Viessmann Vitogas 100 GS1 Series User manual

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IMPORTANT
VITOGAS 100
Installation 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 0 kW
Please file in Service Binder
516 463 v1.3 02/2011

Safety, Installation and Warranty Requirements
2
Safety, Installation an Warranty Requirements
Please ensure that these instructions are rea an un erstoo before commencing installation. Failure to comply with the
instructions listed below and details printed in this manual can cause pro uct/property amage,severe personal injury, and/or loss of
life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
HLicense 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”.
HPro uct ocumentation
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”.
HA vice 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.
HContaminate 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 upply”.
HCarbon monoxi e
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 upply” and “Venting
Connection”.
HFresh 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 upply”.
HEquipment venting
Never operate boiler without an
installed venting system. An improper
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.
HWarranty
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 drywall 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 amage the boiler and may lead to substantial property damage, severe personal injury
and/or death. 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.
516 463 v1.3
Installers must follow local
regulations with respect to
installation of carbon monoxi e
etectors. Follow manufacturer’s
maintenance sche ule of boiler.
WARNING

Contents
3
Page
Safety Important Regulatory an Installation Requirements 4....
General Information About these Installation Instructions 6.................................
Pro uct Information 6................................................................
Mechanical Room ....................................................................
Pro uct Installation Alternatives .........................................
Set-up Before Set-up 8............................................................................
Minimum Clearances 8..............................................................
Recommended minimum clearances for service 8............
Recommended minimum clearances to combustibles 9...
Boiler Set-up an Orientation 10...............................................
Boiler Control Boiler Control Base Installation 11............................................
Connections Electrical Connections 11............................................................
Boiler wiring 12...............................................................................
Venting Connection 13................................................................
Gas Connection an Piping 1...................................................
Proper piping practice 1.............................................................
Gas piping pressure test 1........................................................
Water Si e Connections 18........................................................
Safety Connections an Pressure Testing 19.......................
Installing safety device on the boiler 19.................................
Performing pressure test on the boiler 20..............................
DHW Si e Connections 20.........................................................
Installation Examples 21...............................................................
System with multiple zones 25..................................................
Boiler in a heating/cooling application 26................................
Boiler with low water cut-off 2................................................
Important precautions 28.............................................................
Fresh Air Combustion Air Supply 29..........................................................
Combustion air opening 30.........................................................
Ventilation air opening 30...........................................................
Appen ix Post-Installation ... 31..................................................................
Start-up information 31................................................................
Service Binder 31...........................................................................
Technical Data 31..........................................................................
Wiring Diagrams 32.......................................................................
516 463 v1.3

Safety
4
Important Regulatory an Installation Requirements
Co es
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.
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 0.
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.
Mechanical room
Ensure the mechanical room complies
with the requirements of the System
Design Guideline and/or Technical Data
Manual. In addition, see section entitled
Mechanical Room in this manual.
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 ystem 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.
Working on the equipment
The installation, adjustment, service,
and maintenance of this boiler must be
done by a license 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 eactivate .
Close main gas supply valve. Take
precautions in both instances to avoid
accidental activation of power during
service work.
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.
Technical literature
Literature applicable to the Vitogas
boiler:
- Technical Data Manual
- Installation Instructions
- Start-up/Service Instructions
- Operating Instructions
and User’s Information Manual
- Instructions of other Viessmann
products utilized and installed
- Installation codes mentioned
in this manual
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.
516 463 v1.3

Safety
5
Safety, Installation an Warranty Requirements (continued)
Fiberglass wool an 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,
move the person to a dust free
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.
-kin 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.
Hazar ous materials
516 463 v1.3
Inhalation of fiberglass wool an /or
ceramic fiber materials is a possible
cancer hazar . These materials can
also cause respiratory, skin an eye
irritation.
WARNING Appliance materials of construction,
pro ucts of combustion an the fuel
contain alumina, silica, heavy metals,
carbon monoxi e, nitrogen oxi es,
al ehy es an /or other toxic or
harmful substances which can cause
serious injury or loss of life an which
are known to the State of California
to cause cancer, birth efects an
other repro uctive harm. Always use
proper safety clothing, respirators an
equipment when servicing or working
nearby the appliance.
WARNING

