Viessmann VITOGAS 100 Instruction manual

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Cast iron hot water heating boiler
90 to 240 MBH/26 to 70 kW
5167 462 v1.5 02/2011
Vitogas 100 with boiler stand
beside Vitocell-V 100 domestic hot water storage tank
Vitogas 100
Te hni al Data Manual
Model Nos. and pricing: see Price List
Vitogas 100
GS1 Series – residential fully assembled boiler
Natural Gas-/Propane-Fired Single-Stage Boiler
ast iron se tional onstru tion
atmospheri , fully premix burner
Heating input: 90 to 240 MBH
26 to 70 kW

Produ t Information
2
Vitogas 100
Top performan e in a small pa kage. Thanks
to its ompa t dimensions, the Vitogas 100
is ideal for installation in losets and
al oves. Apart from saving spa e, the
Vitogas 100 is e onomi al in terms of
energy onsumption with redu ed
emissions.
The benefits at a glance:
HHigh operational reliability and a long
service life due to spe ial high-grade gray
ast iron with lamellar graphite and a low
thermal load on the heat ex hanger surfa e.
HClean combustion due to atmospheri
premix burner with super-stoi hiometri
premixing: NO
x
< 27.9 ppm (air-free),
CO < 9.2 ppm (air-free). The Vitogas 100
therefore meets the toughest emission
requirements in North Ameri a, su h as
California regulations (SMAQMD).
HE onomi al and environmentally friendly
operation via modulating boiler water
temperatures.
Annual fuel utilization efficiency (A.F.U.E.)
of up to 85.6 %.
HIntermittent pilot ignition system provides
soft, quiet and extremely reliable ignition.
HCompact dimensions – therefore suitable
for installation in a boiler room, a utility
room or even in an open living area.
HProblem-free transport into
difficult-to-access boiler rooms due to light
weight and ompa t design.
Heat exchanger surfaces of special
high-grade gray cast iron for high
operational reliability and a long
service life
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Produ t Information
Cross-Se tion
Produ t may not be exa tly as illustrated.
3
Extremely effective Heat exchanger surfaces of Vitotronic – the new
insulation special high-grade gray cast generation of boiler controls:
iron with lamellar graphite Intelligent easy to install
operate and service
Stainless steel atmospheric A redundant gas
super-stoichiometric valve doubles
premix burners for low- operational safety
emission combustion
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Te hni al Data
4
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
Net I=B=R rating
*1
MBH
kW
66
19
85
25
107
31
122
36
140
41
177
52
Heat exchanger surface area ft
2
m
2
16.25
1.51
21.42
1.99
26.48
2.46
31.54
2.93
36.60
3.40
46.82
4.35
Min. gas supply pressure
Natural gas
Liquid propane
“w. .
“w. .
5
11
5
11
5
11
5
11
5
11
5
11
Max. gas supply pressure
*2
“w. . 14 14 14 14 14 14
A.F.U.E.
