Viessmann Vitoflame 100 Operating instructions

VitoflameĂ100 gas burner
fitted to VitoplexĂ100
Service instructions
for heating engineers
VitoflameĂ100
Pressure jet gas burner (typeĂVGĂIII)
for VitoplexĂ100
Rate output 90 to 210ĂkW
See notes on applicability, pageĂ2.
VITOFLAME 100
5692Ă534ĂGBăăă5/2003 Please keep safe

2
General information
Safety instructions
Please follow these safety instructions closely to prevent accidents and
material losses.
Work on the equipment
Installation, initial start-up, inspection,
maintenance an repairs must only
be carrie out by a competent
person (heating engineer/installation
contractor).
Before working on the equipment/
heating system, isolate the mains
electrical supply (e.g. by removing a
separate mains fuse or by means of
a mains electrical isolator) an
safeguar against unauthorise
reconnection.
Close the main gas shut-off valve
an safeguar against unauthorise
reopening.
Work on gas equipment
This must only be carrie out by an
approve contractor.
Please observe all commissioning
work for gas installations specifie
acc. to TRGI or TRF, or local
regulations.
epair work
It is not permitte to carry out repairs
on parts that fulfil a safety function.
Use only original Viessmann spare
parts, or equivalent parts that have
been approve by Viessmann.
Initial start-up
The initial start-up must be carrie
out by the system installer or a
esignate commissioning engineer;
all actual values shoul be recor e
in a commissioning/service report.
Instructing the system user
The system installer must han the
operating instructions to the system
user an instruct him/her in the
operation of the system.
¨ĂSafety instruction
In this instruction manual, this
heading denotes information which
must be observed to prevent
accidents and material losses.
¨ĂThis symbol denotes important
information which must be
observed to prevent material
losses.
Applicability
From serial no.
7174931Ă3Ă00001Ăkkk, 7174932Ă3Ă00001Ăkkk, 7174933Ă3Ă00001Ăkkk an
7174934Ă3Ă00001Ăkkk
5692Ă534ĂGB

3
Contents
Index
Page
General information
Safety instructionsĂ 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ApplicabilityĂ 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating an service ocumentsĂ 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start-up, inspection and maintenance
StepsĂćĂinitial start-up, inspection an maintenanceĂ 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further etails regar ing the in ivi ual stepsĂ 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
DiagnosticsĂ 25
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component summaryĂ34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection and wiring diagramsĂ37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts listĂ40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
SpecificationĂ 46
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stan ar values for burner settingsĂ 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service reportĂ 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keywor in exĂ 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating and service documents
1. Complete an etach the
customer registration car :
HGive the system user this part
for safe-keeping.
HRetain the heating engineer
portion.
2. Keep all parts lists, operating an
service instructions in the fol er
an han this over to the system
user.
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4
Initial start-up, inspection an maintenance
StepsĂćĂinitial start-up, inspection and maintenance
For further instructions on individual steps, see pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
C1. Commissioning preparationsĂ 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 2. System start-upĂ 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 3. Checking adjustment of the air damper actuatorĂ 9. . . . . . .
C I M 4. Checking static and supply pressureĂ 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M5. Checking nozzle pressureĂ 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M6. Adjusting start-up gas volumeĂ 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 7. Air volume adjustmentĂ 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 8. Checking ionisation currentĂ 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 9. Checking burner
(record values on pageĂ50 of commissioning report)
I M 10. Checking air pressure switchĂ 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 11. System shutdownĂ 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 12. Checking electrical connections
M13. Cleaning burnerĂ 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 14. Checking blast tube fixings
I M 15. Checking impeller fixings
I M 16. Cleaning gas orifices in sensor plate
(if necessary)Ă 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 17. Checking ignition and ionisation electrodesĂ 21. . . . . . . . . . . . . . . . .
M18. Burner installation
I M 19. Checking both valves of the gas train for leaksĂ 22. . . . . . . . . . . .
I M 20. Checking filter insert of gas train (make: Dungs)Ă 23. . . . . . . . .
