Viessmann Vitoflame 100 Operating instructions

Service instructions
for contractors
VIESMANN
Vitoflame 100
Type VEH III
Pressure-jet oil burner
for Vitoplex 200 and 300, 80 to 300 kW
for Vitorond 100 and 200, 80 to 270 kW
for Vitoradial 300-T, 90 to 300 kW
For applicability, see the last page
VITOFLAME 100
5692 870 GB 8/2010 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain 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 fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental 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,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical appli-
ances 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 build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5692 870 GB

3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the
living space.
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 sup-
ply 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 unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged 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 ful-
fil a safety function can compro-
mise 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 com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5692 870 GB

4
Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 6
Burner control unit............................................................................................. 20
Troubleshooting
Diagnosis.............................................................................................................. 24
Component overview......................................................................................... 29
Connection and wiring diagram........................................................................ 31
Parts list.............................................................................................................. 34
Commissioning/service report.......................................................................... 41
Specification....................................................................................................... 43
Standard values for burner settings................................................................. 48
Appendix
Information on fuel oil........................................................................................... 52
Keyword index.................................................................................................... 53
Index
Index
5692 870 GB

5
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Starting the heating system........................................... 6
••• 2. Checking the adjustment of the air damper
servomotor...................................................................... 7
• • 3. Adjusting the oil pressure and checking the vacuum 7
• • 4. Adjusting the air volume................................................ 10
•5. Checking the 0-point setting of the blast tube
connection....................................................................... 11
• • 6. Fully checking the burner
• • 7. Cleaning and testing the flame monitor....................... 13
• • 8. Shutting down the system
• • 9. Checking electrical connections for firm seating
•10. Cleaning the burner........................................................ 14
• • 11. Checking the impeller fixings
• • 12. Checking the flame tube fixings
•13. Replacing the nozzle...................................................... 15
• • 14. Checking and adjusting the ignition electrodes.......... 16
•15. Installing the burner cover on the burner casing
•16. Cleaning or, if required, replacing the oil pump filter. 18
•17. Replacing pre-filter elements
• • 18. Starting the system
• • 19. Checking the oil lines and connections for leaks
•20. Checking the burner again and entering the actual
values into the report
•21. Operating and service documents................................ 19
Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance
5692 870 GB

6
Starting the heating system
To obtain optimum combustion values, the burner must be adjusted with the boiler
at operating temperature (min. 60 ºC). Also carry out measurements at base load.
Service instructions boiler circuit
control unit
Note
For fuel details, see chapter "Information
on fuel oil".
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 installation room).
5. Switch ON the system ON/OFF
switch B at the control unit.
Press reset button C on the burner
if fault indicator lamp A on the con-
trol unit illuminates.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 870 GB

7
Checking the adjustment of the air damper servomotor
90 30
60 0
90 30
60 0
90 30
60 0
90 30
60 0
90 30 0
ST2
BV
SL
ST1
Z
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 controlled shutdown, the burner
air damper moves into the "closed" posi-
tion. This reduces the cool-down los-
ses.
The switch cams are located under the
cover of the air damper servomotor. 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 func-
tions:
Z Air damper closed (0º)
Never alter the setting of Z.
SL Ignition air setting
ST1 Air damper setting stage 1
ST2 Air damper setting stage 2
BV Solenoid valve stage 2
The switch cams for ignition air stage 1
and 2 are set at the factory. For factory
settings, see chapter "Standard values
for burner settings".
The switch cams are adjusted via 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 adjusting the ignition air setting to
match stage 1, always adjust the igni-
tion air setting approx. 1-5° below
stage 1.
Adjusting the oil pressure and checking the vacuum
The oil pressure is preset at the factory according to the oil throughput.
Adjust the oil pressure if required.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 870 GB

