Viessmann GS1B Service Instructions Manual Download Page 1

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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

Summary of Contents for GS1B

Page 1: ...ice 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 ...

Page 2: ...l 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 fla...

Page 3: ...c 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 author...

Page 4: ...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 4 Index 5692 647 GB ...

Page 5: ... 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 ...

Page 6: ...ment block for 108 to 144 kW version A Pressure 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 indivi...

Page 7: ... 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 Na...

Page 8: ...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 LP...

Page 9: ...tem 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...

Page 10: ...simulta 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 re...

Page 11: ...the service report on page 32 11 Secure protective cap B 12 Switch OFF the control unit ON OFF switch the boiler shuts down 13 Close the gas shut off valve 14 Remove the pressure gauge and seal the test connector with the screw previously removed 15 Open the gas shut off valve start the boiler and check the sound ness of the test connector Danger Gas escaping from the test connector leads to a ris...

Page 12: ...d mbar 15 4 15 4 15 4 15 4 15 4 15 4 15 4 Partial load mbar 6 8 6 8 6 8 6 8 6 8 6 8 6 8 Nozzle desig nation 3 20 3 20 3 20 3 20 3 20 3 20 3 20 Air restrictor 7 mm 50 50 50 50 50 50 50 Nozzle pressure at 50 mbar supply pres sure LPG Full load mbar 34 5 34 5 34 5 34 5 34 5 34 5 34 5 Partial load mbar 15 0 15 0 15 0 15 0 15 0 15 0 15 0 Nozzle desig nation 1 90 1 90 1 90 1 90 1 90 1 90 1 90 Air restri...

Page 13: ... sation electrode E 2 Connect the test instrument A according to the above diagram Push plug in adaptor 7 6 4 B into ionisation lead C Push adaptor cable 7 4 6 F onto ionisation electrode E Push test cable plug A into plug in adaptor B and adaptor cable F 3 Start the boiler 4 Checking the ionisation current When the pilot burner is lit min 1 5 µA When the main burner is lit min 5 µA 5 Record the a...

Page 14: ...ce report on page 32 Note Required boiler draught 3 Pa 0 03 mbar The chimney draught must not be greater than 10 Pa 0 1 mbar Install a draught stabiliser agree details with your local flue gas inspector inside the chimney if required Further details regarding the individual steps cont 14 Initial start up inspection maintenance 5692 647 GB ...

Page 15: ...ting on gas supply pipe B 4 Release the nuts and screws and carefully pull burner D out through the front Checking the burner tubes 1 Check the gas outlets for damage 2 Blow through burner tubes with compressed air or rinse with a soapy solution Further details regarding the individual steps cont 15 Initial start up inspection maintenance 5692 647 GB ...

Page 16: ...lot burner C Ignition electrode 1 Check the ionisation electrode the pilot burner and the ignition elec trode for damage 2 Check the electrode gaps Further details regarding the individual steps cont 16 Initial start up inspection maintenance 5692 647 GB ...

Page 17: ...op panel B 2 Release the tension springs and remove thermal insulation mat C 3 Remove front top cover F together with control unit E and hook into the front 4 Undo clean out cover D Further details regarding the individual steps cont 17 Initial start up inspection maintenance 5692 647 GB ...

Page 18: ... the bottom plate 7 Install in reverse order Burner installation Use new gaskets when refitting the burner Checking all gas equipment for soundness at operating pres sure Danger Escaping gas can lead to explosions Check the soundness of all joints of gas pipes and fittings at operating pressure with a foaming test agent leak test spray Further details regarding the individual steps cont 18 Initial...

Page 19: ...adaptor on the draught hood with a suitable object to carry out the function test 4 Start the boiler 5 The flue gas monitor must shut down the burner within 2 minutes The burner will then be locked out for approx 17 minutes Further details regarding the individual steps cont 19 Initial start up inspection maintenance 5692 647 GB ...

Page 20: ...The burner will not start The sensor is corroded 7 Shut down your heating system 8 Remove the cover and push the flue pipe onto the draught hood 9 Start the boiler 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 Further details regarding the individual steps cont 20 Initial start up inspect...

Page 21: ...ng at the burner control unit Fit strapping plug aNS or a flue gas monitoring sensor Strapping plug aYA is missing at the burner control unit Fit strapping plug aYA Burner control unit enters a fault state No gas available air in the supply line Press the reset button at the burner control unit The pilot burner will not light Check the ignition electrode see page 16 Check the gas supply Power supp...

Page 22: ...ve C External LPG valve D HV ignition E Flame signal F Pressure switch open G Main gas valves H Pressure switch closed T1 Dwell time T2 Safety period burner start T3 Pilot burner stabilising time T4 Safety period operation Time chart and function 22 Ignition system 5692 647 GB ...

Page 23: ...signal via the ionisation elec trode E the pressure switches F are de pressurised Main gas valves G are opened after a pilot burner stabilising time Tstab the pressure switches H are pressurised and close with a switching differential of 2 s All burner areas will ignite Note A reset after a fault shutdown can only be implemented after a minimum of 10 s Time chart and function cont 23 Ignition syst...

