Please file in Service Binder 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 VITOGAS 050 WARNING 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. Do not store or use gasoline or other flammable liquids in the vicinity of this or any other appliance.
Safety, Installation and Warranty Requirements 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).
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/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
Contents Page Safety General Information Set-up Important Regulatory and Installation Requirements .... 7 About these Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Excerpt from our Warranty Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Mechanical Room . . . . . . . . .
Contents (continued) Page Initial Start-up and Service 34 34 35 35 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Procedure Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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).
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. WARNING Indicates an imminently hazardous situation which, if not avoided, could result in substantial product/property damage, serious injury or loss of life.
General Information Product Information WARNING 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. The Vitogas 050, ECV boiler is for use in closed-loop forced circulation hot water heating systems only.
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.
Set-up Before Set-up IMPORTANT Do not use fan blower termination or boiler enclosure paneling to lift/move boiler into its installation location. The boiler is shipped on a wooden pallet in a cardboard crate. Crate and wooden pallet must be removed. Before placing boiler in its installation location, ensure all necessary accessories are installed. CAUTION The boiler must be installed in such a way that gas ignition system components are protected from water (spraying, splashing, etc.
Set-up Combustion Air Supply Whenever possible, install boiler near an outside wall so that it is easy to duct fresh air directly to the boiler area. See example in Fig. 2. Refer to national codes for duct sizing. Round ducts can be used. CAUTION Follow local regulations with respect to CO detectors. Follow all safety information from LP or gas supplier. This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air.
Set-up Combustion Air Supply (continued) If boiler is installed in a confined space (a space with a volume of less than 50 cubic feet per 1000 Btu/h of gas input for all fuel burning equipment) or building construction is unusually tight, adequate air for combustion must be provided by two openings: one located about 6” below the ceiling, the other about 6” above the floor.
Set-up Minimum Clearances Recommended minimum service clearances Side mm inches Rear: 610 24 Top: 610 24 Right side: 610 24 Left side: 610 24 1220 48 Front: All clearances are measured from boiler enclosure. Minimum clearances to combustibles Side mm inches Rear: 25 1 Top: 150 6 Right side: 25 1 Left side: 150 6 Front: 150 6 Floor: non combustible 5167 450 v1.4 Above clearances apply to all ECV boilers.
Set-up Minimum Clearances (continued) Closet and alcove installation Vitogas 050, ECV-65 to 155 boilers are approved for closet installation. Vitogas 050, ECV-180, -200 boilers are approved for alcove installations. Do not use models ECV-180, -200 for closet installations. 18” / 457 mm Please note that the minimum clearance to combustibles listed below will apply when the boiler is located in a room large in comparison with the size of the equipment.
Set-up Flushing of Existing Piping Before boiler is connected to a piping/heating system which has previously been in service (the ECV is a replacement boiler), the piping system should be flushed thoroughly with water in order to remove sludge or other contaminants, especially in large piping systems such as old gravity pipe systems. Flush from the top of the system with city water pressure. Failure to flush out system can lead to deposits in boiler resulting in boiler failure.
Set-up Removal of Existing Boiler WARNING The Vitogas 050, ECV boiler has a positive vent pressure when vented horizontally with 3” or 4” pipe. Do not common vent with any other appliance. Failure to heed this warning can cause carbon monoxide poisoning which can result in severe personal injury or loss of life.
Connections Venting Connection The Vitogas 050, ECV boiler must be located so that the vent length is as short and direct as possible. The minimum equivalent length is 10 ft. All products of combustion must be safely vented to the outdoors. Do not common vent with any other appliance. The Vitogas 050, ECV vents under positive pressure and is a Category III boiler.
Connections Venting Connection (continued) Maximum vent length IMPORTANT Maximum equivalent vent length (all models) is 20 ft. for 3” of pipe. Maximum equivalent vent length (all models) is 30 ft. for 4” of pipe. Do not exceed maximum vent length. IMPORTANT The minimum equivalent vent length for all models is 10 ft. Example of maximum vent length calculation: Equivalent length 12 ft. of pipe length 3” dia. 2 90° elbows 3“ dia. Total equivalent length 12 ft. 6 ft. 18 ft.