8
Danfoss oil pump, type BFP 52
Suntec oil pump, type AT 2-55
01. Switch OFF the mains isolator and
safeguard against unauthorised
reconnection.
02. Unscrew plug "P" A from the oil
pump.
03. Unscrew plug "V" B from the oil
pump.
Note
This allows the oil to drain from the
oil pump.
04. Insert a pressure gauge (range 0 -
40 bar) and a vacuum gauge (range
0 - 1 bar).
Note
Seal in the pressure and vacuum
gauges only with copper or alumi-
nium gaskets or with O-rings. Never
use tape to seal these joints.
05. Start the burner.
Note
The solenoid valve opens.
06. Read off the oil and vacuum pres-
sures of the pump on the relevant
gauge (vacuum should be max.
0.35 bar given a height differential of
3 m between the oil pump and the
bottom of the tank).
Note
Where the vacuum measures
higher than 0.35 bar, check the filter
for contamination or check the pipe-
work.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 870 GB

9
07. If required, adjust the oil pressure at
the pressure adjusting screw of the
oil pump C (for Danfoss pumps,
this may be either at the front or at
the side of the pump, subject to
pump type).
Turn clockwise → pressure increa-
ses
Turn anti-clockwise → pressure
decreases
Note
For standard burner settings, see
the chapter with the same title.
08. Check the actual emission values
after adjusting the oil pressure.
09. Switch OFF the mains isolator and
safeguard against unauthorised
reconnection.
10. Remove the pressure and vacuum
gauges.
11. Check the plug seal rings for dam-
age and replace if required.
Insert plugs "P" A and "V" B.
12. Start the burner and check the plugs
for leaks.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 870 GB

10
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 on the blast tube connection.
Starting up the burner may require some fine adjustment.
You should aim for a standard value of 13 % CO2 when adjusting the burner.
Readjusting stage 2
AFlame tube
BSensor plate
CAir damper
DBlast tube connection
EBlast tube connection setting
screw
FLocking screw
Modify position of sensor plate B inside
flame tube A by turning blast tube con-
nection setting screw E:
■ Turn clockwise
→ larger cross-section
→ more air
■ Turn anti-clockwise
→ smaller cross-section
→ less air
Note
For standard burner settings, see the
chapter of the same title.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 870 GB

11
Readjusting stage 1
1. Change service switch G to
position II (automatic mode) and
close the cover flap.
2. Adjust the burner at service switch
G to stage 1.
3. Remove the cover from the servomo-
tor.
4. Change the air volume by turning the
adjusting screw at switch cam ST1
(see Fig. in chapter "Checking the
setting of the air damper servomo-
tor"):
■Turn clockwise → more air
■Turn anti-clockwise → less air
Note
Adjust the switch cam ST1 little by lit-
tle (fine adjustment). The selected
value of switch cam BV 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 turn the
burner to stage 2 and then back to
stage 1.
5. Fit the cover over the servomotor.
Checking the 0-point setting of the blast tube connection
This adjustment is only required if optimum combustion characteristics are not ach-
ieved with the standard values for burner settings (see chapter of the same title).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 870 GB

12
EZero setting at 80 to 230 kW
FZero setting at 270 to 300 kW
1. Fit the burner cover on the burner
casing.
2. Set the scale for blast tube connec-
tion adjustment with blast tube con-
nection adjusting screw A to "0".
3. Undo locking screw B.
4. Position blast tube connection C so
that front of sensor plate D is aligned
with edge of flame tube G.
Note
For 270 to 300 kW the end-stop is
20 mm in front of the edge of the
flame tube.
5. Retighten locking screw B.
6. Adjust the blast tube connection in
accordance with the standard values
for burner settings (see chapter of the
same title).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 870 GB

13
Cleaning and testing the flame monitor
AFlame monitor
Safety check Response
Burner start with
covered flame
monitor
Fault shutdown at the
end of the safety
time
red flashing code,
flashes 2x
Burner start with
flame monitor
illuminated by
external source
Fault shutdown after
max. 40 s
flashes alternately
green-red
Burner operation
with simulated
flame tear-off:
cover the flame
monitor during
operation and
leave in this con-
dition
Restart followed by a
fault shutdown at the
end of the safety
time
red flashing code,
flashes 2x
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 870 GB

