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

11
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
ated output kW Full
load
108ĂkW
Partial
load
70.2ĂkW
Full
load
120ĂkW
Partial
load
78.0ĂkW
Full
load
132ĂkW
Partial
load
85.8ĂkW
Full
load
144ĂkW
Partial
load
9 .6ĂkW
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
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
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
4.5
15.0
1.90
Ċ
Number of burner tubes 9 10 11 12
*1Value relative to 101 .25Ămbar and 15ĂºC.
5692Ă 82 GB

12
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the flue gas values
¨ĂSafety instructions
Measure the CO value before and after any work on gas appliances, to
prevent any health hazards and to ensure perfect system condition.
Record the flue gas values in the
service report.
Checking ionisation current
¨ĂSafety instructions
Switch OFF the system ON/OFF switch on the control unit before connecting
the test equipment.
1. For testing, insert test lead no.Ă1
into TestomatikĆGas and secure.
2. Pull ionisation test leadĂA off
ionisation electrodeĂB and
connect to the Testomatik plug.
3. Connect additional ionisation test
cableĂC to ionisation
electrodeĂB and the Testomatik
socket.
4. Start up the boiler.
The ionisation current must be at
least 1.5ĂmA when operating the
ignition burner and at least 5ĂmA
when operating the main burner.
5. Record the actual value in the
service report.
5692Ă 82 GB
6 mm
4 mm
4 mm
4/6 mm
B
C
A

13
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the draught
Check the supply pressure behind the draught hood in hPa (1ĂhPaĂ=Ă1Ămbar)
and record in the service report.
Please note:
Required boiler draught: 0.0 ĂhPa (0.0 Ămbar).
The chimney draught must not be higher than 0.1ĂhPa (0.1Ămbar), install a
draught stabiliser (agree details with your local flue gas inspector) in the chimney.
Burner removal
1. Switch OFF the control unit
ON/OFF switch.
2. Isolate the mains power supply
(e.g. by removing a separate
mains fuse or by means of a
mains electrical isolator) from the
heating system, and safeguard
against unauthorised reconnection.
3. Close the gas shut-off valve.
4. Remove the front panel; for this
unlock the fastenings and remove
the front panel.
5. Pull plug-connectors (except fA)
from the burner control unit.
6. Pull the earth cable from the gas
combination valve.
7. Release fixing ĂA.
8. Release nutsĂB, and carefully
remove the burner towards the
front.
5692Ă 82 GB
A
BB

14
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the burner tubes
1. Check the gas orifices for damage. 2. Blow out the burner tubes with
compressed air or wash in a soapy
solution.
Checking the ignition burner
1. Check ionisation electrodeĂA,
ignition burnerĂB and ignition
electrodeĂC for damage.
2. Check the electrode gaps.
5692Ă 82 GB
A
B
C
7
A
B
C

15
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Clean the heating surfaces, if required (with the burner removed)
1. Release the self-tapping screws
and remove top panelĂA.
2. Release the tensioning springs,
thermal insulation mat B and
mineral fibre matĂC.
3. Unscrew the lid from flue gas
collectorĂD.
4. Clean the boiler body heating
surfaces (with burner removed)
using the cleaning brush supplied.
¨Never use cleaning agents
containing potassium.
5. Remove residues from the bottom
plate.
6. HFit the lid to the flue gas
collector.
HPosition the mineral fibre mat
and the thermal insulation mat
and secure with the tensioning
springs to the boiler body
thermal insulation mat.
HFit the top panel.
HInstall the burner in reverse
order. Use new gaskets.
System start-up
¨ĂSafety instructions
Check the soundness of all sealing faces of gas pipes and fittings at operating
pressure with a foaming test agent (leak test spray).
5692Ă 82 GB
A
B
C
D

16
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the flue gas monitoring equipment
1. Remove the flue pipe from the
draught hood.
2. Cover up the flue pipe connector of
the draught hood to carry out the
function test.
3. Start up the boiler.
After no later than approx.
2Ăminutes, the flue gas monitor
must switch OFF the burner and
should not switch it ON again
automatically before approx.
10Ăminutes have elapsed.
For safety reasons, the burner will
be locked out for approx.
17Ăminutes.
4. HCheck the position of sensorĂA,
if the flue gas monitoring
equipment switches OFF later
than after 2Ăminutes.
HReplace the sensor or the burner
control unit:
ć if the flue gas monitoring
equipment does not switch
OFF the burner
ć if the burner does not switch
ON
ć if the sensor is corroded.
5. Boiler shutdown.
6. Clear the aperture and push the
flue pipe onto the draught hood.
5692Ă 82 GB
100 28

