Viessmann Vitoflame 300 VHG III Operating instructions

Service instructions
for contractors
VIESMANN
Vitoflame 300
Type VHG III
Pressure-jet oil burner
for the Vitorondens 200-T, 67.6 to 107.3 kW
For applicability, see the last page
VITOFLAME 300
5831447 GB 6/2016 Please keep safe.

2
Please follow these safety instructions closely to
prevent accidents and material losses.
Safety instructions explained
Danger
This symbol warns against the risk of injury.
!Please note
This symbol warns against the risk of material
losses and environmental pollution.
Note
Details identified by the word "Note" contain additional
information.
Target group
These instructions are exclusively intended for quali-
fied contractors.
■Work on electrical equipment may only be carried
out by a qualified electrician.
■The system must be commissioned by the system
installer or a qualified person authorised by the
installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■All relevant safety regulations as defined by DIN, EN,
DVGW, VDE and locally applicable standards
aÖNORM, EN and ÖVE
cSEV, SUVA, SVTI and SWKI
Safety instructions for working on the system
Working on the system
■Isolate the system from the power supply (e.g. by
removing the separate fuse or by means of a mains
isolator) and check that it is no longer 'live'.
■Safeguard the system against reconnection.
Danger
Hot surfaces can cause burns.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the boiler, burner,
flue system or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing any work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions
Safety instructions
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Safety instructions for operating the system
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to prevent flue
gases from spreading.
What to do if water escapes from the appliance
Danger
When water escapes from the appliance there is
a risk of electrocution.
Switch off the heating system at the external iso-
lator (e.g. fuse box, domestic power distribu-
tion).
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of conden-
sate or other causes. Ensure an adequate supply of
combustion air.
Inform system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be non-
closable.
Extractors
Operating appliances that extract air to the outside
(cooker hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to reverse flow of the
flue gas.
Danger
The simultaneous operation of the boiler and
appliances that extract air to the outside can
result in life threatening poisoning due to
reverse flow of the flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
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1. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 5
2. Burner control unit ................................................................................................................ 15
3. Troubleshooting Diagnosis ............................................................................................... 18
■Faults with flash code indication ......................................................... 18
■Faults without flash code indication .................................................... 19
4. Component overview ................................................................................................................ 21
5. Connection and wiring dia-
gram
................................................................................................................ 23
6. Parts lists Parts lists ............................................................................................... 24
■Ordering parts ..................................................................................... 24
Overview of assemblies ......................................................................... 24
Casing assembly ................................................................................... 24
Burner casing assembly ........................................................................ 25
Burner cover assembly, 67.6 kW ........................................................... 26
Burner cover assembly, 85.8 and 107.3 kW .......................................... 27
Blast tube connection assembly ............................................................ 28
Miscellaneous ........................................................................................ 30
7. Report ................................................................................................................ 31
8. Specification ................................................................................................................ 32
9. Standard values for burner
adjustment
................................................................................................................ 33
10. Appendix Information on fuel oil ............................................................................ 34
11. Keyword index ................................................................................................................ 35
Index
Index
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Commissioning steps
Inspection steps
Maintenance steps Page
•1. Commissioning the system............................................................................................... 6
• • 2. Checking the burner
• • 3. Checking the oil pressure and vacuum, adjusting the CO2 value................................. 6
••• 4. Checking the settings of the air damper servomotor..................................................... 8
• • 5. Cleaning and testing the flame monitor........................................................................... 9
• • 6. Installing and adjusting the flame monitor (if available)................................................ 9
• • 7. Shutting down the system
• • 8. Checking the firm seating of electrical connections
•9. Cleaning the burner........................................................................................................... 10
• • 10. Checking the impeller fixings
• • 11. Checking the flame tube fixings
•12. Replacing the nozzle.......................................................................................................... 11
• • 13. Checking and adjusting the ignition electrodes............................................................. 12
•14. Fitting the burner cover on the burner casing
•15. Cleaning the oil pump filter and replacing it if required................................................. 13
•16. Replacing the pre-filter element
• • 17. Commissioning the system
• • 18. Checking the oil lines and connections for leaks
•19. Re-testing the burner and entering the actual values into the report
•20. Operating and service documents................................................................................... 14
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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To obtain optimum combustion values, the burner must be adjusted with the boiler heated up (min. 60 °C). Also
carry out tests at base load.
