Viessmann VITOGAS 100 Operating instructions

VITOGAS 100
Service instructions
for heating engineers
Vitogas100
TypeGS1, 11 to 60kW
Gas fired boiler
See notes on applicability, page2.
5692413GB6/2004 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.
Repair 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.
¨Safety instruction
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
Vitogas100, typeGS1
from serial no.
7143553100000kkk 7143556100000kkk 7143559100000kkk
7143554100000kkk 7143557100000kkk 7143560100000kkk
7143555100000kkk 7143558100000kkk 7143561100000kkk
5692413GB

3
Contents
Index
Page
General information
Safety instructions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicability 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start−up, inspection and maintenance
StepsInitial start−up, inspection and maintenance 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further details regarding the individual steps 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Diagnostics 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Function of the ignition burner system 17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time chart 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection diagram for burner control 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining/frost protection 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minimum clearances 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts lists 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service report 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specification 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of conformity 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer’s certificate 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyword index 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692413GB

4
Initial start−up, inspection and maintenance
StepsInitial 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 vessel 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 2. Checking gas type 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 3. Checking static and supply pressure 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 4. Checking nozzle pressure 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 5. Checking flue gas values 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 6. Checking ionisation current 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 7. Checking draught 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 8. Burner removal 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 9. Checking burner tubes 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 10. Checking ignition burner 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M11. Cleaning heating surfaces 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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−up 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 17. Checking closing function of gas combination valves
C I M 18. Checking flue gas monitoring equipment 15. . . . . . . . . . . . . . . . . . . . . . .
5692413GB

5
Initial start−up, inspection and maintenance
Further details regarding the individual steps
Preparing for commissioning
1. Check that the boiler room
ventilation aperture is open.
2. Check the inlet 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 gaugeA.
(Min. system pressure 0.8bar,
permiss. operating pressure 3bar).
5. Return the check valves to their
operating position.
5692413GB

6
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking gas type
1. Enquire the gas type and Wobbe
index(Wo) from your local mains
gas or LPG supplier.
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/m3
(43.2 to 58.0MJ/m3).
2. Compare the gas category (gas
type) and gas group with the
details on the burner label.
3. The burner must be converted
according 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 gasE to natural gasLL:
This boiler can be operated
in the Wobbe index range
10.0 to 13.1kWh/m3
(36.0 to 47.2MJ/m3).
HNatural gasE to LPGP:
The boiler can be operated
in the Wobbe index range
21.4 to 22.5kWh/m3
(76.9 to 81.0MJ/m3).
4. Record the gas type in the service
report from page26.
5692413GB

7
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking static and supply pressure
¨Safety instruction
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. Release the screw inside test
nippleAon the gas connection
pipe, but do not remove
completely, and connect the
pressure gauge.
3. Open the gas shut−off valve.
4. Check static pressure; it should be
Hmax. 25mbar for natural gas,
Hmax. 57.5mbar for LPG.
Record the actual value in the
service report.
Supply pressure (flow pressure)
5. Start up the boiler.
Note
On start−up, the boiler can enter a
fault state because of airlocks in
the gas pipe.
After approx. 5seconds, press the
reset button on the burner control
unit; this repeats the ignition
process.
5692413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 25mbar for natural gas,
H42.5 to 57.5mbar for LPG.
Record the actual value in the
service report.
Take the action shown in the table.
Supply pressure (flow pressure)
for
Remedy
natural gas LPG
below
17.4mbar
below
42.5mbar
Make no adjustments and notify your
mains gas or LPG supplier.
17.4 to 25mbar 42.5 to
57.5mbar
Start up boiler.
above 25mbar above
57.5mbar
Install a separate gas governor
downstream 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.
7. Shut down the boiler, close the
gas shut−off valve, remove the
pressure gauge, and close test
nippleAwith the screw.
8. ¨Safety instructions
Open the gas shut−off valve and
check test nippleAfor
soundness.
5692413GB

9
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking nozzle pressure
1. Close the gas shut−off valve.
2. Release the screw inside test
nippleA, but do not remove
completely, and connect the
pressure gauge.
3. Open the gas shut−off valve.
Start up the boiler.
4. Check the nozzle pressure.
In case of deviation from the
value in the table on page10,
remove protective capB.
Adjust the nozzle pressure
with screwC.
5. Check setting values and record
in the service report.
6. Fit capB.
7. Switch OFF the system at the
control unit (the boiler shuts
down), close the gas shut−off
valve, remove the pressure
gauge and close test nippleA
with the screw.
8. ¨Safety instructions
Open the gas shut−off valve,
start up the boiler and check
soundness of test nippleA.
5692413GB
C
B
A

10
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Rated output kW 11 15 18 22 29 35 42 48 60
Natural gasE
with Wobbe index Wo
15.0kWh/m3
54.0MJ/m3
 Nozzle pressure*1
based on a supply
pressure of 20mbar
 Nozzle ID
 Air restrictor
mbar
∅mm
14.1
2.00
33
14.0
2.35

