Viessmann VITOGAS 100 Operating instructions

VIESMANN
Service instructions
for heating engineers
Vitogas 100
Type GS1B
Rated output 72 to 144 kW
Gas fired boiler
Natural gas and LPG version
For applicability, see the last page
VITOGAS 100
5692 647 GB 1/2006 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 647 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 647 GB

Initial start-up, inspection, maintenance
Steps –initial start-up, inspection and maintenance .................................... 5
Further details regarding the individual steps .............................................. 6
Troubleshooting
Diagnostic system ...................................................................................... 21
Ignition system
Time chart and function............................................................................... 22
Designs
Connection diagrams –burner control unit .................................................. 24
Connection diagrams –burners 72 to 96 kW................................................ 25
Connection diagrams –burners 108 to 144 kW............................................ 26
Parts lists .................................................................................................. 27
Commissioning/service reports ............................................................... 32
Specification............................................................................................. 33
Certificates
Declaration of conformity ............................................................................ 34
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 34
Keyword index .......................................................................................... 36
Index
4
Index
5692 647 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......................................................... 7
••• 03. Changing the gas type (if required)................................ 7
••• 04. Checking the static and supply pressure .................... 8
••• 05. Checking the nozzle pressure.......................................... 10
••• 06. Determining the flue gas values...................................... 13
••• 07. Checking the ionisation current ..................................... 13
••• 08. Checking the draught .......................................................... 14
• • 09. Burner removal ...................................................................... 15
• • 10. Checking the burner tubes ................................................ 15
• • 11. Checking the pilot burner .................................................. 16
•12. Cleaning the heating surfaces (if required) ................ 17
• • 13. Burner installation................................................................ 18
••• 14. Checking all hydraulic connections for leaks
••• 15. Checking all safety equipment
••• 16. Checking the tightness of electrical connections
••• 17. Checking all gas equipment for soundness at
operating pressure............................................................... 18
••• 18. Checking the external LPG safety valve (if
installed)
••• 19. Starting the heating system
••• 20. Checking the closing function of the gas
combination valves
••• 21. Checking the flue gas monitor ......................................... 19
•22. Instructing the system user .............................................. 20
Steps –initial start-up, inspection and maintenance
5
Initial start-up, inspection, maintenance
5692 647 GB

Preparing for commissioning
Only for an initial start‐up with Vitotronic 300, type GW2
Check that the safety temperature limiter of the control unit is not set above
110 °C; adjust to max. 110 °C, if required.
Safety equipment block for 72 to
96 kW version
Safety equipment block for 108 to
144 kW version
APressure gauge
1. Check that the boiler room ventila-
tion aperture is open.
2. Check the inlet pressure of the dia-
phragm expansion vessel.
If it 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 pressure.
3. Open any installed check valves.
Further details regarding the individual steps
6
Initial start-up, inspection, maintenance
5692 647 GB

4. Fill the heating system with water
and vent it, until the pressure indi-
cated at the pressure gauge is
higher (0.1 to 0.2 bar) than the inlet
pressure of the diaphragm expan-
sion vessel.
Minimum system pressure 0.8 bar,
permissible operating pressure
3 bar.
5. Return the check valves to their
operating position.
Checking the gas type
Note
The boiler is set up in the factory for natural gas E.
The boiler can be operated 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 the details provided by the
mains gas or LPG supplier to
match the fuel provided, if these
details diverge.
Conversion kit installation
instructions
3. Record the gas type in the service
report on page 32.
Wobbe index range
Wobbe index Wo Natural gas LPG
E LL P
kWh/m
3
12.0 to 16.1 10.0 to 13.1 20.3 to 21.3
MJ/m
3
43.2 to 58.0 36.0 to 47.2 72.9 to 76.8
Changing the gas type (if required)
Conversion kit installation
instructions
Further details regarding the individual steps (cont.)
7
Initial start-up, inspection, maintenance
5692 647 GB

