Viessmann VITOGAS 100 Operating instructions

VIESMANN
Service instructions
for heating engineers
Vitogas 100
Type GS1B
Rated output 11 to 60 kW
Gas fired boiler
Natural gas and LPG version
For applicability, see the last page
VITOGAS 100
5692 632 GB 10/2005 Please keep safe

Please follow these safety instructions closely to prevent accidents and
material losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and
environmental pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
&Work on gas equipment must only
be carried out by a qualified gas fit-
ter.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
&The system must be commissioned
by the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&the Code of Practice of relevant
trade associations,
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances ON or OFF.
&Close the gas shut‐off valve.
&Open windows and doors.
&Remove all people from the
danger zone.
&Notify your gas or electricity
supplier from outside the
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life‐threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close all doors leading to the
living space.
Safety instructions
2
Safety instructions
5692 632 GB

Working on the system
&When using gas as fuel, also close
the main gas shut‐off valve and
safeguard against unauthorised
reopening.
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a mains isola-
tor.
&Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electro‐static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which
fulfil a safety function can com-
promise the safe operation of
your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function. Instal-
ling non‐authorised compo-
nents and non‐approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 632 GB

Initial start-up, inspection, maintenance
Steps –initial start-up, inspection and maintenance .................................... 5
Further details regarding the individual steps .............................................. 6
Troubleshooting
Diagnostic system ...................................................................................... 18
Ignition system
Time chart and function............................................................................... 20
Designs
Burner control connection diagram.............................................................. 22
Draining/frost protection .......................................................................... 23
Parts lists .................................................................................................. 24
Commissioning/service reports ............................................................... 28
Specification............................................................................................. 29
Certificates
Declaration of conformity ............................................................................ 31
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 31
Keyword index .......................................................................................... 33
Index
4
Index
5692 632 GB

For further information regarding individual steps, see the pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
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••• 01. Preparing for commissioning .......................................... 6
••• 02. Checking the gas type......................................................... 6
••• 03. Changing the gas type (if required)................................ 7
••• 04. Checking the static and supply pressure .................... 7
••• 05. Checking the nozzle pressure.......................................... 9
••• 06. Checking the ionisation current ..................................... 11
••• 07. Checking the draught .......................................................... 12
• • 08. Burner removal ...................................................................... 12
• • 09. Checking the burner tubes ................................................ 13
• • 10. Checking the pilot burner .................................................. 13
•11. Cleaning the heating surfaces (if required)................. 14
• • 12. Burner installation................................................................ 15
••• 13. Checking all hydraulic connections for leaks
••• 14. Checking all safety equipment
••• 15. Checking the tightness of electrical connections
••• 16. Checking the external LPG safety valve (if
installed)
••• 17. Starting the heating system
••• 18. Checking all gas equipment for soundness at
operating pressure............................................................... 15
••• 19. Checking the closing function of the gas
combination valves
••• 20. Determining the flue gas values...................................... 16
••• 21. Checking the flue gas monitor ......................................... 16
•22. Instructing the system user .............................................. 17
Steps –initial start-up, inspection and maintenance
5
Initial start-up, inspection, maintenance
5692 632 GB

Preparing for commissioning
1. Check that the boiler room ventila-
tion aperture is open.
2. Check the inlet pressure of the dia-
phragm expansion vessel.
If the inlet pressure of the dia-
phragm expansion vessel is lower
than the static system pressure,
top up with sufficient nitrogen to
raise the inlet pressure above (0.1
to 0.2 bar) the static system pres-
sure.
3. Open any installed check valves.
4. Fill the heating system with water
and vent it, until the pressure indi-
cated at pressure gauge Ais
higher (0.1 to 0.2 bar) than the inlet
pressure of the diaphragm expan-
sion vessel.
Minimum system pressure 0.8 bar,
permiss. operating pressure 3 bar.
5. Return the check valves to their
operating position.
Checking the gas type
Note
In the delivered condition, the boiler is set up for natural gas E and can be oper-
ated in the Wobbe index range 12.0 to 16.1 kWh/m
3
(43.2 to 58.0 MJ/m
3
).
1. Check the gas category and
Wobbe index (Wo) with your mains
gas or LPG supplier and compare
them with the details on the burner
label.
2. Convert the burner in accordance
with to the details provided by the
mains gas or LPG supplier to
match the fuel provided, if these
details diverge.
Conversion kit installation
instructions
Further details regarding the individual steps
6
Initial start-up, inspection, maintenance
5692 632 GB

