Viessmann VITOGAS 100 Istruzioni operative

VITOGAS 100

Service instructions

for heating engineers

Vitogas100

TypeGS1, 11 to 60kW

Gas fired boiler

See notes on applicability, page2.

5692413GB6/2004 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.

Repair 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.

¨Safety instruction

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

Vitogas100, typeGS1

from serial no.

7143553100000kkk 7143556100000kkk 7143559100000kkk

7143554100000kkk 7143557100000kkk 7143560100000kkk

7143555100000kkk 7143558100000kkk 7143561100000kkk

5692413GB

Contents

Index

Page

General information

Safety instructions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicability 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial start−up, inspection and maintenance

StepsInitial start−up, inspection and maintenance 4

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

Further details regarding the individual steps 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

Diagnostics 16

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

Appendix

Function of the ignition burner system 17

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

Time chart 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection diagram for burner control 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining/frost protection 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimum clearances 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts lists 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning/service report 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specification 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Declaration of conformity 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manufacturer’s certificate 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keyword index 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5692413GB

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

C I M 1. Preparing for commissioning and checking

diaphragm expansion vessel 5

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

C I M 2. Checking gas type 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 3. Checking static and supply pressure 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 4. Checking nozzle pressure 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 5. Checking flue gas values 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 6. Checking ionisation current 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 7. Checking draught 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 8. Burner removal 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 9. Checking burner tubes 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 10. Checking ignition burner 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M11. Cleaning heating surfaces 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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−up 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

C I M 18. Checking flue gas monitoring equipment 15. . . . . . . . . . . . . . . . . . . . . . .

5692413GB

Initial start−up, inspection and maintenance

Further details regarding the individual steps

Preparing for commissioning

1. Check that the boiler room

ventilation aperture is open.

2. Check the inlet 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 gaugeA.

(Min. system pressure 0.8bar,

permiss. operating pressure 3bar).

5. Return the check valves to their

operating position.

5692413GB

Initial start−up, inspection and maintenance

Further details regarding the individual steps (cont.)

Checking gas type

1. Enquire the gas type and Wobbe

index(Wo) from your local mains

gas or LPG supplier.

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/m3

(43.2 to 58.0MJ/m3).

2. Compare the gas category (gas

type) and gas group with the

details on the burner label.

3. The burner must be converted

according 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 gasE to natural gasLL:

This boiler can be operated

in the Wobbe index range

10.0 to 13.1kWh/m3

(36.0 to 47.2MJ/m3).

HNatural gasE to LPGP:

The boiler can be operated

in the Wobbe index range

21.4 to 22.5kWh/m3

(76.9 to 81.0MJ/m3).

4. Record the gas type in the service

report from page26.

5692413GB

Initial start−up, inspection and maintenance

Further details regarding the individual steps (cont.)

Checking static and supply pressure

¨Safety instruction

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. Release the screw inside test

nippleAon the gas connection

pipe, but do not remove

completely, and connect the

pressure gauge.

3. Open the gas shut−off valve.

4. Check static pressure; it should be

Hmax. 25mbar for natural gas,

Hmax. 57.5mbar for LPG.

Record the actual value in the

service report.

Supply pressure (flow pressure)

5. Start up the boiler.

Note

On start−up, the boiler can enter a

fault state because of airlocks in

the gas pipe.

After approx. 5seconds, press the

reset button on the burner control

unit; this repeats the ignition

process.

5692413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 25mbar for natural gas,

H42.5 to 57.5mbar for LPG.

Record the actual value in the

service report.

Take the action shown in the table.

Supply pressure (flow pressure)

for

Remedy

natural gas LPG

below

17.4mbar

below

42.5mbar

Make no adjustments and notify your

mains gas or LPG supplier.

17.4 to 25mbar 42.5 to

57.5mbar

Start up boiler.

above 25mbar above

57.5mbar

Install a separate gas governor

downstream 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.

7. Shut down the boiler, close the

gas shut−off valve, remove the

pressure gauge, and close test

nippleAwith the screw.

8. ¨Safety instructions

Open the gas shut−off valve and

check test nippleAfor

soundness.

5692413GB

Initial start−up, inspection and maintenance

Further details regarding the individual steps (cont.)

Checking nozzle pressure

1. Close the gas shut−off valve.

2. Release the screw inside test

nippleA, but do not remove

completely, and connect the

pressure gauge.

3. Open the gas shut−off valve.

Start up the boiler.

4. Check the nozzle pressure.

In case of deviation from the

value in the table on page10,

remove protective capB.

Adjust the nozzle pressure

with screwC.

5. Check setting values and record

in the service report.

6. Fit capB.

7. Switch OFF the system at the

control unit (the boiler shuts

down), close the gas shut−off

valve, remove the pressure

gauge and close test nippleA

with the screw.

8. ¨Safety instructions

Open the gas shut−off valve,

start up the boiler and check

soundness of test nippleA.

5692413GB

Initial start−up, inspection and maintenance

Further details regarding the individual steps (cont.)

Rated output kW 11 15 18 22 29 35 42 48 60

Natural gasE

with Wobbe index Wo

15.0kWh/m3

54.0MJ/m3

 Nozzle pressure*1

based on a supply

pressure of 20mbar

 Nozzle ID

 Air restrictor

mbar

∅mm

14.1

2.00

14.0

2.35



13.9

2.10

14.5

2.30



14.4

2.30



14.0

2.30



14.8

2.25



14.2

2.25



15.0

2.25



Natural gasLL

with Wobbe index Wo

12.4kWh/m3

44.6MJ/m3

 Nozzle pressure*1

based on a supply

pressure of 20mbar

 Nozzle ID

 Air restrictor

mbar

∅mm

14.1

2.25

13.9

2.60

14.1

2.30

13.7

2.55

13.8

2.55

14.0

2.55

14.2

2.50

13.7

2.50

13.5

2.50

LPG

with Wobbe index Wo

21.322.5kWh/m3

76.981.1MJ/m3

 Nozzle pressure*1

based on a supply

pressure of 50mbar

 Nozzle ID

 Air restrictor

mbar

∅mm

36.0

1.25

36.5

1.45

35.3

1.35

35.3

1.45



35.0

1.45



35.0

1.45



35.0

1.45



35.5

1.40



36.2

1.40



Number of burner tubes 223345679

*1Value relative to 1013.25mbar and 15ºC.

5692413GB

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