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Contents
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Table of Contents
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Troubleshooting
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Bookmarks
Quick Links
Service instructions
for heating engineers
Vitogas 100
Type GS1, 11 to 60 kW
Gas fired boiler
See notes on applicability, page 2.
VITOGAS 100
Please keep safe
5692 413 GB
6/2004
Related Manuals for Viessmann Vitogas 100
Summary of Contents for Viessmann Vitogas 100
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Page 1
Service instructions for heating engineers Vitogas 100 Type GS1, 11 to 60 kW Gas fired boiler See notes on applicability, page 2. VITOGAS 100 Please keep safe 5692 413 GB 6/2004… -
Page 2: General Information
(heating engineer/installation Use only original Viessmann spare contractor). parts, or equivalent parts that have been approved by Viessmann. Before working on the equipment/ heating system, isolate the mains Initial start−up…
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Page 3: Table Of Contents
Contents Index Page General information Safety instructions ……………………Applicability .
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Page 4: Initial Start−Up, Inspection And Maintenance
Initial start−up, inspection and maintenance Steps Initial start−up, inspection and maintenance For further instructions on individual steps, see pages indicated. Commissioning steps Inspection steps Maintenance steps Page 1. Preparing for commissioning and checking diaphragm expansion vessel ……….2.
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Page 5: Further Details Regarding The Individual Steps
Initial start−up, inspection and maintenance Further details regarding the individual steps Preparing for commissioning 1. Check that the boiler room ventilation aperture is open. 2. Check the inlet pressure of the diaphragm expansion vessel. 3. Open any check valves that may be fitted.
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Page 6: Checking Gas Type
Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking gas type After conversion from 1. Enquire the gas type and Wobbe H Natural gas E to natural gas LL: index (Wo) from your local mains gas or LPG supplier. This boiler can be operated in the Wobbe index range Note…
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Page 7: Checking Static And Supply Pressure
Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking static and supply pressure ¨ Safety instruction Measure the CO value before and after any work on gas appliances, to prevent any health hazards and to ensure the perfect operational condition of the system. LPG version Flush the LPG tank twice after installation or replacement.
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Page 8
Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) 6. Check the supply (flow) pressure; it should be H 17.4 to 25 mbar for natural gas, H 42.5 to 57.5 mbar for LPG. Record the actual value in the service report. -
Page 9: Checking Nozzle Pressure
Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking nozzle pressure 1. Close the gas shut−off valve. 2. Release the screw inside test nipple A, but do not remove completely, and connect the pressure gauge. 3. Open the gas shut−off valve. Start up the boiler.
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Page 10
Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Rated output Natural gas E with Wobbe index Wo 15.0 kWh/m 54.0 MJ/m Nozzle pressure mbar 14.1 14.0 13.9 14.5 14.4 14.0 14.8 14.2 15.0 based on a supply pressure of 20 mbar Nozzle ID 2.00… -
Page 11: Checking Flue Gas Values
Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking flue gas values ¨ Safety instruction Measure the CO value before and after any work on gas appliances, to prevent any health hazards and to ensure perfect system condition. Determine the flue gas values and record them in the service report.
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Page 12: Checking Draught
Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking draught Check the supply pressure behind the draught hood in hPa (1 hPa = 1 mbar) and record in the service report. Note Required boiler draught: 0.03 hPa (0.03 mbar). The chimney draught must not be higher than 0.1 hPa (0.1 mbar), install a draught stabiliser (agree details with your local flue gas inspector) inside the chimney.
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Page 13: Checking Ignition Burner
Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking ignition burner 1. Check ionisation electrode A, ignition burner B and ignition electrode C for damage. 2. Check the electrode gaps.
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Page 14: M 11. Cleaning Heating Surfaces
Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Clean heating surface, if required (with the burner removed) 1. Release the self−tapping screws and remove top panel A. 2. Release the tensioning springs, thermal insulation mat B. 3.
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Page 15: Checking Flue Gas Monitoring Equipment
Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking flue gas monitoring equipment 1. Remove the flue pipe from the draught hood. 2. Cover the flue pipe adaptor on the draught hood to carry out the function test.
