Viessmann VITOGAS 100 Guide

VITOGAS 100
Operating Instructions
and User’s Information Manual
Vitogas 100
GS10 Series
Natural gas-/propane-fired, two-stage
atmospheric cast iron boiler
Heating input 300 to 380 MBH
88 to 111 kW
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
WARNING
Improper installation, adjustment, and/or
operation could cause carbon monoxide
poisoning resulting in injury or loss of life.
This product must be installed and serviced by a
professional service technician who is
experienced and qualified in hot water boiler
installation and gas combustion.
WARNING
Do not store or use gasoline or other flammable
liquids in the vicinity of this or any other
appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliances.
Do not touch any electrical switches, do not
use any phone in your building.
Immediately call your gas supplier from a
neighbor’s phone. Follow the gas supplier’s
instructions.
If you cannot reach your gas supplier, call the
fire department.
Installation and service must be performed by a
qualified installer, service agency or the gas
supplier.
Read and save these instructions
for future reference.
IMPORTANT
5167 469 v1.1 12/2003
Please file in Service Binder

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” in the
Installation Instructions.
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”
in the Installation Instructions.
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.
5167 469 v1.1
Installers must follow local
regulations with respect to
installation of carbon monoxide
detectors. Follow manufacturer’s
maintenance schedule of boiler.
WARNING

Safety
3
About these 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.
Safety
HOperation
Before operating the boiler, make sure
you fully understand its method of
operation. Your heating contractor
should always perform the initial
start-up and explain the system. Any
warranty is null and void if these
instructions are not followed.
HWorking on the equipment
All personnel working on the equipment
or the heating system must have the
proper qualifications and hold all
necessary licenses.
Ensure main power to equipment,
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.
HMaintenance and cleaning
Regular inspection and service by a
qualified heating contractor is critical to
the performance of the Viessmann
Vitogas 100, GS10. Neglected
maintenance impacts on warranty;
regular cleaning and maintenance
ensures clean, environmentally friendly
and efficient operation. We recommend
a maintenance contract with a qualified
heating contractor.
HFlue gas smell
- Deactivate heating equipment.
- Open windows and doors.
- Inform your heating contractor.
HDangerous conditions
- Deactivate main power immediately.
- Close gas supply valve.
HTechnical information
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
- Accessory manuals
5167 469 v1.15167 469 v1.1
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
Incomplete combustion and poisonous
gases result if the fresh air intakes in
the mechanical room are closed. Never
close these openings.
CAUTION

Safety
4
Safety (continued)
HFor safe operation
We recommend that you frequently:
- Check for debris which could obstruct
the flow of flue gases. The vent or
chimney must not be blocked. A
blocked or partially blocked vent or
chimney can cause flue gases to leak
into the structure. Flue gases leaking
into the house can cause injury or
death. Blocked or partially blocked
chimneys must have the blockage
removed by a qualified heating
contractor.
- Check pressure gage for correct
system (water) pressure. Check for
water on the floor from the discharge
pipe of the pressure relief valve or any
other pipe, pipe joint, valve or air vent.
- Check for moisture, water, or
appearance of rust on the flue gas
pipes, their joints as well as vent
dampers, or side wall vent terminals (if
so equipped).
- Ensure that nothing is obstructing the
flow of combustion and ventilation air
and no chemicals, garbage, gasoline,
combustible materials, flammable
vapors and liquids are stored (not even
temporarily) in the vicinity of the
boiler.
-Donot allow unsupervised children
near the boiler.
Service/inspection of the boiler and the
system is recommended once a year.
Maintenance, service and cleaning are
specified in the Installation Instructions.
Before the heating season begins, the
boiler with its burners should be
serviced by a qualified heating
contractor. Service contracts may be
established through gas suppliers or
other licensed contractors in your area.
This product comes with several safety
instruction labels attached.
Do not remove!
Contact Viessmann immediately if
replacement labels are required.
Do not use this boiler if any part has been
under water. Immediately call a qualified
heating contractor to inspect the boiler
and to replace any part of the control
system and any gas control which has
been under water.
Do not store chemicals containing chlorine
or other corrosive materials near the
boiler, such as bleach, cleaning solvents,
detergents, acids, hair spray, spray cans,
paint thinners, paint, or water softener
salt.
5167 469 v1.1
There are no user serviceable parts on
the boiler, burners or control. Failure to
heed this warning can cause property
damage, severe personal injury, or loss
of life.
WARNING
Improper installation, adjustment,
service, or maintenance can cause flue
products to flow into living space. Flue
products contain poisonous carbon
monoxide gas which can cause nausea
or asphyxiation resulting in severe
personal injury or loss of life.
WARNING
Should overheating occur or the gas
supply fail to shut off, do not
disconnect the electrical supply to the
pump. Instead, shut off the gas supply
at a location external to the appliance.
CAUTION
The operator/ultimate owner is required
to have the heating boiler, burners, and
controls checked, as a minimum once
per year, by the original installer or by a
competent heating contractor familiar
with the equipment. Defects must be
corrected immediately.
WARNING
IMPORTANT

