Viessmann VITOGAS 100 Betriebsanleitung

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

5692 632 GB 10/2005 Please keep safe

Please follow these safety instructions closely to prevent accidents and

material losses.

Safety instructions explained

Danger

This symbol warns against the

risk of injury.

!Please note

This symbol warns against the

risk of material losses and

environmental pollution.

Note

Details identified by the word "Note"

contain additional information.

Target group

These instructions are exclusively

designed for qualified personnel.

&Work on gas equipment must only

be carried out by a qualified gas fit-

ter.

&Work on electrical equipment must

only be carried out by a qualified

electrician.

&The system must be commissioned

by the system installer or a qualified

person authorised by the installer.

Regulations

Observe the following when working

on this system

&all legal instructions regarding the

prevention of accidents,

&all legal instructions regarding

environmental protection,

&the Code of Practice of relevant

trade associations,

&all current safety regulations as

defined by DIN, EN, DVGW, TRGI,

TRF, VDE and all locally applicable

standards.

If you smell gas

Danger

Escaping gas can lead to

explosions which may result in

serious injury.

&Never smoke. Prevent naked

flames and sparks. Never

switch lights or electrical

appliances ON or OFF.

&Close the gas shut‐off valve.

&Open windows and doors.

&Remove all people from the

danger zone.

&Notify your gas or electricity

supplier from outside the

building.

&Shut off the electricity supply

to the building from a safe

place (outside the building).

If you smell flue gas

Danger

Flue gas can lead to life‐threa-

tening poisoning.

&Shut down the heating sys-

tem.

&Ventilate the boiler room.

&Close all doors leading to the

living space.

Safety instructions

5692 632 GB

Working on the system

&When using gas as fuel, also close

the main gas shut‐off valve and

safeguard against unauthorised

reopening.

&Isolate the system from the power

supply and check that it is no longer

'live', e.g. by removing a separate

fuse or by means of a mains isola-

tor.

&Safeguard the system against

unauthorised reconnection.

!Please note

Electronic modules can be

damaged by electro‐static dis-

charges.

Touch earthed objects, such as

heating or water pipes, to dis-

charge static loads.

Repair work

!Please note

Repairing components which

fulfil a safety function can com-

promise the safe operation of

your heating system.

Replace faulty components

only with original Viessmann

spare parts.

Ancillary components, spare and

wearing parts

!Please note

Spare and wearing parts which

have not been tested together

with the heating system can

compromise its function. Instal-

ling non‐authorised compo-

nents and non‐approved

modifications/conversion can

compromise safety and may

invalidate our warranty.

For replacements, use only ori-

ginal spare parts from

Viessmann or those which are

approved by Viessmann.

Safety instructions (cont.)

Safety instructions

5692 632 GB

Initial start-up, inspection, maintenance

Steps –initial start-up, inspection and maintenance .................................... 5

Further details regarding the individual steps .............................................. 6

Troubleshooting

Diagnostic system ...................................................................................... 18

Ignition system

Time chart and function............................................................................... 20

Designs

Burner control connection diagram.............................................................. 22

Draining/frost protection .......................................................................... 23

Parts lists .................................................................................................. 24

Commissioning/service reports ............................................................... 28

Specification............................................................................................. 29

Certificates

Declaration of conformity ............................................................................ 31

Manufacturer's certificate according to the 1st BImSchV [Germany]............. 31

Keyword index .......................................................................................... 33

Index

5692 632 GB

For further information regarding individual steps, see the pages indicated.

Commissioning steps

Inspection steps

Maintenance steps Page

!!!



••• 01. Preparing for commissioning .......................................... 6

••• 02. Checking the gas type......................................................... 6

••• 03. Changing the gas type (if required)................................ 7

••• 04. Checking the static and supply pressure .................... 7

••• 05. Checking the nozzle pressure.......................................... 9

••• 06. Checking the ionisation current ..................................... 11

••• 07. Checking the draught .......................................................... 12

• • 08. Burner removal ...................................................................... 12

• • 09. Checking the burner tubes ................................................ 13

• • 10. Checking the pilot burner .................................................. 13

•11. Cleaning the heating surfaces (if required)................. 14

• • 12. Burner installation................................................................ 15

••• 13. Checking all hydraulic connections for leaks

••• 14. Checking all safety equipment

••• 15. Checking the tightness of electrical connections

••• 16. Checking the external LPG safety valve (if

installed)

••• 17. Starting the heating system

••• 18. Checking all gas equipment for soundness at

operating pressure............................................................... 15

••• 19. Checking the closing function of the gas

combination valves

••• 20. Determining the flue gas values...................................... 16

••• 21. Checking the flue gas monitor ......................................... 16

•22. Instructing the system user .............................................. 17

Steps –initial start-up, inspection and maintenance

Initial start-up, inspection, maintenance

5692 632 GB

Preparing for commissioning

1. Check that the boiler room ventila-

tion aperture is open.

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-

sure.

3. Open any installed check valves.

4. Fill the heating system with water

and vent it, until the pressure indi-

cated at pressure gauge Ais

higher (0.1 to 0.2 bar) than the inlet

pressure of the diaphragm expan-

sion vessel.

