Viessmann VITOGAS 100 Istruzioni operative

VITOGAS 100

Service instructions

for heating engineers

VitogasĂ100

TypeĂGS1, 72 to 144ĂkW

Gas fired boiler

for natural gas and LPG

See notes on applicability, pageĂ2.

5692Ă 82 GBăăă2/2004 Please keep safe

General information

Safety instructions

Please follow these safety instructions closely to prevent accidents and

material losses.

Work on the equipment

Installation, initial start-up, inspection,

maintenance and repairs must only

be carried out by a competent

person (heating engineer/installation

contractor).

Before working on the equipment/

heating system, isolate the mains

electrical supply (e.g. by removing a

separate mains fuse or by means of

a mains electrical isolator) and

safeguard against unauthorised

reconnection.

Close the main gas shut-off valve

and safeguard against unauthorised

reopening.

Work on gas equipment

This must only be carried out by an

approved contractor.

Please observe all commissioning

work specified for gas installations to

TRGI or TRF and all local regulations.

Please observe all commissioning

work specified for gas systems.

epair work

It is not permitted to carry out repairs

on parts that fulfil a safety function.

Use only original Viessmann spare

parts, or equivalent parts that have

been approved by Viessmann.

Initial start-up

The initial start-up must be carried

out by the system installer or a

designated commissioning engineer.

All actual values should be recorded

in a commissioning/service report.

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.

¨ĂSafety instructions

In this instruction manual, this

heading denotes information which

must be observed to prevent

accidents and material losses.

¨This symbol denotes important

information which must be

observed to prevent material

losses.

Applicability

VitogasĂ100, typeĂGS1

from serial no.

714 298Ă1Ă00000Ăkkk, 714 299Ă1Ă00000Ăkkk, 714 00Ă1Ă00000Ăkkk,

714 01Ă1Ă00000Ăkkk, 714 02Ă1Ă00000Ăkkk, 714 0 Ă1Ă00000Ăkkk,

714 04Ă1Ă00000Ăkkk, 75184 6Ă0Ă00000Ăkkk, 75184 7Ă0Ă00000Ăkkk,

75184 8Ă0Ă00000Ăkkk, 75184 9Ă0Ă00000Ăkkk, 7518440Ă0Ă00000Ăkkk,

7518441Ă0Ă00000Ăkkk, 7518442Ă0Ă00000Ăkkk, 751844 Ă0Ă00000Ăkkk,

7518444Ă0Ă00000Ăkkk, 7518445Ă0Ă00000Ăkkk, 7518446Ă0Ă00000Ăkkk,

7518447Ă0Ă00000Ăkkk, 7518448Ă0Ă00000Ăkkk, 7518449Ă0Ă00000Ăkkk

5692Ă 82 GB

Contents

Index

Page

General information

Safety instructionsĂ 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ApplicabilityĂ 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial start-up, inspection and maintenance

StepsĂćĂinitial start-up, inspection and maintenanceĂ 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Further details regarding the individual stepsĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

DiagnosticsĂ 17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix

Function of the ignition burner systemĂ 18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time chartĂ 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection diagram

HĂBurner controlĂ 19

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HĂBurner, ă72ĂĆĂă96ĂkWĂ 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HĂBurner, 108ĂĆĂ144ĂkWĂ 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts listsĂ 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning/service reportĂ 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SpecificationĂ 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Declaration of conformityĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manufacturer's certificateĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keyword indexĂ 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5692Ă 82 GB

Initial start-up, inspection and maintenance

StepsĂćĂinitial start-up, inspection and maintenance

For further instructions on individual steps, see pages indicated.

Commissioning steps

Inspection steps

Maintenance steps Page

C I M 1. Preparing for commissioning and checking

diaphragm expansion vesselĂ 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 2. Checking gas typeĂ 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 3. Checking static and supply pressureĂ 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 4. Checking nozzle pressureĂ 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 5. Checking flue gas valuesĂ 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 6. Checking ionisation currentĂ 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 7. Checking draughtĂ 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 8. Burner removalĂ 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 9. Checking burner tubesĂ 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 10. Checking ignition burnerĂ 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M11. Cleaning heating surfacesĂ 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 12. Burner installation

C I M 13. Checking all water connections for leaks

C I M 14. Checking all safety equipment

C I M 15. Checking tightness of electrical connections

C M 16. System start-upĂ 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 17. Checking closing function of gas combination valves

C I M 18. Checking flue gas monitoring equipmentĂ 16. . . . . . . . . . . . . . . . . . . . . . .

5692Ă 82 GB

Initial start-up, inspection and maintenance

Further details regarding the individual steps

Preparing for commissioning and checking the diaphragm

expansion vessel

¨ĂSafety instructions

Only for commissioning with VitotronicĂ 00, typeĂGW2

Check that the high limit safety cut-out of the control unit is not set higher

than 110ĂºC. Set to a maximum of 110ĂºC if required.

1. Check that the boiler room

ventilation aperture is open.

2. Check the charge pressure of the

diaphragm expansion vessel.

3. Open any check valves that may

be fitted.

4. Fill the heating system, vent it and

check the system pressure on

pressure gaugeĂA.

(Min. system pressure 0.8Ăbar,

permiss. operating pressure Ăbar).

5. Return the check valves to their

operating position.

5692Ă 82 GB

Safety equipment block 72 to 96ĂkW

Safety equipment block 108 to 144ĂkW

Initial start-up, inspection and maintenance

Further details regarding the individual steps (cont.)

Checking the gas type

1. Enquire the gas type and Wobbe

indexĂ(Wo) from your local mains

gas or LPG supplier.

Please note:

The boiler is set up in the factory

for natural gasĂE.

