Viessmann Vitogas 100 GS1 Series User manual

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IMPORTANT
VITOGAS 100
Start-up/Service Instructions
Vitogas 100
GS1 Series
Natural gas-/propane-fired, single-stage
atmospheric cast-iron boiler
Heating input 90 to 240 MBH
26 to 70 kW
for Use by Heating Contractor
Please file in Service Binder
5167 464 v1.2 01/2008

Safety, Installation and Warranty Requirements
2
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).
HLicensed 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”.
HProduct 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”.
HAdvice 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.
HContaminated 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”
in the Installation Instructions.
HCarbon 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” in the Installation
Instructions.
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 Supply”
in the Installation Instructions.
HEquipment 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” in the Installation
Instructions. 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 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 death. Ensure boiler/burner is inspected and serviced by a qualified heating contractor at least once a year in
accordance with these Start-up/Service Instructions.
5167 464 v1.2
Installers must follow local
regulations with respect to
installation of carbon monoxide
detectors. Follow manufacturer’s
maintenance schedule of boiler.
WARNING

Contents
3
Page
Safety Important Regulatory and Installation Requirements 4....
General Information About these Start-up/Service Instructions 5.......................
Necessary Tools 5.......................................................................
Initial Start-up
and Service
Troubleshooting Guide
Overview 7....................................................................................
Procedures 8.................................................................................
Diagnosis and Correction 21......................................................
Additional Information Functioning of Burner Ignition System 24..............................
Ignition System Wiring Diagram 25..........................................
Parts List 26....................................................................................
Maintenance Record 30...............................................................
Lighting and Operating Instructions 31....................................
5167 464 v1.2

Safety
4
Important Regulatory and Installation Requirements
Instructing the system user
The installer of the system is
responsible to ensure the system
operator/ultimate owner is made
familiar with the system functioning, its
activation, and its shut-down.
Initial start-up
Initial start-up must be performed by a
qualified heating contractor. Completion
of the Maintenance Record by the
heating contractor is also required.
The following topics must be covered:
Proper system operation sequence.
Explain the equipment as well as the
need for combustion air.
Demonstrate an emergency
shut-down, what to do and what not.
Explain that there is no substitute for
proper maintenance to help ensure
safe operation.
The Maintenance Record is located on
page 30 of this manual.
Working on the equipment
The installation, adjustment, service,
and maintenance of this equipment
must be done by a licensed professional
heating contractor who is qualified and
experienced in the installation, service,
and maintenance of hot water heating
systems. There are no user serviceable
partsonthisequipment.
Please carefully read this manual prior
to attempting start-up, maintenance
or service. 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.
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.
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 all aspects of
the Vitogas 100:
- Technical Data Manual
- Installation Instructions
- Start-up/Service Instructions
- Operating Instructions
and User’s Information Manual
Additional applicable literature:
- Vitotronic controls manuals
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 464 v1.2

Safety
5
Safety, Installation and Warranty Requirements (continued)
HFiberglass 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.
HHazardous materials
5167 464 v1.2
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

General Information
6
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
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.
Necessary Tools
Special Items
HApproved leak detection fluid for
natural gas and propane gas
HLoctite
Testing/analysis equipment
HMultimeter to measure 0 - 120 VAC,
0-12AACand0-20μADC
HFlue gas analyzer to measure % CO2
or O2 (i.e. Bacharach fluid samplers or
suitable electronic analyzer)
HManometer to measure gas
pressure
0 to 7” w.c. (accurately) and up to
28” w.c. gas pressure (or a
non-electric Magnehelic® manometer
may also be utilized)
HStack thermometer 0 to 500°F /
0 to 260°C
HBacharach calculator or suitable tables
to calculate efficiency
HCarbon monoxide measuring
equipment 0 to 400 ppm
H1/8” NPT male to 1/4” barb adaptor
fitting plus tubing for pressure
measurement
Use only calibrated equipment.
Cleaning supplies
HHand brush
HRags
HVacuum cleaner
HCleaning brush (standard equipment)
5167 464 v1.25167 464 v1.2
Indicates an imminently hazardous
situation which, if not avoided, could
result in death, serious injury or
substantial product/property damage.
WARNING
Indicates an imminently hazardous
situation which, if not avoided, may
result in minor injury or
product/property damage.
CAUTION
IMPORTANT
5167 464 v1.2

