Viessmann Vitoflame 100 Operating instructions

VITOFLAME 100
Service instructions
for heating contractors
Vitoflame100
Pressure−jet gas burner (typeVGIII)
Hfor Vitoplex100, 200 and 300
Rated output 80 to 225kW
Hfor Vitorond200
Rated output 125 to 195kW
For applicability, see the last page.
5692622 GB7/2005 Please keep safe

2
General information
Safety instructions
¨Follow these safety instructions closely to prevent accidents and
material losses.
Safety instructions explained
¨Danger
This symbol warns against
personal injuries.
!Please note
This symbol warns against
material losses and
environmental pollution.
Note
Information containing the reference
"Note" comprise additional details.
Target group
These instructions are exclusively
designed for qualified personnel.
HWork on gas appliances must only
be carried out by a qualified gas
fitter.
HWork on electrical equipment must
only be carried out by a qualified
electrician.
HThe system must be
commissioned by the system
installer or a qualified person
authorised by the installer.
Regulations
Observe the following when working
on this system
Hall legal requirements regarding
the prevention of accidents,
Hall legal instructions regarding
environmental protection,
Hregulations issued by professional
bodies,
Hall current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
¨Danger
Escaping gas can lead to
explosions which may result in
serious injury.
HNever smoke! Prevent naked
flames and sparks. Never
switch lights or electrical
appliances ON or OFF.
HClose the gas shut−off valve.
HOpen windows and doors.
HRemove all people from the
danger zone.
HNotify your gas or electricity
supplier from outside the
building.
HShut off the electricity supply
to the building from a safe
place (outside the building).
5692622 GB

3
General information
Safety instructions (cont.)
If you smell flue gas
¨Danger
Flue gas can lead to
life−threatening poisoning.
HShut down the heating
system.
HVentilate the boiler room.
HClose all doors leading to the
living space.
Working on the system
HIsolate the system from the power
supply, e.g. by removing a
separate fuse or by means of a
mains isolator and check that it is
no longer ’live’.
HSafeguard the system against
unauthorised reconnection.
HWhen using gas as fuel, also close
the main gas shut−off valve and
safeguard against unauthorised
reopening.
Repair work
!Please note
Repairing components which
fulfil a safety function can
compromise the safe operation
of your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function.
Installing non−authorised
components and non−
approved modifications/
conversion can compromise
safety and may invalidate our
warranty.
For replacements, use only
original spare parts from
Viessmann or those which are
approved by Viessmann.
5692622 GB

4
Index
Index
Page
General information
Safety instructions 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start−up, inspection and maintenance
Stepsinitial start−up, inspection and maintenance 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further details regarding the individual steps 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner control unit 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Diagnostics 27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component overview32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection and wiring diagram34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts list36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Specification 42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard values for burner adjustment 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service report 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyword index 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicability 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692622 GB

5
Initial start−up, inspection and maintenance
StepsInitial start−up, inspection and maintenance
For further instructions on individual steps, see pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
C1. Preparing for commissioning 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 2. Starting the heating system 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 3. Checking the air damper servomotor adjustment 9. . . . . .
C I M 4. Checking the static and the supply pressure 10. . . . . . . . . . . . . . . . .
M5. Checking the nozzle pressure 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M6. Adjusting the volume of starting gas 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 7. Adjusting the air volume 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 8. Checking the ionisation current 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 9. Fully checking the burner
(record actual values − service report from page47)
I M 10. Checking the air pressure switch 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 11. Shutting down the heating system 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 12. Checking the electrical connections
M13. Cleaning the burner 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 14. Checking the blast tube fixings
I M 15. Checking the fan impeller fixing
I M 16. Cleaning the sensor plate gas outlet holes (if req.) 20. . . .
I M 17. Checking the ignition and ionisation electrodes 21. . . . . . . . .
M18. Fitting the burner
I M 19. Checking gas combination valves (2) for soundness 22.
I M 20. Checking gas combination valve filter insert
(make: Dungs) 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 21. Checking all gas connections for soundness 24. . . . . . . . . . . . . . . . .
M20. Implementing a final test 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E23. Operating and service documents 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692622 GB