3. Record the gas type in the service
report from page 28.
Wobbe index
range Wo
Natural gas E Natural gas LL LPG P
kWh/m
3
12.0 to 16.1 10.0 to 13.1 21.4 to 22.5
MJ/m
3
43.2 to 58.0 36.0 to 47.2 76.9 to 81.0
Changing the gas type (if required)
Conversion kit installation
instructions
Checking the static and supply pressure
Danger
CO build‐up as a result of an incorrect burner setup can have serious
health implications.
Carry out a CO test prior to, and after, work on gas equipment.
Operation with LPG
Flush the LPG tank twice during commissioning/replacement. Thoroughly vent
the tank and gas lines after flushing.
ATest connector
Further details regarding the individual steps (cont.)
7
Initial start-up, inspection, maintenance
5692 632 GB

1. Close the gas shut‐off valve.
2. Release the screw inside test
connector Aon the gas combi-
nation valve, but do not remove it;
then connect the pressure gauge.
3. Open the gas shut‐off valve.
4. Check the static pressure:
&Natural gas: max. 25 mbar
&LPG: max. 57.5 mbar
Record the actual value in the
service report.
5. Start the boiler.
Note
During commissioning, the boiler
can enter a fault state because of
airlocks in the gas pipe. You can
reset the burner after approx.
10 seconds. For this, switch the
boiler OFF and ON at the control
unit (ON/OFF switch).
6. Check the supply (flow) pressure:
&Natural gas: 17.4 to 25 mbar
&LPG: 42.5 to 57.5 mbar
Record the actual value in the
service report.
Note
Use suitable test equipment with
a resolution of at least 0.1 mbar to
test the supply pressure.
7. Take the action shown in the fol-
lowing table.
Supply (flow)
pressure for nat-
ural gas
Supply (flow)
pressure for
LPG
Measures
below 17.4 mbar below 42.5 mbar Do not start the boiler. Notify your
mains gas or LPG supplier.
17.4 to 25 mbar 42.5 to 57.5 mbar Start the boiler.
in excess of
25 mbar
in excess of
57.5 mbar
Install a separate gas governor down-
stream of the system and regulate the
pressure to 20 mbar for natural gas or
50 mbar for LPG. Notify your mains
gas or LPG supplier.
8. Switch OFF the control unit ON/
OFF switch (the boiler shuts
down).
9. Close the gas shut‐off valve.
10. Remove the pressure gauge and
seal test connector Awith the
screw previously undone.
Further details regarding the individual steps (cont.)
8
Initial start-up, inspection, maintenance
5692 632 GB

11. Open the gas shut‐off valve and
check test connector Afor
soundness.
Danger
Gas escaping from test
connector Aleads to a
risk of explosion.
Check test connector A
for soundness.
Checking the nozzle pressure
1. Close the gas shut‐off valve.
2. Release the screw in test connec-
tor A, but do not remove it, and
connect the pressure gauge.
3. Open the gas shut‐off valve.
Start the boiler.
4. Check the nozzle pressure.
In case of deviation from the
value in the table on page 11
remove protective cap B.
Adjust the nozzle pressure with
screw C.
5. Check the setting values and
record them in the service report.
6. Fit protective cap B.
Further details regarding the individual steps (cont.)
9
Initial start-up, inspection, maintenance
5692 632 GB