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Page 16: Troubleshooting Diagnostics
Troubleshooting Diagnostics Fault Cause Remedy Boiler will not No voltage Check fuse and connections of main start power supply. Check switches on control unit for their settings. Boiler water Wait until boiler water temperature temperature too high has fallen by approx. 20 K High limit safety Press reset button on control unit cut−out has tripped…
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Page 17: Appendix
Appendix Function of the ignition burner system Power is supplied to the burner on top of the equipment illuminates. control unit when there is a heat demand, and the LED on top of the After the pilot flame has stabilised, equipment illuminates.
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Page 18: Connection Diagram For Burner Control
Appendix Connection diagram for burner control System plug no. Terminal no. 14 13 12 11 10 9 Reset Fault External Sensor valve flue monitoring Ignition monitor or plug or jumper with resistance Ionisation B4 S3 T2 T1 N…
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Page 19: Draining/Frost Protection
Appendix Draining/frost protection For draining the boiler completely (e.g. when there is a risk of frost) also drain the l.h. boiler section via drain valve A on the side of the boiler. Minimum clearances Maintain a distance between the flue pipe and the surface of the thermal insulation (also of accessories) of at least 20 mm.
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Page 20: Parts Lists
Appendix Parts lists When ordering spare parts 208 Insulating casing Quote the type and serial no. (see 212 Fastener type plate) and the item no. of the 213 Decorative cap required part (as per parts list). 214 Edge protector Obtain common parts from your 217 Spacers local supplier.
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Page 21
Parts list Parts list (cont.) -
Page 22
Parts list Parts list (cont.) -
Page 23
Parts list Parts list (cont.) -
Page 24
Parts list Parts list (cont.) -
Page 25
Parts list… -
Page 26: Commissioning/Service Report
Appendix Commissioning/service report Setting and test values Set value Initial start−up Date: Static pressure mbar max. 57.5 mbar Supply pressure (flow pressure) j for natural gas E mbar 17.4 25 mbar j for natural gas LL mbar 17.4 25 mbar j for LPG mbar 42.5 57.7 mbar…
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Page 27
Appendix Maint./service Maint./service Maint./service Maint./service… -
Page 28
Appendix Commissioning/service report (cont.) Setting and test values Set value Maint./service Date: Static pressure mbar max. 57.5 mbar Supply pressure (flow pressure) j for natural gas E mbar 17.4 25 mbar j for natural gas LL mbar 17.4 25 mbar j for LPG mbar 42.5 57.7 mbar… -
Page 29
Appendix Maint./service Maint./service Maint./service Maint./service… -
Page 30
Appendix Commissioning/service report (cont.) Setting and test values Set value Maint./service Date: Static pressure mbar max. 57.5 mbar Supply pressure (flow pressure) j for natural gas E mbar 17.4 25 mbar j for natural gas LL mbar 17.4 25 mbar j for LPG mbar 42.5 57.7 mbar… -
Page 31
Appendix Maint./service Maint./service Maint./service Maint./service… -
Page 32: Specification
Appendix Specification Rated output ∅ mm Flue outlet (int. diameter) 90 110 130 130 150 150 150 180 180 Required draught mbar 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 Maximum draught mbar Flue gas ºC Temperature (gross) Mass flow rate Natural gas kg/h kg/h…
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Page 33: Declaration Of Conformity
This product meets the requirements of the Efficiency Directive (92/42/EEC) for: Low temperature boilers. The product characteristics determined as system values for Vitogas 100 as part of EC type testing according to the Efficiency Directive (see specification table) can be utilised for the energy assessment of heating and ventilation equipment to DIN V 4701 10 specified by the EnEV [Germany].
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Page 34: Keyword Index
Appendix Keyword index As delivered condition (gas type), 6 Ignition electrode, 13 Inlet pressure, diaphragm expansion vessel, 5 Burner, 12 Ionisation current, 11, 16 Ionisation electrode, 11 Cleaning agent, 14 Check valves, 5 Manufacturer’s certificate, 33 Commissioning/service report, 26 Minimum system pressure, 5 Conformity, 33 CO test, 7 Nozzle pressure table, 10…
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Page 36
Viessmann Werke GmbH & Co D 35107 Allendorf Tel: +49 6452 70 0 Fax: +49 6452 70 27 80 www.viessmann.de Viessmann Limited Hortonwood 30, Telford Shropshire, TF1 7YP , GB Tel: +44 1952 675000 Fax: +44 1952 675040 E−mail: info−uk@viessmann.com…
This manual is also suitable for:
Gs1
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Contents
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Table of Contents
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Bookmarks
Quick Links
Start-up/Service Instructions
for Use by Heating Contractor
Vitogas 100
GS1 Series
Natural gas-/propane-fired, single-stage
atmospheric cast-iron boiler
Heating input
90 to 240 MBH
26 to
70 kW
VITOGAS 100
5167 464 v1.2 01/2008
IMPORTANT
Read and save these instructions
for future reference.