Minimum system pressure 0.8 bar,

permiss. operating pressure 3 bar.

5. Return the check valves to their

operating position.

Checking the gas type

Note

In the delivered condition, the boiler is set up for natural gas E and can be oper-

ated in the Wobbe index range 12.0 to 16.1 kWh/m

(43.2 to 58.0 MJ/m

1. Check the gas category and

Wobbe index (Wo) with your mains

gas or LPG supplier and compare

them with the details on the burner

label.

2. Convert the burner in accordance

with to the details provided by the

mains gas or LPG supplier to

match the fuel provided, if these

details diverge.

Conversion kit installation

instructions

Further details regarding the individual steps

Initial start-up, inspection, maintenance

5692 632 GB

3. Record the gas type in the service

report from page 28.

Wobbe index

range Wo

Natural gas E Natural gas LL LPG P

kWh/m

12.0 to 16.1 10.0 to 13.1 21.4 to 22.5

MJ/m

43.2 to 58.0 36.0 to 47.2 76.9 to 81.0

Changing the gas type (if required)

Conversion kit installation

instructions

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. Thoroughly vent

the tank and gas lines after flushing.

ATest connector

Further details regarding the individual steps (cont.)

Initial start-up, inspection, maintenance

5692 632 GB

1. Close the gas shut‐off valve.

2. Release the screw inside test

connector Aon the gas combi-

nation valve, but do not remove it;

then connect the pressure gauge.

3. Open the gas shut‐off valve.

4. Check the static pressure:

&Natural gas: max. 25 mbar

&LPG: max. 57.5 mbar

Record the actual value in the

service report.

5. Start the boiler.

Note

During commissioning, the boiler

can enter a fault state because of

airlocks in the gas pipe. You can

reset the burner after approx.

10 seconds. For this, switch the

boiler OFF and ON at the control

unit (ON/OFF switch).

6. Check the supply (flow) pressure:

&Natural gas: 17.4 to 25 mbar

&LPG: 42.5 to 57.5 mbar

Record the actual value in the

service report.

Note

Use suitable test equipment with

a resolution of at least 0.1 mbar to

test the supply pressure.

7. Take the action shown in the fol-

lowing table.

Supply (flow)

pressure for nat-

ural gas

Supply (flow)

pressure for

LPG

Measures

below 17.4 mbar below 42.5 mbar Do not start the boiler. Notify your

mains gas or LPG supplier.

17.4 to 25 mbar 42.5 to 57.5 mbar Start the boiler.

in excess of

25 mbar

in excess of

57.5 mbar

Install a separate gas governor down-

stream of the system and regulate the

pressure to 20 mbar for natural gas or

50 mbar for LPG. Notify your mains

gas or LPG supplier.

8. Switch OFF the control unit ON/

OFF switch (the boiler shuts

down).

9. Close the gas shut‐off valve.

10. Remove the pressure gauge and

seal test connector Awith the

screw previously undone.

Further details regarding the individual steps (cont.)

Initial start-up, inspection, maintenance

5692 632 GB

11. Open the gas shut‐off valve and

check test connector Afor

soundness.

Danger

Gas escaping from test

connector Aleads to a

risk of explosion.

Check test connector A

for soundness.

Checking the nozzle pressure

1. Close the gas shut‐off valve.

2. Release the screw in test connec-

tor A, but do not remove it, and

connect the pressure gauge.

3. Open the gas shut‐off valve.

Start the boiler.

4. Check the nozzle pressure.

In case of deviation from the

value in the table on page 11

remove protective cap B.

Adjust the nozzle pressure with

screw C.

5. Check the setting values and

record them in the service report.

6. Fit protective cap B.

Further details regarding the individual steps (cont.)

Initial start-up, inspection, maintenance

5692 632 GB

7. Switch OFF the control unit ON/

OFF switch (the boiler shuts

down).

8. Close the gas shut‐off valve.

9. Remove the pressure gauge and

seal test connector Awith the

screw previously undone.

10. Open the gas shut‐off valve, start

the boiler and check the sound-

ness of test connector A.

Danger

Gas escaping from test

connector Aleads to a

risk of explosion.

Check test connector A

for soundness.

Note

The values in the nozzle pressure table apply to the following ambient condi-

tions:

&Air pressure: 1013 mbar

&Temperature: 15 °C

Wobbe index see page 7.

Rated out-

put

kW 11 15 18 22 29 35 42 48 60

Natural gas

Nozzle pres-

sure at 20

mbar supply

pressure

mbar 14.1 14.0 13.9 14.5 14.4 14.0 14.8 14.2 15.0

Nozzle des-

ignation 2.00 2.35 2.10 2.30 2.30 2.30 2.25 2.25 2.25

Air restrictor 7mm 33 —34 ——————

Natural gas

Nozzle pres-

sure at 20

mbar supply

pressure

mbar 14.1 13.9 14.1 13.7 13.8 14.0 14.2 13.7 13.5

Nozzle des-

ignation 2.25 2.60 2.30 2.55 2.55 2.55 2.50 2.50 2.50

Air restrictor 7mm 33 35 32 37 37 37 37 37 37

Further details regarding the individual steps (cont.)

Initial start-up, inspection, maintenance

5692 632 GB

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