Viessmann VITOGAS 100 Instruction manual

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Cast iron hot water heating boiler
300 to 380 MBH/88 to 111 kW
Vitogas 100
GS10 Series – commercial, assembled cast iron block
with separate enclosure panels
Natural Gas-/Propane-Fired, wo-Stage Boiler
cast iron sectional construction
with atmospheric, fully premi burner
Heating input: 300 to 380 MBH
88 to 111 kW
Technical Data Manual
Model Nos. and pricing: see Price List
5167 466 v1.3 02/2011

Product Information
2VITOGAS 100, GS10
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With a rated input of 300 to 380 MBH/
88 to 111 kW, the Vitogas 100 makes a
grand entry into the heating technology
industry.
The new Vitotronic control generation,
minimum noise levels and economical
operation, make the Vitogas 100, GS10 the
choice for single- as well as multiple-boiler
applications.
he benefits at a glance:
HHigh operational reliability and a long
service life due to special high-grade gray
cast iron with lamellar graphite and a low
thermal load on the heat e changer
surface.
HClean combustion due to atmospheric
premi burner with super-stoichiometric
premi ing: NO < 27.9 ppm (air-free),
CO < 9.2 ppm (air-free). The Vitogas 100
therefore satisfies the requirements of the
German environmental emblem “Blue
Angel”, Swiss Clean Air Regulations and
California Regulations.
HEconomical and environmentally friendly
operation via modulating boiler water
temperatures.
Combustion efficiency of up to 85.6%.
HEven during partial-load operation, the entire
combustion chamber is used allowing for
balanced usage of burner and boiler.
HIntermittent pilot ignition system provides
soft, quiet and extremely reliable ignition.
Heat exchanger surfaces of special
high-grade gray cast iron for high
operational reliability and a long
service life
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Product Information
Cross-Section
Product may not be e actly as illustrated.
VITOGAS 100, GS10 3
Extremely effective insulation
Heat exchanger surface Vitotronic 300 –
of high-grade gray cast iron the new control generation:
with lamellar graphite Intelligent, easy to install, operate
and service
Stainless steel
atmospheric premix
burners for low emission
combustion
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Technical Data
4VITOGAS 100, GS10
echnical Data
Boiler Model Model No. GS10-72 GS10-84 GS10-96
CSA input full load
partial load
MBH
kW
MBH
kW
300
88
210
62
340
100
238
70
380
111
266
78
CSA output full load
partial load
MBH
kW
MBH
kW
257
75
180
53
291
85
204
60
325
95
228
67
Net I=B=R rating*1 MBH
kW
224
66
253
74
283
83
Heat exchanger surface area ft.2
m2
67
6.23
78
7.25
89
8.26
Max. operating pressure psig
bar
60
4
60
4
60
4
Min. gas supply pressure
Natural Gas
Liquid Propane
”w.c.
”w.c.
7
11
7
11
7
11
Max. gas supply pressure*2 ”w.c. 14 14 14
Combustion efficiency % 85.6 85.6 85.6
Dimensions boiler shell
Length boiler shell*3
as delivered
Overall length
Overall width
Overall height
– with Vitotronic 100,
200 or 300
inches
mm
inches
mm
inches
mm
inches
mm
inches
mm
36
912
37
1007
40
1010
43
1088
48
1227
36
912
37
1007
44
1120
43
1088
48
1227
36
912
42
1057
48
1220
43
1088
48
1227
Dimensions of cast iron
sections
Side section W × H × T*4
Mid section W× H × T
inches
mm
inches
mm
22 29 4.7
557 × 734 ×120
22 23 4.1
557 × 585 ×105
Number of cast iron sections 7 8 9
Number of burner tubes 6 7 8
Weight boiler shell lbs
(as delivered incl. burner) kg
Overall weight lbs
(boiler with insul., burner, kg
boiler control, install. fittings and draft hood)
714
324
927
420
805
365
1036
470
895
406
1194
542
Boiler water content USG
ltr
9.9
37.6
11.4
43.0
12.8
48.3
Boiler connections
Boiler supply and return
Safety supply
Drain valve
Ø” (NPTM) 2
Ø” (straight male thread) 1½
Ø” (NPTM) 1
2
1½
1
2
1½
1
*1Net I=B=R rating based on piping and pick-up allowance of 1.15.