Connections Venting Connection (continued) Installing Z-FLEX pipe and fittings IMPORTANT Fan outlet Remove top panel to access locking band tightening screw Slide clamp over screws High temp. silicone C F #8 stainless steel self drilling screws Fig. 7 J Use liberal beads of silicone to seal joints. J Use pipe hangers or metal strapping to support vent pipe. J Vent length should be as short and as direct as possible. J Clearance to combustibles must be maintained at 3”.
Connections Venting Connection (continued) Vent terminal connection The vent must be installed observing local regulations in addition to National Codes, CAN/CSA-B149.1 or 2, or ANSI Z223.1. A vent shall not terminate: 1. directly above a paved sidewalk or paved driveway which is located between two single-family dwellings and serves both dwellings; 2. less than 7 ft. (2.13 m) above a paved sidewalk or a paved driveway located on public property; 3. within 6 ft. (1.
Connections Venting Connection (continued) Riser box If unable to find sufficient clearance above grade at the point where the vent passes through the outside wall, a vent riser box may be used. If a vent riser box is being considered, remember to include the equivalent lengths of two elbows (6 ft. / 1.83 m) plus the height of the riser in the vent length calculations. Do not exceed the total equivalent length of 20 ft. / 6 m. Also, the termination tee must be ordered.
Connections Installation Checklist Prior to and after the installation, use the following check list to ensure proper installation. Improper installation could create a hazard, resulting in property damage, severe personal injury, or loss of life. The correct answer is “yes” to all of the following questions. Yes No Is the pump electrically connected to the pump aquastat? Yes No Is the boiler located so that the vent pipe length is minimized? Yes No Is the outside vent terminal at least 1 ft. / 0.
Connections Low Water Cut-off Air vent (field supplied) If the ECV boiler is installed above radiation level, a low water cut-off device must be installed. See Figs. 9 and 10 for location of low water cut-off device. Note: Flow direction must be as shown in Fig. 9. Low water cut-off supplied by others. When required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.
Connections Initial System Fill Treatment for boiler feed water should be considered in areas of known problems, such as high mineral content and hardness. In areas where freezing might occur, an antifreeze may be added to the system water to protect the system. Please adhere to the specifications given by the antifreeze manufacturer. Do not use silicate based automotive anti-freeze solutions.
Connections Gas Piping Before connecting gas boiler to gas line, install main gas shut-off valve, union, and capped drip leg (see Fig. 11 below). Size gas supply piping to boiler according to local utility requirements. Identify the main shut-off valve as such with a tag and familiarize owner of boiler with this valve. Support piping by proper suspension method. Piping must not rest on or be supported by boiler. Testing Gas Pipe Min. gas supply pressure 4.5 “w.c. for natural gas 12 “w.c. for L.P.
Connections Gas Pressure - Orifice Sizes PILOT PRESSURE FOR Q3451A PILOT Natural Gas 5 - 7 ”w.c. Propane Gas 8 - 10 ”w.c. Natural Gas Minimum gas valve inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4½ ”w.c. Maximum gas valve inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 ”w.c. Propane Gas Minimum gas valve inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ”w.c. Maximum gas valve inlet pressure . . . . . . . . . . . . . .
Connections Gas Burner Removal The main gas burner manifold with the individual stainless steel burners mounted may be easily removed from the boiler. 1. Close the main gas shut-off valve external to boiler. 2. Disconnect all power to boiler. 3. Remove front cover panel from boiler. 4. Break ground joint union before gas valve, remove gas pipe. Fig.
Connections Gas Input Main flame cone CAUTION ¾” / 20 mm Light blue Blue Inner flame cone BURNER Fig. 13 5” / 124 mm 4” / 102 mm \ Do not exceed input rating stamped on rating plate of boiler. 1. Close main gas shut-off valve. 2. Disconnect main power supply to boiler. 3. Remove plug 1/8“ NPT on manifold. Install test plug and connect U-tube manometer or equivalent. 4. Place boiler/burner in operation. 5. Read manifold gas pressure and compare with stamped rating on rating plate.
