to avoid

accidental activation of power during

service work.

Technical literature

Literature for the Vitogas boiler:

- Technical Data Manual

- Installation and Service Instructions

- Operating Instructions

and User’s Information Manual

- Instructions of other Viessmann

products utilized and installed on the

Vitogas 050, ECV boiler

- Installation codes mentioned

in this manual

The completeness and functionality of

field supplied electrical controls and

components must be verified by the

heating contractor. These include low

water cut-offs, flow switches (if used),

staging controls, pumps, motorized

valves, air vents, thermostats, etc.

This product comes with several

safety instruction labels attached.

Do not remove!

Contact Viessmann immediately if

replacement labels are required.

Leave all literature at the installation

site and advise the system

operator/ultimate owner where the

literature can be found. Contact

Viessmann for additional copies.

5167 450 v1.4

General Information

About these Installation Instructions

Take note of all symbols and notations intended to draw attention to potential hazards or important product

information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below.

Warnings draw your attention to the

presence of potential hazards or

important product information.

Cautions draw your attention to the

presence of potential hazards or

important product information.

Helpful hints for installation, operation

or maintenance which pertain to the

product.

This symbol indicates that additional,

pertinent information is to be found in

column three.

This symbol indicates that other

instructions must be referenced.

5167 450 v1.4

Indicates an imminently hazardous

situation which, if not avoided, could

result in substantial product/property

damage, serious injury or loss of life.

WARNING

Indicates an imminently hazardous

situation which, if not avoided, may

result in product/property damage or

minor injury.

CAUTION

IMPORTANT

General Information

Product Information

The Vitogas 050, ECV boiler is for use in closed-loop forced circulation hot water

heating systems only. Boiler operation is limited by ASME Code to maximum water

pressure of 50 psig and maximum water temperature of 248°F/120°C. The vast

majority of applications operate below 30 psig and below 194°F/90°C.

The boiler model selected should be based on an accurate heat loss calculation of

the building.

Necessary permits from local authorities must be obtained before installing boiler.

Installation must be made in accordance with local ordinances which may differ

from the instructions in this manual.

Excerpt from our Warranty Terms

The Vitogas 050, ECV boiler is not

covered under any warranty terms for

damages resulting from the following:

Improper application and installation,

installation by unqualified personnel,

ignorance of instructions, improper

service and maintenance work,

incorrect replacement component

selection or application, incorrect field

wiring. Full warranty applies only when

boiler is installed and operated

according to instructions and used only

with the proper gas and the applicable

gas pressures.

Please read boiler warranty card.

Installation, service and maintenance

work must be done by qualified and

experienced technicians only.

Improper installation, service or

maintenance could create a hazard,

which could result in property

damage, severe personal injury and/or

loss of life.

WARNING

5167 450 v1.4

This boiler is not for use in systems

where water is constantly or

frequently replenished. Minerals such

as calcium in make-up water can

deposit on heat exchanger causing

overheating and eventual boiler

leakage. This type of failure is not

covered by warranty. Water must not

be drained from system for use by

cleaning personnel. Do not draw

water from boiler for any purpose.

CAUTION

The boiler warranty does not cover

leaks resulting from corrosion caused

by the use of underfloor plastic tubing

without an oxygen diffusion barrier.

Such systems must have the

non-oxygen diffusion barrier tubing

separated from the boiler with a heat

exchanger. Viessmann recommends

the use of underfloor plastic tubing

with an oxygen diffusion barrier.

CAUTION

Set-up

Mechanical Room

During the early stages of new home design, we recommend that proper

consideration be given to constructing a separate mechanical room dedicated to

gas- or 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 close

as possible to the vertical chimney or vent.

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 outside air for safe operation - do not install where

chemicals are stored or in a room with negative pressure. See section entitled

“Combustion Air Supply” starting on page 12 for further details regarding the

above.

Locate boiler on flooring capable of supporting the weight of the boiler filled with

water. Pour a concrete pad if necessary. Ensure that the boiler location does not

interfere with the proper circulation of combustion and ventilation air within the

mechanical room.

The maximum room temperature of the mechanical room where the boiler is located

must not exceed 104°F/40°C.

Standard Equipment

HWet base sectional cast iron heat

exchanger with stainless steel burners

HInduced draft blower and pressure

switch

HElectronic ignition

H24 VAC redundant seat gas valve

HBoiler fully insulated with 1½”/38 mm

fiberglass wrap-around blanket

HBoiler control panel with adjustable

operating limit (122°F - 194°F), fixed

high limit (248°F) and temperature

gage

HPump aquastat to turn pump on at

104°F / 40°C and off at 91°F / 33°.

HOne 120/24 VAC transformer

H30 psig pressure relief valve, pressure

gage and fittings

HOne cleaning brush

Boiler comes standard equipped with

30 psig ASME-rated pressure relief

valve. This 30 psig pressure relief valve

may be exchanged at the job site with a

50 psig ASME-rated pressure relief

valveonlybystrictlyobservingthe

minimum relief valve capacity in lb/h

marked on the nameplate. The

maximum allowable working pressure is

50 psig.

Be aware that best overall performance

is achieved when all components are

properly sized. Sizing of the required

circulation pump according to the pipe

layout and calculation of a proper

volume expansion tank is vital to obtain

the system’s peak performance.

5167 450 v1.4

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