Viessmann VITOGAS 100 Operating instructions

VITOGAS 100
Service instructions
for heating engineers
VitogasĂ100
TypeĂGS1, 72 to 144ĂkW
Gas fired boiler
for natural gas and LPG
See notes on applicability, pageĂ2.
5692Ă 82 GBăăă2/2004 Please keep safe

2
General information
Safety instructions
Please follow these safety instructions closely to prevent accidents and
material losses.
Work on the equipment
Installation, initial start-up, inspection,
maintenance and repairs must only
be carried out by a competent
person (heating engineer/installation
contractor).
Before working on the equipment/
heating system, isolate the mains
electrical supply (e.g. by removing a
separate mains fuse or by means of
a mains electrical isolator) and
safeguard against unauthorised
reconnection.
Close the main gas shut-off valve
and safeguard against unauthorised
reopening.
Work on gas equipment
This must only be carried out by an
approved contractor.
Please observe all commissioning
work specified for gas installations to
TRGI or TRF and all local regulations.
Please observe all commissioning
work specified for gas systems.
epair work
It is not permitted to carry out repairs
on parts that fulfil a safety function.
Use only original Viessmann spare
parts, or equivalent parts that have
been approved by Viessmann.
Initial start-up
The initial start-up must be carried
out by the system installer or a
designated commissioning engineer.
All actual values should be recorded
in a commissioning/service report.
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.
¨ĂSafety instructions
In this instruction manual, this
heading denotes information which
must be observed to prevent
accidents and material losses.
¨This symbol denotes important
information which must be
observed to prevent material
losses.
Applicability
VitogasĂ100, typeĂGS1
from serial no.
714 298Ă1Ă00000Ăkkk, 714 299Ă1Ă00000Ăkkk, 714 00Ă1Ă00000Ăkkk,
714 01Ă1Ă00000Ăkkk, 714 02Ă1Ă00000Ăkkk, 714 0 Ă1Ă00000Ăkkk,
714 04Ă1Ă00000Ăkkk, 75184 6Ă0Ă00000Ăkkk, 75184 7Ă0Ă00000Ăkkk,
75184 8Ă0Ă00000Ăkkk, 75184 9Ă0Ă00000Ăkkk, 7518440Ă0Ă00000Ăkkk,
7518441Ă0Ă00000Ăkkk, 7518442Ă0Ă00000Ăkkk, 751844 Ă0Ă00000Ăkkk,
7518444Ă0Ă00000Ăkkk, 7518445Ă0Ă00000Ăkkk, 7518446Ă0Ă00000Ăkkk,
7518447Ă0Ă00000Ăkkk, 7518448Ă0Ă00000Ăkkk, 7518449Ă0Ă00000Ăkkk
5692Ă 82 GB

3
Contents
Index
Page
General information
Safety instructionsĂ 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ApplicabilityĂ 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start-up, inspection and maintenance
StepsĂćĂinitial start-up, inspection and maintenanceĂ 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further details regarding the individual stepsĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
DiagnosticsĂ 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Function of the ignition burner systemĂ 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time chartĂ 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection diagram
HĂBurner controlĂ 19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HĂBurner, ă72ĂĆĂă96ĂkWĂ 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HĂBurner, 108ĂĆĂ144ĂkWĂ 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts listsĂ 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service reportĂ 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SpecificationĂ 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of conformityĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer's certificateĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyword indexĂ 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692Ă 82 GB

4
Initial start-up, inspection and maintenance
StepsĂćĂinitial start-up, inspection and maintenance
For further instructions on individual steps, see pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
C I M 1. Preparing for commissioning and checking
diaphragm expansion vesselĂ 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 2. Checking gas typeĂ 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 3. Checking static and supply pressureĂ 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 4. Checking nozzle pressureĂ 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 5. Checking flue gas valuesĂ 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 6. Checking ionisation currentĂ 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 7. Checking draughtĂ 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 8. Burner removalĂ 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 9. Checking burner tubesĂ 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 10. Checking ignition burnerĂ 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M11. Cleaning heating surfacesĂ 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 12. Burner installation
C I M 13. Checking all water connections for leaks
C I M 14. Checking all safety equipment
C I M 15. Checking tightness of electrical connections
C M 16. System start-upĂ 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 17. Checking closing function of gas combination valves
C I M 18. Checking flue gas monitoring equipmentĂ 16. . . . . . . . . . . . . . . . . . . . . . .
5692Ă 82 GB

5
Initial start-up, inspection and maintenance
Further details regarding the individual steps
Preparing for commissioning and checking the diaphragm
expansion vessel
¨ĂSafety instructions
Only for commissioning with VitotronicĂ 00, typeĂGW2
Check that the high limit safety cut-out of the control unit is not set higher
than 110ĂºC. Set to a maximum of 110ĂºC if required.
1. Check that the boiler room
ventilation aperture is open.
2. Check the charge pressure of the
diaphragm expansion vessel.
3. Open any check valves that may
be fitted.
4. Fill the heating system, vent it and
check the system pressure on
pressure gaugeĂA.
(Min. system pressure 0.8Ăbar,
permiss. operating pressure Ăbar).
5. Return the check valves to their
operating position.
5692Ă 82 GB
Safety equipment block 72 to 96ĂkW
Safety equipment block 108 to 144ĂkW