Connections Main Burner Proper flame: Upper main flame cone with light orange coloring, sharply defined individual flames. See Fig. 13 on previous page. Underfired: Lazy-burning main flame cone, mushy flame appearance throughout, smaller flame sizes than in Fig. 13. Overfired: Increased burner noise, larger flame sizes than in Fig. 13.
Connections Gas Burner Positioningg Left (continued) Every ECV boiler will have a flame roll-out switch (set at 200 °F / 93 °C) located in the burner area (see Fig.12 on page 28). Right WARNING If a flame roll-out switch trips during start-up operation, it indicates a hazardous condition to be corrected immediately. Figure 15 shows pilot burner flame with proper flame adjustment. ECV-(140,155) For proper pilot pressure for Q3451B pilot see table on page 27. Fig.
Electrical Connections Terminal strip Separate breaker N L 120V power input Transformer/relay (field supplied) L N G 24V 120V Jumper Thermostat connections WR 8A02A 120V pump over 4 Amp. Using transformer/relay to switch pumps over 4 Amp. WR 8A02A contact can switch 120VAC, 12 Amp. Fig. 16 32 120V pump output N L T T Refer to wiring diagrams on pages 46 and 47. All wiring must be properly grounded! Before attempting to wire unit, disconnect power supply at main service panel first.
Connections Electrical Connections (continued) Pumps under 4 Amp. can be connected directly to boiler terminal strip. Pumps over 4 Amp. must be switched by an external relay or transformer/relay to prevent failure of the pump aquastat See Fig. 16 on previous page. Pump will not activate until boiler water temperature reaches 116°F. Refer to pump aquastat shown on wiring diagrams. If boiler has been underwater, all electrical parts must be replaced.
Initial Start-up Initial Start-up The boiler, piping and radiation must be full of water and purged of all air before boiler can be fired. Pressure relief valve must be installed as described on page 25. All installation requirements as described in this manual must be completed. Follow Lighting and Operating Instructions on page 51. If the system was shut down for an extended period of time, have a qualified service technician restart and recondition your system. 1.
Initial Start-up and Service Initial Start-up Annual shut-down If boiler is used for comfort heating only and not used with an indirect-fired domestic hot water storage tank, the boiler/heating system should be shut down during the summer. 1. Turn down operating control (thermostat). 2. Disconnect main power switch. 3. Close main gas shut-off valve and turn knob on gas valve to “off” (see Figs. 11 on page 26 and the Lighting and Operating Instructions on page 51).
Initial Start-up and Service Service Schedule CAUTION In order to ensure that the boiler continues to operate at its peak performance, safety and efficiency, observe and follow the recommendations for maintenance, inspection and service routine. Early detection of problems and their immediate repair will usually result in less damage, lower repair cost and continued safe operation. Frequently - by owner Check pressure gage for correct system (water) pressure.
Initial Start-up and Service Service Procedure Overview Service steps 1. Shut down heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 38 2. Clean heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Start-up and Service Service Procedure Service 1. Shut down heating system 1. Deactivate main power and ensure against accidental reactivation. 2. Disconnect plug. 3. Close gas supply valve. Service 2. Cleaning heat exchanger 1. Disconnect power supply to boiler and all heating related components. 2. Close main gas shut-off valve. Allow boiler to cool if necessary. 3. Remove top panel, upper front panel and front access panel. 4. Disconnect vent pipe from fan assembly. 5.
Initial Start-up and Service Procedure Service (continued) 2. Cleaning heat exchanger (continued) 10. Inspect combustion chamber by using a flashlight between front section legs. 11. Before reinserting burner manifold, clean stainless steel burners with a soft brush. Vacuum or sweep away particles. CAUTION Do not use water to clean. 12. Inspect pilot burner system. Check igniter for deterioration. 13.
Initial Start-up and Service Procedure Service (continued) 3. Check flue pipe and vent termination CAUTION Repair or replace as necessary. Under certain climatic conditions, some building materials may be affected by flue products expelled in close proximity to unprotected surfaces. Sealing or shielding of the exposed surfaces with a corrosion resistant material (e.g. aluminum sheeting) may be required to prevent staining or deterioration.
