Viessmann VITOFLAME 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitoflame 300
Type VHG III
Pressure-jet oil burner
for the Vitorondens 200-T, 67.6 to 107.3 kW
VITOFLAME 300
5834343 GB 7/2019 Please keep safe.

2
Please follow these safety instruc-
tions 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 environmen-
tal pollution.
Note
Details identified by the word "Note"
contain additional information.
Target group
These instructions are exclusively inten-
ded for qualified contractors.
■Work on electrical equipment may only
be carried out by a qualified electrician.
■The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations to be observed
■National installation regulations
■Statutory regulations for the prevention
of accidents
■Statutory regulations for environmental
protection
■Codes of practice of the relevant trade
associations
■Relevant country-specific safety regu-
lations
Safety instructions for working on the system
Working on the system
■Isolate the system from the power sup-
ply (e.g. by removing the separate fuse
or by means of a mains isolator) and
check that it is no longer live.
■Safeguard the system against recon-
nection.
Danger
Hot surfaces can cause burns.
■Before maintenance and service
work, switch OFF the appliance
and let it cool down.
■Never touch hot surfaces on the
boiler, burner, flue system or pipe-
work.
Safety instructions
Safety instructions
5834343

3
!Please note
Electronic assemblies can be dam-
aged by electrostatic discharge.
Prior to commencing any work,
touch earthed objects such as heat-
ing or water pipes to discharge
static loads.
Repair work
!Please note
Repairing components that fulfil a
safety function can compromise the
safe operation of the system.
Replace faulty components only
with genuine Viessmann spare
parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that have
not been tested together with the
system can compromise its func-
tion. Installing non-authorised com-
ponents and making non-approved
modifications or conversions can
compromise safety and may invalid-
ate our warranty.
For replacements, use only original
spare parts supplied or approved by
Viessmann.
Safety instructions for operating the system
If you smell flue gas
Danger
Flue gas can lead to life threatening
poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close the doors to living spaces to
prevent flue gases from spread-
ing.
What to do if water escapes from the
appliance
Danger
If water escapes from the appliance
there is a risk of electric shock.
Switch OFF the heating system at
the external isolator (e.g. fuse box,
domestic distribution board).
Danger
If water escapes from the appliance
there is a risk of scalding.
Never touch hot heating water.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
external causes. Ensure an adequate
supply of combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or
an inadequate supply of combus-
tion air can cause life threatening
poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good
working order. Vents for supplying
combustion air must be non-seala-
ble.
Safety instructions
Safety instructions (cont.)
5834343

4
Extractors
Operating appliances that extract air to
the outside (extractor hoods, extractors,
air conditioning units, etc.) can create
negative pressure. If the boiler is oper-
ated at the same time, this can lead to a
reverse flow of flue gas.
Danger
The simultaneous operation of the
boiler and appliances that extract
air to the outside can result in life
threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suita-
ble steps to ensure an adequate
supply of combustion air.
Safety instructions
Safety instructions (cont.)
5834343