*3
%85.6 85.5 85.5 85.5 85.5 85.4
Overall dimensions
*4
Overall length
Overall width
Width
Overall height (operation)
– Height 1 ( ontrol unit in
position for operation)
– Height 2 ( ontrol unit in
position for servi ing)
Height in l. flue pipe elbow
Height of boiler stand
Height of DHW tank
positioned under the boiler
– 42 to 53 USG/
160 to 200 liter apa ity
in hes
mm
in hes
mm
in hes
mm
in hes
mm
in hes
mm
in hes
mm
in hes
mm
in hes
mm
in hes
mm
33¼
844
25½
650
21½
546
33¼
845
37½
955
46½
1180
39
992
9¾
250
26
660
33¼
844
25½
650
21½
546
33¼
845
37½
955
46½
1180
39¾
1012
9¾
250
26
660
34
864
33
840
29
736
33¼
845
37½
955
46½
1180
39¾
1012
9¾
250
26
660
34
864
33
840
29
736
33¼
845
37½
955
46½
1180
39¾
1012
9¾
250
26
660
34
864
36½
930
32½
826
33¼
845
37½
955
46½
1180
42½
1082
9¾
250
––
34
864
43¾
1110
39½
1006
33¼
845
37½
955
46½
1180
42½
1082
9¾
250
––
Weight, boiler with insulation, lbs
burner and boiler ontrol unit kg
273
124
326
148
375
170
428
194
481
218
582
264
Boiler water content USG
ltr
2.6
9.7
3.1
11.7
3.6
13.8
4.2
15.9
4.7
17.9
5.8
21.9
Max. operating pressure psig 60 60 60 60 60 60
Number of intermediate
cast iron sections
2 3 4 5 6 8
Number of burners 3 4 5 6 7 9
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Te hni al Data
5
Technical data (continued)
Boiler connections
Boiler supply and return
Safety supply
Drain valve
” (male thread)
” (male thread)
” (male thread)
1½
1½
¾
1½
1½
¾
1½
1½
¾
1½
1½
¾
1½
1½
¾
1½
1½
¾
Gas supply connection ” (NPT) ½ ½ ½ ½ ½ ½
Flue gas
*5
Temperature (gross)
Mass flow rate
– with natural gas
– with liquid propane
°F
°C
lbs/h
kg/h
lbs/h
kg/h
230
110
161
73
148
67
230
110
216
98
209
95
235
113
236
107
209
95
266
130
231
105
223
101
230
110
342
155
322
146
252
122
353
160
337
153
Vent pipe collar outside Ø” 5 6 6 6 7 7
*1
Net I=B=R rating based on piping and pick-up allowance of 1.15.
*2
If t e gas supply pressure is ig er t an t e maximum permissible value, a separate gas regulator must be installed upstream of t e
boiler system.
*3
Wit intermittent pilot electronic ignition system and vent damper.
*4
Heig t dimensions for Vitogas 100 include leveling bolts.
*5
Measured flue gas temperature after dilution air wit combustion air temperature of 68 °F/20 °C.
"For information regarding ot er Viessmann System Tec nology componentry, please reference documentation of t e respective product.
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Te hni al Data
6
Boiler Stand (A essory)
Vito ell-H – only those
ombinations whi h are stated
in the Pri e List are possible.
See Boiler/Tank Compatibility Chart
on following page.
Dimensions
Boiler
Model
GS1 -22 -29 -35 -42 -48 -60
a
b
in hes
mm
in hes
mm
12¼
313
13¼
337
14¼
359
11½
291
15¾
402
17¼
438
17¾
448
15½
392
19½
494
17¼
436
23
587
20½
523
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Legend
BD Boiler Drain
BWR Boiler Water Return
BWS Boiler Water Supply
DH Draft Hood
GC Gas Conne tion
SS Safety Supply
Overall height
Height 1
Height 2
Overall length
Height in l. flue pipe elbow
Width
Overall width
48” / 1217 mm
38½” / 979 mm
42¼” / 1072 mm
33¼” / 842 mm
26” / 660 mm
58¾” / 1493 mm
9¾” 250 mm
28¼” / 719 mm
22” / 557 mm
16¼” / 412 mm
12½” / 319 mm
7¼” 182 mm
30¾” / 780 mm
BD
GC
BWR
BWS
SS
DH
6¾” / 173 mm
3” / 78 mm
26” / 663 mm
20” / 510 mm
6¾” / 173 mm
BD
NGC
BWR
BWS
SS
DH
54¼” / 1379 mm

Te hni al Data
7
Boiler/Tank Compatibility
Support bars may be required when
mounting a Vitogas 100, GS1 boiler on a
Viessmann Vito ell-H Series tank.
Refer to the following hart to determine
whether support bars are required for your
appli ation.
Order numbers are listed for boiler/tank
ombinations requiring support bars.
Certain boilers (listed with a “z” in the
hart) are dire tly ompatible with the
Vito ell-H tank and thus do not require
additional hardware.