13.9
2.10
34
14.5
2.30

14.4
2.30

14.0
2.30

14.8
2.25

14.2
2.25

15.0
2.25

Natural gasLL
with Wobbe index Wo
12.4kWh/m3
44.6MJ/m3
 Nozzle pressure*1
based on a supply
pressure of 20mbar
 Nozzle ID
 Air restrictor
mbar
∅mm
14.1
2.25
33
13.9
2.60
35
14.1
2.30
32
13.7
2.55
37
13.8
2.55
37
14.0
2.55
37
14.2
2.50
37
13.7
2.50
37
13.5
2.50
37
LPG
with Wobbe index Wo
21.322.5kWh/m3
76.981.1MJ/m3
 Nozzle pressure*1
based on a supply
pressure of 50mbar
 Nozzle ID
 Air restrictor
mbar
∅mm
36.0
1.25
33
36.5
1.45
37
35.3
1.35
35
35.3
1.45

35.0
1.45

35.0
1.45

35.0
1.45

35.5
1.40

36.2
1.40

Number of burner tubes 223345679
*1Value relative to 1013.25mbar and 15ºC.
5692413GB

11
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking flue gas values
¨Safety instruction
Measure the CO value before and after any work on gas appliances, to
prevent any health hazards and to ensure perfect system condition.
Determine the flue gas values and
record them in the service report.
Checking ionisation current
¨Safety instruction
Switch OFF the system ON/OFF switch at the control unit before connecting
the test equipment.
FBurner control unit
1. For testing, insert test lead no.1
into TestomatikGas and secure.
2. Pull ionisation leadAoff
ionisation electrodeB.
3. Push plug−in adaptorCinto
ionisation leadA.
4. Push test cable plugDinto
plug−in adaptorC.
5. Push adaptor cableEonto
ionisation electrodeB.
6. Push adaptor cableEonto the
test cable socketD.
7. Start up the boiler.
The ionisation current must be at
least 1.5mA when operating the
ignition burner and at min. 5mA
when operating the main burner.
8. Record the actual value in the
service report.
5692413GB
D C A
B
E
F
o

12
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking draught
Check the supply pressure behind the draught hood in hPa (1hPa=1mbar)
and record in the service report.
Note
Required boiler draught: 0.03hPa (0.03mbar).
The chimney draught must not be higher than 0.1hPa (0.1mbar), install a
draught stabiliser (agree details with your local flue gas inspector) inside 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 fastening (60kW:
2fastenings) and remove the front
panel.
5. Pull plug−in connector off the
burner control unit.
6. Pull the earth cable from the gas
combination valve.
7. Release screw fixingA.
8. Release nutsB. Carefully remove
the burner towards the front.
Checking burner tubes
1. Check the gas outlet for damage. 2. Blow out the burner tubes with
compressed air or wash in a soapy
solution.
5692413GB
B
BA

13
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking ignition burner
1. Check ionisation electrodeA,
ignition burnerBand ignition
electrodeCfor damage.
2. Check the electrode gaps.
5692413GB
A
B
C
7
A
B
C

14
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Clean heating surface, if required (with the burner removed)
1. Release the self−tapping screws
and remove top panelA.
2. Release the tensioning springs,
thermal insulation matB.
3. Unscrew the lid from flue gas
collectorC.
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
¨Safety instruction
Check the soundness of all joints of gas pipes and fittings at operating
pressure with a foaming test agent (leak test spray).
5692413GB
A
B
C

15
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking flue gas monitoring equipment
1. Remove the flue pipe from the
draught hood.
2. Cover the flue pipe adaptor on the
draught hood to carry out the
function test.
3. Start up the boiler.
No later than after approx.
2minutes, the flue gas monitor
must switch OFF the burner and
should not switch it ON again
automatically before approx.
10minutes have elapsed.
For safety reasons, the burner will
be locked out for approx.
17minutes.
4. HCheck the position of sensorA,
if the flue gas monitoring
equipment switches OFF later
than after 2minutes.
HReplace the sensor or the burner
control unit:
 if the flue gas monitoring
equipment does not switch
OFF the burner
 if the burner does not switch
ON
 if the sensor is corroded.
5. Boiler shutdown.
6. Clear the aperture and push the
flue pipe onto the draught hood.
5692413GB
A
28 40