7. Switch OFF the control unit ON/
OFF switch (the boiler shuts
down).
8. Close the gas shut‐off valve.
9. Remove the pressure gauge and
seal test connector Awith the
screw previously undone.
10. Open the gas shut‐off valve, start
the boiler and check the sound-
ness of test connector A.
Danger
Gas escaping from test
connector Aleads to a
risk of explosion.
Check test connector A
for soundness.
Note
The values in the nozzle pressure table apply to the following ambient condi-
tions:
&Air pressure: 1013 mbar
&Temperature: 15 °C
Wobbe index see page 7.
Rated out-
put
kW 11 15 18 22 29 35 42 48 60
Natural gas
E
Nozzle pres-
sure at 20
mbar supply
pressure
mbar 14.1 14.0 13.9 14.5 14.4 14.0 14.8 14.2 15.0
Nozzle des-
ignation 2.00 2.35 2.10 2.30 2.30 2.30 2.25 2.25 2.25
Air restrictor 7mm 33 —34 ——————
Natural gas
LL
Nozzle pres-
sure at 20
mbar supply
pressure
mbar 14.1 13.9 14.1 13.7 13.8 14.0 14.2 13.7 13.5
Nozzle des-
ignation 2.25 2.60 2.30 2.55 2.55 2.55 2.50 2.50 2.50
Air restrictor 7mm 33 35 32 37 37 37 37 37 37
Further details regarding the individual steps (cont.)
10
Initial start-up, inspection, maintenance
5692 632 GB

Rated out-
put
kW 11 15 18 22 29 35 42 48 60
LPG
Nozzle pres-
sure at 50
mbar supply
pressure
mbar 36.0 36.5 35.3 35.3 35.0 35.0 35.0 35.5 36.2
Nozzle des-
ignation 1.25 1.45 1.35 1.45 1.45 1.45 1.45 1.40 1.40
Air restrictor 7mm 33 37 35 ——————
Number of burner
tubes
223345679
Checking the ionisation current
FBurner control unit
1. For testing, insert and secure test
lead no.1 into Testomatik‐Gas.
2. Pull off ionisation lead Afrom ioni-
sation electrode B.
3. Push plug‐in adaptor Cinto ioni-
sation lead A.
4. Push test cable plug Dinto plug‐in
adaptor C.
5. Push adaptor cable Eonto ionisa-
tion electrode B.
6. Push adaptor cable Eonto test
cable socket D.
7. Start the boiler.
8. Checking the ionisation current
&When the pilot burner is lit:
&min. 1.5 µA
&When the main burner is lit:
&min. 5 µA
9. Record the actual values in the ser-
vice report from page 28.
Further details regarding the individual steps (cont.)
11
Initial start-up, inspection, maintenance
5692 632 GB

Checking the draught
Check the draught behind the draught hood in Pa (100 Pa = 1 mbar) and record
it in the service report from page 28.
Note
Required boiler draught: 3 Pa (0.03 mbar).
The chimney draught must not be greater than 10 Pa (0.1 mbar). Install a
draught stabiliser (agree details with your local flue gas inspector) inside the
chimney, if required.
Burner removal
1. Pull the plug‐in connector off burn-
er control unit A.
2. Pull earth cable Bfrom the gas
combination valve.
3. Release the fitting Con the gas
supply pipe.
4. Release nuts Dand carefully pull
the burner out through the front.
Further details regarding the individual steps (cont.)
12
Initial start-up, inspection, maintenance
5692 632 GB

Checking the burner tubes
1. Check the gas outlets for damage. 2. Blow through burner tubes with
compressed air or rinse with a
soapy solution.
Checking the pilot burner
1. Check ionisation electrode A,
pilot burner Band ignition elec-
trode Cfor damage.
2. Check the electrode gaps.
Further details regarding the individual steps (cont.)
13
Initial start-up, inspection, maintenance
5692 632 GB

Note
Both pilot burners shown may be
installed in Vitogas 100, type GS1B.
Cleaning the heating surfaces (if required)
Further details regarding the individual steps (cont.)
14
Initial start-up, inspection, maintenance
5692 632 GB

