Viessmann VITOGAS 100 Betriebsanleitung

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

5692 647 GB 1/2006 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 647 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 647 GB

Initial start-up, inspection, maintenance

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

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

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................................................ 25

Connection diagrams –burners 108 to 144 kW............................................ 26

Parts lists .................................................................................................. 27

Commissioning/service reports ............................................................... 32

Specification............................................................................................. 33

Certificates

Declaration of conformity ............................................................................ 34

Manufacturer's certificate according to the 1st BImSchV [Germany]............. 34

Keyword index .......................................................................................... 36

Index

5692 647 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......................................................... 7

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

••• 04. Checking the static and supply pressure .................... 8

••• 05. Checking the nozzle pressure.......................................... 10

••• 06. Determining the flue gas values...................................... 13

••• 07. Checking the ionisation current ..................................... 13

••• 08. Checking the draught .......................................................... 14

• • 09. Burner removal ...................................................................... 15

• • 10. Checking the burner tubes ................................................ 15

• • 11. Checking the pilot burner .................................................. 16

•12. Cleaning the heating surfaces (if required) ................ 17

• • 13. Burner installation................................................................ 18

••• 14. Checking all hydraulic connections for leaks

••• 15. Checking all safety equipment

••• 16. Checking the tightness of electrical connections

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

operating pressure............................................................... 18

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

installed)

••• 19. Starting the heating system

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

combination valves

••• 21. Checking the flue gas monitor ......................................... 19

•22. Instructing the system user .............................................. 20

Steps –initial start-up, inspection and maintenance

Initial start-up, inspection, maintenance

5692 647 GB

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 72 to

96 kW version

Safety equipment block for 108 to

144 kW version

APressure gauge

1. Check that the boiler room ventila-

tion aperture is open.

2. Check the inlet pressure of the dia-

phragm expansion vessel.

If it 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 pressure.

3. Open any installed check valves.

Further details regarding the individual steps

Initial start-up, inspection, maintenance

5692 647 GB

4. Fill the heating system with water

and vent it, until the pressure indi-

cated at the pressure gauge is

higher (0.1 to 0.2 bar) than the inlet

pressure of the diaphragm expan-

sion vessel.

Minimum system pressure 0.8 bar,

permissible operating pressure

3 bar.

5. Return the check valves to their

operating position.

Checking the gas type

Note

The boiler is set up in the factory for natural gas E.

The boiler can be operated 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 the details provided by the

mains gas or LPG supplier to

match the fuel provided, if these

details diverge.

Conversion kit installation

instructions

3. Record the gas type in the service

report on page 32.

Wobbe index range

Wobbe index Wo Natural gas LPG

E LL P

kWh/m

12.0 to 16.1 10.0 to 13.1 20.3 to 21.3

MJ/m

43.2 to 58.0 36.0 to 47.2 72.9 to 76.8

Changing the gas type (if required)

Conversion kit installation

instructions

Further details regarding the individual steps (cont.)

Initial start-up, inspection, maintenance

5692 647 GB

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

1. Close the gas shut‐off valve.

2. Remove the screw inside test

connector Aat the gas combina-

tion valve and connect the pres-

sure 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 on page 32.

5. Start the boiler.

Note

During commissioning, the boiler

can (several times) enter a fault

state because of airlocks in the

gas pipe. Press the reset button

on the burner control unit after

approx. 10 seconds.

6. Check the supply (flow) pressure:

&Natural gas: 17.4 to 25 mbar

&LPG: 42.5 to 57.5 mbar (at

50 mbar inlet pressure)

Record the actual value in the

service report on page 32.

Note

Use suitable test equipment with

a resolution of at least 0.1 mbar to

test the supply pressure.

Further details regarding the individual steps (cont.)

Initial start-up, inspection, maintenance

5692 647 GB

7. Take the action shown in the fol-

lowing table.

Supply (flow)

pressure for nat-

ural gas

Supply (flow)

pressure for

LPG (at 50 mbar

flow pressure)

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 the test connector with the

screw previously removed.

11. Open the gas shut‐off valve and

check the test connector for

soundness.

Danger

Gas escaping from the test

connector leads to a risk of

explosion.

Check the test connector

for soundness.

Further details regarding the individual steps (cont.)

Initial start-up, inspection, maintenance

5692 647 GB

Checking the nozzle pressure

ATest connector

BProtective cap

CPhillips screw

DHexagon screw

1. Close the gas shut‐off valve.

2. Remove the screw inside test

connector Aand connect the

pressure gauge.

3. Open the gas shut‐off valve.

Start the boiler.

4. Activate the emissions test switch

"S" (full load):

&For Vitotronic 100, type KC4

and Vitotronic 200, type KW5:

&Press Oand Fsimulta-

neously for approx. 2 s.

&For Vitotronic 100, type GC1

and Vitotronic 300, type GW2:

&Set the emissions test switch to

"Æ".

5. Test the nozzle pressure at full

load.

In case of deviation from the

value in the table on page 12:

&Remove protective cap B.

&Counter Phillips screw C.

&Adjust the nozzle pressure at

hexagon screw D(turn clock-

wise —nozzle pressure rises).

6. Record the setting values in the

service report on page 32.

7. Pull plug‐in connector lÖ apart

(partial load).

Further details regarding the individual steps (cont.)

Initial start-up, inspection, maintenance

5692 647 GB

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