Viessmann Vitoflame 100 Page 1 Service Instructions Manual Download

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VitoflameĂ100 gas burner

fitted to VitoplexĂ100

Service instructions

for heating engineers

VitoflameĂ100

Pressure jet gas burner (typeĂVGĂIII)

for VitoplexĂ100

Rated output 90 to 210ĂkW

See notes on applicability, pageĂ2.

VITOFLAME 100

5692Ă534ĂGBăăă5/2003

Please keep safe

Summary of Contents for Vitoflame 100

Page 1: ... VitoplexĂ100 Service instructions for heating engineers VitoflameĂ100 Pressure jet gas burner typeĂVGĂIII for VitoplexĂ100 Rated output 90 to 210ĂkW See notes on applicability pageĂ2 VITOFLAME 100 5692Ă534ĂGBăăă5 2003 Please keep safe ...

Page 2: ...ed acc to TRGI or TRF or local regulations Repair 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 commi...

Page 3: ...icsĂ 25 Component summaryĂ 34 Connection and wiring diagramsĂ 37 Parts listĂ 40 Appendix SpecificationĂ 46 Standard values for burner settingsĂ 47 Commissioning service reportĂ 50 Keyword indexĂ 68 Operating and service documents 1 Complete and detach the customer registration card H Give the system user this part for safe keeping H Retain the heating engineer portion 2 Keep all parts lists operat...

Page 4: ... start up gas volumeĂ 14 C M 7 Air volume adjustmentĂ 15 I M 8 Checking ionisation currentĂ 17 C M 9 Checking burner record values on pageĂ50 of commissioning report I M 10 Checking air pressure switchĂ 18 I M 11 System shutdownĂ 18 I M 12 Checking electrical connections M 13 Cleaning burnerĂ 19 I M 14 Checking blast tube fixings I M 15 Checking impeller fixings I M 16 Cleaning gas orifices in sen...

Page 5: ...itial start up inspection and maintenance For further instructions on individual steps see pages indicated Commissioning steps Inspection steps Maintenance steps Page I M 21 Checking all gas unions for leaksĂ 24 M 22 Implementing final testsĂ 24 5692Ă534ĂGB ...

Page 6: ...mbar 5 Wait approx 5 minutes for the temperature to level out then observe the pressure gauge display The test area is free from leaks if the display pressure does not fall by more than 1 mbar within a further five minutes ĂSafety instruction Check the test nipple for gas leaks 6 Purge the gas supply pipe Please note Vent the gas supply pipe and the gas float before initial start up To do this rou...

Page 7: ...5 If a heat demand is present Ă demand lamp at the plug in terminal block lights up the air damper actuator goes from the closed position to stage 2 and reverts back to air damper position stage 1 ST0Ă ĂST2Ă ĂST1 The burner control unit sequence is started with the following functions Burner motor starts and combustion chamber is purged approx 30 s Electric ignition is switched ON pre ignition tim...

Page 8: ...t off valve 3 Check the supply pressure see page 11 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 control unit Please note Function sequence during initial start up see pages 25 and 37 During the initial start up the equipment can ent...

Page 9: ...ated adjacent to each switching cam which enables the set angle of the air damper to be checked The switching cams have the following function STĂ0Air damper closed 0º Never alter the STĂ0 setting STĂ1Air damper setting stageĂ1 STĂ2Air damper setting stageĂ2 MV Solenoid valve stageĂ2 The switching cams for stageĂ1 and 2 are set up at the factory For factory settings see the following table The swi...

Page 10: ...ust the nozzle pressure for operation with natural gas LL according to the table on pageĂ47 Record the gas type in the service report on page 50 Static pressure 1 Close the gas shut off valve 2 Loosen the screw in test nippleĂA but do not remove 3 Connect the U shaped pressure gauge 4 Open the gas shut off valve 5 Measure the static pressure max 50Ămbar 6 Record the actual values in the commission...

Page 11: ...cord the actual values in the commissioning report on page 50 10 Close the gas shut off valve 11 Remove the U shaped pressure gauge and close test nippleĂ Supply pressure flow pressure Remedy below 15 mbar Do not change the settings Check the filter in the gas train and notify your local gas supply company 15 to 18 mbar Please note The boiler may only be temporarily operated at this setting on sta...

Page 12: ...eĂA 3 Open the gas shut off valve 4 Start up the burner see page 8 5 Check the nozzle pressure in accordance with the Wobbe index and the output rating in the nozzle pressure table on pageĂ47 Please note During the adjustment also check the gas throughput by means of a volumetric test 6 Check and if necessary adjust the nozzle pressure The adjusted gas pressure will be present approx 10 seconds af...