Page 24: ... Burner control unit B Connections to the control unit C Gas combination valve D Sensor flue gas monitoring E Reset button F Fault display G Only for LPG Gas governor H Only for natural gas Jumpers K Ignition unit Connection diagrams burner control unit 24 Designs 5692 647 GB ...

Page 25: ... cable 3 Pilot gas valve connecting cable 4 Ionisation lead 5 Ignition cable 6 Gas connection A Burner control unit B Boiler control unit C External LPG valve D Pilot gas valve E Main gas valves F HV ignition G Ionisation H Ignition unit K Pilot burner L Distributor pipes Connection diagrams burners 72 to 96 kW 25 Designs 5692 647 GB ...

Page 26: ...cable 3 Pilot gas valve connecting cable 4 Ionisation lead 5 Ignition cable 6 Gas connection A Burner control unit B Boiler control unit C External LPG valve D Pilot gas valve E Main gas valves F HV ignition G Ionisation H Ignition unit K Pilot burner L Distributor pipes Connection diagrams burners 108 to 144 kW 26 Designs 5692 647 GB ...

Page 27: ...Back panel 204 Front panel 205 Front top panel for Vitotronic 100 type GC1 206 Front top panel for Vitotronic 100 type KC4 and Vitotronic 200 type KW5 207 Centre panel 208 Threaded stud 209 Insulation casing 210 Front insulation mat 211 Upper insulation mat 212 Logo 213 Diaphragm bushing nipple 214 Edge protector 215 Tension spring 216 Control unit cover strip Wearing parts 006 Cleaning brushes 11...

Page 28: ...or natural gas LL 325 Small parts pack 326 Torque set 327 Threaded rod M12 Legend A Type plate B Boiler control unit Vitotronic 100 type GC1 see separate installa tion and service instructions C Boiler control unit Vitotronic 100 type KC4 or Vitotronic 200 type KW5 see separate installa tion and service instructions Parts lists cont 28 Parts lists 5692 647 GB ...

Page 29: ...Parts lists cont 29 Parts lists 5692 647 GB ...

Page 30: ...Parts lists cont 30 Parts lists 5692 647 GB ...

Page 31: ...Parts lists cont 31 Parts lists 5692 647 GB ...

Page 32: ...bar 17 4 25 mbar for LPG at 50 mbar supply pressure mbar 42 5 57 5 mbar Tick gas type Nozzle pressure mbar Carbon dioxide content CO2 vol Oxygen content O2 vol Carbon monoxide con tent CO ppm Gross flue gas tempera ture C Flue gas loss Ionisation current µA min 5 µA Draught Pa max 10 Pa 0 1 mbar min 3 Pa 0 03 mbar Commissioning service reports 32 Commissioning service reports 5692 647 GB ...

Page 33: ...165 195 233 244 268 277 Efficiency η 100 of rated output 92 1 92 1 92 3 92 4 92 4 92 4 92 5 30 of rated out put 93 0 93 5 93 4 93 3 93 5 93 4 93 4 Standby loss qB 70 1 0 0 9 0 9 0 9 0 8 0 8 0 8 Power consump tion standard value at 100 of rated output W 351 377 402 426 448 469 489 30 of rated out put W 117 126 134 142 149 156 163 Chimney information Observe the required draught when sizing the chim...

Page 34: ... for Low temperature boilers LT The product characteristics determined as system values for the product Vitogas 100 as part of EC type testing according to the Efficiency Directive see specification table can be utilised to assess the energy consumption of heating and ventilation equipment to DIN V 4701 10 which is specified by the EnEV Germany Allendorf 10 12 05 Viessmann Werke GmbH Co KG pp Manf...

Page 35: ...Allendorf 10 12 05 Viessmann Werke GmbH Co KG pp Manfred Sommer Manufacturer s certificate according to the 1st cont 35 Certificates 5692 647 GB ...

Page 36: ...er control unit 24 Diagnosis 21 Diaphragm expansion vessel 6 Draught 14 33 E Efficiency 33 Electrode gaps 16 F Fault 21 Flue gas 33 G Gas combination valve 8 Gas supply pressure 8 Gas train 10 I Ignition system 22 Initial start up 6 Ionisation current 13 M Manufacturer s declaration 34 Minimum system pressure 7 N Nozzle pressure table 12 P Parts lists 27 Pressure gauge 7 R Reports 32 S Static pres...

Page 37: ...37 5692 647 GB ...

Page 38: ...38 5692 647 GB ...

Page 39: ...39 5692 647 GB ...

Page 40: ...iendly chlorine free bleached paper 5692 647 GB Subject to technical modifications Viessmann Werke GmbH Co KG D 35107 Allendorf Telefon 49 6452 70 0 Telefax 49 6452 70 2780 www viessmann com Viessmann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com ...

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