Initial Start-up and Service Procedure (continued) Service 6. Check for proper combustion air supply and ventilation for the boiler Service 7. Ensure no combustible materials or chemicals are stored near the boiler Service 8. Check high limits, pumps and low water cut-off Operate high limits by dialing lower settings, switching burner on/off to verify function of same. If low water cut-off is installed, check and verify proper function according to manufacturer’s instructions.
Additional Information Troubleshooting Guide Fan does not start Remedy Thermostat not calling for heat Turn up room thermostat No 120V power Check 120V power with voltmeter Fuse or breaker blown Replace fuse or breaker Fan relay defective Replace 24V fan relay Defective 24V transformer Replace 24V transformer Thermostat defective Replace 24V thermostat Thermostat wires defective Check continuity of wires; if necessary, replace wires Check wires in 120V quick connect plug Push wire terminal
Additional Information Troubleshooting Guide (continued) Remedy Thermostat anticipator too low Set anticipator to 0.9A on mercury bulb thermostats No ground or weak ground connection on pilot Replace ground wire on pilot burner Pilot on wrong burner Ensure five-port burner is used (see Fig. 13).
Additional Information Technical Data 10½” / 265 mm 12½” / 320 mm Fig. 20 Front view 12¼” / 310 mm 26” / 660 mm 41¾” / 1060 mm C F 2¾” / 72 mm 11” / 279 mm 17½” / 445 mm 19¾” / 502 mm Fig. 21 Legend Vent connection, Ø 3” / 76 mm Boiler water supply, 1¼” / 32 mm 120V power in 120V outlet for pump (max. 4 Amp.) 24V thermostat 0.9A anticipator setting Gas connection, ½” / 13 mm Boiler water return, 1¼” / 32 mm Fig. 22 44 5167 450 v1.
Additional Information Technical Data (continued) Boiler Model Model No. CSA input CSA output DOE heating capacity AFUE*1 MBH kW MBH kW % 65 19 55 16 83.1 80 23 67 19 83.1 100 29 84 24 83.1 115 34 97 28 83.1 140 41 118 34 83.1 155 45 131 38 83.1 180 53 151 44 83.1 200 58 168 49 83.1 Steady state efficiency % 84.5 84.3 84.2 84.5 84.5 84.5 84.0 84.
Additional Information 120V 5167 450 v1.
Additional Information Ladder Diagram - Vitogas 050, ECV with Honeywell Intermittent Pilot 120V, 60 Hz Less than 12A N SHL1 Adjustable high limit aquastat (Maximum setting 194°F) G PA 1 Pump 120V 4A max. Blower motor M Transformer 120V L SHL2 Manual reset aquastat (Fixed setting 248°F) Pump Aquastat PA Pump on at 40°C (104°F) Pump off at 33°C ( 91°F) FRS Flame roll-out switch 24V Relay 1 R1 C1R N.0. contact of relay 1 S1 Sequencer 24V C1S N.O.
Additional Information Parts List 48 037 Gas valve VR8204M 039 Pilot orifice NG .020” LP .
Additional Information Parts List (continued) 45 7 51 54 56 14 Honeywell 50 35 53 55 43 57 52 4 2 58 6 15 19 9 13 17 3 44 16 12 49 21 46 8 18 10 1 42 48 23 20 47 25 5 24 26 22 27 31 37 33 34 41 40 39 29 30 32 5167 450 v1.
Additional Information Maintenance Record Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Maintenance/Service Mainten
Additional Information 5167 450 v1.
Printed on environmentally friendly (recycled and recyclable) paper. Technical information subject to change without notice. 52 Viessmann Manufacturing Company Inc. 750 McMurray Road Waterloo, Ontario • N2V 2G5 • Canada Tel. (519) 885-6300 • Fax (519) 885-0887 www.viessmann.ca • mail@viessmann.ca 5167 450 v1.4 Viessmann Manufacturing Company (U.S.) Inc. 45 Access Road Warwick, Rhode Island • 02886 • USA Tel. (401) 732-0667 • Fax (401) 732-0590 www.viessmann-us.com • mail@viessmann-us.