Page 13: ...ctivate the emissions test switch on the control unit Service switch B must be in position II ĂĂ7 Move the cover over both sides of adjusting screw Fā ĂĂ8 Adjust the nozzle pressure on adjusting screw F using a screw driver ĂĂ9 Record the actual values in the commissioning report on page 50 Adjusting stage 1 10 Switch the burner over to stage 1 by pulling plug lÖ 11 Unscrew locking screw C b turn ...

Page 14: ... you do not need to change this setting 1 Set the quick action opening characteristics with protective capĂGĂinverted Please note At the factory the quick action is fully set to Ionisation current at least 5 mA Check the ionisation current see pageĂ17 2 Fit protective capĂG 3 Close the gas shut off valve 4 Remove the U shaped pressure gauge and close test nippleĂA see page 12 ĂSafety instruction C...

Page 15: ... The air volume is preset at the factory If necessary readjust the air volume first adjusting the air volume for stageĂ2 Fine adjustment stageĂ2 Adjust the air volume at adjusting screwĂA to modify the mixer assembly H Anti clockwise Ălarger cross section Ămore air H Clockwise Ăsmaller cross section Ăless air 5692Ă534ĂGB ...

Page 16: ...amsĂSTĂ1 see fig on pageĂ9 H ClockwiseĂ Ămore air H Anti clockwiseĂ Ăless air Please note Adjust switching camsĂSTĂ1 fine adjustment in small steps The set value for switching camĂMV must not lie below the set value of switching camĂSTĂ1 and not above that of switching camĂSTĂ2 After every adjustment of switching cam ST1 briefly drive the burner to stageĂ2 and back again to stageĂ1 connect plug lÖ...

Page 17: ... ON OFF switch Please note The system then initiates a fault shutdown 4 Press the reset button at the burner control unit and switch OFF the system ON OFF switch 5 Connect ionisation current test equipment or a TestomatikĆGas device 6 Switch the system ON OFF switch ON and check the ionisation current Please note Ionisation current at least 5 mA 7 Record the actual values in the commissioning repo...

Page 18: ...g and correct if required in accordance with the details below by rotating black scaled ring B A Adjustment markings shutdown when pressure drops B Scaled ring black Rated output range kW 90 to 100 125 to 140 150 to 165 190 to 210 Air pressure switch setting values mbar 3 8ĂĆĂ4 3 3 8ĂĆĂ4 3 3 8ĂĆĂ4 3 5 0ĂĆĂ5 5 System shutdown 1 Switch OFF the mains electric power the system ON OFF switch or the mai...

Page 19: ...ner to maintenance 2 Clean housingĂC flame tubeĂA mixer assemblyĂB and impellerĂD For cleaning the combustion chamber and hot gas flues see boiler service instructions 3 Check the gas orifices in the sensor plate for contamination and clean if required seeĂpageĂ20 4 Check the tightness of flame tubeĂA and impellerĂD 5692Ă534ĂGB ...

Page 20: ...trode holdersĂK andĂA and remove the ignition and ionisation electrodes 3 Remove the nut from earth electrodeĂF and unscrew the electrode 4 Unscrew the Allen screws from sensor plateĂE 5 Remove sensor plateĂE spring washerĂD and end plateĂC from mixer assemblyĂB and clean 6 Assemble in reverse order Please note Observe the correct orientation of the gas orifices in the end plate see page 21 5692Ă5...

Page 21: ...rodes 90 to 100 kW 125 to 210 kW A Earth electrode B Sensor plate C Ionisation electrode D End plate E Ignition electrode F 8 gas orifices in end plate G Slightly turn the ionisation electrode in accordance with the gap towards the earth electrode H Direct the tip of the ignition electrode towards the edge of the gas orifice 5692Ă534ĂGB ...

Page 22: ...ge with a manual pump to test nippleĂB 5 By gently activating the manual pump create a test pressure of approx 50 mbar 6 Wait approximately five minutes for the temperature to level out and then observe the display on the U shaped pressure gauge If the displayed pressure does not fall within a further five minutes by more than 1 mbar the gas train is not leakingĂ continue with item 7 Otherwise the...

Page 23: ...hecking filter insert of gas train make Dungs 1 Close the gas shut off valve 2 Unscrew filter lidĂD 3 Withdraw filter elementĂB 4 If necessary clean or replace the filter element 5 Replace filter lid gasketĂC 6 Secure filter lidĂD 7 Check the breather hole in plugĂA and clean if necessary 5692Ă534ĂGB ...