General Information
6
About these Installation Instructions
Take note of all symbols an notations inten e to raw attention to potential hazar s or important pro uct information.
These inclu e ”WARNING”, ”CAUTION”, an ”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.
Pro uct Information
Sectional cast-iron boiler with atmospheric, fully pre-mix burner.
For operation with modulating boiler water temperatures in closed loop, forced
circulation hot water heating systems.
The Vitogas 100, GS1 Series is factory-calibrated for use with natural gas or
propane gas. Order appropriately.
The boiler model size selected should be based on an accurate heat loss calculation
of the building. The boiler selected must be compatible with the connected
radiation.
516 463 v1.3516 463 v1.3
In icates an imminently hazar ous
situation which, if not avoi e , coul
result in eath, serious injury or
substantial pro uct/property amage.
WARNING
In icates an imminently hazar ous
situation which, if not avoi e , may
result in minor injury or
pro uct/property amage.
CAUTION
IMPORTANT
516 463 v1.3
Vitogas 100, GS1 boilers for use with
propane gas are constructe with
ifferent orifices, gas valves, an
other components unique for
operation with propane gas.
Specify gas type at time of or er.
Use only the fuel state on boiler
rating plate.
CAUTION

General Information
7
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” for further details regarding the above.
Locate boiler on flooring capable of supporting the weight of the boiler filled with
water. 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 95°F / 35°C.
Pro uct Installation Alternatives
Installation without boiler stan
Instructions provided in
this manual
Installation with boiler stan
Installation Instructions
Boiler tand
Installation on Vitocell tank
Installation Instructions
Domestic Hot Water Tank
and Installation Instruction
upplement supplied with the
tank.
516 463 v1.3

Set-upSet-up
8
Before Set-up
Before placing boiler in its installation
location, ensure all necessary
accessories (e.g. boiler stand) are
installed. Do not use raft hoo or boiler
enclosure paneling to lift/move boiler
into its installation location.
Installation Instructions
Boiler tand
Minimum Clearances
Recommen e minimum clearances for service
When the Divicon pre-assembled mixing
valve station is installed the minimum
distance beside the boiler must be
19¾” / 500 mm
There must be sufficient space for a
heating contractor to access the rear of
the boiler to inspect the blocked vent
switch.
516 463 v1.3
IMPORTANT
The boiler must be installe in such a
way that gas ignition system
components are protecte from water
(spraying, splashing, etc.) uring
boiler system operation an service.
CAUTION
min. 250 mm
min.
250 mm
min. 2 ½” / 00 mm
9¾”
9¾”
min. 250 mm 9¾”
Diagram is not to scale.
top min.
600 mm
24” /

Set-up
9
Minimum Clearances
Recommen e minimum clearances to combustibles
For typical installations, Viessmann recommends installing the boiler with
clearances as published on the previous page in subsection entitled “Recommended
minimum clearances for service”.
The Vitogas 100, G 1 boiler is approved for closet and alcove installations with the
following clearances to combustibles:
Boiler Mo el GS1 -22 -29 -35 -42 -48 -60
Rear (from raft hoo ) inches
mm
6
150
6
150
6
150
6
150
6
150
6
150
Si es inches
mm
0
0
0
0
0
0
0
0
0
0
0
0
Flue inches
mm
6
150
6
150
6
150
6
150
6
150
6
150
Top inches
mm
6
150
6
150
6
150
6
150
6
150
6
150
Floor Combustibles
All clearances are measured from boiler enclosure.

Set-up
10
Boiler Set-up an Orientation
For Vitogas 100, G 1
installations on a Vitocell tank,
reference the Installation
Instruction upplement
supplied with the tank.
1. Move boiler as close as possible to
chimney and set up using leveling
bolts. Use a level to ensure boiler is
level.
A special boiler base/foundation is
not necessary.
2. Ensure air flow to front and rear of
boiler is not restricted in any way.
3. Ensure compliance with local codes
where wood flooring or flooring other
than concrete is present.
4. Ensure fresh air intake is not located
too close to the burner to avoid
drafts which may cause abnormal
burner operation.
516 463 v1.3
kg
4.
1.
2.
3.
1.