Boiler control unit service instructions Note
For fuel details, see chapter "Information on fuel oil".
A B
C
Fig. 1
1. Check the heating system pressure and the oil
level in the tank.
2. Open the shut-off valves in the oil lines on the oil
tank and on the filter.
3. Fill the oil suction line and the filter with fuel oil
using a manual oil suction pump before switching
the burner on.
4. Switch ON the mains isolator (outside the installa-
tion room).
5. Switch ON system ON/OFF switch B at the con-
trol unit.
If fault indicator A on the control unit illuminates,
press reset button C on the burner.
Checking the burner
Checking the oil pressure and vacuum, adjusting the CO2 value
The oil pressure is factory-set according to the oil
throughput.
When commissioning or using a sound insulation set
(accessories), select the CO2 value by adjusting the oil
pressure.
Commissioning, inspection, maintenance
Commissioning the system
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Fig. 2 Oil pump make: Danfoss
Fig. 3 Oil pump make: Suntec
01. Switch system OFF at mains isolator and safe-
guard against unauthorised reconnection.
02. Unscrew plug "P" A from the oil pump.
03. Unscrew plug "V" B from the oil pump.
Note
Oil may leak from the oil pump when doing this.
04. Insert a pressure gauge (measuring range 0 -
40 bar) and a vacuum gauge (measuring range 0 -
1 bar).
Note
Only seal in the pressure and vacuum gauges with
copper or aluminium gaskets or with O-rings.
Never use sealing tape.
05. Start the burner.
Note
The solenoid valve opens.
06. Read off the oil pressure and the vacuum of the
pump on the relevant gauge (vacuum should be
max. 0.35 bar at a height differential of 3 m
between the oil pump and the bottom of the tank).
Note
If the vacuum pressure is higher than 0.35 bar,
check the filter for contamination and check the
pipe run.
E
Fig. 4
07. Should the CO2 value fall outside the range of 13
to 14 % by vol., adjust the CO2 value by regulating
the oil pressure.
Note
Subject to pump type, the pressure adjusting
screws may be located at the front or on the side
of the oil pump.
■For burner stage 2, set the oil pressure at pres-
sure adjusting screw D. The service switch E
is factory-set to setting 2.
■For burner stage 1, set service switch E to set-
ting 1; open the flap to do so. Adjust the oil pres-
sure by means of pressure adjusting screw C.
Clockwise turn → pressure increases.
Anti-clockwise turn → pressure decreases.
Note
For standard values for burner settings, see page.
Commissioning, inspection, maintenance
Checking the oil pressure and vacuum , adjusting… (cont.)
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08. Test to check the actual emission values after
adjusting the oil pressure.
09. Switch system OFF at mains isolator and safe-
guard against unauthorised reconnection.
10. Undo the pressure and vacuum gauges.
11. Check the plug seal rings for damage and replace
if necessary.
Insert plugs "P" A and "V" B.
12. Start the burner and check the plugs for leaks.
Checking the settings of the air damper servomotor
The air damper servomotor is factory-set and must only be adjusted in exceptional cases. Exceptions are the
replacement of the air damper servomotor, soot build-up and the altitude above sea level of the installation
site. The CO2 value must only be adjusted by regulating the oil pressure.
90 30
60 0
90 30
60 0
90 30
60 0
90 30
60 0
90 30 0
ST2
BV
SL
ST1
Z
Fig. 5
The burner is equipped with an air damper servomotor
with adjustable switching cams for the positioning of
the air damper and the solenoid valve control.
During a controlled shutdown, the burner air damper
moves into the "closed" position. This reduces the
cool-down losses.
The switching cams are located under the cover of the
air damper servomotor. A scale ring is located adjacent
to each switching cam, where the selected angle of the
air damper can be checked.
The switching cams have the following function:
Z Air damper closed (0 °)
Never alter the setting of Z.
SL Ignition air setting
ST1 Air damper stage 1
ST2 Air damper position stage 2
BV Solenoid valve stage 2
The switching cams for ignition air stage 1 and 2 are
set at the factory. Factory settings, see chapter "Stand-
ard values for burner adjustment".