6
Initial start−up, inspection and maintenance
Further details regarding the individual steps
Preparing for commissioning
Soundness test
1. Close the gas shut−off valve.
2. Release the screw in test portA,
but do not remove.
3. Connect the soundness test set at
test portA.
4. Gently activate the manual pump
to build a test pressure of approx.
100mbar.
5. Wait approx. 5minutes for the
temperature to level out and then
observe the display on the
pressure gauge:
The tested area is sound if, within
a further 5minutes, the displayed
pressure does not drop by more
than 1mbar.
¨Danger
Check the test connector for
gas soundness.
6. Vent the gas supply pipe.
Note
Prior to commissioning, vent the
gas pipe and gas float; for this
route the venting line outside.
Check with a test burner, whether
the gas/air mixture is combustible.
7. Leave the soundness test set fitted
to the equipment.
5692622 GB

7
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Function test without gas supply
HCheck the function sequence (see
program sequence on page25).
HSwitch ON the mains isolator
(outside the installation room).
HStart the burner; for this, switch ON
the system ON/OFF switch at the
control unit.
HWith the soundness test set still
connected, gently build a pressure
of approx. 20mbar (gas shut−off
valve closed).
The following program must now
run (see also program sequence on
page25):
When there is a heat demand
(control indicator "Demand"
illuminates at the plug−in panel), the
air damper servomotor moves from
the "Closed" position to air damper
position stage2 and returns to
stage1 (ST0−ST2−ST1).
The burner control unit program
sequence is started with the
following functions:
HThe burner motor starts and the
combustion chamber is purged
(approx. 30s).
HThe electric ignition is started
(pre−ignition time approx. 2s).
HThe gas solenoid valve for stage1
opens.
HThe pressure inside the valves
drops.
HThe gas pressure limiter switches
the burner OFF (not a fault
shutdown).
The burner control unit enters a
fault shutdown after the expiry of a
safety interval of 2s, if the gas
pressure limiter does not shut
down the burner.
Remove the soundness test set and
close test portA.
5692622 GB

8
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
To obtain optimum combustion values, it is essential to adjust the burner with
the boiler at operating temperature (min. 60ºC).
Also carry out measurements at base load.
Starting the heating system
Service instructions
Boiler control unit
1. Check the heating system
pressure.
2. Open the gas shut−off valve.
3. Check the supply pressure (see
page11).
4. Switch ON the mains isolator
(outside the installation room).
5. Switch ON system ON/OFF
switchBat the control unit.
If fault indicator lampAat the
control unit illuminates, initially
reset the system by pressing reset
buttonCat the burner control
unit.
Note
For the commissioning program
sequence, see page25.
The system can enter a fault state
during the commissioning, if it has
insufficient gas in the supply line (the
fault indicator at the control unit
illuminates).
Vent the gas supply line again and
reset the burner control unit.
5692622 GB

9
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the adjustment of the air damper servomotor
The burner is equipped with an air
damper servomotor with adjustable
switch cams for the positioning of the
air damper and the solenoid valve
control.
During a regular shutdown, the burner
air damper moves to "closed". This
reduces the cool−down losses.
The switch cams are located under
the cover of the air damper
servomotor. A scale ring is
positioned adjacent to each switch
cam, which enables the selected
positioning angle of the air damper
to be checked.
The switch cams have the following
functions:
ST0 Air damper closed (0º)
Never alter the setting of ST0.
ST1 Air damper stage 1 position
ST2 Air damper stage 2 position
MV Solenoid valve stage2
The switch cams for stage1 and 2
are pre−selected at the factory.
For the factory−set values, see the
following table.
The switch cams are adjusted via
slotted screws in the cams.
In conjunction with Vitoplex100 and 300
Rated output kW 80 105 130 170 225
Std. values for switch cams
ST1
ST2
MV
º
º
º
8
70
30
11
70
30
13
70
30
18
70
30
20
70
30
In conjunction with Vitoplex200 Vitorond200
Rated output kW 90 120 150 200 125 160 195
Std. values for switch cams
ST1
ST2
MV
º
º
º
8
70
30
18
70
30
21
70
30
25
70
30
16
70
30
18
70
30
20
70
30
5692622 GB