Operating Instructions
5
Vitogas 100, GS10
Pressure gage
Fuel
This boiler is factory calibrated for use
only with the fuel stated on the boiler
rating plate.
Boiler is factory supplied for use with one
fuel only (natural gas or propane).
Safety switches
Blocked vent safety switch
The manual reset blocked vent safety
switch is located at the back of the
boiler in the draft hood. In the event of
complete vent blockage by snow, ice,
debris, animals’ nests or other material,
the spill switch heats up and interrupts
24V to the gas control, thereby
shutting down the burner. Do not
attempt to reset the switch - call a
qualified heating contractor. If the
switch activates, the vent system must
be checked inside and out. The
blockage must be removed by the
heating contractor before the boiler is
put back into operation. Do not operate
the boiler without the blocked vent
safety switch being fully operational.
Do not attempt to operate the boiler
without the blocked vent safety switch
being fully operational. Advise the
system operator/ultimate owner to
contact a qualified heating contractor
for service immediately should the
switch activate.
5167 469 v1.1
System power switch
I=Poweron
O=Poweroff
Front view
VITOGAS 100
VIEßMANN
Rear view
For burner status indication
reference applicable Vitotronic
control manual.
Do not use propane gas on a boiler
equipped for use with natural gas.
Do not use natural gas on a boiler
equipped for use with propane gas.
WARNING
IMPORTANT
Do not bypass this safety device.
WARNING

Operating Instructions
6
Start-up
Initial start-up
The heating contractor must perform the
initial start-up and explain the operation of
the system. Refer to “Lighting and
Operating Instructions” on the following
page.
The operation of the boiler control must
also be explained to the system
operator/ultimate owner by the heating
contractor. Refer to literature packaged
with boiler control.
Necessary preparations prior to
initial start-up
(as well as for successive start-ups)
1. Check for water on the floor from the
discharge pipe of the pressure relief
valve or any other pipe, pipe joint, valve
or air vent.
If pressure relief valve is discharging,
contact contractor to locate source of
problem and take corrective measures.
Never cap or plug end of pressure relief
valve discharge pipe.
Ensure correct system (water) pressure.
See pressure gage. If the system
pressure is below 10 psig, please call
your heating contractor.
2. Ensure fresh combustion air supply
vents to boiler room are open and
unobstructed.
Nothing must obstruct the flow of
combustion and ventilation air.
3. Open main gas supply valve.
4. Activate the system. Ensure power
supply is activated and then activate
system power switch “ ”.
Your heating system is now ready for
operation.
Start-up
Refer to “Lighting and Operating
Instructions” on following page. The boiler
control regulates operation of the heating
system automatically in conjunction with
the indoor/outdoor control and any
programmed settings (if applicable).
Changes to the settings or programming
can be made according to separate
instructions provided with the boiler
control.
For optimum operation
HKeep the boiler and the boiler room
clean and free of dust and dirt.
HEnsure proper system pressure by
occasionally checking pressure gage.
HAllow a qualified heating contractor to
regularly service and maintain your
heating system.
Neglected maintenance impacts on
product warranty; regular cleaning and
maintenance ensures clean,
environmentally friendly and efficient
operation.
Viessmann recommends a maintenance
contract with a qualified heating
contractor.
If you require assistance finding a
qualified heating contractor, contact
Viessmann.
Shut-down
Brief shut-downs
Vitotronic controls
Set system power switch “ ”to“0”and
ensure main power supply to boiler and
control remains activated.
Vitotronic boiler control
manuals
Extended shut-downs
1. Close main gas supply valve.
2. Deactivate system power switch.
3. Deactivate main power supply to boiler
and control.
We recommend that you contact your
heating contractor prior to and after an
extended shut-down period. In this
manner, the appropriate precautions, i.e.
system freeze-up protection or heat
exchanger maintenance, can be taken.
5167 469 v1.1
Under these measures, the heating
system remains electrically activated.
CAUTION

Operating Instructions
7
Lighting and Operating Instructions
5167 469 v1.1

Additional Information
Viessmann Manufacturing Company Inc.
750 McMurray Road
Waterloo, Ontario •N2V 2G5 •Canada
Tel. [phone] •Fax [phone]
www.viessmann.ca •[e-mail]
Viessmann Manufacturing Company (U.S.) Inc.
45 Access Road
Warwick, Rhode Island •02886 •USA
Tel. [phone] •Fax [phone]
www.viessmann-us.com •[e-mail]
8
Troubleshooting Guide
Failure Cause Correction
Heating system does not activate System power switch “ ” on the boiler
control has not been activated.
Activate
Main power supply to boiler and control
has not been activated.
Activate
Breaker or fuse in building electrical panel
has blown.
Contact heating contractor.
Safety temperature high limit has
deactivated.
Contact heating contractor.
Vent damper motor does not open (if
applicable).
Contact heating contractor.
Burner does not activate, or does so Fuel supply inadequate Open main gas supply valve.
,
sporadically Boiler control or boiler system control is
improperly set.
Ensure proper setting of switching times
and program selection switch.
Fault indication on boiler control (if
applicable)
Contact heating contractor.
Burner does not activate Ignition system fault Turn off system power switch and wait
5 minutes. Turn on system power
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switch. Do not repeat more than twice.
If unsuccessful, contact heating
contractor.
Heating circuit cold Priority to (indirect-fired) DHW production Wait until DHW tank has completed its
heating cycle.
Room temperature is too cold or too hot
during different periods of the year
Heating curves not properly set Make appropriate adjustments
(see Operating Instructions of Vitotronic
control).
Please notify your heating contractor in the event of additional fault occurrences.
5167 469 v1.1 Technical information subject to change without notice. Printed on environmentally friendly
(recycled and recyclable) paper.