Related Manuals for Viessmann Vitogas 100 GS1 Series
Summary of Contents for Viessmann Vitogas 100 GS1 Series
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Page 1
Start-up/Service Instructions for Use by Heating Contractor Vitogas 100 GS1 Series Natural gas-/propane-fired, single-stage atmospheric cast-iron boiler Heating input 90 to 240 MBH 26 to 70 kW VITOGAS 100 IMPORTANT Read and save these instructions for future reference. 5167 464 v1.2 01/2008… -
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Viessmann equipment. Please see section For a listing of For information » «… -
Page 3: Table Of Contents
Contents Page Safety Important Regulatory and Installation Requirements ..General Information About these Start-up/Service Instructions ….. . . Necessary Tools .
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Page 4: Important Regulatory And Installation Requirements
Vitogas 100: operator/ultimate owner where the — Technical Data Manual literature can be found. Contact — Installation Instructions Viessmann for additional copies. — Start-up/Service Instructions — Operating Instructions and User’s Information Manual Additional applicable literature: — Vitotronic controls manuals…
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Page 5
Safety Safety, Installation and Warranty Requirements (continued) Suppliers of fiberglass wool products H Fiberglass wool and ceramic fiber H Hazardous materials materials recommend the following precautions be taken when handling these materials: WARNING WARNING Precautionary measures Appliance materials of construction, — Avoid breathing fiberglass dust and Inhalation of fiberglass wool and/or products of combustion and the fuel… -
Page 6: About These Start-Up/Service Instructions
General Information About these Start-up/Service 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 WARNING presence of potential hazards or important product information.
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Page 7: Overview
Initial Start-up and Service Overview Steps to carry out for Initial start-up Steps to carry out for Service 1. Preparations prior to start-up Page ……2.
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Page 8: Procedures
Initial Start-up and Service Procedures 1. Preparations prior to start-up nitial start-up Vitotronic Boiler Controls 1. Ensure fresh air intake of mechanical room is open and that chimney and all flue pipes are connected, sealed and unobstructed inside. Verify that all requirements in the Combustion Air Supply section in the Vitogas 100, GS1 Installation Instructions are met.
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Page 9: Select Appropriate Gas Type
Initial Start-up and Service Initial Start-up and Service Procedures (continued) 2. Select appropriate gas type nitial start-up ervice 1. Ensure that the fuel type listed on IMPORTANT the boiler rating plate is the correct type for the installation being attempted. The Maintenance Record is located in the back of this manual.
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Page 10: Check Static, Running And Manifold Gas Supply Pressure
Initial Start-up and Service Initial Start-up and Service Procedures (continued) 3. Check static, running and manifold gas supply pressure nitial start-up ervice Gas supply static pressure: 1. Ensure manual gas shut-off valve (field supplied) is closed. 2. Remove screw in inlet pressure tap ®…
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Page 11
Initial Start-up and Service Initial Start-up and Service Procedures (continued) 3. Check static, running and manifold gas supply pressure (continued) nitial start-up ervice Manifold pressure: 9. Remove gas valve outlet pressure tap and connect U-tube manometer or ® non-electric Magnehelic manometer. -
Page 12
Initial Start-up and Service Initial Start-up and Service Procedures (continued) 3. Check static, running and manifold gas supply pressure (continued) nitial start-up ervice WARNING Always ensure the correct orifices are installed in the boiler. See table below. The boiler must be fired to achieve the output stated on the rating plate. -
Page 13: Measure Flue Gas Values
Initial Start-up and Service Procedures (continued) 4. Measure flue gas values nitial start-up ervice H Carbon dioxide CO WARNING H Oxygen content O A CO analysis must be performed H Carbon monoxide CO before and after any work activities H Flue gas temperature (gross) to ensure that equipment operation is H Flue gas loss safe (health-wise) to inhabitants, and…
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Page 14: Measure Chimney Draft
Initial Start-up and Service Procedures (continued) 6. Measure chimney draft nitial start-up ervice The boiler shall be connected to a chimney having sufficient draft at all times to ensure safe and proper operation. Down drafting and condensation problems must be corrected. H Measure the chimney draft after the draft hood and record value in Maintenance Record on page 30 of…
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Page 15: Shut Down Heating System
Initial Start-up and Service Procedures (continued) 7. Shut down heating system ervice 1. Deactivate power on boiler control. 2. Deactivate main power supply to equipment and take precautions to avoid accidental activation. 3. Close manual gas supply valve. 8. Remove burner tray ervice 1.