10
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the static and the supply pressure
Check the gas type with your local gas supplier.
The burner is factory−adjusted for natural gasE.
Adjust the nozzle pressure for operation with natural gasLL according to the
table on pages44 to 46.
Record the gas type in the service report (see from page47).
Static pressure
1. Close the gas shut−off valve.
2. Release the screw in test portA,
but do not remove.
3. Connect the U−shaped pressure
gauge.
4. Open the gas shut−off valve.
5. Measure the static pressure (max.
50mbar).
6. Record the actual values in the
service report (see from page47).
5692622 GB

11
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Supply pressure
7. Start up the burner.
Note
Start up the burner at stage2; for
this set the emissions test switch
at the control unit to ON. Service
switchBmust be in positionII.
8. Check the supply pressure (flow
pressure), see the following
table.
Note
The supply pressure (flow
pressure) should be between 20
and 25mbar. The gas pressure
limiter is factory set to 12.5mbar.
Never alter this setting.
9. Record the actual value in the
service report (see from page47).
10. Close the gas shut−off valve.
11. Remove the U−shaped pressure
gauge and close test portA.
Supply
pressure
(flow pressure)
Measure
Below 15mbar Never change this setting; check the filter in the gas
combination valve and notify your gas supply company.
15 to 18mbar Please note: The boiler may only be temporarily operated
with this setting at stage1 (emergency mode).
Check the filter in the gas combination valve.
Notify your gas supply company.
18 to 50mbar Start up the boiler.
Above 50mbar Install a separate gas governor with zero off upstream of the
boiler and regulate the pressure to 20mbar.
Notify your gas supply company.
5692622 GB
A
B

12
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the nozzle pressure
1. Release the screw in test portA,
but do not remove.
2. Connect the U−shaped pressure
gauge to the test portA.
3. Open the gas shut−off valve.
4. Start the burner (see page8).
5. Check the nozzle pressure in
accordance with the Wobbe index
and the output against the nozzle
pressure table on pages44 to 46.
Note
During the adjustment, also check
the gas throughput by means of a
volumetric test.
6. Check and, if necessary, adjust the
nozzle pressure.
The selected gas pressure will be at
the burner approx. 10s after the
burner start.
5692622 GB

13
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Note
Never turn the pressure regulator
outside its setting range. Turn set
screwFonly as long as the
nozzle pressure noticeably changes.
Main volume butterflyDshould be
turned fully to "+".
Setting stage2
Note
Start the burner at stage2; for this
set the emissions test switch at the
control unit to ON. Service switchB
must be in positionII.
7. Move the cover above set
screwFaside.
8. With a screwdriver, adjust the
nozzle pressure at set screwF.
9. Record the actual value in the
service report (see from page47).
Setting stage1
10. Change the burner to stage1 by
pulling pluglÖ off.
11. Release locking screwCby
½revolution, but do not fully
remove.
12. Adjust the nozzle pressure at the
partial volume butterflyE.
13. Record the actual value in the
service report (see from page47).
5692622 GB

14
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Adjusting the volume of starting gas
The opening characteristics of the gas solenoid valve has been matched to
the boiler and been preset at the factory.
Generally you never need to change this setting; continue with point3.
1. Set the quick−lift (opening
characteristics) with protective
capGpositioned upside down.
Note
Quick−lift is factory−set to "+".
Min. ionisation current 3.5mA.
Checking the ionisation current,
see page17.
2. Fit protective capG.
3.Close the gas shut−off valve.
4. Remove the U−shaped pressure
gauge and close test portA(see
page12).
¨Danger
Check the test connector and
fittings for gas soundness.
5692622 GB

15
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Adjusting the air volume
The air volume is preset at the factory. If required, adjust the air volume; for
this, initially adjust the air volume for stage2.
Fine adjusting stage2
Regulate the air volume at set
screwAto adjust the mixing
assembly:
HAnti−clockwise
³larger cross−section
³more air,
HClockwise
³smaller cross−section
³less air.
5692622 GB