Combinations listed with “n.a.” are
in ompatible. Do not attempt to install these
ombinations.
For more information see Viessmann Pri e
List.
Boiler/Tank Compatibility
Vitocell-H 100
DHW storage tank
Vitocell-H 300
DHW storage tank
Vitogas 100 CHA-160 CHA-200 EHA-160 EHA-200 EHA-350 EHA-450
GS1-22/-29
GS1-35
GS1-42
GS1-48
GS1-60
z
z
n.a.
n.a.
n.a.
z
z
z
n.a.
n.a.
z
z
n.a.
n.a.
n.a.
z
z
z
n.a.
n.a.
n.a.
z
z
z
n.a.
n.a.
n.a.
n.a.
Z001 060
n.a.
Order No. = Support bars are required.
z= Support bars are not required. Boiler/tank are directly compatible.
n.a. = Boiler/tank are incompatible. Neit er mounting wit support bars, nor direct-mounting possible.
Waterside Flow (primary circuit) Typical Flow Rates
Boiler Model GS1 -22 -29 -35 -42 -48 -60
20°F rise
30°F rise
GPM
m
3
/h
GPM
m
3
/h
7.5
1.7
5.0
1.1
9.8
2.2
6.5
1.5
12.3
2.8
8.2
1.9
14.0
3.2
9.3
2.1
16.1
3.6
10.7
2.4
24
5.4
16.0
3.6
Use standard friction loss method for pipe sizing.
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Pressure drop
Water flow
ltr/h
GPM
“w. . mbar
16 40
20 50
1.6 4
2.0 5
3.2 8
4 10
8 20
12 30
1.2 3
2.2 500 2.6 600 3.5 800 4.4 1 000
9 2 000
13 3 000 18 4 000 22 5 000 26 6 000 35 8 000
0.8 2
0.4 1
2.4 6
1.3 300 1.8 400
GS1-22
GS1-29
GS1-35 and -42
GS1-48 and -60

Te hni al Data
Standard Equipment/Boiler Control Alternatives
8
Recommended Minimum Service Clearances
Minimum Clearances to Combustibles
Boiler Model GS1 -22 -29 -35 -42 -48 -60
Rear (from
draft hood)
in hes
mm
6
150
6
150
6
150
6
150
6
150
6
150
Sides in hes
mm
0
0
0
0
0
0
0
0
0
0
0
0
Flue in hes
mm
6
150
6
150
6
150
6
150
6
150
6
150
Top in hes
mm
6
150
6
150
6
150
6
150
6
150
6
150
Floor Combustible
All clearances are measured from boiler enclosure panel.
Standard Equipment
Note:
Boiler controls and burners are purc ased
separately. Please see Price List for details.
Boiler shell with mounted insulating ja ket and
atmospheri premix burners for natural gas or
liquid propane onforming to lo al regulations.
1 arton with boiler installation fittings
1 arton with safety header
1 arton ontaining either a vent damper or a
power venter (please spe ify at time of
order).
Carrying handles (a essory) are available to
fa ilitate transport to the boiler lo ation. See
Pri e List.
See previous page and/or Pri e List for
possible boiler/DHW tank ombinations.
Boiler Control Alternatives
Vitotronic 100 KK10
standard boiler ontrol for high temperature
heating systems
Vitotronic 100 KW10
standard boiler ontrol for high temperature
heating systems with indoor/outdoor system
ontrol
Vitotronic 100 KW10A / KW10B
standard boiler ontrol for high temperature
heating systems with indoor/outdoor system
ontrol
With or without DHW
Vitotronic 200 KW2
for multiple-temperature heating systems
with or without a mixing valve,
with indoor/outdoor digital boiler and heating
system ontrol
Vitotronic 300 KW3
for multiple-temperature heating systems
with up to two mixing valves,
with indoor/outdoor digital boiler and heating
system ontrol
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min.
27½” / 700 mm
min.
9¾”
250 mm
min. 9¾” 250 mm
min. 9¾” 250 mm
top min.
