Viessmann GS1 Service Instructions Manual Download

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VITOGAS 100

Service instructions

for heating engineers

Vitogas100
TypeGS1,

11 to 60kW

Gas fired boiler

See notes on applicability, page2.

5692413GB6/2004

Please keep safe

Summary of Contents for GS1

Page 1: ...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 ...

Page 2: ...t 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 ...

Page 3: ...er 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 ...

Page 4: ... 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 M 11 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 tightne...

Page 5: ...oom 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 ...

Page 6: ...e 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 H Natural 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...

Page 7: ...s after flushing Static pressure 1 Close the gas shut off valve 2 Release the screw inside test nipple A on 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 H max 25 mbar for natural gas H max 57 5 mbar for LPG Record the actual value in the service report Supply pressure flow pressure 5 Start up ...

Page 8: ...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 pr...

Page 9: ... 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 instructio...

Page 10: ...as 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 33 13 9 2 60 35 14 1 2 30 32 13 7 2 55 37 13 8 2 55 37 14 0 2 55 37 14 2 2 50 37 13 7 2 50 37 13 5 2 50 37 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...

Page 11: ...tch at the control unit before connecting the test equipment F Burner control unit 1 For testing insert test lead no 1 into Testomatik Gas and secure 2 Pull ionisation lead A off ionisation electrode B 3 Push plug in adaptor C into ionisation lead A 4 Push test cable plug D into plug in adaptor C 5 Push adaptor cable E onto ionisation electrode B 6 Push adaptor cable E onto the test cable socket D...

Page 12: ... OFF switch 2 Isolate the mains power supply e g by removing a separate mains fuse or by means of a mains electrical isolator from the heating system and safeguard against unauthorised reconnection 3 Close the gas shut off valve 4 Remove the front panel for this unlock the fastening 60 kW 2 fastenings and remove the front panel 5 Pull plug in connector off the burner control unit 6 Pull the earth ...

Page 13: ... and maintenance Further details regarding the individual steps cont Checking ignition burner 1 Check ionisation electrode A ignition burner B and ignition electrode C for damage 2 Check the electrode gaps 5692 413 GB A B C 7 A B C ...

Page 14: ...r removed using the cleaning brush supplied Never use cleaning agents containing potassium 5 Remove residues from the bottom plate 6 H Fit the lid to the flue gas collector H Position the mineral fibre mat and the thermal insulation mat and secure with the tensioning springs to the boiler body thermal insulation mat H Fit the top panel H Install the burner in reverse order Use new gaskets System s...

Page 15: ...F the burner and should not switch it ON again automatically before approx 10 minutes have elapsed For safety reasons the burner will be locked out for approx 17 minutes 4 H Check the position of sensor A if the flue gas monitoring equipment switches OFF later than after 2 minutes H Replace the sensor or the burner control unit if the flue gas monitoring equipment does not switch OFF the burner if...

Page 16: ...t see page 15 Strapping plug aNS is missing in burner control unit Fit strapping plug aNS or a flue gas monitoring sensor Strapping plug aYA is missing in burner control unit Fit strapping plug aYA Burner control unit enters a fault state No gas available Air in gas supply pipe Press reset button on burner control unit to repeat start procedure Ignition burner will not start Check ignition electro...

Page 17: ... equipment illuminates After the pilot flame has stabilised the main gas valve opens and the burner ignites Note A reset after a fault shutdown can only be implemented after a minimum of 10 seconds Time chart Tstab Pilot flame stabilisation time TFR Safety time operation Tc Self monitoring time Tw Waiting time TTTB Shutdown duration flue gas monitoring Ts Safety time burner start 5692 413 GB Heat ...

Page 18: ...ner control 5692 413 GB 50 41A 34 111 41 162 1 2 3 14 13 12 11 10 9 8 7 6 5 4 Reset Fault System plug no Terminal no P B4 S3 T2 T1 N L1 External valve Gas monitor or jumper Sensor flue monitoring or plug with resistance Ignition Ionisation ...

Page 19: ...l h boiler section via drain valve A on the side of the boiler Minimum clearances Maintain a distance between the flue pipe and the surface of the thermal insulation also of accessories of at least 20 mm This safeguards that the surface temperature of the thermal insulation never exceeds 85 ºC at rated output 5692 413 GB A ...