The switching cams are adjusted by means of slotted
screws A in the cams. When doing this observe the
following:
■The ignition air setting cannot be turned beyond the
setting of stage 1 (turning further is blocked by
cams).
■After setting, match the start air setting to stage 1;
always adjust the start air setting approx. 1-5 ° below
stage 1.
Commissioning, inspection, maintenance
Checking the oil pressure and vacuum , adjusting… (cont.)
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A
Fig. 6
AFlame monitor
Safety check Response
Burner start with dark-
ened flame monitor
Fault shutdown at the end
of the safety time.
Red flashing code, flashes
2x.
Burner start with exter-
nally lit flame monitor
Fault shutdown after max.
40 s.
Flashes alternately green-
red.
Burner operation with si-
mulated flame tear-off:
Cover the flame monitor
during operation and
leave in this condition
Restart followed by a fault
shutdown at the end of the
safety time.
Red flashing code, flashes
2x.
Installing and adjusting the flame monitor (if available)
Before fitting, check whether slider sleeve B is
pushed as far forward as it will go (x = max.).
Push-on restrictor A must sit on flame monitor C.
x
Fig. 7
Shutting down the system
Checking the firm seating of electrical connections
Commissioning, inspection, maintenance
Cleaning and testing the flame monitor
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For cleaning the combustion chamber and flues,
see boiler service instructions.
A
B
F
C
D
E
Fig. 8
1. Set the burner into its maintenance position. To do
this, remove nozzle cover D with mixing device
and slot it onto the burner casing with the blast
tube connection pointing upwards or to the side.
2. Clean flame tube, sensor plate A, ignition electro-
des B and flame monitor C.
3. In the case of severely deviating burner pressure:
Remove burner cover E and clean casing with
impeller; for this, first remove hood adaptor F.
Checking the impeller fixings
Checking the flame tube fixings
Commissioning, inspection, maintenance
Cleaning the burner
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A
B
Fig. 9
1. Remove the nozzle cover with mixer device and
slot it onto the burner casing with the blast tube
connection pointing upwards (service position).
This prevents the formation of bubbles in the blast
tube connection.
2. Remove mixing assembly A from the blast tube
connection.
3. Replace nozzle B (counterhold to prevent the
blast tube connection from turning); during this
step prevent air bubbles from forming in the blast
tube connection.
Note
For the make and type of nozzle, see standard val-
ues for burner settings on page.
4. Mount mixing facility A:
■Position the nozzle in the centre of the sensor
plate and note the distance between the sensor
plate and the nozzle (see page).
■Accurately position the ignition electrodes in the
top centre (12 o'clock position).
Commissioning, inspection, maintenance
Replacing the nozzle
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3-5
A
a
b
Fig. 10
1. Check ignition electrodes A for wear, contamina-
tion and size accuracy (see diagram), replace if
required.
2. Distance between mixing system and nozzle:
Check either dimension a or dimension b and
adjust if required.
Rated heating out-
put
Dim. a Dim. b
63/67.6 kW 9.4 mm
80/85.8 kW 5 mm 10.0 mm
100/107.3 kW 12.0 mm
Fitting the burner cover on the burner casing
Commissioning, inspection, maintenance
Checking and adjusting the ignition electrodes
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Fig. 11 Oil pump make: Danfoss
AFilter plug
BO-ring (replace)
CFilter (replace)
Fig. 12 Oil pump make: Suntec
AFilter (clean or replace)
BFlat gasket (replace)
CO-rings (replace)
DCover
Replacing the pre-filter element
Commissioning the system
Commissioning, inspection, maintenance
Cleaning the oil pump filter and replacing it if required
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Re-testing the burner and entering the actual values into the report
Operating and service documents
1. Complete and detach the customer registration
card:
■Hand system users their section for safekeeping.
■Retain the heating contractor's section.
2. File all parts lists, operating and service instruc-
tions in the folder and hand this over to the system
user.
The installation instructions are no longer required
after the installation is complete and therefore do
not need to be retained.