7
Initial Start-up
and Service
Overview
Steps to carry out for Initial start-up
Steps to carry out for Service
I1. Preparations prior to start-up Page 8..............................
I S 2. Select appropriate gas type Page 9................................
I S 3. Check static, running and manifold gas
supply pressure Page 10
.......................................................
I S 4. Measure flue gas values Page 13.......................................
I S 5. Measure ionization current Page 13.................................
I S 6. Measure chimney draft Page 14.........................................
S7. Shut down heating system Page 15...................................
S8. Remove burner tray Page 15...............................................
S9. Inspect burners Page 16.......................................................
S10. Inspect pilot burner Page 16................................................
S11. Clean heat exchanger Page 16............................................
S12. Reinstall burner tray Page 17..............................................
I S 13. Inspect all water pipe connections Page 17....................
I S 14. Check safety devices Page 17............................................
I S 15. Check precharged expansion and non-diaphragm
tank and pressure of heating system Page 17
...............
I S 16. Check electrical connections Page 18..............................
I S 17. Start up heating system Page 18.......................................
I S 18. Ensure proper automatic shut-off function of
valve in gas train Page 18
.....................................................
I S 19. Check blocked vent safety switch Page 19....................
I S 20. Perform combustion analysis Page 19..............................
I S 21. Combustion air supply Page 20...........................................
I S 22. Draining/frost protection Page 20.......................................
I23. Post start-up checklist Page 20..........................................
5167 464 v1.2

Initial Start-up and Service
8
Initial start-up 1. Preparations prior to 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.
2. Ensure proper operation of expansion
tank (see Maintenance/Service
manual).
3. To remove debris and/or sludge
ensure that the system piping is
flushed out. Failure to do so could
cause settlement in the boiler
causing overheating and damage not
covered by warranty.
4. Fill heating system with water and
bleed out air completely. Ensure
complete system is properly vented
of air.
Max. boiler operating press.
60 psig
........................................................
Pressure relief discharge press.
30 psig
........................................................
5. Perform a pressure test of the boiler
and the water piping. Pressure test
must not exceed 1½ times the
maximum system operating pressure
(60 psi ) of the boiler. Pressure
relief valve must be removed during
pressure test. Any leaks must be
corrected.
6. Adjust fill pressure to a level
compatible with normal operation.
Recommended operational
fill pressure 10 - 15 psig.................
when system is cold.
7. Reinstall pressure relief valve.
8. Ensure proper/adequate fuel supply
exists; open gas shut-off valve.
If the nitrogen pressure of the
precharged expansion tank is less
than the static pressure of the
system, inflate membrane pressure to
slightly exceed pressure of system.
The static pressure required at the
tank is based upon the static height
of the system. The system fill
pressurevaluemustbeequaltothe
expansion tank pressure value at
approx. 60 ºF/15.6 ºC.
Water treatment should be considered
in areas where it is known that boiler
feed water contains a 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 automotive silicate-based
antifreeze.
Please observe that an
antifreeze/water mixture may require
a backflow preventer within the
automatic water feed and influence
components such as diaphragm
expansion tanks, radiation, etc. A
40% antifreeze content will provide
freeze-up protection to -10°F / -23°C.
Do not use antifreeze other than
specifically made for hot water
heating systems. System also may
contain components which might be
negatively affected by antifreeze.
Check total system frequently when
filled with antifreeze.
5167 464 v1.2
Procedures

