Viessmann Vitogas 100 GS1 Series Start-Up/Service Instructions
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Viessmann Vitogas 100 GS1 Series Start-Up/Service Instructions

Vitogas 100 gs1 series natural gas-/propane-fired, single-stage atmospheric cast-iron boiler
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See also: Instruction and Installation Manual
Start-up/Service Instructions
for Use by Heating Contractor
Vitogas 100
GS1 Series
Natural gas-/propane-fired, single-stage
atmospheric cast-iron boiler
Heating input
90 to 240 MBH
26 to
70 kW
VITOGAS 100
5167 464 v1.2 01/2008
IMPORTANT
Read and save these instructions
for future reference.

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  • Page 1 Start-up/Service Instructions for Use by Heating Contractor Vitogas 100 GS1 Series Natural gas-/propane-fired, single-stage atmospheric cast-iron boiler Heating input 90 to 240 MBH 26 to 70 kW VITOGAS 100 IMPORTANT Read and save these instructions for future reference. 5167 464 v1.2 01/2008...
  • Page 2 Viessmann equipment. Please see section For a listing of For information " "...

  • Page 3: Table Of Contents

    Contents Page Safety Important Regulatory and Installation Requirements ..General Information About these Start-up/Service Instructions ..... . . Necessary Tools .

  • Page 4: Important Regulatory And Installation Requirements

    Vitogas 100: operator/ultimate owner where the - Technical Data Manual literature can be found. Contact - Installation Instructions Viessmann for additional copies. - Start-up/Service Instructions - Operating Instructions and User’s Information Manual Additional applicable literature: - Vitotronic controls manuals...
  • Page 5 Safety Safety, Installation and Warranty Requirements (continued) Suppliers of fiberglass wool products H Fiberglass wool and ceramic fiber H Hazardous materials materials recommend the following precautions be taken when handling these materials: WARNING WARNING Precautionary measures Appliance materials of construction, - Avoid breathing fiberglass dust and Inhalation of fiberglass wool and/or products of combustion and the fuel...

  • Page 6: About These Start-Up/Service Instructions

    General Information About these Start-up/Service Instructions Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below. Warnings draw your attention to the WARNING presence of potential hazards or important product information.

  • Page 7: Overview

    Initial Start-up and Service Overview Steps to carry out for Initial start-up Steps to carry out for Service 1. Preparations prior to start-up Page ......2.

  • Page 8: Procedures

    Initial Start-up and Service Procedures 1. Preparations prior to start-up nitial start-up Vitotronic Boiler Controls 1. Ensure fresh air intake of mechanical room is open and that chimney and all flue pipes are connected, sealed and unobstructed inside. Verify that all requirements in the Combustion Air Supply section in the Vitogas 100, GS1 Installation Instructions are met.

  • Page 9: Select Appropriate Gas Type

    Initial Start-up and Service Initial Start-up and Service Procedures (continued) 2. Select appropriate gas type nitial start-up ervice 1. Ensure that the fuel type listed on IMPORTANT the boiler rating plate is the correct type for the installation being attempted. The Maintenance Record is located in the back of this manual.

  • Page 10: Check Static, Running And Manifold Gas Supply Pressure

    Initial Start-up and Service Initial Start-up and Service Procedures (continued) 3. Check static, running and manifold gas supply pressure nitial start-up ervice Gas supply static pressure: 1. Ensure manual gas shut-off valve (field supplied) is closed. 2. Remove screw in inlet pressure tap ®...
  • Page 11 Initial Start-up and Service Initial Start-up and Service Procedures (continued) 3. Check static, running and manifold gas supply pressure (continued) nitial start-up ervice Manifold pressure: 9. Remove gas valve outlet pressure tap and connect U-tube manometer or ® non-electric Magnehelic manometer.
  • Page 12 Initial Start-up and Service Initial Start-up and Service Procedures (continued) 3. Check static, running and manifold gas supply pressure (continued) nitial start-up ervice WARNING Always ensure the correct orifices are installed in the boiler. See table below. The boiler must be fired to achieve the output stated on the rating plate.

  • Page 13: Measure Flue Gas Values

    Initial Start-up and Service Procedures (continued) 4. Measure flue gas values nitial start-up ervice H Carbon dioxide CO WARNING H Oxygen content O A CO analysis must be performed H Carbon monoxide CO before and after any work activities H Flue gas temperature (gross) to ensure that equipment operation is H Flue gas loss safe (health-wise) to inhabitants, and...

  • Page 14: Measure Chimney Draft

    Initial Start-up and Service Procedures (continued) 6. Measure chimney draft nitial start-up ervice The boiler shall be connected to a chimney having sufficient draft at all times to ensure safe and proper operation. Down drafting and condensation problems must be corrected. H Measure the chimney draft after the draft hood and record value in Maintenance Record on page 30 of...

