Viessmann VITOGAS 100-F Instrucciones de funcionamiento

Service instructions

for contractors

VIESMANN

Vitogas 100-F

Type GS1D

Rated heating output of 29 to 60 kW

Gas boiler

Natural gas and LPG version

For applicability, see the last page

VITOGAS 100-F

5692 699 GB 9/2012 Please keep safe.

Please follow these safety instructions closely to prevent accidents and mate-

rial 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 envi-

ronmental pollution.

Note

Details identified by the word "Note" con-

tain 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 fitter.

■ Work on electrical equipment must

only be carried out by a qualified elec-

trician.

■ The system must be commissioned by

the system installer or a qualified per-

son authorised by the installer.

Regulations

Observe the following when working on

this system

■ all legal instructions regarding the pre-

vention of accidents,

■ all legal instructions regarding envi-

ronmental 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,

■ Gas Safety (Installation & Use) Regu-

lations

– the appropriate Building Regulation

either the Building regulations, the

Building Regulation (Scotland),

Building Regulations (Northern Ire-

land),

– the Water Fittings Regulation or

Water Bylaws in Scotland,

– the current I.E.E. Wiring Regula-

tions.

If you smell gas

Danger

Escaping gas can lead to explo-

sions which may result in serious

injury.

■ Never smoke. Prevent naked

flames and sparks. Never

switch lights or electrical appli-

ances 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 build-

ing.

■ Shut off the electricity supply to

the building from a safe place

(outside the building).

Safety instructions

5692 699 GB

If you smell flue gas

Danger

Flue gas can lead to life-threat-

ening poisoning.

■ Shut down the heating system.

■ Ventilate the boiler room.

■ Close all doors leading to the

living space.

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 sup-

ply and check that it is no longer 'live',

e.g. by removing a separate fuse or by

means of a main isolator.

■ Safeguard the system against unau-

thorised reconnection.

!Please note

Electronic modules can be dam-

aged 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 ful-

fil a safety function can compro-

mise 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 com-

promise its function. Installing

non-authorised components and

non-approved modifications/con-

version can compromise safety

and may invalidate our warranty.

For replacements, use only orig-

inal spare parts from Viessmann

or those which are approved by

Viessmann.

Safety instructions

Safety instructions (cont.)

5692 699 GB

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance.......................................... 5

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

Troubleshooting

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

Ignition system

Time chart and function........................................................................................ 19

Designs

Burner control connection diagram...................................................................... 21

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

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

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

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

Certificates

Declaration of conformity...................................................................................... 30

Keyword index.................................................................................................... 31

Index

5692 699 GB

For further information regarding the individual steps, see the page indicated

Commissioning steps

Inspection steps

Maintenance steps Page

••• 1. Preparing for commissioning and filling the heating

system............................................................................. 6

••• 2. Checking the gas type.................................................... 7

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

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

••• 5. Checking the nozzle pressure....................................... 10

••• 6. Determining the flue gas values.................................... 11

••• 7. Checking the ionisation current.................................... 12

••• 8. Checking the draught..................................................... 12

• • 9. Removing the burner...................................................... 13

• • 10. Checking the burner tubes............................................ 13

• • 11. Checking the pilot burner.............................................. 14

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

• • 13. Fitting the burner............................................................ 15

••• 14. Checking connections on the water side for tightness

••• 15. Checking the safety equipment

••• 16. Checking firm seating of electrical connections

••• 17. Checking all gas equipment for tightness at operating

pressure........................................................................... 15

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

••• 19. Commissioning the system

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

train

••• 21. Checking the flue gas monitoring device..................... 16

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

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5692 699 GB

Preparing for commissioning and filling the heating system

Fill water

!Please note

Unsuitable fill water increases

the level of deposits and corro-

sion and may lead to boiler dam-

age.

■ Flush the heating system thor-

oughly before filling.

■ Only use fill water of potable

quality.

■ An antifreeze additive suitable

for heating systems can be

added to the fill water. The anti-

freeze manufacturer must ver-

ify its suitability.

■ Fill and top-up water with a

water hardness in excess of

the following values must be

softened, e.g. with a small soft-

ening system for heating water.

Total permissible hardness of the fill and top-up water

Total heating

output

Specific system volume

kW < 20 l/kW ≥ 20 l/kW to

< 50 l/kW

≥ 50 l/kW

≤ 50 ≤ 3.0 mol/m3

(16.8 °dH)

≤ 2.0 mol/m3

(11.2 °dH)

< 0.02 mol/m3

(0.11 °dH)

> 50 to ≤ 200 ≤ 2.0 mol/m3

(11.2 °dH)

≤ 1.5 mol/m3

(8.4 °dH)

< 0.02 mol/m3

(0.11 °dH)

> 200 to ≤ 600 ≤ 1.5 mol/m3

(8.4 °dH)

≤ 0.02 mol/m3

(0.11 °dH)

< 0.02 mol/m3

(0.11 °dH)

> 600 < 0.02 mol/m3

(0.11 °dH)

< 0.02 mol/m3

(0.11 °dH)

< 0.02 mol/m3

(0.11 °dH)

1. Check that the installation room vent

is open.

