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

VITOGAS 100

5167 463 v1.3 02/2011

IMPORTANT

Read and save these instructions for future reference.

2

Safety, Installation and Warranty Requirements

Safety, Installation and Warranty Requirements

Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).

H Licensed professional heating contractor

The installation, adjustment, service, and maintenance of this equipment must be performed by a licensed professional heating contractor.

" Please see section entitled “Important

Regulatory and

Installation

Requirements”.

H Contaminated air

Air contaminated by chemicals can cause by-products in the combustion process which are poisonous to inhabitants and destructive to

Viessmann equipment.

" For a listing of chemicals which cannot be stored in or near the boiler room, please see section entitled

“Combustion Air Supply”.

WARNING

Installers must follow local regulations with respect to installation of carbon monoxide detectors. Follow manufacturer’s maintenance schedule of boiler.

H Fresh air

This equipment requires fresh air for safe operation and must be installed ensuring provisions for adequate combustion and ventilation air exist.

H Product documentation

Read all applicable documentation before commencing installation. Store documentation near boiler in a readily accessible location for reference in the future by service personnel.

" For a listing of applicable literature, please see section entitled “Important

Regulatory and

Installation Requirements”.

H Carbon monoxide

Improper installation, adjustment, service and/or maintenance can cause flue products to flow into living space.

Flue products contain poisonous carbon monoxide gas.

H Equipment venting

Never operate boiler without an installed venting system. An improper venting system can cause carbon monoxide poisoning.

" 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”.

" For information pertaining to venting and chimney requirements, please see section entitled “Venting

Connection”. All products of combustion must be safely vented to the outdoors.

H Advice to owner

Once the installation work is complete, the heating contractor must familiarize the system operator/ultimate owner with all equipment, as well as safety precautions/requirements, shut-down procedure, and the need for professional service annually before the heating season begins.

" For information pertaining to the fresh air requirements of this product, please see section entitled

“Combustion Air Supply”.

H Warranty

Information contained in this and related product documentation must be read and followed. Failure to do so renders warranty null and void.

Warning

This boiler requires fresh air for safe operation and must be installed with provisions for adequate combustion and ventilation air (in accordance with local codes and regulations of authorities having jurisdiction).

Do not operate this boiler in areas with contaminated combustion air. High levels of contaminants such as drywall dust, lint or chemicals can be found at construction sites, home renovations, in garages, workshops, in dry cleaning/laundry facilities, near swimming pools and in manufacturing facilities.

Contaminated combustion air will damage the boiler and may lead to substantial property damage, severe personal injury and/or death. Ensure boiler/burner is inspected and serviced by a qualified heating contractor at least once a year in accordance with the Start-up/Service Instructions of the boiler.

Safety

General Information

Set-up

Boiler Control

Connections

Fresh Air

Appendix

Page

Important Regulatory and Installation Requirements

. . . .

4

About these Installation Instructions

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6

Product Information

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6

Mechanical Room

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7

Product Installation Alternatives

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7

Before Set-up

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8

Minimum Clearances

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Recommended minimum clearances for service

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

Recommended minimum clearances to combustibles

. . .

8

8

9

Boiler Set-up and Orientation

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10

Boiler Control Base Installation

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11

Electrical Connections

Boiler wiring

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11

12

Venting Connection

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13

Gas Connection and Piping

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Proper piping practice

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Gas piping pressure test

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Water Side Connections

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18

Safety Connections and Pressure Testing

Installing safety device on the boiler

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

Performing pressure test on the boiler

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20

DHW Side Connections

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20

Installation Examples

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System with multiple zones

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Boiler in a heating/cooling application

Boiler with low water cut-off

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Important precautions

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Combustion Air Supply

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Combustion air opening

Ventilation air opening

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Post-Installation ...

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Start-up information

Service Binder

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Technical Data

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Wiring Diagrams

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32

Contents

3

4

Safety

Important Regulatory and Installation Requirements

Codes

The installation of this unit shall be in accordance with local codes or, in the absence of local codes, use

CAN/CSA-B149.1 or .2 Installation

Codes for Gas Burning Appliances for

Canada. For U.S. installations use the

National Fuel Gas Code ANSI Z223.1.

Always use latest editions of codes.

All electrical wiring is to be done in accordance with the latest edition of

CSA C22.1 Part 1 and/or local codes. In the U.S. use the National Electrical

Code ANSI/NFPA 70.

The heating contractor must also comply with the Standard for Controls and Safety Devices for Automatically

Fired Boilers, ANSI/ASME CSD-1 where required by the authority having jurisdiction.

Mechanical room

Ensure the mechanical room complies with the requirements of the System

Design Guideline and/or Technical Data

Manual. In addition, see section entitled

Mechanical Room in this manual.

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 boiler, burners, or control.

Ensure main power supply to equipment, the heating system, and all external controls has been deactivated.

Close main gas supply valve. Take precautions in both instances to avoid accidental activation of power during service work.

Technical literature

Literature applicable to the Vitogas boiler:

- Technical Data Manual

- Installation Instructions

- Start-up/Service Instructions

- Operating Instructions and User’s Information Manual

- Instructions of other Viessmann products utilized and installed

- Installation codes mentioned in this manual

Please carefully read this manual prior to attempting installation. Any warranty is null and void if these instructions are not followed.

For information regarding other

Viessmann System Technology componentry, please reference documentation of the respective product.

