Viessmann VITOGAS 100 Service Instructions Manual
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Viessmann VITOGAS 100 Service Instructions Manual

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VIESMANN
Service instructions
for heating engineers
Vitogas 100
Type GS1B
Rated output 11 to 60 kW
Gas fired boiler
Natural gas and LPG version
For applicability, see the last page
VITOGAS 100
Please keep safe
5692 632 GB
10/2005

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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 11 to 60 kW Gas fired boiler Natural gas and LPG version For applicability, see the last page VITOGAS 100 Please keep safe 5692 632 GB 10/2005...
  • 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 ..................18 Ignition system Time chart and function................20 Designs Burner control connection diagram.............. 22 Draining/frost protection ................23 Parts lists ....................
  • 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 2. Check the inlet pressure of the dia- phragm expansion vessel. If the inlet pressure of the dia- phragm expansion vessel is lower than the static system pressure, top up with sufficient nitrogen to raise the inlet pressure above (0.1 to 0.2 bar) the static system pres-...

  • Page 7: Changing The Gas Type (If Required)

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 3. Record the gas type in the service report from page 28. Wobbe index Natural gas E Natural gas LL LPG P range Wo kWh/m 12.0 to 16.1 10.0 to 13.1 21.4 to 22.5 MJ/m 43.2 to 58.0...
  • Page 8 Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 1. Close the gas shut off valve. 5. Start the boiler. 2. Release the screw inside test Note connector A on the gas combi- During commissioning, the boiler nation valve, but do not remove it; can enter a fault state because of then connect the pressure gauge.

  • Page 9: Checking The Nozzle Pressure

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 11. Open the gas shut off valve and check test connector A for soundness. Danger Gas escaping from test connector A leads to a risk of explosion. Check test connector A for soundness.
  • Page 10 Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 7. Switch OFF the control unit ON/ 10. Open the gas shut off valve, start OFF switch (the boiler shuts the boiler and check the sound- down). ness of test connector A. 8.

  • Page 11: Checking The Ionisation Current

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Rated out- Nozzle pres- mbar 36.0 36.5 35.3 35.3 35.0 35.0 35.0 35.5 36.2 sure at 50 mbar supply pressure Nozzle des- 1.25 1.45 1.35 1.45 1.45 1.45 1.45 1.40 1.40 ignation Air restrictor Number of burner...

  • Page 12: Checking The Draught

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Checking the draught Check the draught behind the draught hood in Pa (100 Pa = 1 mbar) and record it in the service report from page 28. Note Required boiler draught: 3 Pa (0.03 mbar). The chimney draught must not be greater than 10 Pa (0.1 mbar).

  • Page 13: Checking The Burner Tubes

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Checking the burner tubes 1. Check the gas outlets for damage. 2. Blow through burner tubes with compressed air or rinse with a soapy solution. Checking the pilot burner 1.

  • Page 14: Cleaning The Heating Surfaces (If Required)

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Note Both pilot burners shown may be installed in Vitogas 100, type GS1B. Cleaning the heating surfaces (if required)

  • Page 15: Burner Installation

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 1. Release self tapping screws A 5. Clean the heating surfaces of the and remove top panel B. boiler (with the burner removed) with the cleaning brushes supplied. 2. Release the tension springs and remove thermal insulation mat C.

  • Page 16: Determining The Flue Gas Values

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Determining the flue gas values Danger Determine the flue gas values and CO build up as a result of an record them in the service report on incorrect burner setup can page 28.

  • Page 17: Instructing The System User

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 8. Remove the cover, and push the 9. Start the system. flue pipe onto the draught hood. 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.

  • Page 18: 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 control unit ON/OFF switch. Excessive boiler Wait until the boiler water temperature water temperature has dropped by approx.
  • Page 19 Troubleshooting Diagnostic system (cont.) Control unit faults: Service instructions boiler con- trol unit...

  • Page 20: Ignition System

    Ignition system Time chart and function Time chart 1 Standard operation with heat C External LPG valve demand D HV ignition 2 Pilot gas valve faulty E Flame signal 3 Flue gas monitor interference F Main gas valve 4 No flame signal G Flue gas monitor A Heat demand H Fault display...
  • Page 21 Ignition system Time chart and function (cont.) Function Pilot gas valve B and, if installed, After the pilot burner stabilising time external LPG valve C open after a , main gas valve F opens and stab heat demand A. the burner ignites. Gas flows to the pilot burner;...

  • Page 22: Designs

    Designs Burner control connection diagram A Burner control unit E Gas governor B Terminal strip C Sensor, flue gas monitoring Jumper F External LPG valve plug with resistance G Ionisation lead D Burner cable H Ignition cable K Pilot burner...

  • Page 23: Draining/Frost Protection

    Draining/frost protection Draining/frost protection To fully drain the boiler (e.g. when there is a risk of frost), also drain the l. h. boiler section via drain valve A at the front of the boiler.

  • Page 24: 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 Wearing parts 001 Clean out cover 007 Cleaning brushes 002 Draught hood...
  • Page 25 Parts lists Parts lists (cont.)
  • Page 26 Parts lists Parts lists (cont.)
  • Page 27 Parts lists Parts lists (cont.)

  • Page 28: 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 mbar...

  • Page 29: Specification

    Specification Specification Rated out- Flue pipe (clearance) 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 Temperature °C (gross) Mass flow rate Natural gas kg/h kg/h Chimney information Observe the required draught when sizing the chimney. Apply the flue gas values (measured downstream of the draught hood) as calcu- lating values for sizing the chimney in accordance with DIN 4705.
  • Page 30 Specification Specification (cont.) Rated out- Power con- sumption (standard value) at 100 % of rated out- 30 % of rated out-...

  • Page 31: 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 32 Certificates Manufacturer's certificate according to the 1st . . . (cont.) Allendorf 15.10.05 Viessmann Werke GmbH&Co KG pp. Manfred Sommer...

  • Page 33: Keyword Index

    Keyword index Keyword index Burner connection diagram Gas combination valve ......Burner control diagram Gas supply pressure .
  • Page 36 Applicability Vitogas 100, type GS1B Serial number: 7198 128 ... to 7198 136 ... 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.de...

This manual is also suitable for:

Gs1b

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