Page 24: ...f valve 3 Check the inlet seals of the gas train for leaks 4 Start up the burner see page 8 5 Check the outlet seals of the gas train for leaks Implementing final tests 1 Implement all tests in the order of the commissioning report 2 Record the actual values in the commissioning report on page 50 Please note The flue pipe must be sealed at the boiler adaptor Infiltrating air leads to false measure...

Page 25: ... flame relay is forcibly pulled up Fuel is released after t3 has expired t2 Safety time max 2 s At the end of t2 a flame signal needs to be at input 1 of the flame signal amplifier and must remain steady until a controlled shutdown otherwise the flame relay drops out the burner control unit triggers a fault shutdown and is locked in the fault position t4 Interval time stage IĂĆĂII approx 8 s t20 I...

Page 26: ...t 10 s press reset button B for at least 3 s read the flashing code of the fault lamp see fault table after every flashing code a break of approx 3 s reset i e press reset button B 0 5Ăto 3 s long H operational green signal lamp A illuminates constantly press reset button B 0 5 to 3 s long when a code flashes to reinstate system operation 5692Ă534ĂGB ...

Page 27: ...after 65 s 5 x flashing External light during pre purge or internal device fault 7 x flashing Flame tears off during operation 8 17 x flashing Free no fault code 18 x flashing The air pressure switch opens during pre purge or operation 19 x flashing Output contact fault Wiring fault External voltage across output terminals 20 x flashing Internal device fault During the fault cause diagnosis all co...

Page 28: ...ntrol unit Vitoair motor faulty Replace Vitoair motor Fuse in leak detector device blown Replace fuse Fault during leak test fault lamp illuminates Check gas pressure nipple of gas train for leaks Valves leaking replace gas train Fuse blown at plug in terminal block Replace fuse Leak detector device faulty Replace leak detector device Burner does not start demand lamp illuminates Gas flow pressure...

Page 29: ...y short circuit Burner motor starts but a fault 3Ă Dirty air pressure switch connection Clean connection shutdown occurs during pre purge phase 3Ă Air pressure switch incorrectly set or faulty Adjust or replace air pressure switch see page 18 3Ă Air pressure too low Clean impeller see page 19 Burner starts up but no flame is 2Ă Ignition electrode poorly adjusted Adjust correctly see page 21 formed...

Page 30: ...p and ignition is OK but burner enters a fault 2Ă Start gas volume poorly adjusted Adjust start gas volume or opening characteristics see page 14 state after expiry of safety time 2Ă Ionisation current too low 4 µA Check position of ionisation electrode see page 21 Burner starts up and ignition is OK but burner enters a fault state after expiry of safety time 2Ă While gas train is opened voltage b...

Page 31: ...urner settings flame is already 7Ă Faulty earthing Check earthing already established 7Ă Burner control unit faulty Replace burner control unit Flame tears off during 7Ă Mixer assembly contaminated Clean mixer assembly g operation 7Ă Incorrect air damper position Correct switching cam setting on air damper motor see page 9 Combustion errors through pulsation Gas throughput too high Set gas through...

Page 32: ...r is very sooty Too little or too much air Correct setting Check boiler room ventilation CO2 content too low or O2 content too high Incorrect setting Adjust nozzle pressure in accordance with type of gas used Correct air damper setting Infiltrating air Seal flue pipe at boiler adaptor Re tighten boiler door screws and those on flue outlet cover Flue gas temperature too Gas throughput too high Matc...

Page 33: ...33 Troubleshooting 5692Ă534ĂGB ...

Page 34: ...ner E Actuating motor F Air pressure switch G Fan motor H Reset button K Burner control unit L Ignition transformer M Ball shut off valve N Flange O Air regulating damper P Burner housing R Fan impeller S Inlet air silencer T Blast tube U Ignition electrode V Sensor plate W Ionisation electrode X Mixer assembly 5692Ă534ĂGB ...

Page 35: ...35 Component summary Component summary cont 5692Ă534ĂGB ...

Page 36: ...36 Component summary 5692Ă534ĂGB ...

Page 37: ...lug in terminals on burner control unit A Start command B B Interval for flame to be established C Burner operating position achieved C D Burner operation D Controlled switch off St0 Actuator switching position Stage 0 St1 Actuator switching position Stage 1 St2 Actuator switching position Stage 2 Colour coding to DIN IECĂ757 BK black BK black cable with imprint BN brown BU blue GNYE green yellow ...

Page 38: ...ram cont 5692Ă534ĂGB Control Control unit components Actuator Actuator Control burner stage 2 hours run counter stage 2 external Fuel valve 2 Burner motor Control demand stage 1 stage 2 Control demand Actuator Fuel valve 2 Burner motor slow slow unit components ...