We offer frequent installation and service seminars to familiarize our partners with our products. Please inquire.

The completeness and functionality of field supplied electrical controls and components must be verified by the heating contractor. These include low-water cut-offs, flow switches (if used), staging controls, pumps, motorized valves, air vents, thermostats, etc.

Leave all literature at the installation site and advise the system operator/ultimate owner where the literature can be found. Contact

Viessmann for additional copies.

Safety

Safety, Installation and Warranty Requirements

(continued)

Fiberglass wool and ceramic fiber materials

WARNING

Inhalation of fiberglass wool and/or ceramic fiber materials is a possible cancer hazard. These materials can also cause respiratory, skin and eye irritation.

The state of California has listed the airborne fibers of these materials as a possible cancer hazard through inhalation. When handling these materials, special care must be applied.

Suppliers of ceramic fiber products recommend the following first aid measures:

- Respiratory tract (nose and throat) irritation

If respiratory tract irritation develops, move the person to a dust free location.

- Eye irritation

If eyes become irritated, flush immediately with large amounts of lukewarm water for at least 15 minutes. Eyelids should be held away from the eyeball to ensure thorough rinsing. Do not rub eyes.

- Skin irritation

If skin becomes irritated, remove soiled clothing. Do not rub or scratch exposed skin. Wash area of contact thoroughly with soap and water.

Using a skin cream or lotion after washing may be helpful.

- Gastrointestinal irritation

If gastrointestinal tract irritation develops, move the person to a dust free environment.

Suppliers of fiberglass wool products recommend the following precautions be taken when handling these materials:

Hazardous 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 concentration requiring additional protection.

WARNING

Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause serious injury or loss of life and which are known to the State of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby the appliance.

First aid measures

- If eye contact occurs, flush eyes with water to remove dust. If symptoms persist, seek medical attention.

- If skin contact occurs, wash affected areas gently with soap and warm water after handling.

5

6

General Information

About these Installation Instructions

Take note of all symbols and notations intended to draw attention to potential hazards or important product information.

These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below.

WARNING

Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury or substantial product/property damage.

CAUTION

Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or product/property damage.

IMPORTANT

Warnings draw your attention to the presence of potential hazards or important product information.

Cautions draw your attention to the presence of potential hazards or important product information.

Helpful hints for installation, operation or maintenance which pertain to the product.

This symbol indicates that additional, pertinent information is to be found in column three.

This symbol indicates that other instructions must be referenced.

Product Information

Sectional cast-iron boiler with atmospheric, fully pre-mix burner.

CAUTION

Vitogas 100, GS1 boilers for use with propane gas are constructed with different orifices, gas valves, and other components unique for operation with propane gas.

For operation 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.

Specify gas type at time of order.

Use only the fuel stated on boiler rating plate.

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.

General Information

Mechanical Room

During the early stages of new home design, we recommend that proper consideration be given to constructing a separate mechanical room dedicated to gas- or oil-fired equipment including domestic hot water storage tanks.

The boiler must be located in a heated indoor space, near a floor drain, and as close as possible to the vertical chimney or vent.

Whenever possible install boiler near an outside wall so that it is easy to duct fresh air directly to the boiler area. In addition, do not use exhaust fans in the boiler room and do not install the boiler in rooms with refrigeration equipment. This equipment requires uncontaminated 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 within the mechanical room.

The maximum room temperature of the mechanical room where the boiler is located must not exceed 95°F / 35°C.

Product Installation Alternatives

Installation without boiler stand Installation with boiler stand Installation on Vitocell tank

Instructions provided in this manual

Installation Instructions

Boiler Stand

Installation Instructions

Domestic Hot Water Tank and Installation Instruction

Supplement supplied with the tank.

7

8

Before Set-up

Before placing boiler in its installation location, ensure all necessary accessories (e.g. boiler stand) are installed.

IMPORTANT

Do not use draft hood or boiler enclosure paneling to lift/move boiler into its installation location.

CAUTION

The boiler must be installed in such a way that gas ignition system components are protected from water

(spraying, splashing, etc.) during boiler system operation and service.

Minimum Clearances

Recommended minimum clearances for service min.

9¾”

250 mm

When the Divicon pre-assembled mixing valve station is installed the minimum distance beside the boiler must be

19¾” / 500 mm

There must be sufficient space for a heating contractor to access the rear of the boiler to inspect the blocked vent switch.

top min.

24” /

600 mm

Installation Instructions

Boiler Stand min. 27½” / 700 mm

Diagram is not to scale.

Set-up

Minimum Clearances

Recommended minimum clearances to combustibles

For typical installations, Viessmann recommends installing the boiler with clearances as published on the previous page in subsection entitled “Recommended minimum clearances for service”.

The Vitogas 100, GS1 boiler is approved for closet and alcove installations with the following clearances to combustibles:

Boiler Model

Rear (from draft hood)

Sides

Flue

Top

GS1 inches mm inches mm inches mm inches mm

Floor

All clearances are measured from boiler enclosure.

-22

6

150

6

150

0

0

6

150

-29

6

150

6

150

0

0

6

150

-35

6

150

6

150

0

0

6

150

Combustibles

-42

6

150

6

150

0

0

6

150

-48

6

150

6

150

0

0

6

150

-60

6

150

6

150

0

0

6

150

9

Set-up

Boiler Set-up and Orientation

1.

