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
!!!





















••• 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