5
1. Information Symbols ................................................................................................. 6
Spare parts lists ..................................................................................... 6
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 7
3. Burner control unit ................................................................................................................ 16
4. Troubleshooting Diagnosis ............................................................................................... 19
■Faults with flash code indication ......................................................... 19
■Faults without flash code indication .................................................... 20
5. Component overview ................................................................................................................ 22
6. Connection and wiring dia-
gram
................................................................................................................ 24
7. Report ................................................................................................................ 25
8. Specification ................................................................................................................ 26
9. Standard values for burner
adjustment
................................................................................................................ 27
10. Appendix Information on fuel oil ............................................................................ 28
11. Keyword index ................................................................................................................ 29
Index
Index
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Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Spare parts lists
Information about spare parts can be found on the
Viessmann spare parts app.
Information
Symbols
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Commissioning steps
Inspection steps
Maintenance steps Page
•1. Commissioning the system............................................................................................... 8
• • 2. Checking the burner
• • 3. Checking the oil pressure and vacuum, adjusting the CO2 value................................. 8
••• 4. Checking the settings of the air damper servomotor..................................................... 10
• • 5. Cleaning and testing the flame monitor........................................................................... 11
• • 6. Installing and adjusting the flame monitor (if available)................................................ 11
• • 7. Shutting down the system
• • 8. Checking the firm seating of electrical connections
•9. Cleaning the burner........................................................................................................... 12
• • 10. Checking the impeller fixings
• • 11. Checking the flame tube fixings
•12. Replacing the nozzle.......................................................................................................... 13
• • 13. Checking and adjusting the ignition electrodes............................................................. 13
•14. Fitting the burner cover on the burner casing
•15. Cleaning the oil pump filter and replacing it if necessary.............................................. 14
•16. Replacing the filter element of the fuel oil filter
• • 17. Commissioning the system
• • 18. Checking the oil lines and connections for leaks
•19. Re-testing the burner and entering the actual values into the report
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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To obtain optimum combustion values, the burner must be adjusted with the boiler heated up (min. 60 ºC). Also
carry out tests at base load.
Boiler control unit service instructions Note
For fuel details, see chapter "Information on fuel oil".
A B
C
Fig. 1
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 installa-
tion room).
5. Turn on system ON/OFF switch B at the control
unit.
If fault indicator A on the control unit illuminates,
press reset button C on the burner.
Checking the burner
Checking the oil pressure and vacuum, adjusting the CO2 value
The oil pressure is factory-set according to the oil
throughput.
When commissioning or using a sound insulation set
(accessories), select the CO2 value by adjusting the oil
pressure.
Commissioning, inspection, maintenance
Commissioning the system
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Fig. 2 Oil pump make: Danfoss
Fig. 3 Oil pump make: Suntec
01. Switch system OFF at mains isolator and safe-
guard against unauthorised reconnection.
02. Unscrew plug "P" A from the oil pump.
03. Unscrew plug "V" B from the oil pump.
Note
Oil may leak from the oil pump when doing this.
04. Insert a pressure gauge (measuring range
0-40 bar) and a vacuum gauge (measuring range
0-1 bar).
Note
Only seal in the pressure and vacuum gauges with
copper or aluminium gaskets or with O-rings.
Never use sealing tape.
05. Start the burner.
Note
The solenoid valve opens.
06. Read off the oil pressure and the vacuum of the
pump on the relevant gauge (vacuum should be
max. 0.35 bar at a height differential of 3 m
between the oil pump and the bottom of the tank).
Note
If the vacuum pressure is higher than 0.35 bar,
check the filter for contamination and check the
pipe run.
E
Fig. 4
07. If the CO2 content is not between 13 to 14 % by
vol., adjust it by regulating the oil pressure.
Note
Subject to pump type, the pressure adjusting
screws may be located at the front or on the side
of the oil pump.
■For burner stage 2, set the oil pressure at pres-
sure adjusting screw D. Service switch E is
factory-set to setting 2.
■For burner stage 1, set service switch E to set-
ting 1; open the flap to do so. Adjust the oil pres-
sure by means of pressure adjusting screw C.
Clockwise turn → pressure increases.
Anti-clockwise turn → pressure decreases.
Note
For standard values for burner adjustment, see
page 27.
Commissioning, inspection, maintenance
Checking the oil pressure and vacuum , adjusting… (cont.)
5834343

10
08. Test to check the actual emission values after
adjusting the oil pressure.
09. Switch system OFF at mains isolator and safe-
guard against unauthorised reconnection.
10. Undo the pressure and vacuum gauges.
11. Check the plug seal rings for damage and replace
if necessary.
Insert plugs "P" A and "V" B.
12. Start the burner and check the plugs for leaks.
Checking the settings of the air damper servomotor
The air damper servomotor is factory-set and must only be adjusted in exceptional cases. Exceptions are the
replacement of the air damper servomotor, soot build-up and the altitude above sea level of the installation
site. The CO2 value must only be adjusted by regulating the oil pressure.
90 30
60 0
90 30
60 0
90 30
60 0
90 30
60 0
90 30 0
ST2
BV
SL
ST1
Z
Fig. 5
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" position. This reduces the
cool-down losses.
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 functions:
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 "Stand-
ard 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 ignition air setting approx. 1-5°
below stage 1.
Commissioning, inspection, maintenance
Checking the oil pressure and vacuum , adjusting… (cont.)
5834343

11
A
Fig. 6
AFlame monitor
Safety check Response
Burner start with dark-
ened flame monitor
Fault shutdown at the end
of the safety time
Red flashing code,
flashes 2x
Burner start with exter-
nally lit flame monitor
Fault shutdown after max.
40 s
Flashes alternately green-
red
Burner operation with si-
mulated flame tear-off:
Cover the flame monitor
during operation and
leave in this condition
Restart followed by a fault
shutdown at the end of the
safety time
Red flashing code,
flashes 2x
Installing and adjusting the flame monitor (if available)
Before fitting, check whether slider sleeve B is
pushed as far forward as it will go (x = max.).
Push-on restrictor A must sit on flame monitor C.
x
Fig. 7
Shutting down the system
Checking the firm seating of electrical connections
Commissioning, inspection, maintenance
Cleaning and testing the flame monitor
5834343