Page 39: ... 5692Ă534ĂGB Jumper up to from Burner control unit Gas governor Fuel valve 1 Hours run counter stage 1 external Air pressure switch Ignition transformer Flame monitor External fault message Flame monitor Ignition transformer Air pressure switch Fuel valve 1 Gas governor ...

Page 40: ...nd plate with compensating ring 041 Profile stud 044 Burner hood latches 048 Ionisation test lead 057 Connector 058 Adjusting screw 060 Quick action fastener 066 Dungs gas governor lead with plug in connectorĂaCÖ 067 Dungs solenoid valve lead with plug in connectorĂaXL 068 Strapping plugĂaXH 069 Strapping plugĂaYA 073 Earth cable 074 Electrode holder 085 Silencer hood 099 Ignition cable 103 Burner...

Page 41: ...heese head screw MĂ6Ă Ă16 3b Cheese head screw MĂ6Ă Ă10 3c Serrated washer AĂ6 4 3d Cable grommet 3e Double pipe clip 12Ă Ă12 mm 3f Cheese head screw MĂ4Ă Ă8 3g Serrated washer AĂ4 3 3h Cheese head screw MĂ6Ă Ă10 3i Nut MĂ5 3j Countersunk screw MĂ4Ă Ă25 3k Spring washer AĂ5 3l Oval head screw with collar MĂ6Ă Ă3 DINĂ923 3m Test nipple 3o Dowel pin 3p Washer IT 3r Spacer bolt MĂ8Ă Ă60 SWĂ12 3s Pipe...

Page 42: ...42 Parts list Parts list cont 5692Ă534ĂGB ...

Page 43: ...43 Parts list Parts list cont 5692Ă534ĂGB ...

Page 44: ...44 Parts list Parts list cont 5692Ă534ĂGB ...

Page 45: ...45 Parts list Parts list cont 5692Ă534ĂGB ...

Page 46: ...kW 59 98 65 109 82 136 91 152 98 163 107 179 124 207 137 228 Type of burner VGĂIIIĆ2 VGĂIIIĆ3 VGĂIIIĆ4 VGĂIIIĆ5 Product ID CEĆ0085 AQ 0222 Voltage V 230 Frequency Hz 50 Power consumption W 200 250 340 390 Motor speed rpm 2800 Version Two stage Gas supply pressure mbar 20 Gas connection GĂ cyl Ăfem Ăāthread 1 1 1Corresponds to the boiler rated thermal load 5692Ă534ĂGB ...

Page 47: ...as LL 12 40 44 60 20 0 Gas Gas Rated boiler output in kW Gas Gas Rated boiler output in kW type group 90 ć 100 125 ć 140 150 ć 165 190 ć 210 Boiler output in kW 90 100 125 140 150 165 190 210 Natural E Nozzle pressure mbar 1 Stage 1 Stage 2 3 5 9 2 3 8 10 0 2 1 5 3 2 2 5 9 2 4 6 2 2 6 6 8 3 7 9 2 4 1 10 0 Natural gas LL Nozzle pressure mbar 1 Stage 1 Stage 2 4 2 11 0 4 8 12 4 2 4 6 3 2 7 7 0 2 9 7...

Page 48: ...al net calorific value HuB Gas type Gas group Operational net calorific value HUB Gas type Gas group Operational net calorific value HUB kWh m3 MJ m3 Natural gas E 9 45 34 02 Natural gas LL 8 13 29 25 Gas Gas Rated boiler output Gas Gas Rated boiler output type group 90 to 100 kW 125 to 140 kW yp g p Boiler output 90 kW 100 kW 125 kW 140 kW m3 h l min m3 h l min m3 h l min m3 h l min Natural E 10 ...

Page 49: ...ut Gas Gas Rated boiler output type group 150 to 165 kW 190 to 210 kW yp g p Boiler output 150 kW 165 kW 190 kW 210 kW m3 h l min m3 h l min m3 h l min m3 h l min Natural E 17 3 289 19 0 318 21 9 366 24 2 405 Natural gas LL 20 1 336 22 1 370 25 4 424 28 1 470 Please note Partial load gas throughput equals 60Ă of full load gas throughput 5692Ă534ĂGB ...

Page 50: ... for natural gas E mbar 20ĂĆĂ25 mbar j for natural gas LL mbar 20ĂĆĂ25 mbar tick gas type Nozzle pressure Stage 1 located mbar p set mbar see table on Stage 2 located mbar see table on page 47 set mbar Ionisation current located mA min 5 µA set mA min 5 µA Carbon dioxide CO Stage 1 located by vol content CO2 set by vol Stage 2 located by vol set by vol 5692Ă534ĂGB ...