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
1. Close the gas shut‐off valve.
2. Remove the screw inside test
connector Aat the gas combina-
tion valve and connect the pres-
sure 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 on page 32.
5. Start the boiler.
Note
During commissioning, the boiler
can (several times) enter a fault
state because of airlocks in the
gas pipe. Press the reset button
on the burner control unit after
approx. 10 seconds.
6. Check the supply (flow) pressure:
&Natural gas: 17.4 to 25 mbar
&LPG: 42.5 to 57.5 mbar (at
50 mbar inlet pressure)
Record the actual value in the
service report on page 32.
Note
Use suitable test equipment with
a resolution of at least 0.1 mbar to
test the supply pressure.
Further details regarding the individual steps (cont.)
8
Initial start-up, inspection, maintenance
5692 647 GB

7. Take the action shown in the fol-
lowing table.
Supply (flow)
pressure for nat-
ural gas
Supply (flow)
pressure for
LPG (at 50 mbar
flow pressure)
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 the test connector with the
screw previously removed.
11. Open the gas shut‐off valve and
check the test connector for
soundness.
Danger
Gas escaping from the test
connector leads to a risk of
explosion.
Check the test connector
for soundness.
Further details regarding the individual steps (cont.)
9
Initial start-up, inspection, maintenance
5692 647 GB

Checking the nozzle pressure
ATest connector
BProtective cap
CPhillips screw
DHexagon screw
1. Close the gas shut‐off valve.
2. Remove the screw inside test
connector Aand connect the
pressure gauge.
3. Open the gas shut‐off valve.
Start the boiler.
4. Activate the emissions test switch
"S" (full load):
&For Vitotronic 100, type KC4
and Vitotronic 200, type KW5:
&Press Oand Fsimulta-
neously for approx. 2 s.
&For Vitotronic 100, type GC1
and Vitotronic 300, type GW2:
&Set the emissions test switch to
"Æ".
5. Test the nozzle pressure at full
load.
In case of deviation from the
value in the table on page 12:
&Remove protective cap B.
&Counter Phillips screw C.
&Adjust the nozzle pressure at
hexagon screw D(turn clock-
wise —nozzle pressure rises).
6. Record the setting values in the
service report on page 32.
7. Pull plug‐in connector lÖ apart
(partial load).
Further details regarding the individual steps (cont.)
10
Initial start-up, inspection, maintenance
5692 647 GB

8. Test the nozzle pressure at partial
load.
In case of deviation from the
value in the table on page 12:
&Counter the hexagon screw D.
&Adjust the nozzle pressure at
Phillips screw C(turn clock-
wise —nozzle pressure rises).
9. Disable the emissions test func-
tion "S":
&For Vitotronic 100, type KC4
and Vitotronic 200, type KW5:
&Press Oand Fsimulta-
neously for approx. 1 s.
&For Vitotronic 100, type GC1
and Vitotronic 300, type GW2:
&Set the emissions test switch to
"a".
Insert plug‐in connector lÖ.
10. Record the setting values in the
service report on page 32.
11. Secure protective cap B.
12. Switch OFF the control unit ON/
OFF switch (the boiler shuts
down).
13. Close the gas shut‐off valve.
14. Remove the pressure gauge and
seal the test connector with the
screw previously removed.
15. Open the gas shut‐off valve, start
the boiler and check the sound-
ness of the test connector.
Danger
Gas escaping from the test
connector leads to a risk of
explosion.
Check the test connector
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.
Further details regarding the individual steps (cont.)
11
Initial start-up, inspection, maintenance
5692 647 GB