14
Cleaning the burner
For cleaning the combustion
chamber and hot gas flues, see
boiler service instructions.
FContactor (for 270 to 300 kW)
1. Set the burner in its maintenance
position; to do this remove nozzle
cover D with mixing device and
position with blast tube connection on
the top or at the side of the burner
housing.
2. Clean flame tube, sensor plate A,
ignition electrodes B and flame
monitor C.
If visibly dirty, remove burner cover
E and clean housing and impeller;
to do this, first remove hood adaptor
G.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 870 GB

15
Replacing the nozzle
1. Remove nozzle cover with mixer
device and position with blast tube
connection above the burner housing
(service position). This prevents the
formation of bubbles in the blast tube
connection.
2. Remove sensor plate A from the
blast tube connection.
3. Replace nozzle B (prevent the blast
tube connection from turning); during
this step prevent air bubbles from
forming in the blast tube connection.
Note
For the make and type of nozzle, see
standard values for burner settings in
the chapter of the same title.
4. Fit sensor plate A. Position the noz-
zle in the centre of the sensor plate
and observe the clearance between
the sensor plate and the nozzle (see
chapter "Checking and adjusting the
ignition electrodes").
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 870 GB

16
Checking and adjusting the ignition electrodes
Check ignition electrodes A for wear,
contamination and size (see Fig.) and
replace if required.
+0.3
1.5
3+1
12
80 kW In conjunction with Vitorond 100, type VR2B
80 and 105 kW In conjunction with Vitoplex 300, type TX3
90 kW In conjunction with Vitoplex 200, type SX2
1.5+ 0.3
3+1
12
90 and 115 kW In conjunction with Vitoplex 300, type TX3A, and Vitoradial 300-
T, type VR3
100 kW In conjunction with Vitorond 100, type VR2B
120 kW In conjunction with Vitoplex 200, type SX2
125 kW In conjunction with Vitorond 200, type VD2
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 870 GB

17
1.5+ 0.3
+1
3
12
130 to 225 kW In conjunction with Vitoplex 300, type TX3
140 and 235 kW In conjunction with Vitoplex 300, type TX3A, and Vitoradial 300-
T, type VR3
150 and 200 kW In conjunction with Vitoplex 200, type SX2
160 to 230 kW In conjunction with Vitorond 200, type VD2
1.5+ 0.3
+1
3
12
270 kW In conjunction with Vitoplex 200, type SX2
270 kW In conjunction with Vitorond 200, type VD2
285 kW In conjunction with Vitoplex 300, type TX3
300 kW In conjunction with Vitoplex 300, type TX3A, and Vitoradial 300-T,
type VR3
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 870 GB

18
Cleaning or, if required, replacing the oil pump filter
Danfoss oil pump, type BFP 52
AFilter plug
BO-ring (replace)
CFilter (replace)
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 870 GB

19
Suntec oil pump, type AT 2-55
AFilter (clean or replace)
BFlat gasket (replace)
CO-rings (replace)
DCover
Operating and service documents
1. Complete and detach the customer
registration card:
■ Hand the system user their part of
the card for safekeeping.
■ Retain the heating contractor's part
of the card.
2. File all parts lists, operating and serv-
ice instructions in the folder and hand
this over to the system user.
The installation instructions are no
longer required after installation and
therefore do not need to be
retained.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 870 GB

20
Program sequence during commissioning
0
Start
Stage 1
BV2 control cam
Stage 2
BV2
TR/STB
AA' B C D
t1
t40
t3n
t3
TSA
Control signals
Required input signals
Note
The output signal at the solenoid valve stage 2 F is dependent upon the switch
position of the control cam of the solenoid valve stage 2 in the servomotor.
A' Start of oil preheat time
A Start-up
B Time of flame formation
C Burner operating position
D Controlled shutdown
1-qW Plug-in terminals on the burner
control unit
EBurner motor
FSolenoid valve stage 2
HSolenoid valve stage 1
NIgnition transformer
OFlame monitor
ROutput controller
t1 Pre-purge time min. 20 s
t40 Delay time between enabling solenoid
valve stage 1 and enabling controller
input
approx. 11 s
t3 Pre-ignition time approx. 20 s
Burner control unit
Burner control unit
5692 870 GB