17
Troubleshooting
Diagnostics
Fault Cause emedy
The boiler will
not start
No voltage Check the fuse and connections of
the main power supply. Check the
switches on the control unit for their
settings.
Boiler water
temperature too high
Wait until the boiler water temperature
has fallen by approx. 20ĂK
The high limit safety
cut-out has tripped
Press the reset button on the control
unit
The flue gas
monitoring
equipment (if
installed) has shut
the system down
Wait approx. 17Ăminutes. If the boiler
then starts automatically, check the
flue pipe and the chimney.
If the boiler does not start
automatically, check the flue gas
monitoring equipment (see pageĂ16).
Strapping plugĂaNS
is missing in the
burner control unit
Fit strapping plugĂaNS or a flue gas
monitoring sensor
Strapping plugĂaYA is
missing in the burner
control unit
Fit strapping plugĂaYA
The burner
control unit
enters a fault
state
No gas available Air in the gas supply pipe. Press the
reset button on the burner control
unit to repeat the start procedure
The ignition burner
will not start
Check the ignition electrode.
Check the gas supply.
Mains cable
incorrectly connected
Interchange cores L1 and N of the
mains power cable
Ionisation current too
low or
cable break
Check the ionisation current
(minimum value 5ĂmA with the main
burner operating).
Remove the ignition burner and
check for damage.
Check the polarity of the mains
supply cable.
Control unit faults
Service instructions
Boiler control unit
5692Ă 82 GB

18
Appendix
Function of the ignition burner system
The burner control unit is supplied
with current when there is a heat
demand. The control indicator on the
burner control unit illuminates. The
first valve of the gas combination
valve opens. Gas flows from the
ignition burner; at the same time the
HV ignition is switched ON (approx.
15Ăseconds).
After the burner control unit has
received a flame signal via the
ionisation electrode, the second
valve of the gas combination valve is
opened after a flame stabilisation
time of 5 to 8Ăseconds (this may have
been reduced, subject to the expired
safety time TS , to 0Ăseconds).
The pressure switches are controlled
with a switching differential of
<Ă2Ăseconds.
All burner areas are ignited.
Please note:
A reset after a fault shutdown can
only be implemented after a
minimum of 10Ăseconds.
Time chart
T0Heat demand
T1Start ignition gas valve/ignition attempt
T2Flame recognised/ignition OFF
TStart main gas valve
T4Operation
5692Ă 82 GB
T1
Safety time Safety time mode Stabilisation time Pilot light Dwell time
5 -8 s
Time in seconds max. 40s
signal required
max. 10s
Mode
s
Heat demand, control unit
External solenoid valve
Ignition of the ignition burner
Pilot gas valve opens
Pilot light burns
Flame recognition
Burner control unit
Main gas valve opens
Pressure switch switching point
Main flame burns
T0T2TT4

19
Appendix
Connection diagram for burner control
Key to symbols
BV Fuel valve (partial load)
MS Modulation coil (full load)
GDW Gas pressure switch
*1Gas pressure switch only for LPG.
*2Jumper only for natural gas.
5692Ă 82 GB
Sensor
Flue gas
monitoring B4
S
41
T2
T1
N
?
L1
90
4
T8
T7
T6
B5
N
?
L
D
ungs
DGAI
69
F
-
M
o
d
.50. .0
TLL
162 41 41A 50 4
L1 N L1 N L1 N
111
*2
54 5 6 11
P
P
P
Reset Fault Gas
pressure
monitor
Ignition
unit
GDW Br.2
GDW Br.1
P
GDW Br.
BV2.1 BV2.2 MS2 BV1.2 BV1.1 MS1 BV .1 BV .2 MS
*1

20
Appendix
Connection diagram for burner 72 to 96ĂkW
Key to symbols
1Connecting cable ć
modulation coils
2Connecting cable ć
main gas valves
3Connecting cable ć
pilot gas valve
4Ionisation cable
5Ignition cable
BV Fuel valve
MS Modulation coil
GDW Gas pressure switch
(in the ionisation cable)
5692Ă 82 GB
GDW 1
GDW 2
Boiler circuit
control unit
Gas connection
Burner control unit
BV-Extern
Pilot gas valve Main gas valve
Ignition Ionisation
Ignition
unit
Ignition
cable
Pilot
burner
Manifold Manifold
Ionisation cable