12
For cleaning the combustion chamber and flues,
see boiler service instructions.
A
B
F
C
D
E
Fig. 8
1. Set the burner into its maintenance position. To do
this, remove nozzle cover D with mixing device
and slot it onto the burner casing with the blast
tube connection pointing upwards or to the side.
2. Clean flame tube, sensor plate A, ignition electro-
des B and flame monitor C.
3. If the burner pressure differs significantly: Remove
burner cover E and clean casing with impeller; to
do so, first remove hood adaptor F.
Checking the impeller fixings
Checking the flame tube fixings
Commissioning, inspection, maintenance
Cleaning the burner
5834343

13
A
B
Fig. 9
1. Remove the nozzle cover with mixer device and
slot it onto the burner casing with the blast tube
connection pointing upwards (service position).
This prevents the formation of bubbles in the blast
tube connection.
2. Remove mixing assembly A from the blast tube
connection.
3. Replace nozzle B (counterhold to 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 val-
ues for burner adjustment on page 27.
4. Mount mixing facility A:
■Position the nozzle in the centre of the sensor
plate and note the distance between the sensor
plate and the nozzle (see page 13).
■Accurately position the ignition electrodes in the
top centre (12 o'clock position).
Checking and adjusting the ignition electrodes
3-5
A
a
b
Fig. 10
1. Check ignition electrodes A for wear, contamina-
tion and size accuracy (see diagram), replace if
necessary.
2. Clearance between mixing system and nozzle:
Check either dim. a or dim. b and adjust if neces-
sary.
Commissioning, inspection, maintenance
Replacing the nozzle
5834343

14
Rated heating out-
put
Dim. a Dim. b
63/67.6 kW 9.4 mm
80/85.8 kW 5 mm 10.0 mm
100/107.3 kW 12.0 mm
Fitting the burner cover on the burner casing
Cleaning the oil pump filter and replacing it if necessary
Fig. 11 Oil pump make: Danfoss
AFilter plug
BO-ring (replace)
CFilter (replace)
Commissioning, inspection, maintenance
Checking and adjusting the ignition electrodes (cont.)
5834343

15
Fig. 12 Oil pump make: Suntec
AFilter (clean or replace)
BFlat gasket (replace)
CO-rings (replace)
DCover
Replacing the filter element of the fuel oil filter
Commissioning the system
Checking the oil lines and connections for leaks
Re-testing the burner and entering the actual values into the report
Commissioning, inspection, maintenance
Cleaning the oil pump filter and replacing it… (cont.)
5834343

16
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
Fig. 13
Note
The output signal at the solenoid valve stage 2 F is
dependent upon the switch position of the BV2 control
cam of the solenoid valve stage 2 in the servomotor.
A Start-up begins
B Point of flame formation
C Burner operating position
D Controlled shutdown
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
t3n Post-ignition time begins with flame
(max. until end of "TSA")
max. 5 s
TSA Start-up safety time max. 5 s
Function and fault indications of the signal indicator (LED)
During standard operation, the operating conditions are indicated by LED signal indicator A through colour
codes (see the following table).
After a fault shutdown, the indicator permanently illuminates red. In this condition, the optical fault cause indicator
can be activated (see the following chapter "Burner fault sequence diagram").
Burner control unit
Burner control unit
5834343
Parameter

17
B
A
Fig. 14
1. Hold down reset button B for approx. 5 s (>3 s).
2. A flash code is then shown.
The number of flashes in a sequence indicates the
type of fault. For an explanation, see the table in
chapter "Faults with flash code indication".
3. To reset the burner and exit the fault indication,
press the reset button for approx. 1 s (<3 s).
LED colour Operating condition
Yellow, flashing Ignition phase pre-purge, ignition activated
Green, continuous Operation, flame stable
Green, flashing Operation, poor flame stability
Yellow-red, flashing alternately Undervoltage (<195 V)
Red, continuous Fault, burner locked out
Red, flashing Fault code indication (for an explanation, see chapter "Faults with flash
code indication")
Green-red alternately External light before burner start
Red, flickering Interface diagnosis was activated accidentally. Pressing the reset but-
ton once (approx. 3 s) starts the burner in standard mode.
Burner control unit
Burner control unit (cont.)
5834343
Parameter

18
Burner fault flowchart
System cold
LED on burner control unit illumi-
nates red
Reset burner control unit:
Press reset button for approx. 1 s
(<3 s)
Call up flash code:
Press reset button until LED
changes to yellow (approx. 5 s
(>3 s))
Burner start Read off flash code and identify
its meaning in the diagnosis table
Remedy the fault
Reset burner control unit:
Press reset button for approx. 1 s
(<3 s)
Burner start
Burner control unit
Burner control unit (cont.)
5834343
Parameter

