Viessmann Vitoflame 100 Operating instructions

VitoflameĂ100 oil burner
fitted to VitoplexĂ100
Service instructions
for heating engineers
VitoflameĂ100
Oil pressure jet burner (typeĂVEĂIII)
for VitoplexĂ100
Rated output 0 to 210ĂkW
See notes on applicability, pageĂ2.
VITOFLAME 100
56 2Ă533ĂGBăăă5/2003 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 and repairs must only
be carried 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) and
safeguard against unauthorised
reconnection.
epair work
It is not permitted to carry out repairs
on parts that fulfil a safety function.
Use only original Viessmann spare
parts, or equivalent parts that have
been approved by Viessmann.
Initial start-up
The initial start-up must be carried
out by the system installer or a
designated commissioning engineer;
all actual values should be recorded
in a commissioning/service report.
Instructing the system user
The system installer must hand the
operating instructions to the system
user and instruct him/her in the
operation of the system.
Applicability
from serial no.
7170 81Ă3Ă00001Ăkkk, 7174 36Ă3Ă00001Ăkkk, 7174 37Ă3Ă00001Ăkkk and
7174 38Ă3Ă00001Ăkkk
Operating and service documents
1. Complete and detach the
customer registration card:
HGive the system user this part
for safe-keeping.
HRetain the heating engineer
portion.
2. Keep all parts lists, operating and
service instructions in the folder
and hand this over to the system
user.
56 2Ă533ĂGB

3
Contents
Index
Page
General information
Safety instructionsĂ 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ApplicabilityĂ 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating and service documentsĂ 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start-up, inspection and maintenance
StepsĂćĂinitial start-up, inspection and maintenanceĂ 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further details regarding the individual stepsĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
DiagnosticsĂ 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component summaryĂ20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection and wiring diagramsĂ23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts listĂ28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
SpecificationĂ 36
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard values for burner settingsĂ 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service reportĂ 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyword indexĂ 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56 2Ă533ĂGB

4
Initial start-up, inspection and maintenance
StepsĂćĂinitial start-up, inspection and maintenance
For further instructions on individual steps, see pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
C1. System start-upĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 2. Checking adjustment of air damper actuatorĂ 6. . . . . . . . . . . . . . . .
C M 3. Oil pressure adjustment and vacuum checkĂ 7. . . . . . . . . . . . . . . . . .
C M 4. Air volume adjustmentĂ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 5. Checking burner
(record values on pageĂ38 of commissioning report)
I M 6. Checking and cleaning flame monitorĂ 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 7. System shutdown
I M 8. Checking tightness of electrical connections
M9. Cleaning burnerĂ 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 10. Checking impeller fixings
I M 11. Checking flame tube fixings
M12. Nozzle replacementĂ 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 13. Checking and, if required,
adjusting ignition electrodesĂ 14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M14. Burner chassis installation on burner housing
M15. Cleaning and, if required, replacing oil pump filterĂ 15. . . . .
M16. eplacing pre-filter element
I M 17. System start-up
I M 18. Checking oil supply pipes and connections for leaks
M19. Checking burner again and entering actual values
in commissioning report
56 2Ă533ĂGB

5
Initial start-up, inspection and maintenance
Further details regarding the individual steps
To obtain the optimum combustion values, it is essential to adjust the burner
with the boiler heated to operating temperature (min. 60 ºC).
Also carry out measurements at base load.
System start-up
Service instructions
Boiler control unit
1. Check the heating system pressure
and the oil level in the tank.
2. Open the shut-off valves in the oil
supply 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 electrical
isolator (outside the boiler room).
5. Switch ON system ON/OFF
switchĂB on the control unit.
If fault indicator lampĂA on the
control unit lights up, press reset
buttonĂC on the burner.
56 2Ă533ĂGB
C
A
B

6
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking adjustment of air damper actuator
The burner is equipped with an air
damper actuator motor with
adjustable switching cams for setting
the air damper position and for
switching the solenoid valves.
During a regular shutdown, the
burner air damper will drive into the
"closed" position. This reduces
cooldown losses.
The switching cams are located
below the air damper actuator motor
cover. A scaling ring is located
adjacent to each switching cam,
which enables the set angle of the air
damper to be checked.
The switching cams have the
following function:
STĂ0 Air damper closed (0º)
Never alter the STĂ0 setting.
STĂ1 Air damper setting stageĂ1
STĂ2 Air damper setting stageĂ2
MV Solenoid valve stageĂ2
The switching cams for stageĂ1 and 2
are set up at the factory.
For factory settings, see pageĂ37.
The switching cams are adjusted via
the slotted screws on the cams.
56 2Ă533ĂGB

