Viessmann Vitogas 100 Service Instructions Manual
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Viessmann Vitogas 100 Service Instructions Manual

Gas fired boiler
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Service instructions
for heating engineers
Vitogas 100
Type GS1, 11 to 60 kW
Gas fired boiler
See notes on applicability, page 2.
VITOGAS 100
Please keep safe
5692 413 GB
6/2004

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Summary of Contents for Viessmann Vitogas 100

  • Page 1 Service instructions for heating engineers Vitogas 100 Type GS1, 11 to 60 kW Gas fired boiler See notes on applicability, page 2. VITOGAS 100 Please keep safe 5692 413 GB 6/2004...

  • Page 2: General Information

    (heating engineer/installation Use only original Viessmann spare contractor). parts, or equivalent parts that have been approved by Viessmann. Before working on the equipment/ heating system, isolate the mains Initial start−up...

  • Page 3: Table Of Contents

    Contents Index Page General information Safety instructions ........................Applicability .

  • Page 4: Initial Start−Up, Inspection And Maintenance

    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 1. Preparing for commissioning and checking diaphragm expansion vessel ..........2.

  • Page 5: Further Details Regarding The Individual Steps

    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.

  • Page 6: Checking Gas Type

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking gas type After conversion from 1. Enquire the gas type and Wobbe H Natural gas E to natural gas LL: index (Wo) from your local mains gas or LPG supplier. This boiler can be operated in the Wobbe index range Note...

  • Page 7: Checking Static And Supply Pressure

    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.
  • Page 8 Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) 6. Check the supply (flow) pressure; it should be H 17.4 to 25 mbar for natural gas, H 42.5 to 57.5 mbar for LPG. Record the actual value in the service report.

  • Page 9: Checking Nozzle Pressure

    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.
  • Page 10 Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Rated output Natural gas E with Wobbe index Wo 15.0 kWh/m 54.0 MJ/m Nozzle pressure mbar 14.1 14.0 13.9 14.5 14.4 14.0 14.8 14.2 15.0 based on a supply pressure of 20 mbar Nozzle ID 2.00...

  • Page 11: Checking Flue Gas Values

    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.

  • Page 12: Checking Draught

    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.

  • Page 13: Checking Ignition Burner

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking ignition burner 1. Check ionisation electrode A, ignition burner B and ignition electrode C for damage. 2. Check the electrode gaps.

  • Page 14: M 11. Cleaning Heating Surfaces

    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.

  • Page 15: Checking Flue Gas Monitoring Equipment

    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.

  • Page 16: Troubleshooting Diagnostics

    Troubleshooting Diagnostics Fault Cause Remedy Boiler will not No voltage Check fuse and connections of main start power supply. Check switches on control unit for their settings. Boiler water Wait until boiler water temperature temperature too high has fallen by approx. 20 K High limit safety Press reset button on control unit cut−out has tripped...

  • Page 17: Appendix

    Appendix Function of the ignition burner system Power is supplied to the burner on top of the equipment illuminates. control unit when there is a heat demand, and the LED on top of the After the pilot flame has stabilised, equipment illuminates.

  • Page 18: Connection Diagram For Burner Control

    Appendix Connection diagram for burner control System plug no. Terminal no. 14 13 12 11 10 9 Reset Fault External Sensor valve flue monitoring Ignition monitor or plug or jumper with resistance Ionisation B4 S3 T2 T1 N...

  • Page 19: Draining/Frost Protection

    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 A on 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.

  • Page 20: Parts Lists

    Appendix Parts lists When ordering spare parts 208 Insulating casing Quote the type and serial no. (see 212 Fastener type plate) and the item no. of the 213 Decorative cap required part (as per parts list). 214 Edge protector Obtain common parts from your 217 Spacers local supplier.
  • Page 21 Parts list Parts list (cont.)
  • Page 22 Parts list Parts list (cont.)
  • Page 23 Parts list Parts list (cont.)
  • Page 24 Parts list Parts list (cont.)
  • Page 25 Parts list...

  • Page 26: Commissioning/Service Report

    Appendix Commissioning/service report Setting and test values Set value Initial start−up Date: Static pressure mbar max. 57.5 mbar Supply pressure (flow pressure) j for natural gas E mbar 17.4 25 mbar j for natural gas LL mbar 17.4 25 mbar j for LPG mbar 42.5 57.7 mbar...
  • Page 27 Appendix Maint./service Maint./service Maint./service Maint./service...
  • Page 28 Appendix Commissioning/service report (cont.) Setting and test values Set value Maint./service Date: Static pressure mbar max. 57.5 mbar Supply pressure (flow pressure) j for natural gas E mbar 17.4 25 mbar j for natural gas LL mbar 17.4 25 mbar j for LPG mbar 42.5 57.7 mbar...
  • Page 29 Appendix Maint./service Maint./service Maint./service Maint./service...
  • Page 30 Appendix Commissioning/service report (cont.) Setting and test values Set value Maint./service Date: Static pressure mbar max. 57.5 mbar Supply pressure (flow pressure) j for natural gas E mbar 17.4 25 mbar j for natural gas LL mbar 17.4 25 mbar j for LPG mbar 42.5 57.7 mbar...
  • Page 31 Appendix Maint./service Maint./service Maint./service Maint./service...

  • Page 32: Specification

    Appendix Specification Rated output ∅ mm Flue outlet (int. diameter) 90 110 130 130 150 150 150 180 180 Required draught mbar 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 0.03 Maximum draught mbar Flue gas ºC Temperature (gross) Mass flow rate Natural gas kg/h kg/h...

  • Page 33: Declaration Of Conformity

    This product meets the requirements of the Efficiency Directive (92/42/EEC) for: Low temperature boilers. The product characteristics determined as system values for Vitogas 100 as part of EC type testing according to the Efficiency Directive (see specification table) can be utilised for the energy assessment of heating and ventilation equipment to DIN V 4701 10 specified by the EnEV [Germany].

  • Page 34: Keyword Index

    Appendix Keyword index As delivered condition (gas type), 6 Ignition electrode, 13 Inlet pressure, diaphragm expansion vessel, 5 Burner, 12 Ionisation current, 11, 16 Ionisation electrode, 11 Cleaning agent, 14 Check valves, 5 Manufacturer’s certificate, 33 Commissioning/service report, 26 Minimum system pressure, 5 Conformity, 33 CO test, 7 Nozzle pressure table, 10...
  • Page 36 Viessmann Werke GmbH & Co D 35107 Allendorf Tel: +49 6452 70 0 Fax: +49 6452 70 27 80 www.viessmann.de Viessmann Limited Hortonwood 30, Telford Shropshire, TF1 7YP , GB Tel: +44 1952 675000 Fax: +44 1952 675040 E−mail: info−uk@viessmann.com...

This manual is also suitable for:

Gs1

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