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

Gas fired boiler for natural gas and lpg
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Service instructions
for heating engineers
Vitogas 100
Type GS1, 72 to 144 kW
Gas fired boiler
for natural gas and LPG
See notes on applicability, page 2.
VITOGAS 100
Please keep safe
5692 382 GB
2/2004

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Summary of Contents for Viessmann Vitogas 100

  • Page 1 Service instructions for heating engineers Vitogas 100 Type GS1, 72 to 144 kW Gas fired boiler for natural gas and LPG See notes on applicability, page 2. VITOGAS 100 Please keep safe 5692 382 GB 2/2004...

  • Page 2: General Information

    It is not permitted to carry out repairs maintenance and repairs must only on parts that fulfil a safety function. be carried out by a competent Use only original Viessmann spare person (heating engineer/installation parts, or equivalent parts that have contractor).

  • 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 and checking the diaphragm expansion vessel ¨ Safety instructions Only for commissioning with Vitotronic 300, type GW2 Check that the high limit safety cut-out of the control unit is not set higher than 110 ºC.

  • Page 6: Checking Gas Type

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

  • 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 instructions 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.
  • 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 the nozzle pressure 1. Close the gas shut-off valve. 2. Unscrew the screw inside test nipple A 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.) 10. Switch OFF system ON/OFF switch 11. ¨ Safety instructions at the control unit (boiler shuts Open gas shut-off valve, start up down), close gas shut-off valve, boiler and check soundness of remove pressure gauge and close test nipple A.
  • Page 11 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Rated output Full Full Full Full load load load load 108 kW 120 kW 132 kW 144 kW Partial Partial Partial Partial load load load load 70.2 kW 78.0 kW 85.8 kW 93.6 kW...

  • Page 12: Checking Flue Gas Values

    Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the flue gas values ¨ Safety instructions Measure the CO value before and after any work on gas appliances, to prevent any health hazards and to ensure perfect system condition. Record the flue gas values in the service report.

  • Page 13: Checking Draught

    Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the draught Check the supply pressure behind the draught hood in hPa (1 hPa = 1 mbar) and record in the service report. Please 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) in the chimney.

  • Page 14: I M 9. Checking Burner Tubes

    Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the burner tubes 1. Check the gas orifices for damage. 2. Blow out the burner tubes with compressed air or wash in a soapy solution. Checking the ignition burner 1.

  • Page 15: M 11. Cleaning Heating Surfaces

    Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Clean the heating surfaces, 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 and mineral fibre mat C.

  • Page 16: Checking Flue Gas Monitoring Equipment

    Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the flue gas monitoring equipment 1. Remove the flue pipe from the draught hood. 2. Cover up the flue pipe connector of the draught hood to carry out the function test.

  • Page 17: Troubleshooting

    Troubleshooting Diagnostics Fault Cause Remedy The boiler will No voltage Check the fuse and connections of not start the main power supply. Check the switches on the control unit for their settings. Boiler water Wait until the boiler water temperature temperature too high has fallen by approx.

  • Page 18: Appendix

    Appendix Function of the ignition burner system The burner control unit is supplied The pressure switches are controlled with current when there is a heat with a switching differential of demand. The control indicator on the < 2 seconds. burner control unit illuminates. The All burner areas are ignited.

  • Page 19: H Burner Control

    Appendix Connection diagram for burner control Dungs DGAI69F-Mod.50.3.0TLL GDW Br.2 GDW Br.1 Sensor Reset Fault Ignition GDW Br.3 Flue gas pressure unit monitoring B4 monitor BV2.1 BV2.2 BV1.2 BV1.1 BV3.1 BV3.2 Key to symbols Fuel valve (partial load) Modulation coil (full load) GDW Gas pressure switch Gas pressure switch only for LPG.

  • Page 20: H Burner, 72 96 Kw

    Appendix Connection diagram for burner 72 to 96 kW Boiler circuit control unit Burner control unit Ignition cable Gas connection Pilot burner Manifold Manifold GDW 2 GDW 1 Key to symbols 1 Connecting cable Fuel valve modulation coils Modulation coil 2 Connecting cable GDW Gas pressure switch main gas valves...

  • Page 21: H Burner, 108 144 Kw

    Appendix Connection diagram for burner 108 to 144 kW Boiler circuit control unit Burner control unit Ignition unit Gas connection BV 1.1 BV 2.1 BV 3.1 BV 1.2 BV 2.2 BV 3.2 MS 1" MS 2" MS 3" Pilot burner Manifold Manifold Manifold...

  • Page 22: Parts Lists

    056 Cover cap 011 R.h. side panel 057 O-ring 25 × 4 mm 012 L.h. side panel 058 Burner (with items 040, 042, 044, 013 Vitogas 100 logo 048, 050, 059 and 065) 014 Diaphragm grommet 059 Thermal insulation panel 015 Closure...
  • Page 23 Appendix Parts lists (cont.) Parts not shown Wear parts 023 Insulation pack 035 Cleaning brush 038 Gas governor 050 Ignition burner 039 Draught hood pack 051 Gasket set A Type plate intermittent ignition system B Vitotronic, Gkk boiler control 060 Conversion parts for natural unit, see installation and service gas E instructions for the control unit...
  • Page 24 Appendix Parts lists (cont.)
  • Page 25 Appendix Parts lists (cont.)
  • Page 26 Appendix Parts lists (cont.)
  • Page 27 Appendix Parts lists (cont.)

  • Page 28: 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 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 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 33 Appendix Maint./service Maint./service Maint./service Maint./service...

  • Page 34: Specification

    Appendix Specification Rated output Full load Full load Partial load 46.8 54.6 62.4 70.2 78.0 85.8 93.6 Flue pipe (clearance) ∅ mm Required draught mbar 0.03 0.03 0.03 0.03 0.03 0.03 0.03 Flue gas Temperature (gross) upper rated output (full load) ºC lower rated output (part.load) ºC...

  • Page 35: 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 to assess the energy consumption of heating and ventilation equipment to DIN V 4701 10 which is specified by the EnEV.

  • Page 36: Keyword Index

    High limit safety cut-out, 17 Ignition burner, 12, 14 Ignition electrode, 14 Ionisation current, 12, 17 Ionisation electrode, 12 Viessmann Limited Viessmann Werke GmbH & Co Hortonwood 30, Telford D 35107 Allendorf Shropshire, TF1 7YP , GB Tel: +49 6452 70 0...

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Gs1

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