2. Check the pre-charge pressure of the

diaphragm expansion vessel.

If the pre-charge pressure of the dia-

phragm expansion vessel is lower

than the static system pressure, top

up with sufficient nitrogen to raise the

pre-charge pressure 0.1 to 0.2 bar

higher than the static system pres-

sure.

3. Open the check valves (if installed).

Commissioning, inspection, maintenance

Further details regarding the individual steps

5692 699 GB

4. Fill the heating system with water and

vent until the fill pressure indicated at

pressure gauge A is 0.1 to 0.2 bar

higher than the pre-charge pressure

of the diaphragm expansion vessel.

Minimum system pressure 0.8 bar;

permissible operating pressure

3 bar.

5. Return the check valves to their oper-

ating position.

Checking the gas type

Note

The boiler is preset in the factory for nat-

ural gas E.

1. Check the gas type and Wobbe index

with your gas supply utility or your

LPG supplier and compare them with

the details on the burner label.

2. If the details do not match, convert

the burner to the available gas type,

in accordance with the information

provided by the gas supply utility or

the LPG supplier.

Conversion kit installation

instructions

3. Record the gas type in the report on

page 28.

Wobbe index ranges

Gas type Wobbe index range Ws

kWh/m3MJ/m3

Delivered condition

Natural gas E 12.0 to 16.1 43.2 to 58.0

After conversion

LPG P 20.3 to 21.3 72.9 to 76.8

Changing the gas type (if required)

Conversion kit installation

instructions

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 699 GB

Checking the static and supply pressure

Danger

CO build-up as a result of incor-

rect burner adjustment can have

serious health implications.

Carry out a CO test before and

after work on gas appliances.

Operation with LPG

Flush the LPG tank twice during com-

missioning or replacement. Vent the tank

and gas connection line thoroughly after

flushing.

01. Close the gas shut-off valve.

02. Release screw inside test nip-

ple A on the gas train, but do not

remove it; then connect the pres-

sure gauge.

03. Open the gas shut-off valve.

04. Check the static pressure:

■ Natural gas: max. 25 mbar

■ LPG: max. 57.5 mbar

Record the actual value in the serv-

ice report.

05. Start the boiler.

Note

During commissioning, the boiler

can enter a fault state because of

airlocks in the gas line. You can

reset the burner after approx.

10 seconds. For this, switch the

boiler OFF and ON at the control

unit ON/OFF switch.

06. Check the supply pressure (flow

pressure):

■ Natural gas: 8 to 25 mbar

■ LPG: 27.7 to 57.5 mbar

Note

Use a suitable measuring device

with a resolution of at least

0.1 mbar to check the supply pres-

sure.

Record the actual value in the serv-

ice report.

Note

We recommend that the boiler is

equipped with a gas pressure

switch. During assembly, set the

gas pressure switch to the following

values:

■ Natural gas: 8 mbar

■ LPG: 22 mbar

07. Take action as shown in the follow-

ing table.

08. Switch OFF the control unit ON/OFF

switch (the boiler shuts down).

09. Close the gas shut-off valve.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 699 GB

10. Remove the pressure gauge and

seal test nipple A with screw.

11. Open the gas shut-off valve and

check test nipple A for gas tight-

ness.

Danger

Gas escaping from the test

nipple leads to a risk of

explosion.

Check the test nipple for gas

tightness.

Supply pressure (flow pressure): Action

Natural gas LPG

Below 8 mbar Below 27.7 mbar ■ Do not commission the boiler

■ Notify your gas supply utility or your

LPG supplier

8 to 25 mbar 27.7 to 57.5 mbar Commission the boiler

Above 25 mbar Above 57.5 mbar ■ Install a separate gas pressure gover-

nor upstream of the system

■ Setting the pre-charge pressure:

20 mbar for natural gas

30 mbar for LPG

■ Notify your gas supply utility or your

LPG supplier

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 699 GB

Checking the nozzle pressure

B CD

1. Close the gas shut-off valve.

2. Release the screw inside test nipple

A, but do not remove, then 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 following table remove pro-

tective cap B.

Adjust the nozzle pressure with

screw C.

Note

Screw D has no function.

5. Check the setting values and record

them in the report.

6. Reposition protective cap B.

7. Switch OFF the system ON/OFF

switch on the control unit (the boiler

shuts down).

8. Close the gas shut-off valve.

9. Remove the pressure gauge and seal

test nipple A with screw C.

10. Open the gas shut-off valve, start

the boiler and check test nipple A

for gas tightness.

Danger

Gas escaping from the test

nipple leads to a risk of

explosion.

Check the test nipple for gas

tightness.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 699 GB

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