Viessmann Vitoflame 100 Operating instructions

VIESMANN
Service instructions
for contractors
Vitoflame 100
Type VGIII
Pressure‐jet gas burner
for Vitoplex 100, 200 and 300
Rated output 80 to 225 kW
for Vitorond 200
Rated output 125 to 195 kW
For applicability, see the last page
VITOFLAME 100
5692 678 GB 11/2006 Please keep safe.

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
designed for qualified personnel.
&Work on gas equipment must only
be carried out by a qualified gas fit-
ter.
&Work on electrical equipment must
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
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&the Code of Practice of relevant
trade associations,
&all 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.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances ON or OFF.
&Close the gas shut-off valve.
&Open windows and doors.
&Remove all people from the
danger zone.
&Notify your gas or electricity
supplier from outside the
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close all doors leading to the
living space.
Safety instructions
2
Safety instructions
5692 678 GB

Working on the system
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a main isolator.
&Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which
fulfil a safety function can com-
promise 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. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 678 GB

Commissioning, inspection, maintenance
Steps –commissioning, inspection and maintenance .................................. 5
Further details regarding the individual steps .............................................. 6
Burner control unit
Burner control unit LME 21.......................................................................... 25
Troubleshooting
Diagnosis ................................................................................................... 28
Component overview................................................................................ 34
Connection and wiring diagram ............................................................... 36
Parts list .................................................................................................... 38
Report ....................................................................................................... 44
Specification
Specification............................................................................................... 46
Standard values for burner settings............................................................. 47
Keyword index .......................................................................................... 52
Index
4
Index
5692 678 GB

For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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•01. Commissioning preparations........................................... 6
••• 02. Commissioning the heating system .............................. 7
••• 03. Checking the adjustment of the air damper
servomotor .............................................................................. 8
••• 04. Checking the static and supply pressure .................... 9
•05. Checking the nozzle pressure.......................................... 12
•06. Adjusting the volume of starting gas ............................ 13
• • 07. Adjusting the air volume .................................................... 14
• • 08. Checking the ionisation current...................................... 16
• • 09. Fully checking the burner
• • 10. Checking the air pressure switch ................................... 17
• • 11. Shutting down the heating system ................................. 18
• • 12. Checking the electrical connections
•13. Cleaning the burner ............................................................. 18
• • 14. Checking the impeller fixings
• • 15. Checking the flame tube fixings
•16. Cleaning the gas outlet holes in the sensor plate (if
required)................................................................................... 19
• • 17. Checking the ignition and ionisation electrodes ...... 20
•18. Burner installation
• • 19. Checking both valves of the combination valve for
soundness ............................................................................... 22
• • 20. Checking the filter insert in the combination valve
made by Dungs ...................................................................... 23
• • 21. Checking all gas connections for soundness............ 23
•22. Implementing final tests..................................................... 23
•23. Operating and service documents ................................. 24
Steps –commissioning, inspection and maintenance
5
Commissioning, inspection, maintenance
5692 678 GB

Commissioning preparations
Soundness test
1. Close the gas shut‐off valve.
2. Undo the screw inside test connec-
tor A, but do not remove.
3. Connect the soundness tester set
at test connector A.
4. Gently activate the manual pump to
build a test pressure of 100 mbar.
5. Wait approx. 5 minutes for the tem-
perature to level out and then
observe the display on the pres-
sure gauge:
The tested area is sound if, within a
further 5 minutes, the displayed
pressure does not drop by more
than 1 mbar.
Danger
Escaping gas leads to a risk
of explosions.
Check the soundness of the
test connector.
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.
Function test without gas supply
&Check the function sequence (see
program sequence on page 25).
&Switch ON the main isolator (out-
side the installation room).
&Start the burner; for this, switch ON
the system ON/OFF switch at the
control unit.
&With the soundness test set still
connected, gently build a pressure
of approx. 20 mbar (gas shut‐off
valve closed).
Further details regarding the individual steps
6
Commissioning, inspection, maintenance
5692 678 GB

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 servo-
motor moves from the "Closed" posi-
tion to air damper position stage 2 and
returns to stage 1 (ST0 ‐ST2 ‐ST1).
The burner control unit program
sequence is started with the following
functions:
&The burner motor starts and the
combustion chamber is purged
(approx. 30 s).
&The electric ignition is started (pre‐
ignition time approx. 2 s).
&The gas solenoid valve for stage 1
opens.
&The pressure inside the valves
drops.
&The gas pressure switch switches
the burner OFF (not a fault shut-
down).
&The burner control unit enters a fault
shutdown after the expiry of a safety
time of 2 s, if the gas pressure
switch does not shut down the burn-
er.
&Remove the soundness tester set
and close the test connector A.
Commissioning the heating system
To obtain optimum combustion values, the burner must be adjusted with the
boiler heated to operating temperature (min.60 ºC).
Also carry out measurements at base load.
Further details regarding the individual steps (cont.)
7
Commissioning, inspection, maintenance
5692 678 GB