Commissioning, inspection, maintenance
Checking the oil lines and connections for leaks
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Program sequence during commissioning
0
Start
1. Stage 1
BV2 control cam
2. Stage 2
BV2
TR/STB
AA' B C D
t1
t40
t3n
t3
TSA
control signals
required input signals
Fig. 13
Note
The output signal at the solenoid valve stage 2 F is
dependent upon the switch position of the BV2 control
cam of the solenoid valve stage 2 in the servomotor.
A Start-up begins
B Point of flame formation
C Burner operating position
D Controlled shutdown
EBurner motor
FSolenoid valve stage 2
HSolenoid valve stage 1
NIgnition transformer
OFlame monitor
ROutput controller
t1 Pre-purge time min. 20 s
t40 Delay time between enabling solenoid valve stage 1
and enabling controller input
approx. 11 s
t3 Pre-ignition time approx. 20 s
t3n Post-ignition time begins with flame
(max. until end of "TSA")
max. 5 s
TSA Start-up safety time max. 5 s
Function and fault indications of the signal indicator (LED)
During standard operation, the operating conditions are indicated by LED signal indicator A through colour
codes (see the following table).
After a fault shutdown, the indicator permanently illuminates red. In this condition, the optical fault cause indicator
can be activated (see the following chapter "Burner fault sequence diagram").
Burner control unit
Burner control unit
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B
A
Fig. 14
1. Hold down reset button B for approx. 5 s (>3 s).
2. A flash code is then shown.
The number of flashes in a sequence indicates the
type of fault. For an explanation, see the table in
chapter "Faults with flash code indication".
3. To reset the burner and exit the fault display, press
the reset button for approx. 1 s (<3 s).
LED colour Operating condition
Yellow, flashing Ignition phase pre-purge, ignition activated
Green, continuous Operation, flame stable
Green, flashing Operation, poor flame stability
Yellow-red, flashing alternately Undervoltage (<195 V)
Red, continuous Fault, burner locked out
Red, flashing Fault code indication (for an explanation, see chapter "Faults with flash
code indication")
Green-red alternately External light before burner start
Red, flickering Interface diagnosis was activated accidentally. Pressing the reset but-
ton once (approx. 3 s) starts the burner in standard mode.
Burner fault flowchart
System cold
LED on burner control unit illumi-
nates red
Reset burner control unit:
Press reset button for approx. 1 s
(<3 s)
Call up flash code:
Press reset button until LED
changes to yellow (approx. 5 s
(>3 s))
Burner start Read off flash code and identify
its meaning in the diagnosis table
Remedy the fault
Burner control unit
Burner control unit (cont.)
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Reset burner control unit:
Press reset button for approx. 1 s
(<3 s)
Burner start
Burner control unit
Burner control unit (cont.)
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Faults with flash code indication
Fault Red flash
code
Cause of fault Action
Burner does not start (with
fault indication), indicator il-
luminates
10 x Wiring fault or internal burner
fault; not all consumers were rec-
ognised; other error
Check the electrical connection
Burner does not start (with
fault indication)
2 ×Motor faulty Replace motor
2 ×Coupling between motor and oil
pump faulty
Replace coupling
2 ×Oil pump seized up or sluggish Clean the oil pump, or replace if
necessary
6 ×Servomotor faulty Replace the servomotor
Burner starts, but no flame
is formed
2 ×Ignition electrodes incorrectly ad-
justed
Set correctly (see chapter
"Checking and adjusting the igni-
tion electrodes")
2 ×Ignition electrodes damp and
contaminated
Clean ignition electrode block
2 ×Insulation body of ignition electro-
des cracked
Replace ignition electrode block
2 ×Ignition transformer faulty Replace ignition transformer
2 ×Ignition cable faulty Replace ignition cable
2 ×Pump does not supply oil Mount pressure and vacuum
gauges at the pump and check
build-up of pressure (see follow-
ing paragraph)
Pump does not supply oil 2 ×Shut-off valves closed at filter or
in oil line
Open valves
2 ×Filter blocked Clean filter (pre-filter and pump
filter), replace if necessary
2 ×Coupling between motor and
pump faulty
Replace coupling
2 ×Leak in suction line or filter bowl Retighten fittings. Check the oil
lines for leaks; seal if necessary.
