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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