Initial Start-up and ServiceInitial Start-up and Service
9
Initial start-up 2. Select appropriate gas type Service
The Vitogas 100, GS1 boiler is for use
with gases whose characteristics fall
within the following ranges:
1. Ensure that the fuel type listed on
the boiler rating plate is the correct
type for the installation being
attempted.
2. Record fuel type in Maintenance
Record.
The Maintenance Record is located in
the back of this manual.
Natural gas Propane gas
Heating value (gross) Btu/ft3970 to 1100 2466 to 2542
Specific gravity 0.57 to 0.70 1.522 to 1.574
Ultimate carbon dioxide (CO2) % 11.7 to 12.2 13.73 to 13.82
Vitogas 100, GS1 heating boilers
produce the following:
Natural gas
CO2measurement before draft hood
(before dilution air) 6.0 - 9.0 %
CO2measurement in vent pipe
(after draft hood) 2.5 - 5.0 %
Propane gas
CO2measurement before draft hood
(before dilution air) 7.0 - 9.5%
CO2measurement in vent pipe
(after draft hood) 3.0 - 5.8 %
DO NOT OVERFIRE BOILER.
Boilers for use with natural gas have
gas valves, pilot and main burner
orifices different from those used on
propane. Only use the gas specified on
the boiler rating plate.
For high altitude areas, boiler has been
derated by 4% for every 1000 ft. / 305
m elevation above 4500 ft. / 1372 m.
In some high altitude areas the natural
gas heating value may be lower than
970 Btu/ft3.
Consult your local gas supplier for
heating value verification.
Measure manifold pressure as described
in this manual. For natural gas, the gas
meter must be clocked to verify input.
Procedures (continued)
5167 464 v1.25167 464 v1.2
IMPORTANT
Do not make any attempt whatsoever
to increase the % CO2on this
atmospheric gas-fired boiler.
CAUTION
IMPORTANT
IMPORTANT

Initial Start-up and ServiceInitial Start-up and Service
10
Initial start-up 3. Check static, running and manifold gas supply pressure Service
Gas supply static pressure:
1. Ensure manual gas shut-off valve (field
supplied) is closed.
2. Remove screw in inlet pressure tap
and attach non-electric Magnehelic®
manometer or U-tube manometer.
3. Open manual gas shut-off valve.
4. Measure static pressure:
natural gas max. 14” w.c.
propane gas max. 14” w.c.
If pressure exceeds 14” w.c., shut off
gas supply with manual shut-off valve
and contact gas supplier to decrease
gas pressure. If 14” w.c. or less,
proceed to next step.
5. Activate boiler control as described in
separate Operating Instructions. Pilot
burner begins trial for ignition.
Due to air in the gas line, pilot burner may
not light within safety timing (90 sec.).
Turn power off and on (repeating pilot trial
for ignition) until all air is purged. Once all
air is purged, pilot flame will occur
allowing main burner operation.
Gas supply running flow (upstream)
pressure:
6. Measure running gas supply pressure;
value should be,
- natural gas: between 5 and 14” w.c.
- propane gas: between 11 and 14” w.c.
Use inlet pressure tap .
7. Continue with point 9 if the running
flow pressure lies within the stated
range.
If the running pressure is outside of the
stated range, see table below.
8. Close main gas shut-off valve,
deactivate power on Vitotronic control
via the on/off switch (boiler shuts
down), disconnect manometer, and
close inlet pressure tap with 1/8”
Allen screw.
Running supply pressure with Corrective action
Natural gas Propane gas
under 5” w.c. under 11” w.c. Do not attempt adjustment. Call local gas utility to increase pressure.
5 to 14“ w.c. 11 to 14” w.c. Start up boiler.
over 14” w.c. over 14” w.c. Do not attempt adjustment. Call local gas utility to decrease pressure.
Boiler valve must not be exposed to pressure over 14” w.c.
Procedures (continued)
5167 464 v1.25167 464 v1.2
Fig. 1
Measuring static gas supply and running gas supply
pressure using inlet pressure tap
Ensure there are no gas leaks at inlet
pressure tap of gas valve.
WARNING
A 1/8” male NPT to 1/4” barb adaptor is
required to insert in gas valve inlet
pressure tap. This adaptor is used to
connect tubing from gas valve inlet
pressure tap to manometer.
IMPORTANT
Ensure that there are no open flames
in the room.
CAUTION
IMPORTANT

