Viessmann Vitogas 100 GS1 Series, Installation Instructions Manual

Page 1: ...PORTANT VITOGAS 100 Installation Instructions for Use by Heating Contractor Vitogas 100 GS1 Series Natural gas propane fired single stage atmospheric cast iron boiler Heating input 90 to 240 MBH 26 to 70 kW Please file in Service Binder 5167 463 v1 3 02 2011 ...

Page 2: ...in poisonous carbon monoxide gas For information pertaining to the proper installation adjustment service and maintenance of this equipment to avoid formation of carbon monoxide please see sections entitled Combustion Air Supply and Venting Connection H Fresh air This equipment requires fresh air for safe operation and must be installed ensuring provisions for adequate combustion and ventilation a...

Page 3: ... 11 Boiler wiring 12 Venting Connection 13 Gas Connection and Piping 17 Proper piping practice 17 Gas piping pressure test 17 Water Side Connections 18 Safety Connections and Pressure Testing 19 Installing safety device on the boiler 19 Performing pressure test on the boiler 20 DHW Side Connections 20 Installation Examples 21 System with multiple zones 25 Boiler in a heating cooling application 26...

Page 4: ...frequent installation and service seminars to familiarize our partners with our products Please inquire Working on the equipment The installation adjustment service and maintenance of this boiler must be done by a licensed professional heating contractor who is qualified and experienced in the installation service and maintenance of hot water boilers There are no user serviceable parts on the boil...

Page 5: ...s be taken when handling these materials Precautionary measures Avoid breathing fiberglass dust and contact with skin and eyes Use NIOSH approved dust mist respirator Wear long sleeved loose fitting clothing gloves and eye protection Wash work clothes separately from other clothing Rinse washer thoroughly Operations such as sawing blowing tearout and spraying may generate airborne fiber concentrat...

Page 6: ...peration with modulating boiler water temperatures in closed loop forced circulation hot water heating systems The Vitogas 100 GS1 Series is factory calibrated for use with natural gas or propane gas Order appropriately The boiler model size selected should be based on an accurate heat loss calculation of the building The boiler selected must be compatible with the connected radiation 5167 463 v1 ...

Page 7: ...ed outside air for safe operation do not install where chemicals are stored or in a room with negative pressure See section entitled Combustion Air Supply for further details regarding the above Locate boiler on flooring capable of supporting the weight of the boiler filled with water Ensure that the boiler location does not interfere with the proper circulation of combustion and ventilation air w...

Page 8: ...ice When the Divicon pre assembled mixing valve station is installed the minimum distance beside the boiler must be 19 500 mm There must be sufficient space for a heating contractor to access the rear of the boiler to inspect the blocked vent switch 5167 463 v1 3 IMPORTANT The boiler must be installed in such a way that gas ignition system components are protected from water spraying splashing etc...

Page 9: ...es for service The Vitogas 100 GS1 boiler is approved for closet and alcove installations with the following clearances to combustibles Boiler Model GS1 22 29 35 42 48 60 Rear from draft hood inches mm 6 150 6 150 6 150 6 150 6 150 6 150 Sides inches mm 0 0 0 0 0 0 0 0 0 0 0 0 Flue inches mm 6 150 6 150 6 150 6 150 6 150 6 150 Top inches mm 6 150 6 150 6 150 6 150 6 150 6 150 Floor Combustibles Al...

Page 10: ...g leveling bolts Use a level to ensure boiler is level A special boiler base foundation is not necessary 2 Ensure air flow to front and rear of boiler is not restricted in any way 3 Ensure compliance with local codes where wood flooring or flooring other than concrete is present 4 Ensure fresh air intake is not located too close to the burner to avoid drafts which may cause abnormal burner operati...

Page 11: ...right to substitute electrical components as necessary Before attempting to wire the unit ensure main power supply to equipment the heating system and all external controls has been deactivated Close main gas supply valve Take precautions in all instances to avoid accidental activation of power during service work All wiring must be properly grounded A dedicated ground wire must be run from the bo...

Page 12: ...ontrol 4 For vent damper installations the boiler is shipped with a 10 ft 24 V vent damper cable The female end of the Molex connector of the vent damper with the strain relief comes factory channeled through the cable opening 5 Coil excess cabling and tuck between side panel and insulation 6 Close strain relief and tighten screws 7 Mount top panel and fasten using screws 5167 463 v1 3 3 9 x 4 5 3...