Page 20: ...ront panel 202 L h and r h side panel 203 Top front panel 204 Rear panel 205 Centre panel 206 Top insulating mat 207 L h and r h fixing strip 208 Insulating casing 212 Fastener 213 Decorative cap 214 Edge protector 217 Spacers 218 Logo 219 Fixing pack 220 Tensioning spring for thermal insulation 221 Diaphragm grommet 223 Decorative adhesive tape Parts not shown 116 Conversion parts for natural gas...

Page 21: ...21 Parts list Parts list cont 5692 413 GB B 219 201 221 223 220 218 214 204 208 202 219 223 223 203 212 219 217 202 205 213 ...

Page 22: ...22 Parts list Parts list cont 5692 413 GB 206 207 005 A 200 207 004 001 006 001 002 2 003 2 002 1 ...

Page 23: ...23 Parts list Parts list cont 5692 413 GB 100 102 115 113 101 109 121 103 C D 112 106 105 110 111 3 4 114 ...

Page 24: ...24 Parts list Parts list cont 5692 413 GB 007 108 104 120 ...

Page 25: ...25 Parts list 5692 413 GB ...

Page 26: ...flow pressure j for natural gas E mbar 17 4 25 mbar j for natural gas LL mbar 17 4 25 mbar j for LPG mbar 42 5 57 7 mbar j Tick gas type Nozzle pressure mbar Carb dioxide content CO2 by vol Oxygen content O2 by vol Carb monoxide cont CO ppm Flue gas temp gross ºC Flue gas loss Ionisation current mA min 5 mA Draught hPa max 0 1 hPa 0 1 mbar 5692 413 GB ...

Page 27: ...27 Appendix Maint service Maint service Maint service Maint service 5692 413 GB ...

Page 28: ... flow pressure j for natural gas E mbar 17 4 25 mbar j for natural gas LL mbar 17 4 25 mbar j for LPG mbar 42 5 57 7 mbar j Tick gas type Nozzle pressure mbar Carb dioxide content CO2 by vol Oxygen content O2 by vol Carb monoxide cont CO ppm Flue gas temp gross ºC Flue gas loss Ionisation current mA min 5 mA Draught hPa max 0 1 hPa 0 1 mbar 5692 413 GB ...

Page 29: ...29 Appendix Maint service Maint service Maint service Maint service 5692 413 GB ...

Page 30: ...ure flow pressure j for natural gas E mbar 17 4 25 mbar j for natural gas LL mbar 17 4 25 mbar j for LPG mbar 42 5 57 7 mbar j Tick gas type Nozzle pressure mbar Carb dioxide content CO2 vol Oxygen content O2 vol Carb monoxide cont CO ppm Flue gas temp gross ºC Flue gas loss Ionisation current mA min 5 mA Draught hPa max 0 1 hPa 0 1 mbar 5692 413 GB ...

Page 31: ...31 Appendix Maint service Maint service Maint service Maint service 5692 413 GB ...

Page 32: ...6 122 160 153 1Observe when sizing the chimney stack 2Calculation values for sizing the chimney to DIN 4705 Checked downstream of the draught hood 3Flue gas temperature measured at 20 ºC combustion air temperature Product characteristics to EnEV Germany Rated output kW 11 15 18 22 29 35 42 48 60 Efficiency h at 100 of rated output 30 of rated output 90 9 91 7 91 8 92 8 92 5 93 5 91 8 93 3 92 4 93 ...

Page 33: ...rements of the Efficiency Directive 92 42 EEC for Low temperature boilers The product characteristics determined as system values for Vitogas 100 as part of EC type testing according to the Efficiency Directive see specification table can be utilised for the energy assessment of heating and ventilation equipment to DIN V 4701 10 specified by the EnEV Germany Manufacturer s certificate according to...

Page 34: ...13 F Flue gas collector 14 Frost protection 19 G Gas combination valve 7 12 H Heating surfaces 14 High limit safety cut out 16 I Ignition electrode 13 Inlet pressure diaphragm expansion vessel 5 Ionisation current 11 16 Ionisation electrode 11 M Manufacturer s certificate 33 Minimum system pressure 5 N Nozzle pressure table 10 P Pilot burner 11 13 Pressure gauge 5 S Serial number 2 Specification 3...

Page 35: ...35 5692 413 GB ...

Page 36: ...2 70 27 80 www viessmann de Viessmann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Tel 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com 36 Printed on environmentally friendly chlorine free bleached paper 5692 413 GB Subject to technical modifications ...

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