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

Rated output 72 to 144 kw gas fired boiler natural gas and lpg version
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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
Please keep safe
5692 647 GB
1/2006

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Summary of Contents for Viessmann Vitogas 100

  • Page 1 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 Please keep safe 5692 647 GB 1/2006...
  • Page 2 Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained the Code of Practice of relevant trade associations, Danger all current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury.
  • Page 3 For replacements, use only ori- ginal spare parts from Viessmann or those which are approved by Viessmann.

  • Page 4: Table Of Contents

    Index Index Initial start-up, inspection, maintenance Steps initial start-up, inspection and maintenance ........Further details regarding the individual steps ..........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..........
  • Page 5 Initial start-up, inspection, maintenance Steps initial start-up, inspection and maintenance For further information regarding individual steps, see the pages indicated. Commissioning steps Inspection steps Maintenance steps Page 1. Preparing for commissioning ......... . 2.

  • Page 6: Initial Start-Up, Inspection, Maintenance

    Initial start-up, inspection, maintenance Further details regarding the individual steps 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 108 to 144 kW version Safety equipment block for 72 to...

  • Page 7: Checking The Gas Type

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 4. Fill the heating system with water 5. Return the check valves to their and vent it, until the pressure indi- operating position. cated at the pressure gauge is higher (0.1 to 0.2 bar) than the inlet pressure of the diaphragm expan- sion vessel.

  • Page 8: Checking The Static And Supply Pressure

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 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.
  • Page 9 Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 7. Take the action shown in the fol- lowing table. Supply (flow) Supply (flow) Measures pressure for nat- pressure for ural gas LPG (at 50 mbar flow pressure) below 17.4 mbar below 42.5 mbar Do not start the boiler.

  • Page 10: Checking The Nozzle Pressure

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Checking the nozzle pressure 2. Remove the screw inside test connector A and connect the pressure gauge. 3. Open the gas shut off valve. Start the boiler. 4. Activate the emissions test switch "S"...
  • Page 11 Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 8. Test the nozzle pressure at partial 11. Secure protective cap B. load. 12. Switch OFF the control unit ON/ In case of deviation from the OFF switch (the boiler shuts value in the table on page 12: down).
  • Page 12 Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Rated output Full load Partial load 46.8 54.6 62.4 70.2 78.0 85.8 93.6 Nozzle pressure at 20 mbar supply pres- sure Natural gas E Full load mbar 15.4 15.4 15.4 15.4 15.4...

  • Page 13: Determining The Flue Gas Values

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Determining the flue gas values Danger Record the actual flue gas values in CO build up as a result of an the service report on page 32. incorrect burner setup can have serious health implica- tions.

  • Page 14: Checking The Draught

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Checking the draught Check the draught in Pa (100 Pa = 1 mbar) (test port behind the draught hood) and record it in the service report on page 32. Note Required boiler draught: 3 Pa (0.03 mbar).

  • Page 15: Burner Removal

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Burner removal 1. Pull the plug in connector (except 3. Release the fitting on gas supply fA) from burner control unit C. pipe B. 2. Pull the earth cable from gas com- 4.

  • Page 16: Checking The Pilot Burner

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Checking the pilot burner A Ionisation electrode B Pilot burner C Ignition electrode 1. Check the ionisation electrode, the 2. Check the electrode gaps. pilot burner and the ignition elec- trode for damage.

  • Page 17: Cleaning The Heating Surfaces (If Required)

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the heating surfaces (if required) 1. Release self tapping screws A 3. Remove front top cover F and remove top panel B. together with control unit E and hook into the front.

  • Page 18: Burner Installation

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 5. Clean the heating surfaces of the 6. Remove residues from the bottom boiler (with the burner removed) plate. with the cleaning brushes supplied. 7. Install in reverse order. Please note Cleaning agents containing potassium destroy the heat-...

  • Page 19: Checking The Flue Gas Monitor

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Checking the flue gas monitor A Sensor 1. Shut down your boiler. 4. Start the boiler. 2. Pull the flue pipe from the draught 5. The flue gas monitor must shut hood.

  • Page 20: Instructing The System User

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Check the sensor position, if the 7. Shut down your heating system. flue gas monitor shuts down the burner later than after 2 minutes. 8. Remove the cover, and push the Replace the sensor or the burner flue pipe onto the draught hood.