*2If 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.
*3In case of difficulties w en transporting or installing, boiler supply and return pipes can be removed temporarily, reducing t e lengt of
t e boiler s ell to 27.5 inc es/700 mm.
*4W=widt , H= eig t, T=t ickness
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Technical Data
VITOGAS 100, GS10 5
echnical Data (continued)
Safety header pressure relief
valve connection
Ø” (NPTF) ¾ ¾ ¾
Gas supply connection Ø” (NPTM) ¾ ¾ ¾
Flue gas (NG)*5
Temperature (at boiler water
supply temp. of 180 ºF/82 ºC)
– at rated full load
– at rated partial load
Mass flow rates
– full load
– partial load
ºF
ºC
ºF
ºC
lbs/h
lbs/h
237
114
195
90
375
328
226
108
196
91
411
364
231
111
201
94
498
430
Vent pipe collar nominal ∅inches 8 9 10
Combustion and dilution air (appro . CFM) 100 115 125
Standby losses %
at boiler water temperature of 140 ºF/60 ºC
0.72 0.69 0.67
*5Measured flue gas temperature after dilution air wit combustion air temperature of 68 °F/20 °C.
Partial load values are based on an input of 70% of t e rated full load input.
"For information regarding ot er Viessmann System Tec nology componentry, please reference documentation of respective product.
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Technical Data
Legend
BD Boiler Drain
BR Boiler Return
BS Boiler Supply
DH Draft Hood
GC Gas Connection
SS Safety Supply
6.53”/166 mm
30”/767 mm
41”/104.2 mm
Overall height
Overall width 30”/770 mm
57”/1442 mm
Height with flue gas pipe elbow
37.6”/957 mm
Overall length
Flue gas pipe elbow
6.5”/165 mm
18.2”/462 mm
29”/749 mm
ba
DH
SS
BS
GC
BR
BD
12.4”/316 mm
VITOGAS 100
VIEßMANN
48”/1220 mm
3
2
2.9”/74 mm
11.3”/282 mm
6VITOGAS 100, GS10
Dimensions
Boiler shell (delivered as cast iron block)
*1For ease of transportation and/or installation,
boiler supply and return pipes can be
removed temporarily, reducing t e lengt of
t e boiler s ell to 27.5 inc es/700 mm.
Dimensions
Boiler Model Model No. GS10-72 GS10-84 GS10-96
a inches/mm 37/950 42/1060 46/1160
Hot water heating boiler with insulation and boiler control
Dimensions
Boiler Model Model No. GS10-72 GS10-84 GS10-96
a
b
inches/mm
inches/mm
19/484
21/526
21/542
23/578
23/589
25/631
*2Control in operating position
*3Control in service position
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27.5”/700 mm
a
32.4”/823 mm
36”/912 mm
1

Technical Data
VITOGAS 100, GS10 7
Recommended Minimum Service Clearances Minimum Clearances to Combustibles
Top
panel
Front
panel
Rear
panel
Left
panel
Right
panel
Floor Flue
6 6 AL,
CL
600 Combustible 2” CT
0” CI
AL = Alcove
CL = Closet
CT = Single-wall stainless steel vent
CI = Double-wall insulated stainless steel vent
Diagram is not to scale.
Waterside Flow (primary circuit)
The Vitogas 100 is designed only for closed loop, forced circulation
hot water heating systems.
ypical flow rates
Model GS10- 72 84 96
Btu/h output 257 000 291 000 325 000
20 ºF rise (GPM) 25.7 29.1 32.5
30 ºF rise (GPM) 17.1 19.4 21.7
Use standard friction loss met od for pipe sizing.