  • Page 15: Shut Down Heating System

    Initial Start-up and Service Procedures (continued) 7. Shut down heating system ervice 1. Deactivate power on boiler control. 2. Deactivate main power supply to equipment and take precautions to avoid accidental activation. 3. Close manual gas supply valve. 8. Remove burner tray ervice 1.

  • Page 16: Inspect Burners

    4. Replace pilot burner if necessary. See Replacement Pilot Burner Installation Instructions 5. Viessmann pilot orifice (not shown): H Natural gas stamped “26” H Propane gas stamped “24” 11. Clean heat exchanger, if applicable (with burner tray removed) ervice 1.

  • Page 17: Reinstall Burner Tray

    Initial Start-up and Service Procedures (continued) 12. Reinstall burner tray ervice 13. Inspect all water pipe connections nitial start-up ervice Check heating system and domestic hot water connections. Ensure all connections are pressure tight. Correct any leaks found on fittings, pumps, valves, etc..

  • Page 18: Check Electrical Connections

    Initial Start-up and Service Procedures (continued) 16. Check electrical connections nitial start-up ervice Ensure all plug-in connectors and strain reliefs make positive contact and are seated properly. Start-up/Service Instructions Vitotronic Boiler Control 17. Start up heating system nitial start-up ervice Operating Instructions Heating System, Accessories...

  • Page 19: Check Blocked Vent Safety Switch

    Initial Start-up and Service Procedures (continued) 19. Check blocked vent safety switch nitial start-up ervice The blocked vent safety switch is located at the back of the boiler in the draft hood. In the event of a complete vent blockage the bi-metallic spill switch heats up due to flue gas spillage and interrupts 24 VAC to the gas control shutting down the burner.

  • Page 20: Combustion Air Supply

    If outside air duct is by entrainment through the burner front openings. necessary, ensure it is installed. Viessmann recommends the use of combustion air from an outdoor source. Ensure that nothing is obstructing the flow of combustion ventilation air and...

  • Page 21: Diagnosis And Correction

    H Are all plug connections tight and secure? Troubleshooting the Boiler Control see Start-up/Service Instructions of Boiler Control CAUTION Use only Viessmann original components when replacing defective parts. Installation of incorrect replacement parts can cause hazardous operation. Order replacement components from your Viessmann distributor.
  • Page 22 Troubleshooting Guide Diagnosis and Correction (continued) Failure Cause Correction Vent damper (if applicable) is not Boiler does not start up (continued) Ensure unobstructed operation of open, vent damper jammed or vent vent damper blade or replace vent damper motor has not activated damper.
  • Page 23 Troubleshooting Guide Diagnosis and Correction (continued) Check voltage between terminals “N-BK2” and “LI-BK1”. Check boiler control (power supply, power 120 VAC on/off switch, fuses, and fixed high limit). available? Check voltage between terminals “N-BK2” and “T2-BK4”. Check boiler control adjustable high limit call for heat (24 VAC room 120 VAC thermostat) located inside...

  • Page 24: Functioning Of Burner Ignition System

    Additional Information Additional Information Functioning of Burner Ignition System The burner ignition system functions as follows: 1.Demand for heat causes vent damper blade to open, closing vent damper and switch ES. 2.120 V is supplied to the 120 V / 24 V transformer through the safety high limit aquastats of the boiler control.

  • Page 25: Ignition System Wiring Diagram

    Additional Information Ignition System Wiring Diagram (Vitogas 100, GS1 with Vitotronic Controls)

  • Page 26: Parts List

    Placeholder - Parts List...
  • Page 27 Placeholder - Parts List...
  • Page 28 Placeholder - Parts List...
  • Page 29 Placeholder - Parts List...

  • Page 30: Maintenance Record

    Additional Information Platzhalter Maintenance Record...

  • Page 31: Lighting And Operating Instructions

    Additional Information Lighting and Operating Instructions...
  • Page 32 Viessmann Manufacturing Company (U.S.) Inc. Viessmann Manufacturing Company Inc. 45 Access Road 750 McMurray Road Warwick, Rhode Island • 02886 • USA Waterloo, Ontario • N2V 2G5 • Canada Tel. (401) 732-0667 • Fax (401) 732-0590 Tel. (519) 885-6300 • Fax (519) 885-0887 www.viessmann-us.com •...

This manual is also suitable for:

Vitogas 100 gs1-22Vitogas 100 gs1-29Vitogas 100 gs1-35Vitogas 100 gs1-42Vitogas 100 gs1-48Vitogas 100 gs1-60

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