24” /
600 mm

System Design Considerations
9
System Design Considerations
The Vitogas 100 is designed for losed loop,
for ed ir ulation hot water heating systems
only.
Boiler selection
The boiler model size should be based on an
a urate heat loss al ulation of the
building. The boiler sele ted must be
ompatible with the onne ted radiation.
Venting
For proper operation of the Vitogas boiler, all
produ ts of ombustion must be safely
vented to the outdoors, while ensuring that
flue gases do not ool prematurely.
It is riti al that the himney system be
properly designed to handle the relatively
ool flue gas temperatures produ ed by the
Vitogas boiler.
Flue gases whi h ool too qui kly and
produ e ondensation lead to damages if
the himney diameter is too large and the
himney system is not well insulated.
If a al ulated himney diameter lies
between two values, the larger diameter
should be sele ted.
The Vitogas 100, GS1 boiler is a Category I
boiler as defined in the ANSI Z21.13 CSA
4.9 Standard. Use approved vent material
(su h as B-vent) only.
Intermediate section
Use the shortest possible path between the
boiler and the himney. A maximum of two
elbows may be installed in the intermediate
se tion. Avoid the use of two level 90°
elbows.
The intermediate se tion must be sealed gas
tight at the boiler vent pipe ollar and at the
himney onne tion. Ensure any test port
for ombustion values is sealed as well.
The himney onne tion between the boiler
vent pipe ollar and the himney must be
installed with insulation. We re ommend
onsulting a reputable himney installer for
advi e in proje t-spe ifi ir umstan es.
Warranty
Our warranty does not over damages
resulting from the following:
– installation or servi e by unqualified and
not li ensed personnel
– orrosion aused by flue gas ondensation
due to low boiler water and/or return
water temperatures
– operation with ontaminated fill and
supplementary feed water
For detailed warranty information, please
read warranty sheet supplied with produ t.
Combustion air supply
The boiler must not be lo ated in areas or
rooms where hemi als ontaining hlorine,
bromine, fluorine, or other orrosive
hemi als are stored. Examples in lude
refrigerants, blea h, paint, paint thinner, hair
spray, leaning solvents, water softener
salt, et . The ombustion air must not be
ontaminated with any amount of the above
mentioned hemi als.
Boiler should never be installed in areas
where ex essive dust, high humidity, or risk
of frost exist. Ensure adequate ventilation
and supply of fresh ombustion air.
Consult Viessmann if un ertainties exist in
regard to a suitable boiler installation
lo ation.
This boiler/burner unit needs lean fresh air
for safe operation and must be installed so
that there are provisions for adequate
ombustion and ventilation air.
For gas or propane, use the “Natural Gas
Installation Code CAN/CSA-B149.1 or
B149.2” (Canada), or “National Fuel Gas
Code ANSI Z223.1” (USA), and/or
provisions of lo al odes.
The sizing methods outlined in the above
odes should be used when installing a
round du t to supply ombustion air from
the outside.
System layout
The boiler water temperature limit is fa tory
set to 167 °F/75 °C.
The boiler water temperature limit an be
in reased by altering the adjustable high
limit to in rease the supply water
temperature.
To minimize piping losses of the system
however, we re ommend that the radiation
and domesti hot water produ tion in the
system be designed for a 158 °F/70 °C
boiler supply water temperature.
Water quality
Treatment for boiler feed water should be
onsidered in areas of known problems,
su h as where a high mineral ontent and
hardness exist. In areas where freezing
might o ur, an antifreeze may be added to
the system water to prote t the system.
Please adhere to the spe ifi ations given by
the antifreeze manufa turer. Do not use
automotive sili ate based antifreeze. Please
observe that an antifreeze/water mixture
may require a ba kflow preventer within the
automati water feed and influen e
omponents su h as diaphragm expansion
tanks, radiation, et . A 40% antifreeze
ontent will provide freeze-up prote tion to
-10 °F/-23 °C. Do not use antifreeze other
than spe ifi ally made for hot water heating
systems. System also may ontain
omponents whi h might be negatively
affe ted by antifreeze. Che k total system
frequently when filled with antifreeze.