4.

2.

kg

1.

3.

For Vitogas 100, GS1 installations on a Vitocell tank, reference the Installation

Instruction Supplement supplied with the tank.

1. Move boiler as close as possible to chimney and set up using 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 operation.

10

Boiler Control Base Installation

1.

3.9 x 4.5

3.9 x 4.5

closed open

4.

2.

3.

2.

Boiler Control / Connections

1. Loosen screws and remove top panel.

2. Unlock front panel and remove.

3. Carefully push high limits and boiler temperature sensor into sensor wells as far as possible.

IMPORTANT

Boiler temperature sensor is shipped with the boiler control.

Lay excess sensor cabling and capillary tubing on insulation.

WARNING

Do not kink capillaries. Proper operation of sensors is not possible if capillaries are kinked.

4. Insert boiler control base into upper front panel. Fasten with supplied rivets (shipped with boiler control).

Electrical Connections

All electrical wiring is to be done in accordance with the latest editions of

CSA C22.1 Part 1 and/or local codes. In the U.S. use the National Electrical

Code ANSI/NFPA 70.

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 boiler to the service panel.

See wiring diagram label on boiler.

Viessmann reserves the right to substitute electrical components as necessary.

Boiler electrical requirements are

120 VAC, 60 Hz, less than 15 A.

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.

WARNING

The boiler must be grounded in accordance with the latest edition of

ANSI/NFPA 70. In Canada use CSA

C22.1. Do not rely on piping to ground the boiler. Service personnel standing in wet areas may be electrocuted by an ungrounded boiler.

11

Electrical Connections

(continued)

Boiler wiring

6.

4.

1.

3.9 x 4.5

3.9 x 4.5

2.

1

3.

5.

For detailed information regarding connections on control base, see Installation

Instructions for Boiler Control.

IMPORTANT

The power supply cable is shipped with the boiler control.

1. Open strain reliefs located on rear panel.

2. Channel power supply cable or

Power/Pump Module cable (for

Vitotronic 200/300) and all other 120

VAC cabling through strain reliefs toward the boiler control.

3. Channel low voltage cables (i.e.

sensor cables) through cable opening toward boiler control.

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.

WARNING

Do not allow any electrical wires or conduits to touch the draft hood, vent pipe, or water piping.

WARNING

Always route all cables and capillaries between nylon-backed insulation and metal enclosure panels. Never allow cables and capillaries to come in direct contact with metal pressure vessel!

12

Connections

Venting Connection

Safety inspection of existing venting system

When existing boiler is removed from a common venting system, the common venting is likely to be too large for proper venting of the appliances remaining connected to it.

At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation:

H Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code,

ANSI Z223.1 latest edition. When resizing, any portion of the common venting system should be resized to approach the minimum size as determined, using the appropriate tables in the National Fuel Gas Code,

ANSI Z223.1 latest edition.

H Seal any unused openings in the common venting system.

H Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or any other deficiency which could cause an unsafe condition.

H Insofar as is practical, close all building doors and windows, and all doors between the space in which the appliances remain connected to the common venting system, and other spaces of the building. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

H Place in operation the appliance being inspected. Follow the Lighting and

Operating Instructions. Adjust thermostat so appliance will operate continuously.

H Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or a candle.

H After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers, as well as any other gas burning appliance to their previous condition of use.

WARNING

Improper sizing, maintenance, termination of vent or chimney can cause flue gases to enter living space. Any blockage of vent or chimney by birds’ nests, ice, snow, debris, or other materials can cause flue gases to enter living space. Flue gases entering living space can cause carbon monoxide poisoning which can result in severe personal injury or loss of life.

Installation of boiler venting

The boiler should be located as close to the chimney as possible. The vent connection must be made 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 runs should have no less than ¼” rise per ft. from the boiler to the vent terminal and must be properly insulated to reduce cooling of flue gas.

Metal strapping must be used to support horizontal runs every 4 ft. /

1.2 m.

Use approved vent material only.

The vent connector of this boiler must not be connected into any portion of mechanical draft systems operating under positive pressure.

Based upon proper chimney and breeching size, the boiler may be vented into a chimney/breeching with a direct-fired (atmospheric-fired) gas water heater. Observe national codes, local rules and regulations.

Terminate venting system outside with approved termination at least 6 ft. / 1.8

m above boiler. Vent pipe must extend at least 3 ft. / 0.9 m above the point where it passes through the roof. Vent termination must be at least 2 ft. /

0.6 m higher than any portion of the building within 10 ft. / 3 m horizontal, and vent termination must be at least 2 ft. / 0.6 m higher than roof peaks within

10 ft. / 3 m horizontal.

Down draft and condensation problems must be corrected.

Installation of side wall vent system

A side wall power vent system can be ordered from Viessmann. This package includes the appropriate power venter, vent terminal, and adaptor fittings for each Vitogas 100, GS1 boiler model, as well as installation instructions.

The vent system must terminate so that proper clearances are maintained as cited in the National Fuel Gas Code,

ANSI Z223.1 and as detailed in the Side

Wall Vent System Installation

Instructions. Observe and follow these instructions carefully.

WARNING

When the side wall vent system is used, the vent damper MUST NOT be installed.

13

Connections

Venting Connection

(continued)

Chimney Blocked vent and flame roll-out safety switch

A corrosion-resistant approved liner must be installed in masonry or unlined chimneys. The liner should be insulated to prevent condensation of flue gas in cold weather.