  • Page 21: Troubleshooting

    Troubleshooting Diagnostic system System char- Cause Measures acteristics The boiler will No voltage Check the fuse and the connections of not start the power supply cable. Check the setting of the switch on the control unit. Excessive boiler Wait until the boiler water temperature water temperature has dropped by approx.

  • Page 22: Ignition System

    Ignition system Time chart and function Time chart Standard operation with heat demand A Heat demand E Flame signal B Pilot gas valve F Pressure switch open C External LPG valve G Main gas valves D HV ignition H Pressure switch closed Dwell time Safety period, burner start Pilot burner stabilising time...
  • Page 23 Ignition system Time chart and function (cont.) Function Pilot gas valve B and, if installed, Main gas valves G are opened after external LPG valve C open after a a pilot burner stabilising time T , the stab heat demand A. pressure switches H are pressurised Gas flows to the pilot burner;...

  • Page 24: Designs

    Designs Connection diagrams burner control unit Fuel valve (partial load) Reset button Modulation coil (full load) Fault display GDS Gas governor Only for LPG: Burner control unit Gas governor Connections to the control unit Only for natural gas: Gas combination valve Jumpers Sensor, flue gas monitoring Ignition unit...

  • Page 25: Connection Diagrams Burners 72 To 96 Kw

    Designs Connection diagrams burners 72 to 96 kW Fuel valve Gas connection Modulation coil Burner control unit GDS Gas governor (into ionisation Boiler control unit lead) External LPG valve Modulation coil connecting Pilot gas valve cable Main gas valves Main gas valve connection HV ignition cable Ionisation...

  • Page 26: Connection Diagrams Burners 108 To 144 Kw

    Designs Connection diagrams burners 108 to 144 kW Fuel valve Gas connection Modulation coil Burner control unit GDS Gas governor (into ionisation Boiler control unit lead) External LPG valve Modulation coil connecting Pilot gas valve cable Main gas valves Main gas valve connection HV ignition cable Ionisation...

  • Page 27: Parts Lists

    Parts lists Parts lists When ordering spare parts: Quote the part number and serial no. (see type plate) and the item no. of the required part (as per this parts list). Obtain standard parts from your local supplier. Parts 208 Threaded stud 001 Clean out cover 209 Insulation casing 002 Draught hood...
  • Page 28 Parts lists Parts lists (cont.) 320 Ignition transformer primary Legend cable A Type plate 321 Burner cable with plug fA B Boiler control unit Vitotronic 100, 322 Conversion parts for natural gas type GC1; see separate installa- tion and service instructions 323 Conversion parts for LPG C Boiler control unit Vitotronic 100, 324 Conversion parts for natural gas...
  • Page 29 Parts lists Parts lists (cont.)
  • Page 30 Parts lists Parts lists (cont.)
  • Page 31 Parts lists Parts lists (cont.)

  • Page 32: Commissioning/Service Reports

    Commissioning/service reports Commissioning/service reports Setting and test values Set value Initial Service start up Date: Static pressure mbar max. 57.5 mbar Supply pressure (flow pressure) = for natural gas E mbar 17.4 25 mbar = for natural gas LL mbar 17.4 25 mbar = for LPG (at 50 mbar mbar...

  • Page 33: Specification

    Specification Specification Specification and product characteristics (to EnEV [Germany]) Rated output Full load Partial load 46.8 54.6 62.4 70.2 78.0 85.8 93.6 Flue pipe 7 (inter- nal diameter) Required draught mbar 0.03 0.03 0.03 0.03 0.03 0.03 0.03 Flue gas Temperature (gross) Full load °C...

  • Page 34: Certificates

    (92/42/EEC) for Low temperature boilers (LT). The product characteristics determined as system values for the product Vitogas 100 as part of EC type testing according to the Efficiency Directive (see specification table), can be utilised to assess the energy consumption of heating and ventilation equipment to DIN V 4701 10 which is specified by the EnEV [Germany].
  • Page 35 Certificates Manufacturer's certificate according to the 1st . . . (cont.) Allendorf 10.12.05 Viessmann Werke GmbH&Co KG pp. Manfred Sommer...

  • Page 36: Keyword Index

    Keyword index Keyword index Burner control unit Ignition system ........... Burner removal Initial start up .
  • Page 40 Applicability Vitogas 100, Type GS1B Serial number 7198 340 ... to 7198 346 ... 7198 361 ... to 7198 367... Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telefon: +49 6452 70-0 Shropshire, TF1 7YP, GB Telefax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com...

This manual is also suitable for:

Gs1b

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