Initial Start-up and ServiceInitial Start-up and Service
11
Initial start-up 3. Check static, running and manifold gas supply pressure (continued) Service
Manifold pressure:
9. Remove gas valve outlet pressure tap
and connect U-tube manometer or
non-electric Magnehelic®manometer.
10.Open manual gas shut-off valve.
11.Activate boiler control as described in
separate Operating Instructions.
12.Measure manifold pressure. Manifold
pressure must be:
natural gas 3.5” w.c.
propane gas 10” w.c.
for normal operation at sea level. To
increase gas pressure (and flow), turn
pressure regulator adjustment screw
clockwise; to decrease gas pressure
(and flow), turn pressure regulator
adjustment screw counterclockwise.
13.Close main gas shut-off valve,
deactivate power on control via on/off
switch (boiler shuts down), disconnect
manometer, and close outlet with
screw.
14.Install front boiler panel and fasten with
screw provided.
15.For natural gas, the gas meter must be
clocked to verify input. Manifold
pressure may need to be adjusted to
obtain proper input.
Clock natural gas meter to verify input
1. Ensure all other gas equipment served
by the meter is turned off during
timing of gas input to Vitogas 100,
GS1 boiler.
2.Measure the time in seconds it takes
for the boiler to use 10 cu. ft. of gas.
Divide 36,000 by the number of
seconds and you get the number of
cu. ft. of gas used per hour. Multiply
this number by the heating value of
the gas to obtain Btu per hour input.
For example: A Vitogas 100, GS1
(240,000 Btu/h input) requires 2
minutes 30 seconds (150 seconds) to
use 10 cu. ft. of natural gas. After
contacting the local utility, you find the
heating value is 1000 Btu per cu. ft.
Therefore,
36,000/150 x 1000 = 240,000 Btu/h
input.
Therefore, the boiler input is correct.
Burner input formulas (for low altitude
only):
INPUT=3600 ÷t x 1000 where
t=TIME (sec.) for 1 ft.3
INPUT=3600 x .01 x 1000 x 35.31 ÷T
where
T = TIME (sec.) for .01 m3natural gas
A boiler underfired by 5% is acceptable.
Do not overfire the boiler.
Procedures (continued)
5167 464 v1.25167 464 v1.2
Fig. 2
Measuring manifold gas pressure using outlet pressure tap
Ensure there are no gas leaks at inlet
pressure tap of gas valve.
WARNING
A 1/8” male NPT to 1/4” barb adaptor is
required to insert in gas valve outlet
pressure tap. This adaptor is used to
connect tubing from gas valve outlet
pressure tap to manometer.
IMPORTANT
IMPORTANT
Always contact your gas utility to
obtain the correct heating value before
clocking the meter.
CAUTION