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Initial start-up, inspection an maintenance
StepsĂćĂinitial start-up, inspection and maintenance
For further instructions on individual steps, see pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
I M 21. Checking all gas unions for leaksĂ 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M22. Implementing final testsĂ 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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6
Initial start-up, inspection an maintenance
Further details regarding the individual steps
Commissioning preparations
Leak test
1. Close the gas shut-off valve.
2. Loosen the screw in test nipple A
but o not remove.
3. Connect the pressure test
equipment to test nipple A.
4. By gently activating the manual
pump, create a test pressure of
approx. 100 mbar.
5. Wait approx. 5 minutes for the
temperature to level out, then
observe the pressure gauge isplay:
The test area is free from leaks, if
the isplay pressure oes not fall
by more than 1 mbar within a
further five minutes.
¨ĂSafety instruction
Check the test nipple for gas leaks.
6. Purge the gas supply pipe.
Please note:
ent the gas supply pipe and the
gas float before initial start-up.
To do this, route the vent pipe
outdoors. Check with a test
burner, whether the gas:air
mixture is combustible.
7. Leave the leak test equipment
connecte .
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7
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
Function test without gas supply
HCheck the function sequence (see
function iagram on page 25).
HSwitch ON the mains electrical
isolator (outsi e the boiler room).
HStart the burner. To o this, switch
ON the ON/OFF switch at the
control unit.
HWith the leak test equipment still
connecte , buil the pressure to
approx. 20Ămbar (gas shut-off valve
close ).
The following program must now
run (see also the function iagram
on page 25):
If a heat eman is present
(Ă" eman " lamp at the plug-in
terminal block lights up), the air
amper actuator goes from the
"close " position to stage 2 an
reverts back to air amper position
stage 1 (ST0Ă-ĂST2Ă-ĂST1).
The burner control unit sequence is
starte with the following functions:
- Burner motor starts, an
combustion chamber is purge
(approx. 30 s).
- Electric ignition is switche ON
(pre-ignition time approx. 2 s).
- Gas solenoi valve for stage 1
opens.
- Valve pressure rops.
- Gas governor switches burner OFF
(not a fault shut own).
After a safety time of 2Ăs, the
burner control unit enters a fault
shut own state, if the gas governor
oes not switch the burner OFF.
Remove the leak test equipment
an close test nipple A.
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8
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
To obtain the optimum combustion values, it is essential to adjust the burner
with the boiler heated to operating temperature (min. 60ĂºC).
Also carry out measurements at base load.
System start-up
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 electrical
isolator (outsi e the boiler room).
5. Switch ON system ON/OFF
switchĂB on the control unit.
If fault in icator lampĂA on the
control unit lights up, press reset
buttonĂC on the burner control
unit.
Please note:
Function sequence during initial
start-up, see pages 25 and 37.
During the initial start-up, the
equipment can enter a fault state if it
has insufficient gas in the supply line
(fault lamp on the control unit
illuminates).
entilate the gas supply line again
and reset the burner control unit.
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9
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
Checking adjustment of air damper actuator
The burner is equippe with an air
amper actuator motor with
a justable switching cams for setting
the air amper position an for
switching the solenoi valves.
During a regular shut own, the
burner air amper will rive into the
"close " position. This re uces
cool own losses.
The switching cams are locate
below the air amper actuator motor
cover. A scaling ring is locate
a jacent to each switching cam,
which enables the set angle of the air
amper to be checke .
The switching cams have the
following function:
STĂ0 Air amper close (0º)
Never alter the STĂ0 setting.
STĂ1 Air amper setting stageĂ1
STĂ2 Air amper setting stageĂ2
MV Solenoi valve stageĂ2
The switching cams for stageĂ1 an 2
are set up at the factory.
For factory settings, see the
following table.
The switching cams are a juste via
the slotte screws on the cams.
ated output range from kW
to kW
90
100
125
140
150
165
190
210
Boiler output kW 90 100 125 140 150 165 190 210
Standard values for
switching cams
STĂ1Ăº18 20 19 21 22 24 20 22
STĂ2Ăº70 70 70 70 70 70 70 70
MV º30 30 30 30 30 30 30 30
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10
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
Checking static and supply pressure
Check the type of gas with your local gas supplier.