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min.
9.8”/250 mm
min.
9.8”/250 mm
min. 33.5”/850 mm
min 18”/
450 mm
top min.
24”/ 600 mm
Water flow
200
Pressure drop
80
60
50
100
40
30
20
10
8
6
5
4
3
2
1
1000 2000 3000 4000 5000 6000 8000
10000 20000
4.4
9
13 18
22 26 35 44 88
0.4
0.8
1.2
1.6
2.0
2.4
3.2
4
8
12
16
20
24
32
40
80
ltr/h
GPM
“ w.c. mbar

Standard and Optional Equipment/
Boiler Control Alternatives
8VITOGAS 100, GS10
Standard Equipment Optional Equipment
Note:
Boiler controls and burners are purc ased
separately. Please see Price List for details.
Vitogas 100, GS10 boilers are shipped
unassembled with the boiler enclosure
panels, insulation, draft hood, and control
packaged separately from the sectional cast
iron block.
Standard shipment is composed of:
1 skid with cast iron block and prewired
gas train
1 carton with draft hood and vent pipe
adaptor
1 carton with insulation blankets and panels
1 carton with safety header
1 carton with boiler installation fittings
(c/w 30 psig pressure relief valve)
1 carton containing either a stainless steel
vent damper or a Tjernlund power venter
(please specify at time of order).
Boiler Control Alternatives
Vitotronic 100, KK10
standard boiler control for high temperature
heating systems
Vitotronic 100, KW10
standard boiler control for high temperature
heating systems with indoor/outdoor system
control
Vitotronic 100, KW10A / KW10B
standard boiler control for high temperature
heating systems with indoor/outdoor system
control
With or without DHW
Vitotronic 200, KW2
for multiple temperature heating systems
with or without a mi ing valve,
with indoor/outdoor digital boiler and
heating system control
Vitotronic 300, KW3
for multiple temperature heating systems
with up to two mi ing valves,
with indoor/outdoor digital boiler and
heating system control
For multiple-boiler installations:
Multimatik
for multiple-boiler installations. The
Multimatik digital heating system control
acts as the master control and
communicates digitally with the base
control on each Vitogas 100, GS10 boiler.
The Multimatik can control up to 6
single-stage boilers or 3 two-stage boilers.
A wide range of sophisticated standard and
optional features makes the Multimatik a
suitable solution for almost any demanding
application. For assistance in selecting the
appropriate Multimatik control, please
contact your regional Viessmann Sales
Representative.
Custom control panels
In addition, custom control panels for
residential or commercial applications are
designed and manufactured by Viessmann
to suit any customer’s specific
requirements. Both Multimatik and custom
control panels can have features such as
pool heating, hot tub heating, snow melting,
telephone tie-in and/or several other
functions. Please inquire.
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Installation E amples
VITOGAS 100, GS10 9
Installation Examples
hese examples depict possible piping
layouts for Viessmann product equipped
with Viessmann System echnology. For
boiler and tank combinations, please install
only the feasible combinations listed in the
Price List.
hese 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.
Single-stage operation can only occur when
the boiler water temperature is above the
minimum temperature and a demand for
heat is present. When the water
temperature is above the minimum, the
boiler control will determine full input
operation or partial load operation based on
the demand for heat. Refer to boiler control
instructions.
Install LWCO where required by local codes.
IMPOR AN
Vitotronic boiler controls are factory
set for single-stage operation. he
Vitogas 100, GS10 boiler control must
be programmed on-site for two-stage
operation.
Without mixing valve
e.g. with Vitotronic 100
The installation of a flow check valve in the
heating supply pipe prevents uncontrolled
heat flow to the heating system by gravity
during priority switching of domestic hot
water heating or during summer operation.