Initial Start-up and ServiceInitial Start-up and Service
12
Initial start-up 3. Check static, running and manifold gas supply pressure (continued) Service
Technical Data
Boiler Model Model No. GS1-22 GS1-29 GS1-35 GS1-42 GS1-48 GS1-60
CSA input MBH
kW
90
26
115
34
145
42
165
48
190
56
240
70
CSA output / DOE heating capacity MBH
kW
76
22
98
29
123
36
140
41
161
47
203
60
Min. gas supply pressure
Natural gas
LPG
“w.c.
“w.c.
5
11
5
11
5
11
5
11
5
11
5
11
Max. gas supply pressure*1 (flow) “w.c. 14 14 14 14 14 14
Flue gas*2
Temperature (gross) °F
°C
223
106
216
102
235
113
266
130
228
109
252
122
Number of burner tubes 3 4 5 6 7 9
Natural gas flow rate
(0 - 4500 ft. / 0 - 1372 m altitude)
ft3/h
m3/h
90
2.55
115
3.26
145
4.11
165
4.67
190
5.38
240
6.80
Propane gas flow rate
(0 - 4500 ft. / 0 - 1372 m altitude)
ft3/h
m3/h
36
1.02
46
1.30
58
1.64
66
1.86
76
2.15
96
2.71
Main burner orifices
diameter
0 - 4500 ft. / 0 - 1372 m
Natural gas
Propane gas
4500 - 7000 ft. / 1372 - 2134 m*3
Natural gas
Propane gas
7000 - 10 000 ft. / 2134 - 3048m*3
Natural gas
Propane gas
Ømm
Ømm
Ømm
Ømm
Ømm
Ømm
2.60
1.55
2.50
1.50
2.40
1.45
2.55
1.55
2.45
1.50
2.35
1.45
2.55
1.55
2.45
1.50
2.35
1.45
2.50
1.55
2.40
1.50
2.30
1.45
2.50
1.55
2.40
1.50
2.30
1.45
2.45
1.50
2.35
1.45
2.25
1.40
Pilot burner orifices diameter for
intermittent pilot ignition system
Natural gas
Propane gas
Ømm
Ømm
0.38 (#26)
0.24 (#24)
*1If the gas supply pressure is higher than the maximum permissible value, a separate gas regulator must be installed upstream of the
boiler system.
*2Measured flue gas temperature after dilution air with combustion air temperature of 68 °F / 20 °C.
*3Diameters given for altitudes above sea level.
Manifold pressure is 3.5” w.c. for natural gas and 10” w.c. for propane gas for 0 - 4500 ft. / 0 - 1372 m, 4500 - 7000 ft. /
1372 - 2134 m and 7000 - 10 000 ft. / 2134 - 3048 m altitudes.
Procedures (continued)
5167 464 v1.25167 464 v1.2
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.
Do not overfire the boiler.
WARNING
5167 464 v1.2

Initial Start-up and Service
13
Initial start-up 4. Measure flue gas values Service
HCarbon dioxide CO2
or
HOxygen content O2
HCarbon monoxide CO
HFlue gas temperature (gross)
HFlue gas loss
must be measured and recorded in the
Maintenance Record on page 30 of this
manual.
Typical combustion results in the stack
are:
CO2:2.5 to 5%
Gross flue
gas temp.:
200 - 300 ºF /
93 - 149 ºC
CO: < 25 ppm
Flue loss: 15 to 17%
Initial start-up 5. Measure ionization current Service
1. Connect a DC μA multimeter in series
with the “sense” wire from the
S8600B ignition control module.
2. Measure the DC μA (microamp)
current.
3. Ifthecurrentvalueis
Hsteady and greater than 1 μA-OK
Hless than 1 μA - the ignition control
module or the pilot burner must be
replaced.
4. Record value in Maintenance Record
on page 30 of this manual.
Procedures (continued)
5167 464 v1.2
A CO analysis must be performed
before and after any work activities
to ensure that equipment operation is
safe (health-wise) to inhabitants, and
to be able to guarantee optimal
operation of the system.
WARNING
Before connecting testing equipment,
deactivate control via power switch.
CAUTION

Initial Start-up and Service
14
Initial start-up 6. Measure chimney draft Service
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.
HMeasure the chimney draft after the
draft hood and record value in
Maintenance Record on page 30 of
this manual.
HThe chimney draft is recommended to
be between:
-0.012” w.c. and -0.04” w.c.
Chimney and vent system must meet
current safety codes.
Any corroded parts of vent system
must be replaced. Inspect vent system
every year before heating season
begins.
Procedures (continued)
5167 464 v1.2
Never operate boiler without a
venting system which safely vents all
products of combustion to the
outdoors.
WARNING