The burner is factory-set to natural gas E.
Adjust the nozzle pressure for operation with natural gas LL according to the
table on pageĂ47.
Record the gas type in the service report on page 50.
Static pressure
1. Close the gas shut-off valve.
2. Loosen the screw in test nippleĂA
but o not remove.
3. Connect the U-shape pressure
gauge.
4. Open the gas shut-off valve.
5. Measure the static pressure (max.
50Ămbar).
6. Recor the actual values in the
commissioning report on page 50.
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11
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
Supply pressure
ĂĂ7. Start the burner.
Please note:
Initial start-up, see pageĂ8.
Switch the burner to stage 2. To
do this, activate the emissions
test switch on the control unit.
ĂĂ8. Check the supply pressure (flow
pressure), see the table below.
Please note:
The supply pressure (flow
pressure) should be between 20
and 25Ămbar. The gas governor is
factory-set to 12.5 mbar. Do not
change this setting.
ĂĂ9. Recor the actual values in the
commissioning report on page 50.
10. Close the gas shut-off valve.
11. Remove the U-shape pressure
gauge an close test nippleĂ .
Supply pressure
(flow pressure)
Remedy
below 15 mbar Do not change the settings. Check the filter in the gas train
an notify your local gas supply company.
15 to 18 mbar Please note: The boiler may only be temporarily operate
at this setting on stage 1 (emergency mo e).
Check the filter in the gas train. Notify your gas supply
company.
18 to 50 mbar Start up the boiler.
above 50 mbar Install a separate gas pressure valve with zero off
upstream in the boiler system, an regulate the pressure
to 20 mbar.
Notify your gas supply company.
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12
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
Checking nozzle pressure
1. Release the screw in test nippleĂA
but o not remove.
2. Connect the U-shape pressure
gauge to test nippleĂA.
3. Open the gas shut-off valve.
4. Start up the burner (see page 8).
5. Check the nozzle pressure in
accor ance with the Wobbe in ex
an the output rating in the nozzle
pressure table on pageĂ47.
Please note:
During the adjustment, also check
the gas throughput by means of a
volumetric test.
6. Check an , if necessary, a just the
nozzle pressure.
The a juste gas pressure will be
present approx. 10 secon s after the
burner start.
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13
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
Please note:
Never turn the pressure regulator
outside its setting range. Turn set
screw F only as long as the nozzle
pressure noticeably changes.
Main volume butterfly D should be
turned fully to "+".
Adjusting stage 2
Please note:
Start the burner in stage 2. To do
this, activate the emissions test
switch on the control unit. Service
switch B must be in position II.
ĂĂ7. Move the cover over both si es
of a justing screw Fā.
ĂĂ8. A just the nozzle pressure on
a justing screw F using a screw
river.
ĂĂ9. Recor the actual values in the
commissioning report on page 50.
Adjusting stage 1
10. Switch the burner over to stage 1
by pulling plug lÖ.
11. Unscrew locking screw C b turn,
but o not remove.
12. A just the nozzle pressure at
part-volume choke a justing
screw E.
13. Recor the actual values in the
commissioning report on page 50.
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14
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
Adjusting start-up gas volume
The opening characteristics of the gas solenoid valve have been matched to
the boiler and been preset at the factory.
Generally you do not need to change this setting.
1. Set the quick-action (opening
characteristics) with protective
capĂGĂinverte .
Please note:
At the factory, the quick-action is
fully set to "+".
Ionisation current at least 5 mA.
Check the ionisation current, see
pageĂ17.
2. Fit protective capĂG.
3. Close the gas shut-off valve.
4. Remove the U-shape pressure
gauge an close test nippleĂA
(see page 12).
¨ĂSafety instruction
Check the test nipple and unions
for gas leaks.
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15
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
Air volume adjustment
The air volume is preset at the factory. If necessary, readjust the air volume,
first adjusting the air volume for stageĂ2.