Heating circuit
Spring-loaded flow check valve
Circulation pump
Safety header
with automatic air vent,
pressure relief valve, and
pressure gage
E pansion tank
Domestic hot water storage tank
(indirect-fired)
DHW pump module
Bypass pipe (highly recommended)
c/w two regulating valves (V1, V2).
See Installation Instructions for
details.
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IMPOR AN
V1
V1
V2
V2

Installation E amples
10 VITOGAS 100, GS10
Installation Examples (continued)
With 4-way mixing valve for heating circuit control
e.g. with Vitotronic 200, KW2 and mi ing valve actuator accessory kit
Heating circuit
Spring-loaded flow check valve
Circuit pump
Safety header with air vent, pressure
relief valve and pressure gage
E pansion tank
Vitocell-V or -H DHW storage tank
(indirect-fired)
Drain valve
4-Way mi ing valve
I
Bypass pipe with flow regulating valve,
for systems with large water content
(>1 USG/13 000 Btu/h / 15 ltr/kW/h of
boiler input).
See Installation Instructions for details.
Underfloor heating with system isolation
Underfloor heating circuit
Spring-loaded flow check valve
Circuit pump for underfloor heating
Safety header with air vent, pressure
relief valve and pressure gage
E pansion tank
3-Way mi ing valve
Circuit pump for heat e changer
Heat e changer
Supply temperature sensor
Drain valve
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I

Installation E amples
VITOGAS 100, GS10 11
Installation Examples (continued)
With return sensor and bypass pump
for single- and multiple-boiler applications with large water content,
and controlled space heating system via mi ing valve(s)
Bypass pump activates if return temperature drops below minimum boiler temperature.
Mi ing valve(s) will close if return temperature drops lower.
Boiler
Spring-loaded flow check valve
Circuit pump
Shunt pump
Motorized isolation valve
Drain valve
Vitotronic 100 boiler control
Supply temperature sensor
Multimatik-D
Supply distribution header
Return distribution header
Vitocell-V or -H DHW storage tank
(indirect-fired)
T1 Temperature sensor (low limit)
for priority switching of the heating
circuit; switching point 104°F/40°C
T2 Return temperature aquastat for pump
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Installation E amples
12 VITOGAS 100, GS10
Installation Examples (continued)
Distribution header with bypass and return temperature sensor
for single- and multiple-boiler applications with large water content,
and controlled space heating system via mi ing valve(s)
Mi ing valve(s) will close if return temperature falls below minimum boiler temperature.
Boiler
Spring-loaded flow check valve
Circuit pump
Distribution header pump
Motorized isolation valve
Vitotronic 100 boiler control
Supply temperature sensor
Multimatik-D
Supply distribution header
Return distribution header
Vitocell-V or -H DHW storage tank
(indirect-fired)
Drain valve
T1 Temperature sensor (low limit)
for priority switching of the heating
circuit; switching point 104°F/40°C
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System Design Considerations
VITOGAS 100, GS10 13
System Design Considerations
Boiler selection
The boiler model size must be based on an
accurate heat loss calculation of the
building. The boiler selected must be
compatible with connected radiation.
Venting
his boiler is a high efficiency unit. It
operates at an efficiency level which could
yield a condensing condition in the venting
system only. Care should be taken in
providing the proper venting and employing
the best principles of application and sizing.
his boiler is tested to the latest ANSI/CSA
Standard and approved and listed as a
Category II appliance.
A Category II boiler operates with a
non-positive vent static pressure and with a
flue loss of less than 17%.
This type of venting uses natural buoyancy
of the heated flue products to generate a
negative draft in the flue gas pipe.
The Vitogas 100, GS10 boiler requires
special venting. Vent material for a
Category II vent may be purchased locally.
Contact the manufacturer of the vent
material if there is a question about the
suitability of vent material for application on
a Category II vent system.
The vent material must be a Category II
single-wall vent pipe or a Category II
insulated vent pipe. Vent material must be
listed by a nationally recognized testing
agency.