Page 13: ...ade in the shortest possible way with minimum elbows If necessary rearrange existing water piping to achieve closest chimney connection When the vertical pipe becomes the chimney itself the weight must not be supported by the horizontal to vertical draft hood on the boiler Avoid long horizontal runs of vent pipe Horizontal runs must be supported by appropriate means to prevent sagging Horizontal r...

Page 14: ... requires a manual reset by pushing in the red button If the switch activates the vent system must be checked inside and out and the blockage or defect corrected by a qualified heating contractor before boiler is put back in operation The flame roll out switch is located in the burner area In the event of blockage of the cast iron flue ways inside the boiler hot gases will cause the switch to open...

Page 15: ...al adaptor and boiler draft hood connection Drill pilot holes with 11 64 cobalt HSS drill bit and fasten using three equally spaced screws Vent pipe adaptors are shipped in the Installation Fitting Package 4 Connect vent pipe adaptor with chimney via a field supplied slightly inclined intermediate section of venting Draft hood flue pipe diameter GS1 22 Outside 5 GS1 29 to 42 Outside 6 GS1 48 to 60...

Page 16: ...ief on vent damper motor to secure the cable There are no serviceable parts on the vent damper Defective vent dampers must be replaced If a side wall vent system is used the vent damper must not be installed Refer to separate side wall vent system instructions for series boiler The side wall vent system must be purchased separately Sequence of operation with vent damper 1 Thermostat calls for heat...

Page 17: ... individual shut off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of psig 14 w c 3 Unions and gas manifold have been factory tested Leak test must be repeated during initial trial operation of burner by a licensed gas fitter 4 Perform leak test Use approved liquid spray solution for bubble test Ensure than no li...

Page 18: ...or pressure relief valve and air vent non NPT 11 2 Boiler water supply and return non NPT 11 2 Boiler drain for precharged expansion tank and automatic feed NPT Drain connection for left cast iron section located at boiler front Gasket Connect this end using gasket to non NPT threads of welded supply and return boiler nipples 11 2 NPT male threads IMPORTANT CAUTION Failure to flush the heating sys...

Page 19: ...ge pipe 3 4 Piping to precharged expansion tank 3 4 Install the approved factory supplied pressure relief valve Removal of air from the system must occur via use of air vent s in the system supply To ensure the boiler can be purged of all air ensure supply return water lines do not contain restrictive piping where air could be trapped This boiler does not require a flow switch Low water cut off A ...

Page 20: ... boiler base with flashlight for leaks 6 After 15 minutes release water pressure from boiler by opening boiler drain valve slowly remove caps from supply and return connections as well as cap from safety nipple and install pressure relief valve immediately instead of cap After boiler has passed pressure test proceed with installation Max operating pressure 60 psig 413 kPa Max testing pressure 90 p...

Page 21: ...elationship between boiler flow rate and temperature rise is according to the formula Boiler output Btu h 500 x flow USGPM x Rise F The following chart lists typical flow rates for the Vitogas 100 GS1 boiler Boiler Model GS1 22 29 35 42 48 60 20 F rise 30 F rise USGPM m3 h USGPM m3 h 7 5 1 7 5 0 1 1 9 8 2 2 6 5 1 5 12 3 2 8 8 2 1 9 14 0 3 2 9 3 2 1 16 1 3 6 10 7 2 4 24 5 4 16 0 3 6 5167 463 v1 3 F...

Page 22: ... heating contractor Without mixing valve e g with Vitotronic 100 The installation of the check valve to restrict gravity circulation in the heating supply pipe prevents uncontrolled heat flow to the heating system by gravity during priority switching of domestic hot water heating or during summer operation Heating circuit Spring loaded flow check valve Circulation pump Safety header with automatic...

Page 23: ...r accessory kit Heating circuit Spring loaded flow check valve Circulation pump Safety header with automatic air vent pressure relief valve and pressure gage Expansion tank Domestic hot water storage tank indirect fired 3 way mixing valve Bypass pipe highly recommended c w two regulating valves V1 V2 See page 28 for installation details 5167 463 v1 3 V1 V2 V1 V2 ...