19
Faults with flash code indication
Fault Red flash
code
Cause of fault Measure
Burner does not start (with
fault indication), indicator il-
luminates
10 x Wiring fault or internal burner
fault; not all consumers were rec-
ognised; other error
Check the electrical connection
Burner does not start (with
fault indication)
2 ×Motor faulty Replace motor
2 ×Coupling between motor and oil
pump faulty
Replace coupling
2 ×Oil pump seized up or sluggish Clean the oil pump, or replace if
necessary
6 ×Servomotor faulty Replace the servomotor
Burner starts, but no flame
is formed
2 ×Ignition electrodes incorrectly ad-
justed
Set correctly (see chapter
"Checking and adjusting the igni-
tion electrodes")
2 ×Ignition electrodes damp and
contaminated
Clean ignition electrode block
2 ×Insulation body of ignition electro-
des cracked
Replace ignition electrode block
2 ×Ignition transformer faulty Replace ignition transformer
2 ×Ignition cable faulty Replace ignition cable
2 ×Pump does not supply oil Mount pressure and vacuum
gauges at the pump and check
build-up of pressure (see follow-
ing paragraph)
Pump does not supply oil 2 ×Shut-off valves closed at filter or
in oil line
Open valves
2 ×Filter blocked Clean filters (fuel oil filter and
pump filter), replace if necessary
2 ×Coupling between motor and
pump faulty
Replace coupling
2 ×Leak in suction line or filter bowl Retighten fittings. Check the oil
lines for leaks; seal if necessary.
2 ×Oil flow and return hoses inter-
changed
Connect correctly acc. to mark-
ings on pump
2 ×Vacuum in suction line too high
(above 0.35 bar)
Check sizing of oil line cross-sec-
tion. Replace filter. Check the ex-
ternal oil valve.
2 ×External oil valve faulty Check external oil valve and re-
place if necessary
Burner starts, but no oil is
injected
2 ×Solenoid valve coil faulty Replace solenoid valve coil
2 ×Oil pump faulty Replace oil pump
2 ×Nozzle blocked Replace nozzle
External light during the
pre-purge phase
4 ×Oil pump solenoid valve fails to
close
Replace oil pump
4 ×Flame monitor faulty Replace flame monitor
4 ×Ignition electrodes incorrectly ad-
justed or worn
Check the ignition electrodes; re-
place if necessary
Troubleshooting
Diagnosis
5834343
Diagnosis

20
Fault Red flash
code
Cause of fault Measure
Burner starts and flame
builds, but burner enters
fault state after safety time
expires
2 ×Flame monitor contaminated Clean flame monitor
2 ×Flame monitor receives insuffi-
cient light
Clean sensor plate
2 ×Flame monitor faulty Replace flame monitor
2 ×Burner control unit faulty Replace burner control unit
2 ×Carbon deposits on the flame
tube or on the sensor plate
Clean the flame tube and sensor
plate
Flame tears off more than
3 times during operation
7 ×Air in suction line Seal line and filter
7 ×Nozzle faulty Replace nozzle
7 ×Burner incorrectly adjusted Set default values (see chapter
"Standard values for burner ad-
justment")
7 ×Sensor plate contaminated Clean sensor plate
Ignition switches on during
operation
7 x Flame monitor contaminated Clean flame monitor
7 x Sensor plate contaminated Clean sensor plate
7 x Nozzle contaminated or faulty Replace nozzle
Condensate backup in flue
gas heat exchanger
7 x Siphon or neutralising system
contaminated
Clean siphon and neutralising
system
Faults without flash code indication
Fault Cause of fault Measure
Burner does not start (no
fault indication), indicator
does not illuminate
No power Check fuse or plug-in connector aBÖ in
the control unit, the electrical connec-
tions, the setting of the ON/OFF switch
on the control unit and the mains isolator
High limit safety cut-out has responded Press reset button at the boiler control
unit
The low water indicator has caused the
system to shut down
Check the water level; top-up if necessa-
ry. Press the reset button on the burner.
Servomotor faulty Replace the servomotor
When changing from stage
1 to stage 2, the flame
tears off and the burner
starts again
Flame monitor contaminated Clean flame monitor
Inside of flame tube contaminated Clean inside of flame tube
Sensor plate contaminated Clean sensor plate
Faulty control unit Replace control unit
Solenoid valve stage 2 faulty Replace solenoid coil
Burner sooty Insufficient or excess air Correct the settings. Check and clean im-
peller.
Check fan pressure
Check ventilation in installation room.
Insufficient chimney draught Check chimney and flue gas routing
Nozzle faulty Replace the nozzle, fit the correct nozzle
(see chapter "Standard values for burner
adjustment")
The flame tube extension is missing Install the flame tube extension
CO2 content too low Incorrect setting Check setting (see chapter "Standard val-
ues for burner adjustment")
Troubleshooting
Diagnosis (cont.)
5834343
Diagnosis