Suitable as vent pipe material (vent pipe or
fle ible chimney liner) is stainless steel of
316L or AL-29-4C grade. Never install a
type A, B, C or L vent with this boiler when
vented vertically. The chimney must be
designed to be water-tight.
See vent connection illustration (Fig. 1) and
contact information for manufacturers of
suitable Category II vent materials.
Intermediate section
The intermediate section of venting
between the boiler vent pipe collar and the
chimney must be of identical diameter as
the vent connection of the boiler. Use the
shortest possible path between the boiler
and the chimney. A ma imum of two
elbows may be installed in the intermediate
section. Avoid the use of two level 90°
elbows.
The intermediate section must be sealed
gas-tight at the boiler vent pipe collar and at
the chimney connection. Ensure any test
port for combustion values is sealed as well.
The chimney connection length between the
boiler vent pipe collar and the chimney must
be installed with insulation. We recommend
consulting a reputable chimney installer for
advice in project-specific circumstances.
Recommended manufacturers of
Category II vent material
CHEMINEE LINING.E inc.
8195, Champ d’Eau
St-Léonard, PQ H1P 1Y1
Tel.: [phone]
Fa : [phone]
e-mail: [email protected]m
www.chemineelining.com
Flexmaster Canada Ltd.*
Head Office
20 West Pearce Street
Richmond Hill, ON L4B 1E3
Tel.: [phone]
Fa : [phone]
www.fle master.com
Security Chimneys
International Ltd.*
2125 Monterey
Laval, PQ H7L 3T6
Tel.: [phone]
Fa : [phone]
Selkirk Canada
1400 California Ave.
Brockville, ON K6V 5V3
Toll free: 1-800-267-8178
Fa : [phone]
www.selkirkinc.com
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IMPOR AN
Boiler vent pipe
adaptor (supplied)
90º elbow
ee
Drain tee cap
Horizontal distance must
be as short as possible.
*1 *1
Fig. 1
Recommended venting connection for all Vitogas 100, GS10 installations

System Design Considerations
14 VITOGAS 100, GS10
System Design Considerations (continued)
Recommended manufacturers of
Category II vent material (continued)
Heat-Fab Inc.
130 Industrial Blvd.
Turners Falls, MA 01376
Toll free: 1-800-772-0739
Fa : [phone]
www.heat-fab.com
Metal-Fab, Inc.
P.O. Bo 1138
Wichita, KS 67201-1138
Tel.: [phone]
Fa : [phone]
www.mtlfab.com
Pro ech Systems, Inc.
26 Gansevoort Street
Albany, NY 12202
Tel.: [phone]
Fa : [phone]
Toll free: 1-800-766-3473
e-mail: [email protected]
www.protechinfo.com
he Schebler Co.
Hwy. 67 & Fenno Road
P.O. Bo 1008
Bettendorf, IA 52722
Tel.: [phone]
Fa : [phone]
www.schebler.com
* Stainless steel 316L vent material from
Security C imneys and Flexmaster is
approved by CSA to be used on
Vitogas 100, GS10 Series boilers wit out
UL stickers.
Flexible liner venting option:
The Vitogas 100, GS10 boiler is CSA
approved to be vented using chimney liner
supplied by Fle master Canada Ltd. only.
Follow the installation instructions supplied
by Fle master.
Flexible liner venting option
(continued):
Contact Fle master concerning any
questions regarding the fle ible liner vent
system at:
Flexmaster Canada Ltd.
Head Office
20 West Pearce Street
Richmond Hill, ON L4B 1E3
Tel.: [phone]
Fa : [phone]
www.fle master.com
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Rain cap
Flashing, 316L
Flex liner, 316 i
Base tee, 316L
op support,
316L
Universal
connector
Vent connector, 316 i
flex inner high tempera-
ture blanket with 2-ply
aluminum outer jacket
Appliance
connector
Fig. 1
Flexible liner venting connections
for all Vitogas 100, GS10 boilers
Drain
*1
*1 Horizontal distance of vent
connector must be as short
as possible.
