Viessmann VITOFLAME 100 Service Instructions Manual

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

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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

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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

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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

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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.)

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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.)

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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.)

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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.)

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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

5692 870 GB

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Viessmann VITOFLAME 100 Service Instructions Manual

Viessmann VITOFLAME 100 Service Instructions Manual

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