7
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Oil pressure adjustment and vacuum check
The oil pressure is preset at the factory according to the oil throughput.
Re-adjust the oil pressure if necessary.
1. Isolate the mains electrical isolator
and safeguard against
unauthorised reconnection.
2. Remove plugĂ"P"ĂA from the oil
pump.
3. Remove plugĂ"V"ĂB from the oil
pump.
This allows the oil to drain from
the oil pump.
4. Insert a pressure gauge (range
0ĂĆĂ40Ăbar) and a vacuum gauge
(range 0ĂĆĂ1Ăbar).
Seal the pressure and vacuum
gauges only with copper or
aluminium gaskets or OĆrings. Do
not use sealing tape.
5. Start the burner.
The solenoid valve opens.
6. Read off the oil and vacuum
pressures of the pump on the
relevant gauges (vacuum should
be max. 0.35Ăbar given a head of
3Ăm between the oil pump and the
bottom of the tank).
Where the vacuum measures higher
than 0.35 bar, check the filter for
cleanliness or the pipe run.
56 2Ă533ĂGB
Danfoss oil pump, type BFP 52
Suntec oil pump, type AT 2Ć55
B
C
D
A
A
B
C
D

8
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
ă7. If necessary, adjust the oil
pressure at the pressure
adjusting screw for stageĂ1ĂC
and stageĂ2ĂD.
Turn clockwise ³Ăpressure rises
Anti-clockwise ³Ăpressure falls.
For standard values for burner
settings, see page 37.
ă8. Check the emission values by
taking actual measurements after
checking the oil pressure.
ă9. Switch OFF the mains isolator
and safeguard against
unauthorised reconnection.
10. Remove the pressure and
vacuum gauges.
11. Insert plugsĂ"P"ĂA and "V"ĂB.
Check the plugs for damage and
replace if necessary.
12. Start the burner and check the
plugs for leaks.
56 2Ă533ĂGB

9
Initial start-up, inspection and 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 stage 2 at the blast tube connection.
Starting up the burner may require a fine adjustment.
Fine adjustment stageĂ2
1. Release locking screwĂB.
2. Modify the position of sensor
plateĂD inside flame tubeĂC. To
do this, turn thumb screwĂA:
HClockwise
³Ălarger cross-section
³Ămore air,
HAnti-clockwise
³Ăsmaller cross-section
³Ăless air.
Please note:
For standard values for burner
settings, see page 37.
3. Tighten locking screwĂB.
56 2Ă533ĂGB
DC BA

10
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Fine adjustment stageĂ1
1. Set service switchĂE to positionĂII
(automatic mode), and close the
cover flap.
2. Switch the burner over to stageĂ1
by pulling plug lÖ.
3. Remove the actuator motor cover.
4. Modify the air volume by turning
the adjusting screw on switching
camsĂSTĂ1 (see fig. on pageĂ6):
HClockwiseĂ³Ămore air,
HAnti-clockwiseĂ³Ăless air.
Please note:
Adjust switching cams ST 1 (fine
adjustment) in small steps.
The set value for switching
cam MV must not lie below the set
value of switching cam ST 1 and
not above that of switching
cam ST 2.
After every adjustment of
switching cam ST1, briefly drive
the burner to stage 2 and back
again to stage 1 (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 adjustment.
56 2Ă533ĂGB

11
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking and cleaning flame monitor
Remove flame monitorĂA (photo
resistance) from its holder with the
burner running.
The system should then perform a
fault shutdown, if the flame monitor
is covered up.
Remove flame monitorĂB (flicker
light detector) from its holder, when
the burner has been running for 30Ăs.
When the flame monitor is covered,
the flame must die down and the
start-up should be repeated.
Please note:
The flicker light detector is preset at
the factory to setting 4. Only adjust
to a higher setting if necessary.
56 2Ă533ĂGB
B
A

12
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Cleaning burner
1. Set the burner to maintenance.
2. Clean the housing, the flame tube,
sensor plateĂA, ignition
electrodesĂB, flame monitorĂC
and impellerĂD.
3. Sensor plate 0 kWĂE:
Remove screen cylinderĂF, and
clean sensor plateĂE and baffle
plate G.
For cleaning the combustion
chamber and hot gas flues,
see boiler service
instructions.
56 2Ă533ĂGB

13
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Nozzle replacement
1. Remove sensor plateĂA from the
blast tube connection.
2. Replace nozzleĂB (hold the blast
tube connection to avoid the
formation of air bubbles inside the
blast tube connection).
For make and type of nozzle, see
standard values for burner
settings on page 37.
3. Install sensor plateĂA.
Position the nozzle centrally inside
the sensor plate, and observe the
clearance between the sensor
plate and the nozzle (see pageĂ14).
56 2Ă533ĂGB
B
A

14
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking and, if required, adjusting ignition electrodes
Check ignition electrodesĂA for
wear, contamination and size (see
fig.) and replace if necessary.
56 2Ă533ĂGB
..to
to
..
to
to