Initial Start-up and Service
15
7. Shut down heating system
Service
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
Service
1. Remove front panel; unlock panel using
a flat-head screwdriver (GS1-60 has
two locking mechanisms).
2. Disconnect 7-pole plug-in
connector from 120/24 VAC relay
module assembly.
3. Disconnect ground cable from mid
panel.
4. Disconnect ignition electrode and
ionization electrode cabling from
ignition burner.
5. Loosen mounting bolt of gas valve
flange .
6. Remove screws and carefully pull
out burner tray.
Procedures (continued)
5167 464 v1.2

Initial Start-up and Service
16
9. Inspect burners
Service
1. Ensure gas orifices and slots of
burner tubes are visually free of
defect or damage.
2. Blow out burner tubes with high
pressure air, clean with a soft bristle
(non-metallic) brush.
10. Inspect pilot burner
Service
1. Ensure ionization electrode , pilot
burner and ignition electrode
are visually free of defect or damage.
2. Check spark gap.
3. Use emery cloth to clean ionization
electrode.
4. Replace pilot burner if necessary.
See Replacement Pilot Burner
Installation Instructions
5. Viessmann pilot orifice (not shown):
HNatural gas stamped “26”
HPropane gas stamped “24”
11. Clean heat exchanger, if applicable (with burner tray removed)
Service
1. Loosen sheet metal screws from the
back and remove top panel .
2. Unhook spring-clips and remove
insulation blanket .
3. Loosen screws and remove flue gas
collector cover .
4. Clean heat exchanger of pressure
vessel (with burner tray removed)
using factory supplied cleaning brush.
¨
5. Remove debris from the base plate
6. HReinstall flue gas collector cover.
HPlace mineral wool blanket and
insulation blanket over cover and
fasten to insulation blanket of
boiler, using spring-clips.
HInstall top panel.
Procedures (continued)
5167 464 v1.2
+
-1
14
Viessmann pilot adaptor
(not to scale)
Do not use chemical cleaners under
any circumstance.
CAUTION

Initial Start-up and Service
17
12. Reinstall burner tray
Service
Initial start-up 13. Inspect all water pipe connections Service
Check heating system and domestic hot
water connections. Ensure all
connections are pressure tight.
Correct any leaks found on fittings,
pumps, valves, etc..
Initial start-up 14. Check safety devices Service
Ensure proper operation of low water
cut-off(s) (if applicable), pressure relief
valve, and pump(s).
Check pressure gage, air vent and
pressure relief valve. Ensure that
pressure relief valve does not leak and
that it operates in accordance with
information provided by the
manufacturer.
Refer to maintenance instructions
supplied with low water cut-offs,
pumps, etc.
Flush float water type low water
cut-offs (if used).
Follow local regulations with respect to
backflow preventers.
If oil-lubricated pumps are used, ensure
proper lubrication.
If motorized zone valves are used, refer
to maintenance instructions provided
with zone valves.
Initial start-up 15. Check precharged expansion and non-diaphragm tank and pressure of system Service
Refer to maintenance instructions
supplied with diaphragm expansion tank.
Check fill pressure when system is cold.
Ensure proper operation of expansion
tank.
If an older non-diaphragm expansion
tank is used, ensure the correct water
level is present (2/3 water, 1/3 air).
The usual water fill pressure is between
10and15psigwiththesystemcold.
The system fill pressure value must be
equal to the expansion tank pressure
value at approx. 60 ºF/15.6 ºC.
Check pressure gage on safety
header. A lower pressure gage reading
usually indicates loss of water due to
leakage. All leaks must be corrected.
Refer to instructions packaged with
automatic fill valve.
Procedures (continued)
5167 464 v1.2