Page 24: ...Domestic hot water tank indirect fired Bypass pipe with flow regulating valve for systems with large water content 1 USG 13 000 Btu h 15 ltr kW h of boiler input See page 28 for installation details Underfloor heating system with system separation Underfloor heating circuit Spring loaded flow check valve Circulation pump for underfloor heating circuit Safety header with automatic air vent pressure...

Page 25: ...pump installed operate pump continuously and install pressure by pass around pump Operate zone valves on off by individual room thermostats only Do not connect end switches to burner since overheating of boiler may occur Control boiler burner independently by an additional operating control See illustration on the left 5167 463 v1 3 ...

Page 26: ...ntrol valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle Check installation instructions of the chiller manufacturer carefully for additional requirements Cooling season starts close valve v1 and open valve v2 Heating season starts close valve v2 and open valve v1 Heating Cooling unit Spring loaded flow check valve Circulation pump Safety he...

Page 27: ...ched to of approved type field supplied must be installed in all instances Do not install an isolation valve between boiler and low water cut off See piping to the left for detailed connection of low water cut off Follow the installation instructions of the low water cut off manufacturer 5167 463 v1 3 Low water cut off connection Boiler supply NPT 1 Tee field supplied 1 x 1 x 3 4 Viessmann Safety ...

Page 28: ... from the boiler with a heat exchanger Viessmann recommends the use of underfloor plastic tubing with an oxygen diffusion barrier Supply return bypass for large water content systems For boilers connected to large water content systems such as a previous gravity system with large free standing radiators a bypass line from the supply pipe to the return pipe can be used Bypass can be installed on an...

Page 29: ...for Canada For U S installations use section 5 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 Always use latest editions of codes Whenever possible install boiler near an outside wall so that it is easy to duct fresh air directly to the boiler area Refer to national codes for duct sizing and allowable lengths Round ducts can be used The boiler location must never be...

Page 30: ...y of rain or wind and must not reduce the free are of the air It must not be blocked by snow 5 Manually operated combustion air dampers are not allowed The air opening must not be of a type that could lead to situations where the air supply may be closed off while the burners are in operation 6 If the combined MBH input exceeds 400 MBH for all gas burning appliances the following excerpt from the ...

Page 31: ...pply pressure 1 flow w c 14 14 14 14 14 14 Max operating pressure water psig 60 60 60 60 60 60 Boiler connections Boiler supply and return Safety supply Drain valve Ø male thread Ø male thread Ø male thread 1 1 1 1 1 1 1 1 1 1 1 1 Gas supply connection Ø tapered male thread Flue gas 2 Temperature gross Mass flow rate with natural gas with LPG F C lbs h kg h lbs h kg h 223 106 161 73 148 67 216 102...

Page 32: ...h Vitotronic 100 KW10 KW10A KW10B Not used with KW10A Not used with KW10A 32 Vitogas 100 GS1 with Vitotronic 100 Controls Please refer to wiring label on boiler access panel Viessmann reserves the right to substitute components or wiring methods Boiler wiring label takes precedence 5167 463 v1 3 ...

Page 33: ...gas 100 GS1 with Vitotronic 300 33 Vitogas 100 GS1 with Vitotronic 200 and 300 Controls Please refer to wiring label on boiler access panel Viessmann reserves the right to substitute components or wiring methods Boiler wiring label takes precedence 5167 463 v1 3 ...

Page 34: ... 120 V is available to transformer H Ignition module is energized with 24 V from the 24 V transformer H Pilot valve is energized with 24 V Pilot sparks and pilot gas flows Once pilot proves 24 V is applied to MV PV and MV energizing main valve H Burner cycles on and off in response to operating control room thermostat end switch of zone valve separate indoor outdoor reset control H Ignition system...

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Page 36: ...ssmann ca info viessmann ca Viessmann Manufacturing Company U S Inc 45 Access Road Warwick Rhode Island 02886 USA Tel 401 732 0667 Fax 401 732 0590 www viessmann us com info viessmann us com 36 Printed on environmentally friendly recycled and recyclable paper 5167 463 v1 3 Technical information subject to change without notice ...