15
Initial start-up, inspection and maintenance
Further details regarding the individual steps (cont.)
Oil pump filter, cleaning and replacing if necessary,
Danfoss oil pump, typeĂBFPĂ52
AFilter plug
BOĆring
(replace)
CFilter
(replace)
Suntec oil pump, typeĂATĂ2ĂĆĂ55
AFilter
(clean or
replace)
BFlat gasket
(replace)
COĆrings
(replace)
DCover
56 2Ă533ĂGB
A
B
C
ABCD

16
Troubleshooting
Diagnostics
Fault Cause emedy
Burner does not start No voltage present Check fuse in control
unit and in plug-in
terminal block, check
electrical connections,
position of ON/OFF
switch on control unit
and mains electrical
isolator
High limit safety cut-out
activated
Press reset button on
boiler control unit
Low water indicator has
switched OFF
Check water level and
top up, if necessary.
Press reset button at
boiler control unit.
Motor faulty Replace motor
Actuator faulty Replace actuator
Burner starts, but no
flame builds
Ignition electrodes
poorly adjusted
Adjust correctly (see
pageĂ14)
Ignition electrodes
damp and contaminated
Clean ignition electrode
block
Insulation of ignition
electrodes cracked
Replace ignition
transformer
Ignition transformer
faulty
Replace ignition
electrode block
Pump does not feed oil Install pressure and
vacuum gauges on
pump and check
build-up of pressure
(see following
paragraph)
Actuator faulty Replace actuator
Actuator incorrectly
adjusted
Correct setting
56 2Ă533ĂGB

17
Troubleshooting
Diagnostics (cont.)
Fault Cause emedy
Pump does not feed oil Shut-off valves closed at
filter or in oil pipe
Open valves
Filter blocked Clean filter (pre-filter
and pump filter)
Clutch between motor
and pump faulty
Replace clutch
Suction pipe leaking Tighten connections.
Check oil pipes and
connections for leaks
and tighten.
Oil flow and return
hoses interchanged
Connect correctly acc.
to pump markings
Vacuum in suction line
too high (higher than
0.35Ăbar)
Check cross-section of
oil supply pipe.
Clean filter.
Burner starts up, but no
oil injected; pressure
Solenoid valve does not
open
Replace solenoid coil
j;p
gauge on pump indicates
pressure
Nozzle blocked Replace nozzle
pressure
Control unit issues no
voltage to solenoid
valve
Flame monitor check
(external light)
Flame monitor faulty Replace flame monitor
Burner starts up and
flame is formed, but
Flame monitor
contaminated
Clean flame monitor
,
burner cuts out after
safety time expires Flame monitor receives
insufficient light
Clean sensor plate and
inside of flame tube
Flame monitor faulty Replace flame monitor
Control device faulty Replace control device
Water in tank Pump out water
56 2Ă533ĂGB

18
Troubleshooting
Diagnostics (cont.)
Fault Cause emedy
Flame extinguishes
during operation
Air in suction line Seal line and filter
Nozzle faulty Nozzle replacement
Air incorrectly adjusted,
pump pressure
incorrectly adjusted
Adjust pre-settings
correctly (see pageĂ37)
Sensor plate and inside
of flame tube
contaminated
Clean sensor plate and
inside of flame tube
Flame monitor faulty Replace flame monitor
Ignition switches ON
during operation
at stage 1
Flame monitor
contaminated
Clean flame monitor
gp
at stage 1 Flame monitor faulty Replace flame monitor
Sensor plate or flame
tube contaminated
Clean sensor plate or
flame tube
Burner sooty Too little or too much air Correct setting.
Check and clean
impeller.
Check boiler room
ventilation.
Insufficient chimney
draught
Check flue and flue gas
baffles
Nozzle faulty Replace nozzle and
install correct nozzle
(see pageĂ37)
CO2Ăcontent too low Incorrect setting Check setting (see
pageĂ37)
Infiltrating air Seal flue pipe at boiler
adaptor.
Retighten boiler door
screws and those on
flue outlet.
Flue gas temperature too
high
Oil consumption too
high
Match oil flow to rated
output of boiler
Boiler contaminated
with soot
Clean boiler and correct
burner settings
56 2Ă533ĂGB

19
Troubleshooting
56 2Ă533ĂGB

20
Component summary
Component summary
AService switch
(for burner adjustment)
BHood adaptor
CQuick-action fastener
DIgnition transformer
EBurner control unit
FReset button
GOil supply pipe
HPlug-in terminal block
KSolenoid valve stage 1
LSolenoid valve stage 2
MOil pump
NSuction line
OReturn line
PFan motor
RActuator motor
SFlame monitor
TMounting plate for
burner hood adaptor
UValve housing
VSuction air silencer
WImpeller
XAir regulating damper
YFlame tube
ZBlast tube connection
aGuide brackets
bSensor plate
cFlameĂtubeĂextensionĂ(onlyĂforĂ 0ĂkW)
dOil burner nozzle
eIgnition electrodes
fIgnition cable
gFlange
56 2Ă533ĂGB