Before connection boiler to existing chimney, inspect chimney for inside and outside conditions. Repair or replace immediately if any leaks or other defects are found in the vent system.

To avoid chimney condensation, proper consideration must be given to shortest possible vent connection, type of vent, and chimney size.

The blocked vent switch is located at the back of the boiler in the draft hood.

In the event of a complete vent blockage, the spill switch heats up and interrupts 24 V to the gas control shutting down the burner. The switch 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.

In replacement installations where the previous boiler experienced chimney or vent condensation problems, the

Vitogas 100, GS1 must be installed as close as possible to the vertical chimney (relocate water piping if necessary), and the liner must be insulated. These measures will help reduce the likelihood of chimney or vent flue gas condensation.

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, shutting down the burner. The heat exchanger must be thoroughly examined and cleaned by a qualified heating contractor before the boiler is put back into operation. The switch requires a manual reset by pushing the red button when the switch has sufficiently cooled.

IMPORTANT

When installing piping or venting, or while insulating overhead pipes, do not stand on top panel of boiler. Advise other trades accordingly!

Vitogas

Never operate the boiler without an installed venting system which safely vents all products of combustion to the outdoors. The vent system must comply with all applicable local and/or national codes.

Vitogas boilers are Category I boilers as defined in ANSI Z21.13. Boiler category does not apply when boiler is vented through the wall with optional power venter.

Refer to natural draft venting tables in

CSA B149.1 and .2 (Canada) and ANSI

Z223.1 (USA) for every installation for proper vent diameter. Depending on the lateral and vertical vent lengths, the vent diameter may have to be increased to a size larger than the vent connector on the draft hood.

IMPORTANT

In either of the above functions, do not operate the boiler without the blocked vent or flame roll-out safety switch(es).

Advise the system operator/ultimate owner to contact a qualified heating contractor for service immediately.

Some retrofit installations may require an engineered vent system specific to the project site.

The boiler draft hood must not be altered or modified in the field.

In Canada

For gas boilers install venting system in accordance with all applicable local codes. In the absence of local codes, follow national codes CAN/CSA B149.1

or .2.

If chimney is of multi-fuel design, ensure local codes permit its use with the Vitogas 100, GS1 boiler. Ensure correct flue is chosen for the flue connection of the boiler.

In U.S.A.

For boilers for connection to gas vents or chimneys, vent installations shall be in accordance with Part 7, Venting of

Equipment, of the National Fuel Gas

Code, ANSI Z223.1 or applicable provisions of the local building codes.

14

Connections

Venting Connection

(continued)

D Installation

1. Install the venting so as to achieve the shortest possible way with minimum elbows. If necessary, rearrange existing water piping to achieve closest chimney connection.

2. Horizontal runs must be supported by appropriate means to prevent sagging. Avoid long horizontal runs of vent pipe. Horizontal runs should have no less than ¼” rise per ft.

from the boiler to the vent terminal.

Metal strapping must be used to support horizontal runs every 4 ft. /

1.2 m.

Combustion test opening ∅½”

IMPORTANT

Do not run vent connector along outside wall.

IMPORTANT

3. Fasten sheet metal vent pipe adaptor supplied with boiler (if applicable) to the draft hood flue collar. Use high temperature silicone to seal between sheet metal 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.

The diameter of the vent pipe must be identical to the diameter of the draft hood chimney connection.

WARNING

Failure to securely fasten all vent connections, including vent pipe adaptor to boiler, can cause flue gases to enter living space. Flue gases leaking into living space can cause carbon monoxide poisoning which may result in severe personal injury or loss of life.

4. Connect vent pipe adaptor with chimney via a field supplied, slightly inclined intermediate section of venting. Draft hood flue pipe diameter:

GS1-22

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

GS1-29 to -42

GS1-48 to -60

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

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

Outside ∅ 5”

Outside ∅ 6”

Outside ∅ 7”

5. Drill a ½” opening on the side of the vent pipe approximately two times the vent pipe diameter away from the flue gas collar of the boiler for flue gas analysis equipment.

6. It is recommended to seal all flue pipe joints.

7. Ensure any non-insulated vent pipe is insulated to reduce cooling of flue gas.

15

Connections

Venting Connection

(continued)

Vent damper installation

If boiler is sold with a vent damper

(packaged separately), the vent damper must be installed on the boiler to meet minimum efficiency standards.

The vent damper must be field installed on the boiler. Read the vent damper manufacturer’s instructions before installing the vent damper.

The closing and opening action of the vent damper is driven by a motor.

Spring action is not used to move the vent damper blade. Do not force vent damper blade by hand. Forcing the vent damper blade by hand will damage the motor. To observe the vent damper blade movement, turn thermostat up and down after vent damper has been installed. Vent damper blade must be in open position when burner is firing.

The vent damper must be installed as illustrated below. Ensure that damper blade rotates freely and is not obstructed in any way. Read and save the vent damper manufacturer’s instructions packaged with the vent

.

damper.

1. Review step 4 in subsection entitled

“Boiler wiring” on page 11.

Should the vent damper become defective:

2. Attach Molex female connector of vent damper cable to counter male connector on vent damper motor.

Use supplied plastic strain relief on vent damper cable and metallic strain relief on vent damper motor to secure the cable.