16
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Fine adjusting stage1
1. Bring service switchBinto
positionII (automatic mode) and
close the cover flap.
2. Change the burner to stage1 by
pulling pluglÖ off.
3. Remove the cover from the
servomotor.
4. Change the air volume by turning
the adjusting screw at switch
camST1 (see Fig. on page9):
HClockwise³more air,
HAnti−clockwise³less air.
Note
Adjust switch camST1 (fine
adjustment) in small steps.
The adjustment of switch camMV
must neither be below the
adjustment of switch camST1 nor
above the adjustment of switch
camST2.
After each adjustment of switch
camST1, briefly operate the
burner at stage2 and then back at
stage1 (push pluglÖ into position
and then pull it again or
use the service plug), to balance
the switching hysteresis.
5. Fit the cover over the servomotor.
6. Check the adjustment via the
service plug.
5692622 GB

17
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the ionisation current
1. Switch system ON/OFF switch OFF.
2. Separate the plug connection of
the ionisation current cable (red ).
Note
Test cable no.1 is required when
checking with Testomatik−Gas. You
can also carry out this test with a
megohmmeter.
3. Switch system ON/OFF switch ON.
Note
The system initiates a fault
shutdown.
4. Press the reset button at the
burner control unit and switch OFF
the system ON/OFF switch.
5. Connect an ionisation current
tester or TestomatikGas.
6. Switch the system ON/OFF switch
ON and check ionisation current.
Note
Ionisation current at least 3.5mA.
7. Record the actual value in the
service report (see from page47).
8. Switch system ON/OFF switch OFF,
remove the test equipment and
reconnect the plug−in connector of
the ionisation current cable.
9. Switch system ON/OFF switch ON.
5692622 GB

18
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the air pressure switch
The air pressure switch is factory−set to the relevant switching point, in other
words, an adjustment is generally not required. However, should an
adjustment nevertheless be required, check the air pressure switch setting
and correct, as required, by turning black scale ringBin accordance with the
following details.
ASetting mark (shutdown
when pressure drops)
BScale ring, black
In conjunction with Vitoplex100 and 300
Rated output kW 80 105 130 170 225
Air pressure switch
setting
mbar 4.55.0 3.84.3 3.84.3 5.05.5 5.35.8
In conjunction with Vitoplex200
Rated output kW 90 120 150 200
Air pressure switch
setting
mbar 4.55.0 3.84.3 3.84.3 5.05.5
In conjunction with Vitorond200
Rated output kW 125 160 195
Air pressure switch
setting
mbar 3.84.3 4.95.4 5.56.0
5692622 GB
A
B

19
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Shutting down the heating system
1. Switch OFF/isolate the mains
isolator, the system ON/OFF switch
or the power supply and safeguard
against unauthorised reconnection.
2. Pull plugfA and lÖ off the burner.
3. Close the gas shut−off valve.
Cleaning the burner
1. Set the burner into the service
position.
2. Clean housingC, flame tubeA,
mixing assemblyB(incl. ignition
and ionisation electrode) and fan
impellerD.
For cleaning of the
combustion chamber and
hot gas flues, see boiler
service instructions.
3. Check the gas outlet holes in the
sensor plate for contamination
and clean, if required (see
page20).
4. Check the tight seating of
impellerD.
5. Open the boiler door.
Check flame tubeAfor tight
seating.
5692622 GB
B
D
A
C

20
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Clean the gas outlet holes in the sensor plate (if necessary)
1. Pull the leads off electrodesH
and G.
2. Release electrode retainersKand
Aand remove the ignition and
ionisation electrodes.
3. Remove the nut from earth
electrodeFand unscrew the
electrode.
4. Unscrew the Allen screws from
sensor plateE.
5. Remove and clean sensor
plateE, spring washerDand
end plateCfrom the mixer
assemblyB.
6. Assemble in reverse order.
Note
Ensure the correct orientation of the
gas outlet holes in the end plate (see
page21).
5692622 GB