Initial Start-up and Service
18
Initial start-up 16. Check electrical connections Service
Ensure all plug-in connectors and strain
reliefs make positive contact and are
seated properly.
Start-up/Service Instructions
Vitotronic Boiler Control
Initial start-up 17. Start up heating system Service
Operating Instructions
Heating System,
Accessories
Install front panel prior to start-up.
Initial start-up 18. Ensure proper automatic shut-off function of valve in gas train Service
1. Deactivate power on boiler control.
2. Burner deactivation must occur
evenly and quickly (see burner
observation port near pilot burner).
3. Replace gas valve if deactivation
does not occur evenly and quickly.
Procedures (continued)
5167 464 v1.2
The gas supply piping must be leak
tested before placing the boiler in
operation.
WARNING
Ensure all joints of gas line are
pressure tight and that gas valves do
not leak when under normal operating
pressure (use approved leak detection
liquid).
CAUTION

Initial Start-up and Service
19
Initial start-up 19. Check blocked vent safety switch Service
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. The switch requires a manual reset by pushing in the red button. If the
switch activates, the vent system must be checked inside and out and the blockage
or defect corrected by a qualified heating contractor before the boiler is put back in
operation.
1. Disconnect chimney piping from the
draft hood.
2. Cover draft hood chimney connection
in order to test functionality of
blocked vent safety switch.
3. Activate boiler.
The blocked vent safety switch must
deactivate the burners not more than
2 minutes after activation.
HCheck position of switch if
blocked vent safety switch requires
more than 2 minutes to deactivate.
HReplace switch or check wiring:
- if blocked vent safety switch does
not deactivate
- if burners do not activate
- ifswitchiscorrodedinanyway.
4. Deactivate boiler.
5. Uncover draft hood chimney
connection and reconnect chimney
piping to draft hood.
Vitogas 100, GS1 GS1-22 GS1-29 GS1-35 GS1-42 GS1-48 GS1-60
A (mm) 135 181 218 264 310 401
Initial start-up 20. Perform combustion analysis Service
1. For a combustion analysis, please
repeat steps commencing on
page 13.
2. Record measurements and settings
on page 30 of this manual.
3. Reclock burners if necessary.
Procedures (continued)
5167 464 v1.2
Bottom of blocked vent safety switch
bracket, sensing cup must point upward.
Must line up with bottom
of draft hood skirt
Ensure that windows in the room are
open. Provide proper ventilation.
WARNING
Never test functionality of blocked
vent safety switch using an open
flame. Direct, intense heat may
damage sensor. A short-circuit or
tripping of the sensor deactivates
burners.
WARNING

Initial Start-up and Service
20
Initial start-up 21. Combustion air supply Service
Ensure an adequate supply of
combustion and ventilation air is
available. If outside air duct is
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
no chemicals, garbage, gasoline,
combustible materials, flammable
vapors and liquids are stored (not even
temporarily) in the vicinity of the boiler.
Vitogas 100, GS1 Installation
Instructions
Initial start-up 22. Draining/frost protection Service
To completely drain the boiler (e.g.
when frost protection is required), drain
left boiler section using drain A on the
boiler front.
23. Post start-up checklist
Service
HOnce system water is heated,
deactivate circulating pump/boiler
and vent system of any remaining air
within piping, radiation and boiler.
HCheck for proper boiler circulation,
pump, zone valve, thermostat or
operating control functions.
HCheck adjustable high limit aquastat
by dialing it to a setting below the
water temperature in the boiler. The
gas burner must be deactivated.
Turning the dial back to a setting
higher than the present boiler water
temperature must result in
reactivation of gas burner.
HCycle boiler on and off with the
room thermostat (or other operating
control) to verify that the burner
shuts down when the room
thermostat is adjusted below room
temperature.
Procedures (continued)
5167 464 v1.2
Please note:
This boiler is equipped with pre-mix burner tubes. Both
primary and secondary air for combustion are supplied
by entrainment through the burner front openings.
A
To drain boiler use drain connection
on the back of the boiler first. Then
use the front drain connection to
drain the left cast-iron section.
CAUTION