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Page 16: Inspect Burners
4. Replace pilot burner if necessary. See Replacement Pilot Burner Installation Instructions 5. Viessmann pilot orifice (not shown): H Natural gas stamped “26” H Propane gas stamped “24” 11. Clean heat exchanger, if applicable (with burner tray removed) ervice 1.
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Page 17: Reinstall Burner Tray
Initial Start-up and Service Procedures (continued) 12. Reinstall burner tray ervice 13. Inspect all water pipe connections nitial start-up ervice Check heating system and domestic hot water connections. Ensure all connections are pressure tight. Correct any leaks found on fittings, pumps, valves, etc..
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Page 18: Check Electrical Connections
Initial Start-up and Service Procedures (continued) 16. Check electrical connections nitial start-up ervice Ensure all plug-in connectors and strain reliefs make positive contact and are seated properly. Start-up/Service Instructions Vitotronic Boiler Control 17. Start up heating system nitial start-up ervice Operating Instructions Heating System, Accessories…
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Page 19: Check Blocked Vent Safety Switch
Initial Start-up and Service Procedures (continued) 19. Check blocked vent safety switch nitial start-up ervice The blocked vent safety switch is located at the back of the boiler in the draft hood. In the event of a complete vent blockage the bi-metallic spill switch heats up due to flue gas spillage and interrupts 24 VAC to the gas control shutting down the burner.
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Page 20: Combustion Air Supply
If outside air duct is by entrainment through the burner front openings. necessary, ensure it is installed. Viessmann recommends the use of combustion air from an outdoor source. Ensure that nothing is obstructing the flow of combustion ventilation air and…
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Page 21: Diagnosis And Correction
H Are all plug connections tight and secure? Troubleshooting the Boiler Control see Start-up/Service Instructions of Boiler Control CAUTION Use only Viessmann original components when replacing defective parts. Installation of incorrect replacement parts can cause hazardous operation. Order replacement components from your Viessmann distributor.
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Page 22
Troubleshooting Guide Diagnosis and Correction (continued) Failure Cause Correction Vent damper (if applicable) is not Boiler does not start up (continued) Ensure unobstructed operation of open, vent damper jammed or vent vent damper blade or replace vent damper motor has not activated damper. -
Page 23
Troubleshooting Guide Diagnosis and Correction (continued) Check voltage between terminals “N-BK2” and “LI-BK1”. Check boiler control (power supply, power 120 VAC on/off switch, fuses, and fixed high limit). available? Check voltage between terminals “N-BK2” and “T2-BK4”. Check boiler control adjustable high limit call for heat (24 VAC room 120 VAC thermostat) located inside… -
Page 24: Functioning Of Burner Ignition System
Additional Information Additional Information Functioning of Burner Ignition System The burner ignition system functions as follows: 1.Demand for heat causes vent damper blade to open, closing vent damper and switch ES. 2.120 V is supplied to the 120 V / 24 V transformer through the safety high limit aquastats of the boiler control.
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Page 25: Ignition System Wiring Diagram
Additional Information Ignition System Wiring Diagram (Vitogas 100, GS1 with Vitotronic Controls)
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Page 26: Parts List
Placeholder — Parts List…
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Page 27
Placeholder — Parts List… -
Page 28
Placeholder — Parts List… -
Page 29
Placeholder — Parts List… -
Page 30: Maintenance Record
Additional Information Platzhalter Maintenance Record…
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Page 31: Lighting And Operating Instructions
Additional Information Lighting and Operating Instructions…
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Page 32
Viessmann Manufacturing Company (U.S.) Inc. Viessmann Manufacturing Company Inc. 45 Access Road 750 McMurray Road Warwick, Rhode Island • 02886 • USA Waterloo, Ontario • N2V 2G5 • Canada Tel. (401) 732-0667 • Fax (401) 732-0590 Tel. (519) 885-6300 • Fax (519) 885-0887 www.viessmann-us.com •…
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