Rated output
Full load kW 72 84 96 108 120 132 144
Partial load kW 46.8 54.6 62.4 70.2 78.0 85.8 93.6
Nozzle pressure at
20 mbar supply pres-
sure
Natural gas E
Full load mbar 15.4 15.4 15.4 15.4 15.4 15.4 15.4
Partial load mbar 6.8 6.8 6.8 6.8 6.8 6.8 6.8
Nozzle desig-
nation 2.90 2.90 2.90 2.90 2.90 2.90 2.90
Air restrictor
7
mm ———————
Natural gas
LL
Full load mbar 15.4 15.4 15.4 15.4 15.4 15.4 15.4
Partial load mbar 6.8 6.8 6.8 6.8 6.8 6.8 6.8
Nozzle desig-
nation 3.20 3.20 3.20 3.20 3.20 3.20 3.20
Air restrictor
7
mm 50 50 50 50 50 50 50
Nozzle pressure at
50 mbar supply pres-
sure
LPG
Full load mbar 34.5 34.5 34.5 34.5 34.5 34.5 34.5
Partial load mbar 15.0 15.0 15.0 15.0 15.0 15.0 15.0
Nozzle desig-
nation 1.90 1.90 1.90 1.90 1.90 1.90 1.90
Air restrictor
7
mm ———————
Number of burner
tubes
6 7 8 9 10 11 12
Further details regarding the individual steps (cont.)
12
Initial start-up, inspection, maintenance
5692 647 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.
Record the actual flue gas values in
the service report on page 32.
Checking the ionisation current
DBurner control unit
1. Pull off ionisation lead Cfrom ioni-
sation electrode E.
2. Connect the test instrument A
according to the above diagram.
&Push plug‐in adaptor (76/4) B
into ionisation lead C.
&Push adaptor cable (74/6) F
onto ionisation electrode E.
&Push test cable plug Ainto
plug‐in adaptor Band adaptor
cable F.
3. Start the boiler.
4. Checking the ionisation current
&When the pilot burner is lit:
&min. 1.5 µA
&When the main burner is lit:
&min. 5 µA
5. Record the actual values in the ser-
vice report on page 32.
Further details regarding the individual steps (cont.)
13
Initial start-up, inspection, maintenance
5692 647 GB

Checking the draught
ATest port 710 mm
Check the draught in Pa (100 Pa = 1
mbar) (test port behind the draught
hood) and record it in the service
report on page 32.
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.
Further details regarding the individual steps (cont.)
14
Initial start-up, inspection, maintenance
5692 647 GB

Burner removal
1. Pull the plug‐in connector (except
fA) from burner control unit C.
2. Pull the earth cable from gas com-
bination valve A.
3. Release the fitting on gas supply
pipe B.
4. Release the nuts and screws and
carefully pull burner Dout through
the front.
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.
Further details regarding the individual steps (cont.)
15
Initial start-up, inspection, maintenance
5692 647 GB

Checking the pilot burner
AIonisation electrode BPilot burner
CIgnition electrode
1. Check the ionisation electrode, the
pilot burner and the ignition elec-
trode for damage.
2. Check the electrode gaps.
Further details regarding the individual steps (cont.)
16
Initial start-up, inspection, maintenance
5692 647 GB

Cleaning the heating surfaces (if required)
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 top cover F
together with control unit Eand
hook into the front.
4. Undo clean‐out cover D.
Further details regarding the individual steps (cont.)
17
Initial start-up, inspection, maintenance
5692 647 GB

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.)
18
Initial start-up, inspection, maintenance
5692 647 GB

Checking the flue gas monitor
ASensor
1. Shut down your boiler.
2. Pull the flue pipe from the draught
hood.
3. Cover the flue pipe adaptor on the
draught hood with a suitable object
to carry out the function test.
4. Start the boiler.
5. The flue gas monitor must shut
down the burner within 2 minutes.
The burner will then be locked out
for approx. 17 minutes.
Further details regarding the individual steps (cont.)
19
Initial start-up, inspection, maintenance
5692 647 GB

6. &Check the sensor position, if the
flue gas monitor shuts down the
burner later than after 2 minutes.
&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 will not start.
––The sensor is corroded.
7. Shut down your heating system.
8. Remove the cover, and push the
flue pipe onto the draught hood.
9. Start the boiler.
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.)
20
Initial start-up, inspection, maintenance
5692 647 GB