The boiler can be operated in

the Wobbe index range

12.0 to 16.1ĂkWh/m

(4 .2 to 58.0ĂMJ/m ).

2. Compare the gas category (type)

and group with the details on the

burner label.

3. The burner must be converted acc.

to the details provided by the

mains gas or the LPG supplier to

match the fuel provided, if these

details do not match.

Installation instructions

Conversion kit

After conversion from

HNatural gasĂE to natural gasĂLL:

This boiler can be operated in

the Wobbe index range

10.0 to 1 .1ĂkWh/m

( 6.0 to 47.2ĂMJ/m ).

HNatural gasĂE to LPGĂP:

The boiler can be operated in

the Wobbe index range

21.4 to 22.5ĂkWh/m

(76.9 to 81.0ĂMJ/m ).

4. Record the gas type in the service

report from pageĂ28.

5692Ă 82 GB

Initial start-up, inspection and maintenance

Further details regarding the individual steps (cont.)

Checking static and supply pressure

¨ĂSafety 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.

LPG version

Flush the LPG tank twice after installation or replacement.

Thoroughly vent the tank and gas lines after flushing.

Static pressure

1. Close the gas shut-off valve.

2. Unscrew the screw inside test

nippleĂA on the gas combination

valve and connect pressure gauge.

3. Open the gas shut-off valve.

4. Check static pressure; it should be

Hmax. 25Ămbar for natural gas,

Hmax. 57.5Ămbar for LPG.

Record the actual value in the

service report.

Supply pressure (flow pressure)

5. Start up the boiler.

Please note:

On start-up, the boiler can enter a

fault state because of airlocks in

the gas pipe.

After approx.Ă10Ăseconds, press the

reset button on the burner control

unit, this repeats the ignition

process.

5692Ă 82 GB

Initial start-up, inspection and maintenance

Further details regarding the individual steps (cont.)

6. Check the supply (flow) pressure;

it should be

H17.4 to 25Ămbar for natural gas,

H42.5 to 57.5Ămbar for LPG

Record the actual value in the

service report.

Take the action shown in the table.

Supply pressure (flow pressure) emedy

Natural gas LPG

below 17.4Ămbar below 42.5Ămbar Make no adjustments and notify your

mains gas or LPG supplier.

17.4 to 25Ămbar 42.5 to

57.5Ămbar

Start up boiler.

above 25Ămbar above 57.5Ămbar Install a separate gas pressure governor

upstream of the system and regulate the

pressure to 20Ămbar for natural gas or

50Ămbar for LPG.

Notify your mains gas or LPG supplier.

7. Shut down the boiler, close the

gas shut-off valve, remove the

pressure gauge, and seal test

nippleĂA with screw.

8. ¨ĂSafety instructions

Open the gas shut-off valve and

check test nippleĂA for soundness.

5692Ă 82 GB

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

nippleĂA and connect the

pressure gauge.

3. Open the gas shut-off valve.

Start up the boiler.

4. Check the nozzle pressure for full

load, and adjust to the values in

the table on pageĂ10, if required:

HSet emissions test switchĂS to h

(full load).

HRemove protective capĂB.

HHold up crosshead screwĂC.

HAdjust the nozzle pressure at

hexagon screwĂD (turning

clockwiseĂć nozzle pressure

increases).

Please note:

Check and adjust the nozzle

pressure at full loa , if required.

5. Check setting values and record in

the service report.

6. Separate plug-in connectorĂlÖ

(partial load).

7. Check the nozzle pressure for

partial load, and adjust to the

values in the table on pageĂ10, if

required:

HHold up hexagon screwĂD.

HAdjust the nozzle pressure at

crosshead screwĂC (turning

clockwiseĂć nozzle pressure

increases).

8. Set emissions test switchĂS to a,

and insert plug-in connectorĂlÖ.

9. Fit capĂB.

5692Ă 82 GB

Initial start-up, inspection and maintenance

Further details regarding the individual steps (cont.)

10. Switch OFF system ON/OFF switch

at the control unit (boiler shuts

down), close gas shut-off valve,

remove pressure gauge and close

test nippleĂA with screw.

11. ¨ĂSafety instructions

Open gas shut-off valve, start up

boiler and check soundness of

test nippleĂA.

ated output kW Full load

72ĂkW

Partial load

46.8ĂkW

Full load

84ĂkW

Partial load

54.6ĂkW

Full load

96ĂkW

Partial load

62.4ĂkW

Natural gasĂE

with Wobbe index Wo

15.0ĂkWh/m

54.0ĂMJ/m

ć Nozzle pressure*1 Full load

relative to Part. load

20Ămbar supply pressure

ć Nozzle ID

ć Air restrictor

mbar

∅Ămm

15.4

6.8

2.90

15.4

6.8

2.90

15.4

6.8

2.90

Natural gasĂLL

with Wobbe index Wo

12.4ĂkWh/m

44.6ĂMJ/m

ć Nozzle pressure*1 Full load

relative to Part. load

20Ămbar supply pressure

ć Nozzle ID

ć Air restrictor

mbar

∅Ămm

15.4

6.8

.20

15.4

6.8

.20

15.4

6.8

.20

LPG

with Wobbe index Wo

21. ĂĆĂ22.5ĂkWh/m

76.9ĂĆĂ81.1ĂMJ/m

ć Nozzle pressure*1 Full load

relative to Part. load

50Ămbar supply pressure

ć Nozzle ID

ć Air restrictor

mbar

∅Ămm

4.5

15.0

1.90

4.5

15.0

1.90

4.5

15.0

1.90

Number of burner tubes 6 7 8

*1Value relative to 101 .25Ămbar and 15ĂºC.

5692Ă 82 GB

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