2 ×Oil flow and return hoses inter-
changed
Connect correctly acc. to mark-
ings on pump
2 ×Vacuum in suction line too high
(above 0.35 bar)
Check sizing of oil line cross-sec-
tion. Replace filter. Check the ex-
ternal oil valve.
2 ×External oil valve faulty Check external oil valve and re-
place if required
Burner starts, but no oil is
injected
2 ×Solenoid valve coil faulty Replace solenoid valve coil
2 ×Oil pump faulty Replace oil pump
2 ×Nozzle blocked Replace nozzle
External light during the
pre-purge phase
4 ×Oil pump solenoid valve fails to
close
Replace oil pump
4 ×Flame monitor faulty Replace flame monitor
4 ×Ignition electrodes incorrectly ad-
justed or worn
Check the ignition electrodes; re-
place if necessary
Troubleshooting
Diagnosis
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Fault Red flash
code
Cause of fault Action
Burner starts and flame
builds, but burner enters
fault state after safety time
expires
2 ×Flame monitor contaminated Clean flame monitor
2 ×Flame monitor receives insuffi-
cient light
Clean sensor plate
2 ×Flame monitor faulty Replace flame monitor
2 ×Burner control unit faulty Replace burner control unit
2 ×Carbon deposits on the flame
tube or on the sensor plate
Clean the flame tube and sensor
plate
Flame tears off more than
3 times during operation
7 ×Air in suction line Seal line and filter
7 ×Nozzle faulty Replace nozzle
7 ×Burner incorrectly adjusted Set default values (see chapter
"Standard values for burner ad-
justment")
7 ×Sensor plate contaminated Clean sensor plate
Ignition switches on during
operation
7 x Flame monitor contaminated Clean flame monitor
7 x Sensor plate contaminated Clean sensor plate
7 x Nozzle contaminated or faulty Replace nozzle
Condensate backup in flue
gas heat exchanger
7 x Siphon or neutralising system
contaminated
Clean siphon and neutralising
system
Faults without flash code indication
Fault Cause of fault Action
Burner does not start (no
fault display), indicator
does not illuminate
No power Check fuse or plug-in connector aBÖ in
the control unit, the electrical connec-
tions, the setting of the ON/OFF switch
on the control unit and the mains isolator
High limit safety cut-out has responded Press reset button at the boiler control
unit
The low water indicator has caused the
system to shut down
Check the water level; top-up if required.
Press the reset button on the burner.
Servomotor faulty Replace the servomotor
When changing from stage
1 to stage 2, the flame
tears off and the burner
starts again
Flame monitor contaminated Clean flame monitor
Inside of flame tube contaminated Clean inside of flame tube
Sensor plate contaminated Clean sensor plate
Faulty control unit Replace control unit
Solenoid valve stage 2 faulty Replace solenoid coil
Burner sooty Insufficient or excess air Correct the settings. Check and clean im-
peller.
Check fan pressure.
Check ventilation in installation room.
Insufficient chimney draught Check chimney and flue gas routing
Nozzle faulty Replace the nozzle, fit the right nozzle
(see chapter "Standard values for burner
adjustment")
The flame tube extension is missing Install the flame tube extension
CO2 content too low Incorrect setting Check setting (see chapter "Standard val-
ues for burner adjustment")
Troubleshooting
Diagnosis (cont.)
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Fault Cause of fault Action
Excessive flue gas temper-
ature
Excessive oil throughput Match oil throughput to rated boiler heat-
ing output
Boiler contaminated Clean boiler and correct burner settings
Air in flue gas heat exchanger Vent flue gas heat exchanger
Flue gas heat exchanger contaminated Clean flue gas heat exchanger
Not all consumers are connected to the
flue gas heat exchanger
Connect consumers correctly
Pump faulty: Insufficient throughput
through the flue gas heat exchanger
Replace pump
Burner operates, constant
red flickering light on the
burner control unit
Not a fault; interface diagnosis was acti-
vated accidentally
Press the reset button for >3 s until the
LED illuminates yellow, then release
Condensate backup in flue
gas heat exchanger
Siphon or neutralising system contami-
nated
Clean siphon and neutralising system
Troubleshooting
Diagnosis (cont.)
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