Oxygen diffusion barrier
underfloor tubing
The boiler warranty does not over leaks
resulting from orrosion aused by the use
of underfloor plasti tubing without an
oxygen diffusion barrier. Su h systems must
have the non-oxygen diffusion barrier tubing
separated from the boiler with a heat
ex hanger. Viessmann re ommends the use
of underfloor plasti tubing with an oxygen
diffusion barrier.
Low water cut-off
A low water ut-off may be required by lo al
odes. If boiler is installed above the
radiation level, a low water ut-off devi e of
approved type must be installed in all
instan es. An approved type low water
ut-off devi e must be provided by the
heating ontra tor. Do not install an
isolation valve between the boiler and the
low water ut-off.
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Installation Examples
10
Installation Examples
These examples depict possible piping layouts
for Viessmann product equipped with
Viessmann System Technology. For boiler and
tank combinations please install only the
feasible combinations listed in the Price List.
These are simplified conceptual drawings only!
Piping and necessary componentry must be field
verified.
Proper installation and functionality in the field is
the responsibility of the heating contractor.
Without mixing valve
e.g. with Vitotroni 100
The installation of the he k valve to restri t
gravity ir ulation in the heating supply pipe
prevents un ontrolled heat flow to the heating
system by gravity during priority swit hing of
domesti hot water heating or during summer
operation.
Heating ir uit
Spring-loaded flow he k valve
Cir ulation pump
Safety header
with automati air vent,
pressure relief valve, and
pressure gage
Expansion tank
Domesti hot water storage tank
(indire t-fired)
DHW pump module
Bypass pipe (highly re ommended)
/w two regulating valves (V
1
, V
2
)
See Installation Instru tions for details.
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IMPORTANT
V
1
V
2
V
1
V
2

Installation Examples
11
With 3-way mixing valve to regulate heating circuit
e.g. with Vitotroni 200, KW2 ombined with a mixing valve a tuator a essory kit
Heating ir uit
Spring-loaded flow he k valve
Cir ulation pump
Safety header
with automati air vent,
pressure relief valve, and
pressure gage
Expansion tank
Domesti hot water storage tank
(indire t-fired)
3-way mixing valve
Bypass pipe (highly re ommended)
/w two regulating valves (V
1
, V
2
)
See Installation Instru tions for details.
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V
1
V
2
V
1
V
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Viessmann Manufa turing Company In .
750 M Murray Road
Waterloo, Ontario •N2V 2G5 •Canada
Tel. [phone] •Fax [phone]
www.viessmann. a •mail@viessmann. a
Viessmann Manufa turing Company (U.S.) In .
45 A ess Road
Warwi k, Rhode Island •02886 •USA
Tel. [phone] •Fax [phone]
www.viessmann-us. om •mail@viessmann-us. om
Installation Examples
12
With 4-way mixing valve to regulate heating circuit
e.g. with Vitotroni 200, KW2 ombined with a mixing valve a tuator a essory kit
Heating ir uit
Spring-loaded flow he k valve
Cir ulation pump
Safety header
with automati air vent,
pressure relief valve, and
pressure gage
Expansion tank
4-way mixing valve
Domesti hot water tank
(indire t-fired)
Bypass pipe with flow regulating
valve, for systems with large water
ontent (>1 USG/13 000 Btu/h / 15
ltr/kW/h of boiler input).
See Installation Instru tions for details.
Underfloor heating system with system separation
Underfloor heating ir uit
Spring-loaded flow he k valve
Cir ulation pump for underfloor
heating ir uit
Safety header
with automati air vent,
pressure relief valve, and
pressure gage
Expansion tank
3-way mixing valve
Cir ulation pump for heat ex hanger
Heat ex hanger
Supply temperature sensor
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Printed on environmentally friendly
(re y led and re y lable) paper.
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