Vent connector should
have a 3º downwards slope
toward the chimney liner
for proper condensate
collection at the base tee.

System Design Considerations
VITOGAS 100, GS10 15
System Design Considerations (continued)
Side wall vent system
A side wall power vent system (optional)
can be ordered from Viessmann. This
package includes the appropriate power
venter, vent terminal, and adaptor fittings
for each Vitogas 100, GS10 boiler model,
as well as the installation instructions.
The vent system must terminate so that
proper clearances are maintained as cited in
the National Fuel Gas Code, ANSI Z223.1
and as detailed in the Side Wall Vent
System Installation Instructions. Observe
and follow these instructions carefully.
Warranty
Our warranty does not cover damages
resulting from the following:
- Corrosion caused by flue gas condensation
-due to low boiler water and/or return water
-temperatures
-Operation with contaminated fill and
-supplementary feed water
Combustion air supply
The boiler must not be located in areas or
rooms where chemicals containing chlorine,
bromine, fluorine, or other corrosive
chemicals are stored. E amples include
refrigerants, bleach, paint, paint thinner, hair
spray, cleaning solvents, water softener
salt, etc. The combustion air must not be
contaminated with any amount of the above
mentioned chemicals.
Boiler should never be installed in areas
where e cessive dust, high humidity, or risk
of frost e ist. Ensure adequate ventilation
and supply of fresh combustion air.
Consult Viessmann if uncertainties e ist in
regard to a suitable boiler installation
location.
This boiler/burner unit needs clean fresh air
for safe operation and must be installed so
that there are provisions for adequate
combustion 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 local codes.
The sizing methods outlined in the above
codes should be used when installing a
round duct to supply combustion air from
the outside.
System layout
The boiler water temperature limit is factory
set to 167°F/75°C.
The boiler water temperature limit can be
increased by altering the adjustable high
limit to increase the supply water
temperature.
To minimize piping losses of the system,
however, we recommend that the radiation
and domestic hot water production in the
system be designed for a 158°F/70°C
boiler supply water temperature.
Water quality
Treatment for boiler feed water should be
considered in areas of known problems,
such as where a high mineral content and
hardness e ist. 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 mi ture
may require a backflow preventer within the
automatic water feed and influence
components such as diaphragm e pansion
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. The system may contain
components which might be negatively
affected by antifreeze. Check total system
frequently when filled with antifreeze.
Oxygen diffusion barrier
underfloor tubing
The boiler warranty does not cover leaks
resulting from corrosion caused by the use
of underfloor plastic tubing without an
o ygen diffusion barrier. Such systems must
have the non-o ygen-diffusion barrier tubing
separated from the boiler with a heat
e changer. Viessmann recommends the use
of underfloor plastic tubing with an o ygen
diffusion barrier.
Low water cut-off
A low water cut-off may be required by
local codes. If boiler is installed above the
radiation level, a low water cut-off device of
approved type must be installed in all
instances. An approved type low water
cut-off device must be provided by the
heating contractor. Do not install an
isolation valve between the boiler and the
low water cut-off.
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When the side wall vent system
(optional) is used, the vent damper
(optional) MUS NO be installed.
WARNING

Viessmann Manufacturing Company Inc.
750 McMurray Road
Waterloo, Ontario •N2V 2G5 •Canada
Tel. [phone] •Fa [phone]
www.viessmann.ca •[e-mail]
Viessmann Manufacturing Company (U.S.) Inc.
45 Access Road
Warwick, Rhode Island •02886 •USA
Tel. [phone] •Fa [phone]
www.viessmann-us.com •[e-mail]
16 VITOGAS 100, GS10
Technical information subject to change without notice. Printed on environmentally friendly
(recycled and recyclable) paper.
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