6
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the gas type
1. Enquire the gas type and Wobbe
indexĂ(Wo) from your local mains
gas or LPG supplier.
Please note:
The boiler is set up in the factory
for natural gasĂE.
The boiler can be operated in
the Wobbe index range
12.0 to 16.1ĂkWh/m
(4 .2 to 58.0ĂMJ/m ).
2. Compare the gas category (type)
and group with the details on the
burner label.
3. The burner must be converted acc.
to the details provided by the
mains gas or the LPG supplier to
match the fuel provided, if these
details do not match.
Installation instructions
Conversion kit
After conversion from
HNatural gasĂE to natural gasĂLL:
This boiler can be operated in
the Wobbe index range
10.0 to 1 .1ĂkWh/m
( 6.0 to 47.2ĂMJ/m ).
HNatural gasĂE to LPGĂP:
The boiler can be operated in
the Wobbe index range
21.4 to 22.5ĂkWh/m
(76.9 to 81.0ĂMJ/m ).
4. Record the gas type in the service
report from pageĂ28.
5692Ă 82 GB

7
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking static and supply pressure
¨ĂSafety instructions
Measure the CO value before and after any work on gas appliances, to
prevent any health hazards and to ensure the perfect operational condition of
the system.
LPG version
Flush the LPG tank twice after installation or replacement.
Thoroughly vent the tank and gas lines after flushing.
Static pressure
1. Close the gas shut-off valve.
2. Unscrew the screw inside test
nippleĂA on the gas combination
valve and connect pressure gauge.
3. Open the gas shut-off valve.
4. Check static pressure; it should be
Hmax. 25Ămbar for natural gas,
Hmax. 57.5Ămbar for LPG.
Record the actual value in the
service report.
Supply pressure (flow pressure)
5. Start up the boiler.
Please note:
On start-up, the boiler can enter a
fault state because of airlocks in
the gas pipe.
After approx.Ă10Ăseconds, press the
reset button on the burner control
unit, this repeats the ignition
process.
5692Ă 82 GB
A

8
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
6. Check the supply (flow) pressure;
it should be
H17.4 to 25Ămbar for natural gas,
H42.5 to 57.5Ămbar for LPG
Record the actual value in the
service report.
Take the action shown in the table.
Supply pressure (flow pressure) emedy
Natural gas LPG
below 17.4Ămbar below 42.5Ămbar Make no adjustments and notify your
mains gas or LPG supplier.
17.4 to 25Ămbar 42.5 to
57.5Ămbar
Start up boiler.
above 25Ămbar above 57.5Ămbar Install a separate gas pressure governor
upstream of the system and regulate the
pressure to 20Ămbar for natural gas or
50Ămbar for LPG.
Notify your mains gas or LPG supplier.
7. Shut down the boiler, close the
gas shut-off valve, remove the
pressure gauge, and seal test
nippleĂA with screw.
8. ¨ĂSafety instructions
Open the gas shut-off valve and
check test nippleĂA for soundness.
5692Ă 82 GB

9
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the nozzle pressure
1. Close the gas shut-off valve.
2. Unscrew the screw inside test
nippleĂA and connect the
pressure gauge.
3. Open the gas shut-off valve.
Start up the boiler.
4. Check the nozzle pressure for full
load, and adjust to the values in
the table on pageĂ10, if required:
HSet emissions test switchĂS to h
(full load).
HRemove protective capĂB.
HHold up crosshead screwĂC.
HAdjust the nozzle pressure at
hexagon screwĂD (turning
clockwiseĂć nozzle pressure
increases).
Please note:
Check and adjust the nozzle
pressure at full loa , if required.
5. Check setting values and record in
the service report.
6. Separate plug-in connectorĂlÖ
(partial load).
7. Check the nozzle pressure for
partial load, and adjust to the
values in the table on pageĂ10, if
required:
HHold up hexagon screwĂD.
HAdjust the nozzle pressure at
crosshead screwĂC (turning
clockwiseĂć nozzle pressure
increases).
8. Set emissions test switchĂS to a,
and insert plug-in connectorĂlÖ.
9. Fit capĂB.
5692Ă 82 GB
A
B
C
D

10
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
10. Switch OFF system ON/OFF switch
at the control unit (boiler shuts
down), close gas shut-off valve,
remove pressure gauge and close
test nippleĂA with screw.
11. ¨ĂSafety instructions
Open gas shut-off valve, start up
boiler and check soundness of
test nippleĂA.
ated output kW Full load
72ĂkW
Partial load
46.8ĂkW
Full load
84ĂkW
Partial load
54.6ĂkW
Full load
96ĂkW
Partial load
62.4ĂkW
Natural gasĂE
with Wobbe index Wo
15.0ĂkWh/m
54.0ĂMJ/m
ć Nozzle pressure*1 Full load
relative to Part. load
20Ămbar supply pressure
ć Nozzle ID
ć Air restrictor
mbar
mbar
∅Ămm
15.4
6.8
2.90
Ċ
15.4
6.8
2.90
Ċ
15.4
6.8
2.90
Ċ
Natural gasĂLL
with Wobbe index Wo
12.4ĂkWh/m
44.6ĂMJ/m
ć Nozzle pressure*1 Full load
relative to Part. load
20Ămbar supply pressure
ć Nozzle ID
ć Air restrictor
mbar
mbar
∅Ămm
15.4
6.8
.20
50
15.4
6.8
.20
50
15.4
6.8
.20
50
LPG
with Wobbe index Wo
21. ĂĆĂ22.5ĂkWh/m
76.9ĂĆĂ81.1ĂMJ/m
ć Nozzle pressure*1 Full load
relative to Part. load
50Ămbar supply pressure
ć Nozzle ID
ć Air restrictor
mbar
mbar
∅Ămm
4.5
15.0
1.90
Ċ
4.5
15.0
1.90
Ċ
4.5
15.0
1.90
Ċ
Number of burner tubes 6 7 8
*1Value relative to 101 .25Ămbar and 15ĂºC.
5692Ă 82 GB