1. Follow the vent damper manufacturer’s instructions to leave the vent damper in the “Service” or

“Hold Open Damper” (Effikal) mode by using the service switch on the damper motor. Vent damper blade should stay open and boiler should operate normally.

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.

2. If the procedure described above does not work, remove vent damper, install transitional piece of vent pipe, disconnect and remove vent damper cable from the 120 V / 24 V relay module assembly. Connect jumper to terminals 2 (orange) and 3 (yellow) as illustrated below. Refer to wiring diagrams. Boiler will operate without vent damper.

Sequence of operation with vent damper:

1. Thermostat calls for heat.

Please note:

The “Effikal” damper can be field replaced with a similar size “Field

Controls” damper.

2. Vent damper blade opens.

3. Pilot sparks and ignites.

4. Pilot is proven and main valve is energized.

5. Main burner and pilot will continue to operate until thermostat is satisfied.

Burner may turn off and on in response to the adjustable high limit aquastat setting during call for heat.

16

Molex connector

Strain relief

Boiler strain relief openings

Jumper connected to terminals 2 and 3

Removed vent damper cable

Connections

Gas Connection and Piping

1. Size and connect gas supply piping in accordance with local and national codes.

2. Before connecting boiler to gas line, install main gas shut-off valve, ground joint union, and capped drip leg. Connect boiler gas connection to the above.

Gas connection (NPT)

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

∅ 1 /

2

“

3. Perform gas piping pressure test. See

.

section below

WARNING

The gas supply piping must be leak tested before placing the boiler in operation.

4. Identify the main shut-off valve as such with a tag and familiarize operator/ultimate owner of boiler with this valve.

Gas connection

Drip leg

Ground joint union

Approved manual gas shut-off valve

IMPORTANT

Max. gas supply pressure: 14 “w.c.

Proper piping practice

2 imperfect threads

Use moderate amount of dope

Support piping by proper suspension method. Piping must not rest on or be supported by boiler.

Thread pipe right length

Leave 2 end threads bare

Gas piping pressure test

Perform gas piping pressure test. Ensure the following requirements are met:

1. Isolate the boiler from the gas supply piping system using the individual manual shut-off valve during pressure tests equal to or less than ½ psig /

14” w.c..

2. The boiler and its 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

½ 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 liquid is sprayed on any electrical components, wires or connectors. Do not allow leak detection fluid to contact gas valve regulator or regulator vent opening.

5. Correct any and all deficiencies.

6. Remove air from gas line.

WARNING

Exposing boiler gas pressure regulator and gas valve to extreme pressures renders warranty null and void.

IMPORTANT

½ psig = 14 ”w.c.

WARNING

Never check for gas leaks with an open flame.

17

Connections

Water Side Connections

Safety supply, for pressure relief valve and air vent (non-NPT)

Boiler water supply and return (non-NPT)

. . . . . . . .

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

Boiler drain, for precharged expansion tank and automatic feed (NPT)

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

Drain connection for left cast-iron section (located at boiler front)

∅ 1 1 /

2

“

∅ 1 1 /

2

“

∅ ¾”

Installation Instructions

Divicon Station

IMPORTANT

This boiler is designed for closed loop, forced circulation heating systems only.

1. Flush heating system thoroughly

(particularly existing systems which have been in operation for years).

CAUTION

Failure to flush the heating system could cause system sludge to settle in the boiler, causing overheating and failure. This type of failure is not covered under warranty.

2. Attach two 1½” NPT adaptors and gaskets (Installation Fittings Package) to the welded supply and return non-NPT nipples on boiler.

Do not connect system piping directly to supply and return nipples.

3. Connect heating circuits.

Do not connect the system return to the safety return .

IMPORTANT

We recommend the installation of a spring-loaded flow-check valve in heating circuits without mixing valves.

This serves to avoid uncontrolled gravity circulation of heat into the heating system during prioritized DHW production, or during summer months.

CAUTION

To drain the boiler use drain connection on the back of the boiler first. Then use the front drain connection to drain the left cast-iron section.

Service Instructions

Vitogas 100, GS1

CAUTION

The boiler warranty does not cover leaks resulting from corrosion caused by the use of underfloor plastic tubing without an oxygen diffusion barrier.

Such systems must have the non-oxygen-diffusion barrier tubing separated from the boiler with a heat exchanger. Viessmann recommends the use of underfloor plastic tubing with an oxygen diffusion barrier.

18

Gasket

Connect this end using gasket to non-NPT threads of welded supply and return boiler nipples

1 1 /

2

“ NPT male threads

Connections

Safety Connections and Pressure Testing

Installation Instructions

Viessmann Safety Header

(accessory)

Installing safety devices on the boiler

Installing safety devices.

IMPORTANT

1. Install pressure relief valve, discharge pipe, air vent and pressure gage as described in installation instructions of Safety Header.

A 30 psig pressure relief valve is shipped with the boiler (standard equipment).

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.

2. Install discharge pipe on pressure relief valve. The end of the pipe must not be threaded.

The pressure relief discharge pipe should extend to a floor drain and end approximately 6” / 150 mm above the drain.

Do not install shut-off valve in discharge pipe.

Do not reduce discharge pipe diameter.

Do not pipe discharge to outdoors!

Minimum connection diameters:

Pressure relief valve

Discharge pipe

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

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

Piping to precharged expansion tank

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

3 /

4

“

3 /

4

“

3 /

4

“

WARNING

Do not install an isolation valve between boiler and pressure relief valve.