Service instructions boiler con-
trol unit
1. Check the heating system pres-
sure.
2. Open the gas shut‐off valve.
3. Check the supply pressure (see
page 10).
4. Switch ON the main isolator (out-
side the installation room).
5. Switch ON system ON/OFF switch
Bat the control unit.
Press reset button Con the burn-
er, if fault indicator lamp Aon the
control unit illuminates.
Note
For the commissioning sequence, see
page 25.
The system can enter a fault state
during commissioning, if insufficient
gas is in the supply line (the fault indi-
cator at the control unit illuminates).
Vent the gas supply line again and
reset the burner control unit.
Checking the adjustment of the air damper servomotor
The burner is equipped with an air
damper servomotor with adjustable
switch cams used to position the air
damper plus a solenoid valve control.
During a controlled shutdown, the
burner air damper moves into the
"closed" position. This reduces the
cool‐down losses.
Further details regarding the individual steps (cont.)
8
Commissioning, inspection, maintenance
5692 678 GB

The switch cams are located under
the cover of the air damper servomo-
tor. A scale ring is located adjacent to
each switch cam, where the selected
angle of the air damper can be
checked.
The switch cams have the following
function:
ST0 Air damper closed (0º)
Never alter the setting of ST 0.
ST1 Air damper position stage 1
ST2 Air damper position stage 2
MV Solenoid valve stage 2
The switch cams for stage 1 and 2 are
set at the factory, see the following
table for the factory‐set values.
The switch cams are adjusted via the
slotted screws in the cams.
In conjunction with Vitoplex 100 and 300
Rated output kW 80 105 130 170 225
Standard values for switch
cams
ST1 ° 8 11 13 18 20
ST2 ° 70 70 70 70 70
MV ° 30 30 30 30 30
In conjunction with Vitoplex 200 Vitorond 200
Rated output kW 90 120 150 200 125 160 195
Standard values for switch
cams
ST1 ° 8 18 21 25 16 18 20
ST2 ° 70 70 70 70 70 70 70
MV ° 30 30 30 30 30 30 30
Checking the static and supply pressure
Check the type of gas with your local gas supply utility.
The burner is factory‐set for natural gas E.
Adjust the nozzle pressure for operation with natural gas LL according to the
tables from page 48.
Record the gas type in the service report (see from page 44).
Further details regarding the individual steps (cont.)
9
Commissioning, inspection, maintenance
5692 678 GB

Static pressure
1. Close the gas shut‐off valve.
2. Undo the screw inside test connec-
tor 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 value in the ser-
vice report (see from page 44).
Supply pressure
1. Start the burner.
Note
Start 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.
Further details regarding the individual steps (cont.)
10
Commissioning, inspection, maintenance
5692 678 GB

2. Check the supply pressure (flow
pressure), see the following table.
Note
The supply pressure (flow pres-
sure) should be between 20 and
25 mbar. The gas pressure switch
is factory‐set to 12.5 mbar. Never
alter this setting.
3. Record the actual value in the ser-
vice report (see from page 44).
4. Close the gas shut‐off valve.
5. Remove the U‐shaped pressure
gauge and close test connector A.
Supply pressure
(flow pressure)
Measures
below 15 mbar Never change this setting; check the filter in the gas com-
bination valve and notify your gas supply utility.
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
utility.
18 to 50 mbar Start the boiler.
above 50 mbar Install a separate gas pressure governor with zero off up-
stream in the boiler system, and regulate the pressure to
20 mbar. Notify your gas supply utility.
Further details regarding the individual steps (cont.)
11
Commissioning, inspection, maintenance
5692 678 GB

Checking the nozzle pressure
1. Undo the screw inside test connec-
tor A, but do not remove.
2. Connect the U‐shaped pressure
gauge to test port A.
3. Open the gas shut‐off valve.
4. Start the burner (see page 6).
5. Check the nozzle pressure in
accordance with the Wobbe index
and the output in the nozzle pres-
sure table from page 48.
Note
During the adjustment, also check
the gas throughput by means of a
volumetric test.
6. Check and, if required, adjust the
nozzle pressure.
Note
The adjusted gas pressure will be
available at the burner approx.
10 seconds after the burner start.
Further details regarding the individual steps (cont.)
12
Commissioning, inspection, maintenance
5692 678 GB

Note
Never turn the pressure regulator out-
side the setting range. Turn the set
screw Fonly as long as the nozzle
pressure noticeably changes. The
main volume butterfly Dshould be
turned fully to "+".
Setting stage 2
Start up 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.
1. Move the cover above set screw
Faside.
2. With a screwdriver, adjust the noz-
zle pressure at set screw F.
3. Record the actual value in the ser-
vice report (see from page 44).
Setting stage 1
1. Change the burner to stage 1 by
pulling plug lÖ off.
2. Undo screw Cby ½ revolution,
but do not remove.
Note
Never open the sealed counter-
sunk screw.
3. Adjust the nozzle pressure at the
partial volume butterfly E.
4. Record the actual value in the ser-
vice report (see from page 44).
Adjusting the volume of starting gas
The opening characteristics of the gas solenoid valve have been matched to the
boiler and been preset at the factory.
Generally you never need to change this setting; continue with point 3.
Further details regarding the individual steps (cont.)
13
Commissioning, inspection, maintenance
5692 678 GB