Fine adjustment stageĂ2
A just the air volume at a justing
screwĂA to mo ify the mixer
assembly:
HAnti-clockwise
Ălarger cross-section
Ămore air,
HClockwise
Ăsmaller cross-section
Ăless air.
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16
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
Fine adjustment stageĂ1
1. Set service switchĂB to positionĂII
(automatic mo e), an close the
cover flap.
2. Change the burner over to stageĂ1
by pulling plug lÖ.
3. Remove the actuator motor cover.
4. Mo ify the air volume by turning
the a justing screw on switching
camsĂSTĂ1 (see fig. on pageĂ9):
HClockwiseĂĂmore air,
HAnti-clockwiseĂĂless air.
Please note:
Adjust switching camsĂSTĂ1 (fine
adjustment) in small steps.
The set value for switching
camĂM must not lie below the set
value of switching camĂSTĂ1 and
not above that of switching
camĂSTĂ2.
After every adjustment of switching
cam ST1, briefly drive the burner to
stageĂ2 and back again to stageĂ1
(connect plug lÖ and remove
again or use the service plug), to
balance out the switching
hysteresis.
5. Fit the actuator motor cover.
6. Check the service plug a justment.
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17
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
Checking ionisation current
1. Switch OFF the system ON/OFF
switch.
2. Separate the plug connection of the
ionisation current cable (re cable).
Please note:
When checking with a
TestomatikĆGas, test cable no.Ă1 is
required. You can also carry out
this check with a multimeter.
3. Switch ON the system ON/OFF
switch.
Please note:
The system then initiates a fault
shutdown.
4. Press the reset button at the
burner control unit an switch OFF
the system ON/OFF switch.
5. Connect ionisation current test
equipment or a TestomatikĆGas
evice.
6. Switch the system ON/OFF switch
ON an check the ionisation current.
Please note:
Ionisation current at least 5 mA.
7. Recor the actual values in the
commissioning report on page 50.
8. Switch the system ON/OFF switch
OFF, remove the test equipment
an reconnect the plug connector
of the ionisation current cable.
9. Switch ON the system ON/OFF
switch.
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18
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
Checking air pressure switch
At the factory, the air pressure switch is adjusted to the corresponding
switching point, so that readjustment is generally not required. However,
should an adjustment nevertheless be required, check the air pressure switch
setting and correct, if required, in accordance with the details below by
rotating black scaled ring B.
AA justment markings (shut own
when pressure rops)
BScale ring, black
Rated output range kW 90 to 100 125 to 140 150 to 165 190 to 210
Air pressure switch
setting values
mbar 3.8ĂĆĂ4.3 3.8ĂĆĂ4.3 3.8ĂĆĂ4.3 5.0ĂĆĂ5.5
System shutdown
1. Switch OFF the mains electric
power, the system ON/OFF switch
or the mains isolator an
safeguar against unauthorise
reconnection.
2. Pull plug-connectorĂfA an lÖ
from the burner.
3. Close the main gas shut-off valve.
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19
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
Cleaning burner
1. Set the burner to maintenance.
2. Clean housingĂC, flame tubeĂA,
mixer assemblyĂB an
impellerĂD.
For cleaning the combustion
chamber and hot gas flues,
see boiler service
instructions.
3. Check the gas orifices in the
sensor plate for contamination
an clean, if require (seeĂpageĂ20).
4. Check the tightness of flame
tubeĂA an impellerĂD.
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20
Initial start-up, inspection an maintenance
Further details regarding the individual steps (cont.)
Cleaning gas orifices in sensor plate (if necessary)
1. Pull the lea s from electro esĂH
an ĂG.
2. Loosen electro e hol ersĂK
an ĂA, an remove the ignition
an ionisation electro es.
3. Remove the nut from earth
electro eĂF an unscrew the
electro e.
4. Unscrew the Allen screws from
sensor plateĂE.
5. Remove sensor plateĂE, spring
washerĂD an en plateĂC from
mixer assemblyĂB an clean.
6. Assemble in reverse or er.
Please note:
Observe the correct orientation of
the gas orifices in the end plate (see
page 21).
5692Ă534ĂGB