The discharge pipe for the pressure relief valve must be oriented to prevent scalding of attendants.

Pipe pressure relief valve discharge pipe close to floor drain. Never pipe discharge pipe to the outdoors.

IMPORTANT

This boiler does not require a flow switch.

Low water cut-off

A low water cut-off may be required by local codes. If boiler is installed above radiation level, a low water cut-off device of approved type (field supplied) must be installed in all instances. Do not install an isolation valve between boiler and low water cut-off.

19

Connections

Safety Connections and Pressure Testing

(continued)

Performing pressure test on the boiler

The boiler must be leak tested before being placed in operation. Before boiler is connected to piping or electrical power supply, it must be hydrostatically pressure tested with a maximum of 1½ times the maximum operating pressure of the boiler.

1. After installing safety devices (see previous page), install temporary cap on ¾” nipple extension (nipple for pressure relief valve mounting).

2. Cap supply and return connections.

3. Connect ½” garden hose to boiler drain valve at the back of the boiler and fill boiler slowly until pressure gage indicates max. 90 psig / 620 kPa.

4. Maintain pressure for 15 minutes.

During time of pressure testing, do not leave boiler unattended.

5. Inspect all pipe joint connections, the safety devices and 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 ¾” cap from safety nipple, and install pressure relief valve immediately instead of ¾” cap.

After boiler has passed pressure test, proceed with installation.

Max. operating pressure

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

Max. testing pressure

60 psig / 413 kPa

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

90 psig / 620 kPa

Max. boiler temperature

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

250 °F / 120 °C

CAUTION

Do not use the front drain valve to fill the boiler.

WARNING

Exposing the boiler to pressures and temperatures in excess of those listed will result in damages, and will render warranty null and void.

DHW Side Connections

For the production of domestic hot water, the boiler must be connected to an indirect-fired domestic hot water storage tank. Contact Viessmann for control options. Water for domestic use must not be drawn from the boiler for any purpose. This boiler does not use a tankless coil.

20

Installation Instructions

Domestic Hot Water Storage

Tank

Connections

Installation Examples

General

The schematics on the following pages are to be seen as guidelines only. They further do not display all system varieties, safety devices, or concepts possible. Specific system layouts may be further discussed with the local

Viessmann sales representative office.

Clearances

A minimum of 2” circumferential clearance from non-insulated hot water pipes to combustible construction must be maintained. In cases where the pipes are insulated with pipe insulation of appropriate and sufficient thickness and insulation values, the above clearance may be reduced to 0” (refer to local gas codes).

Waterside flow

20

16

12

8

4

3.2

2.4

2.0

1.6

1.2

0.8

10

8

6

5

4

3

2

50

40

30

20

CAUTION

For underfloor heating applications, an additional immersion or strap-on aquastat must be installed in the low temperature underfloor loop (ahead of the mixing valve) to de-energize the pump and/or boiler to prevent overheating. High water temperatures can damage concrete slabs.

0.4

1

Water flow

GS1-22

GS1-29

GS1-35 and -42

GS1-48 and -60 ltr/h

USGPM

Flow rates

The relationship 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

20°F rise

30°F rise

GS1

USGPM m 3 /h

USGPM m 3 /h

-22

7.5

1.7

5.0

1.1

-29

9.8

2.2

6.5

1.5

-35

12.3

2.8

8.2

1.9

-42

14.0

3.2

9.3

2.1

-48

16.1

3.6

10.7

2.4

-60

24

5.4

16.0

3.6

21

Connections

Installation Examples

(continued)

Installation Examples

IMPORTANT

These examples show possible piping layouts for Viessmann product equipped with

Viessmann System Technology. For boiler and tank combinations, please install only the feasible combinations listed in the Price List.

These are simplified conceptual drawings only!

Piping and necessary componentry must be field verified.

Proper installation and functionality in the field is the responsibility of the heating contractor.

Without mixing valve

e.g. with Vitotronic 100

V

2

V

1

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.

V

1

V

2

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)

DHW pump module

Bypass pipe (highly recommended) c/w two regulating valves (V

1

, V

2

)

See page 28 for installation details.

22

Connections

Installation Examples

(continued)

With 3-way mixing valve to regulate heating circuit

e.g. with Vitotronic 200, KW2 combined with a mixing valve actuator accessory kit

V

1

V

2

V

1

V

2

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 (V

1

, V

2

)

See page 28 for installation details.

23

Connections

Installation Examples

(continued)

With 4-way mixing valve to regulate heating circuit

e.g. with Vitotronic 200, KW2 combined with a mixing valve actuator accessory kit

Underfloor heating system with system separation

Heating circuit

Spring-loaded flow check valve

Circulation pump

Safety header with automatic air vent, pressure relief valve, and pressure gage

Expansion tank

4-way mixing valve

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 circuit

Spring-loaded flow check valve

Circulation pump for underfloor heating circuit

Safety header with automatic air vent, pressure relief valve, and pressure gage

Expansion tank

3-way mixing valve

Circulation pump for heat exchanger

Heat exchanger

Supply temperature sensor

24

Installation Examples

(continued)

System with multiple zones

Connections

If system has motorized zone valves and single circulating 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.