1. Adjust the quick‐action (opening
characteristics) with protective cap
Gpositioned in reverse.
Note
The quick‐action is set at the fac-
tory fully to "+".
Ionisation current min. 8 μA.
Checking the ionisation current,
see page 16.
2. Fit protective cap G.
3. Close the gas shut‐off valve.
4. Remove the U‐shaped pressure
gauge and close test connector A
(see page 12).
Danger
Escaping gas leads to a risk of
explosions.
Check the soundness of the
test connector and all fittings.
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.
Further details regarding the individual steps (cont.)
14
Commissioning, inspection, maintenance
5692 678 GB

Readjusting stage 2
Regulate the air volume at set screw
Ato adjust the mixing assembly:
&Turning anti‐clockwise
&→larger cross‐section
&→more air,
&Turning clockwise
&→smaller cross‐section
&→less air.
Readjusting stage 1
Further details regarding the individual steps (cont.)
15
Commissioning, inspection, maintenance
5692 678 GB

1. Change service switch Bto posi-
tion II (automatic mode) and close
the cover flap.
2. Change the burner to stage 1 by
pulling off plug lÖ.
3. Remove the cover from the servo-
motor.
4. Change the air volume by turning
the adjusting screw at switch cam
ST1 (see Fig. on page 9):
&Turning clockwise→more air,
&Turning anti‐clockwise→less air.
Note
Adjust the switch cam ST1 in small
steps (fine adjustment). The
selected value of switch cam MV
must not be lower than that of
switch cam ST1 and must not be
greater than that of switch cam
ST2.
After each adjustment of switch
cam ST1, briefly return the burner
to stage 2 and then back to stage 1
(push on plug lÖ and then remove
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 ser-
vice plug.
Checking the ionisation current
1. Switch OFF the system ON/OFF
switch.
2. Separate the plug connection of
the ionisation current cable (red
cable).
Note
You can also carry out this test with
a multimeter.
3. Switch ON the system ON/OFF
switch.
Note
The system initiates a fault shut-
down.
Further details regarding the individual steps (cont.)
16
Commissioning, inspection, maintenance
5692 678 GB

4. Press the reset button at the burner
control unit and switch OFF the
system ON/OFF switch.
5. Connect the ionisation tester.
6. Switch the system ON/OFF switch
ON and check the ionisation cur-
rent.
Note
Ionisation current min. 8 μA.
7. Record the actual value in the ser-
vice report (see from page 44).
8. Switch the system ON/OFF switch
OFF, remove the test equipment
and reconnect the plug‐in connec-
tor of the ionisation current cable.
9. Switch ON the system ON/OFF
switch.
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 it,
as required, by turning black scale ring Bin accordance with the following
details.
ASetting mark (shutdown when the
pressure drops)
BScale ring, black
In conjunction with the 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
Further details regarding the individual steps (cont.)
17
Commissioning, inspection, maintenance
5692 678 GB

In conjunction with the 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 the 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
Shutting down the heating system
1. Switch OFF/isolate the main isola-
tor, the system ON/OFF switch or
the power supply and safeguard
against unauthorised reconnection.
2. Pull connecting plugs fA and lÖ
from the burner.
3. Close the gas shut‐off valve.
Cleaning the burner
Further details regarding the individual steps (cont.)
18
Commissioning, inspection, maintenance
5692 678 GB

1. Set the burner into its maintenance
position.
2. Clean casing C, flame tube A,
mixer assembly B(together with
the ignition and ionisation elec-
trode) and impeller D.
For cleaning of the combus-
tion chamber and hot gas
flues, see boiler service
instructions.
3. Check the gas outlet holes in the
sensor plate for contamination, if
required (see page 19).
4. Check the seating of impeller D
for tightness.
5. Open the boiler door.
Check flame tube Afor tightness.
Cleaning the gas outlet holes in the sensor plate (if required)
1. Pull the cables from the electrodes
Hand G.
2. Release electrode retainers K
and A, and remove the ignition
and ionisation electrodes.
3. Remove the nut from earth elec-
trode Fand unscrew the earth
electrode.
4. Undo the Allen screws from sensor
plate E.
Further details regarding the individual steps (cont.)
19
Commissioning, inspection, maintenance
5692 678 GB

5. Remove and clean sensor plate
E, spring washer Dand cover
Cfrom the mixer assembly B.
6. Assemble in reverse order.
Note
Ensure the correct orientation of the
gas outlet holes in the end panel (see
page 20).
Checking the ignition and ionisation electrodes
80 to 105 kW
AEarth electrode
BSensor plate
CIonisation electrode
DCover
EIgnition electrode
F8 gas outlet holes in the cover
GSlightly turn the ionisation elec-
trode towards the earth electrode
in accordance with the actual gap
Further details regarding the individual steps (cont.)
20
Commissioning, inspection, maintenance
5692 678 GB