1. Release self‐tapping screws A
and remove top panel B.
2. Release the tension springs and
remove thermal insulation mat C.
3. Remove front cover Etogether
with the control unit and hook into
the front.
4. Undo clean‐out cover D.
5. Clean the heating surfaces of the
boiler (with the burner removed)
with the cleaning brushes supplied.
!Please note
Cleaning agents containing
potassium destroy the heat-
ing surfaces.
Only use potassium‐free
cleaning agents.
6. Remove residues from the bottom
plate.
7. Install in reverse order.
Burner installation
Use new gaskets when refitting the
burner.
Checking all gas equipment for soundness at operating pres-
sure
Danger
Escaping gas can lead to
explosions.
Check the soundness of all
joints of gas pipes and fittings
at operating pressure with a
foaming test agent (leak test
spray).
Further details regarding the individual steps (cont.)
15
Initial start-up, inspection, maintenance
5692 632 GB

Determining the flue gas values
Danger
CO build‐up as a result of an
incorrect burner setup can
have serious health implica-
tions.
Carry out a CO test prior to,
and after, work on gas equip-
ment.
Determine the flue gas values and
record them in the service report on
page 28.
Checking the flue gas monitor
ASensor
1. Shut down the heating system.
2. Pull the flue pipe from the draught
hood.
3. To carry out the function test cover
the flue outlet at the draught hood.
4. Start the system.
5. The flue gas monitor must shut
down the burner within 2 minutes.
The burner will then be locked out
for approx. 17 minutes.
6. &Check the position of sensor A,
if the flue gas monitor shuts down
the burner later than after 2 min-
utes.
&Replace the sensor or the burner
control unit, if any of the following
faults occur:
––The flue gas monitor does not
switch off
––The burner does not start
––The sensor is corroded
7. Shut down the heating system.
Further details regarding the individual steps (cont.)
16
Initial start-up, inspection, maintenance
5692 632 GB

8. Remove the cover, and push the
flue pipe onto the draught hood.
9. Start the system.
Instructing the system user
The system installer must hand the operating instructions to the system user
and instruct him/her in the operation of the system.
Further details regarding the individual steps (cont.)
17
Initial start-up, inspection, maintenance
5692 632 GB

System char-
acteristics
Cause Measures
The boiler will
not start
No voltage Check the fuse and the connections of
the power supply cable.
Check the control unit ON/OFF switch.
Excessive boiler
water temperature
Wait until the boiler water temperature
has dropped by approx. 20 K (scan
the boiler water temperature with "c",
see control unit service instructions).
High limit safety cut‐
out activated
Press the reset button on the control
unit.
Check the setting and the function of
the thermostat (see control unit ser-
vice instructions).
The flue gas monitor
has responded (if in-
stalled)
Wait approx. 17 min;
if the boiler then starts automatically,
check the flue pipe and the chimney.
If the boiler does not start automati-
cally, check the flue gas monitor (see
page 16).
Strapping plug aNS is
missing at the burner
control unit
Fit strapping plug aNS or a flue gas
monitoring sensor.
Strapping plug aYA is
missing at the burner
control unit
Fit strapping plug aYA.
Burner control
unit enters a
fault state
No gas available (air
in the supply line)
Reset by switching the main ON/OFF
switch on the control unit ON and OFF.
If required, repeat the reset (vent the
gas supply pipe).
The pilot burner will
not light
Check the ignition electrode (see
page 13).
Check the gas supply.
Power supply incor-
rectly connected
Interchange cores "L1" and "N" of the
power supply cable.
Ionisation current too
low or lead broken
Check the ionisation current (minimum
value 5 µA with the main burner oper-
ating)(see page 11).
Remove the pilot burner and check for
damage (see page 13).
Check the polarity of the power supply
cable.
Diagnostic system
18
Troubleshooting
5692 632 GB

Control unit faults: Service instructions boiler con-
trol unit
Diagnostic system (cont.)
19
Troubleshooting
5692 632 GB

Time chart
1Standard operation with heat
demand
2Pilot gas valve faulty
3Flue gas monitor interference
4No flame signal
AHeat demand
BPilot gas valve
CExternal LPG valve
DHV ignition
EFlame signal
FMain gas valve
GFlue gas monitor
HFault display
Tstab Pilot burner stabilising time
TFR Safety period, operation
TCSelf test time
TWDwell time
TTTB Shutdown duration, flue gas
monitoring
TSSafety period, burner start
Time chart and function
20
Ignition system
5692 632 GB