25

Connections

Installation Examples

(continued)

Boiler in a heating/cooling application v2 v1

The boiler, when used in connection with a refrigeration system, must be installed ensuring the chilled medium is piped in parallel to the boiler with appropriate valves to prevent the chilled medium from entering the boiler. See illustration on the left.

The boiler piping system of a hot water heating boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control 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 header with automatic air vent, pressure relief valve, and pressure gage

Expansion tank

Water chiller

IMPORTANT

We strongly suggest that the valves pictured above be labelled “v1” and

“v2”.

IMPORTANT

In the above system, the circulating pump must be operated from a separate on/off switch - not from the pump aquastat on the boiler.

26

Connections

Installation Examples

(continued)

Boiler with low water cut-off

Low water cut-off connection

Boiler supply (NPT)

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

∅ 1½“

Tee (field supplied)

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

1” x 1” x 3 /

4

”

Viessmann Safety Header

A low water cut-off may be required by local codes. If boiler is installed above radiation level, a low water cut-off device attached 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.

27

Connections/Fresh Air

Installation Examples

(continued)

Important precautions

Avoid frequent system water replenishment

Oxygen diffusion barrier underfloor tubing

This boiler is not for use in systems where water is constantly or frequently replenished. Minerals such as calcium in make-up water can deposit on the heat exchanger causing overheating, and eventually the boiler will leak. This type of failure is not covered by warranty.

Water must not be drained from system for use by cleaning personnel or be constantly replenished due to inadequately sized expansion tanks, flooded expansion tanks, system leaks, etc.

The boiler warranty does not cover leaks resulting from corrosion caused by the use of underfloor plastic tubing without an oxygen diffusion barrier.

Such systems must have non-oxygen-diffusion barrier tubing separated 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 any system as a preventative measure. Viessmann strongly recommends installing a bypass pipe on all cast iron boilers.

Install bypass as shown in order to prevent condensation from occurring in the heat exchanger when installing the boiler in a large water volume residential system (typically systems with volume > 1 USG/3.8 ltr for every

13 000 Btu/h).

Install supply/return bypass as follows:

V

2

V

1

1. Install full size bypass pipe (same diameter as boiler supply and return pipes) as shown.

2. Install two flow regulating/throttling valves, V

1 and V

2

, to slow down the flow in the boiler by bypassing some of the water back to the system.

Heating circuit

Spring-loaded flow check valve

Circulation pump

Safety header with automatic air vent, pressure relief valve, and pressure gage

Expansion tank

Bypass (must be min. 12”/305 mm long)

V

1

V

2

Flow regulating/throttling valve

Flow regulating/throttling valve

3. Bypass pipe must be at least

12”/305 mm long.

4. Open valve V

1 and close valve V

2 completely.

5. By trial and error method, gradually open valve V

2

V

1 while regulating valve until the boiler temperature gage reads at least 140 ºF/60 ºC in less than ten minutes.

28

Connections/Fresh Air

Installation Examples

(continued)

Important precautions (continued)

V

Legend:

Heating circuit

Spring-loaded flow check valve

Circuit pump

Safety header with air vent, pressure relief valve and pressure gage

Expansion tank

4-Way mixing valve

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).

Supply/return bypass for large water content systems with mixing valve

Install supply/return bypass as follows:

1. Install full size bypass pipe (same diameter as boiler supply and return pipes) as shown.

2. Install a flow regulating/throttling valve “V” to slow down the flow in the boiler by bypassing some of the water back to the system (approx.

30% to 50%of the total flow).

3. Bypass pipe must be at least

12”/305 mm in length.

4. By trial and error method, regulate valve “V” until the boiler temperature gage reads at least

140 ºF/60 ºC in less than ten minutes.

Combustion Air Supply

This boiler requires fresh air for safe operation and must be installed ensuring there are provisions for adequate combustion and ventilation air.

WARNING

Failure to provide an adequate supply of fresh combustion air can cause poisonous flue gases to enter living space which can cause severe personal injury or loss of life.

Provisions for combustion and ventilation air must be made in accordance with applicable local codes.

In the absence of local codes, use

CAN/CSA-B149.1 or .2 Installation

Codes for Gas Burning Appliances 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.

WARNING

Never cover the boiler or store debris or other materials near the boiler, or in any way block the flow of adequate fresh air to the boiler. Never cover the combustion air opening or put anything inside draft hood. Advise system operator/ ultimate owner accordingly.

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 under negative pressure. Exhaust fans, attic fans, or dryer fans may cause air to be exhausted at a rate higher than air can enter the structure for safe combustion.

WARNING

The boiler must not be located in areas or rooms where chemicals are stored, or aggressive vapors (i.e.

bleach, hair spray, methyl chloride, carbon tetrachloride or perchloroethylene) or high dust levels or humidity levels are present. Heat exchanger corrosion might occur and reduce the lifetime of the boiler significantly. If above criteria are not properly observed and boiler damage results, any warranty on the complete boiler and related components will be null and void.

29

Fresh Air

Combustion Air Supply

(continued)

Louvres and grilles

In calculating free area as specified on page 29 and 30, consideration shall be given to the blocking effect of louvers, grilles, or screens that protect openings.

Screens used shall be not smaller than

¼” / 6 mm mesh and shall be readily accessible for cleaning. If the free area through a design of louvre or grille is known, it shall be used in calculating the size of opening required to provide the free area specified. If the design and free area are not known, it shall be assumed that wood louvres have

20-25% free area and metal louvres and grills have 60-75% free area.