16
Troubleshooting
Diagnostics
Fault Cause Remedy
Boiler will not
start
No voltage Check fuse and connections of main
power supply. Check switches on
control unit for their settings.
Boiler water
temperature too high
Wait until boiler water temperature
has fallen by approx. 20K
High limit safety
cut−out has tripped
Press reset button on control unit
Flue gas monitoring
equipment (if
installed) has shut
system down
Wait approx. 17minutes. If boiler
then starts automatically, check flue
pipe and chimney.
If boiler does not start automatically,
check flue gas monitoring equipment
(see page15).
Strapping plugaNS
is missing in burner
control unit
Fit strapping plugaNS or a flue gas
monitoring sensor
Strapping plugaYA is
missing in burner
control unit
Fit strapping plugaYA
Burner control
unit enters a
fault state
No gas available Air in gas supply pipe. Press reset
button on burner control unit to
repeat start procedure
Ignition burner will
not start
Check ignition electrode.
Check gas supply.
Mains cable
incorrectly connected
Interchange coresL1 and N of mains
power cable
Ionisation current
too low or
cable break
Check ionisation current (minimum
value 5mA with main burner
operating).
Remove ignition burner and check for
damage.
Check polarity of mains power supply
cable.
Control unit faults
Service instructions
Boiler control unit
5692413GB

17
Appendix
Function of the ignition burner system
Power is supplied to the burner
control unit when there is a heat
demand, and the LED on top of the
equipment illuminates. The pilot gas
valve and, if installed, the external
LPG valve open.
Gas flows from the pilot burner. At
the same time, the HV ignition is
switched ON.
After the burner control unit has
received a flame signal via the
ionisation electrode, the green LED
on top of the equipment illuminates.
After the pilot flame has stabilised,
the main gas valve opens and the
burner ignites.
Note
A reset after a fault shutdown can
only be implemented after a
minimum of 10seconds.
Time chart
Tstab Pilot flame stabilisation time
TFR Safety time operation
TcSelf−monitoring time
TwWaiting time
TTTB Shutdown duration, flue gas
monitoring
TsSafety time, burner start
5692413GB
Heat demand
Ignition
Pilot gas valve
External valve
Ionisation signal
Main gas valve
Flue gas
monitor
Fault display
(accessory
LPG version)
PV
LPG
6s
T
stab
<1s
T
FR
max.
25s
T
C+TW
6s
T
stab
approx.
T
TTB
max.
25s
T
c+T w
max.
55s
T
S
MV
15 min.

18
Appendix
Connection diagram for burner control
5692413GB
50 41A 34 111 41 162
12314 13 12 11 10 9 8 7 6 5 4
Reset Fault
System plug no.
Terminal no.
P
B4 S3 T2 T1 N L1
External
valve
Gas
monitor
or jumper
Sensor
flue
monitoring
or plug
with
resistance
Ignition
Ionisation

19
Appendix
Draining/frost protection
For draining the boiler completely
(e.g. when there is a risk of frost)
also drain the l.h. boiler section
via drain valveAon the side of
the boiler.
Minimum clearances
Maintain a distance between the
flue pipe and the surface of the
thermal insulation (also of
accessories) of at least 20mm.
This safeguards that the surface
temperature of the thermal
insulation never exceeds 85ºC
at rated output.
5692413GB
A

20
Appendix
Parts lists
When ordering spare parts
Quote the type and serial no. (see
type plate) and the item no. of the
required part (as per parts list).
Obtain common parts from your
local supplier.
Parts
001 Clean−out cover
002 Draught hood complete*1
002 Draught hood*2
003 Flue gas collector*2
004 Baffle plate
005 Gasket 80×80×3
006 Sensor well
100 Burner tube
101 Gas train
(with item102, 109 and 113)
102 Pilot gas line
103 Ionisation cable
104 Push button and fault indicator
105 Ignition burner fittings
108 Burner control unit
109 Sealing ring A21×30×2
110 Ignition burner nozzle, natural gas*3
111 Ignition burner nozzle, LPG*4
112 Cover cap
113 Oring
114 Burner, complete (with item100,
102, 106, 112, 113 and 115)
115 Thermal insulation panel
119 Ignition cable
120 Burner control unit hood
121 Flue gas monitoring sensor
200 Top panel
201 Bottom front panel
202 L.h. and r.h. side panel
203 Top front panel
204 Rear panel
205 Centre panel
206 Top insulating mat
207 L.h. and r.h. fixing strip
208 Insulating casing
212 Fastener
213 Decorative cap
214 Edge protector
217 Spacers
218 Logo
219 Fixing pack
220 Tensioning spring for thermal
insulation
221 Diaphragm grommet
223 Decorative adhesive tape
Parts not shown
116 Conversion parts for natural gasLL
117 Conversion parts for natural gasE
118 Conversion parts for LPGP
(50mbar)*4
300 Touch−up spray, Vitosilver
301 Touch−up paint stick, Vitosilver
302 Service instructions
303 Installation instructions
304 Strapping plug for burner
control unit
308 Burner cable
Wearing parts
007 Cleaning brush
106 Pilot burner,
(with item105, 110, 111 and 119)
AType plate
BBoiler control unit, see
separate parts list
CGas train for 11 to 35kW
DGas train for 42 to 60kW
*1Only for serial no.7143553100000Ăkkk
to 7143557100000kkk.
*2Only for serial no.7143558100000kkk
to 7143561100000kkk.
*3Only for natural gas version.
*4Only for LPG version.
5692413GB