Combustion air opening

Install a combustion air opening. Ensure the following requirements are met:

Boiler Model

Opening/duct diameter

(free area)

Combustion air opening for below-grade boiler room

Model No.

inches

GS1-22

4

GS1-29

4

GS1-35

5

1. Size combustion air opening according to chart above.

2. Corrosion resistant screens must not have individual grids less than

¼” x ¼” / 6 mm x 6 mm. Screens or louvers must not reduce the free area required for combustion air. Increase duct diameter if louvers are used.

3. A combustion air opening from the outdoors shall be located not less than 12 inches / 30 cm above the outside grade.

4. The outside inlet of the combustion air duct must not permit the entry 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.

Louver

Grade

6. If the combined MBH input exceeds

400 MBH for all gas burning appliances, the following excerpt from the CAN/CSA B-149 Code can be used: Duct size equal to gross louver area

Boiler room floor

GS1-42

6

6½ cm 2

GS1-48

6

Combustion air supply shall have a cross sectional area of not less than

100 inches

2

/ 650 cm

2 plus 1 inch

2

/ for each 14 MBH in excess of 400 MBH. This/these opening(s) shall be either located at, or ducted to, a point neither more than 18 inches / 46 cm nor less than 6 inches

/ 16 cm above the floor level.

The heating contractor must check with local authorities (municipal building department, gas utility) for combustion air requirements particular to the area.

WARNING

GS1-60

7

Whenever your boiler is installed in a structure with airtight features such as weather stripping or tight insulation, there must be a combustion air opening installed to supply air from the outside even though the boiler may be installed in a space with a large volume relative to the boiler. Any building type and structure must be evaluated for proper and adequate combustion air supply before the boiler is put into operation.

Ventilation air opening

In addition to the combustion air opening, a ventilation air opening should be installed at the highest practical point communicating with the outdoors with a minimum area of 10% of the combustion air opening or 10 inches 2

65 cm 2 , whichever is greater.

/

30

Appendix

Post-Installation ...

Start-up information

Start-up/Service Instructions of boiler and control

Service Binder

1. File all Parts Lists, Operating and

Service Instructions into the Service

Binder.

2. Install a protective hanging case near the boiler and store the Service

Binder in this location.

Technical Data

Boiler Model

CSA input

CSA output

DOE heating capacity

Min. gas supply pressure

Natural gas

LPG

Max. gas supply pressure

*1

(flow)

Max. operating pressure

(water)

Boiler connections

Boiler supply and return

Safety supply

Drain valve

Gas supply connection

Flue gas *2

Temperature (gross)

Mass flow rate

– with natural gas

– with LPG

Vent pipe collar

Model No.

MBH kW

MBH kW

“ w.c.

“ w.c.

“ w.c.

psig

Ø” (male thread)

Ø” (male thread)

Ø” (male thread)

Ø” (tapered male thread)

°F

°C lbs/h kg/h lbs/h kg/h outside Ø”

GS1-22

90

26

76

22

5

11

14

60

1½

1½

¾

½

223

106

161

73

148

67

5

GS1-29

115

34

98

29

5

11

14

60

1½

1½

¾

½

216

102

216

98

209

95

6

GS1-35

145

42

123

36

5

11

14

60

1½

1½

¾

½

235

113

236

107

209

95

6

GS1-42

165

48

140

41

5

11

14

60

1½

1½

¾

½

266

130

231

105

223

101

6

GS1-48

190

56

161

47

5

11

14

60

1½

1½

¾

½

228

109

342

155

322

146

7

*1 If the gas supply pressure is higher than the maximum permissible value, a separate gas regulator must be installed upstream of the boiler system.

*2 Measured flue gas temperature after dilution air with combustion air temperature of 68°F / 20°C.

GS1-60

240

70

203

60

5

11

14

60

1½

1½

¾

½

252

122

353

160

337

153

7

31

Wiring Diagrams

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.

*

*

32

Wiring Diagrams

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.

33

Wiring Diagrams

Vitogas 100, GS1 Ladder Diagram of Ignition System

400 ºF / 204 ºC

235 ºF / 113 ºC

Legend

41 Terminals in plug

R Relay coil 1

1R Contact of relay 1

LC Limit contact in boiler control

T 120 V / 24V, class II transformer

F1 Fuse (slow blow)

VD Vent damper

ES End switch in vent damper

FRS Flame roll-out switch

BVS Blocked vent switch

L1 120 V (hot)

N 120 V (neutral)

H Demand for heat causes vent damper blade to open, closing vent damper end switch ES. 120 V is available to transformer.

H Burner cycles on and off in response to operating control (room thermostat, end switch of zone valve, separate indoor/outdoor reset control).

H BVS (blocked vent switch) or FRS

(flame roll-out switch) can de-energize ignition system.

Vitotronic boiler controls and

Vitogas 100, GS1 Service

Instructions

H Ignition module is energized with 24 V from the 24 V transformer.

H Ignition system can cycle off adjustable high limit aquastat in boiler control during a demand for heat.

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.

34

5167 463 v1.3

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 • [email protected]

36

Viessmann Manufacturing Company Inc.

750 McMurray Road

Waterloo, Ontario • N2V 2G5 • Canada

Tel. (519) 885-6300 • Fax (519) 885-0887 www.viessmann.ca • [email protected]