Page 51: ...51 Appendix Maint service Maint service Maint service Maint service 5692Ă534ĂGB ...

Page 52: ...vol yg O2 set by vol Stage 2 located by vol set by vol Carbon monoxide content CO located ppm content CO relative to 0Ă oxygen content set ppm Gross flue gas Stage 1 located ºĂC g temperature set ºĂC Stage 2 located ºĂC set ºĂC Flue gas loss Stage 1 located g set Stage 2 located set Draught at the located hPa g boiler end set hPa 5692Ă534ĂGB ...

Page 53: ...53 Appendix Maint service Maint service Maint service Maint service 5692Ă534ĂGB ...

Page 54: ...t up Output located kW set kW Switch cam i i h i ST 1 located º position at the air damper actuator set º damper actuator ST 2 located º set º MV located º set º Static burner Stage 1 located mbar pressure set mbar Stage 2 located mbar set mbar Mixer assembly located ring no y set ring no 5692Ă534ĂGB ...

Page 55: ...55 Appendix Maint service Maint service Maint service Maint service 5692Ă534ĂGB ...

Page 56: ... j for natural gas E mbar 20ĂĆĂ25 mbar j for natural gas LL mbar 20ĂĆĂ25 mbar tick gas type Nozzle pressure Stage 1 located mbar p set mbar see table on Stage 2 located mbar see table on page 47 set mbar Ionisation current located mA min 5µA set mA min 5µA Carbon dioxide CO Stage 1 located by vol content CO2 set by vol Stage 2 located by vol set by vol 5692Ă534ĂGB ...

Page 57: ...57 Appendix Maint service Maint service Maint service Maint service 5692Ă534ĂGB ...

Page 58: ...l yg O2 set by vol Stage 2 located by vol set by vol Carbon monoxide content CO located ppm content CO relative to 0Ă oxygen content set ppm Gross flue gas Stage 1 located ºĂC g temperature set ºĂC Stage 2 located ºĂC set ºĂC Flue gas loss Stage 1 located g set Stage 2 located set Draught at the located hPa g boiler end set hPa 5692Ă534ĂGB ...

Page 59: ...59 Appendix Maint service Maint service Maint service Maint service 5692Ă534ĂGB ...

Page 60: ...ice Output located kW set kW Switch cam i i h i ST 1 located º position at the air damper actuator set º damper actuator ST 2 located º set º MV located º set º Static burner Stage 1 located mbar pressure set mbar Stage 2 located mbar set mbar Mixer assembly located ring no y set ring no 5692Ă534ĂGB ...

Page 61: ...61 Appendix Maint service Maint service Maint service Maint service 5692Ă534ĂGB ...

Page 62: ... j for natural gas E mbar 20ĂĆĂ25 mbar j for natural gas LL mbar 20ĂĆĂ25 mbar tick gas type Nozzle pressure Stage 1 located mbar p set mbar see table on Stage 2 located mbar see table on page 47 set mbar Ionisation current located mA min 5µA set mA min 5µA Carbon dioxide CO Stage 1 located by vol content CO2 set by vol Stage 2 located by vol set by vol 5692Ă534ĂGB ...

Page 63: ...63 Appendix Maint service Maint service Maint service Maint service 5692Ă534ĂGB ...

Page 64: ...l yg O2 set by vol Stage 2 located by vol set by vol Carbon monoxide content CO located ppm content CO relative to 0Ă oxygen content set ppm Gross flue gas Stage 1 located ºĂC g temperature set ºĂC Stage 2 located ºĂC set ºĂC Flue gas loss Stage 1 located g set Stage 2 located set Draught at the located hPa g boiler end set hPa 5692Ă534ĂGB ...

Page 65: ...65 Appendix Maint service Maint service Maint service Maint service 5692Ă534ĂGB ...

Page 66: ...ice Output located kW set kW Switch cam i i h i ST 1 located º position at the air damper actuator set º damper actuator ST 2 located º set º MV located º set º Static burner Stage 1 located mbar pressure set mbar Stage 2 located mbar set mbar Mixer assembly located ring no y set ring no 5692Ă534ĂGB ...

Page 67: ...67 Appendix Maint service Maint service Maint service Maint service 5692Ă534ĂGB ...

Page 68: ...er insert of gas train checking make Dungs ă23 Final test implementation ă24 Function sequence burner control unit ă25 Function test without gas supply commissioning ă7 Further details regarding the individual steps ă6 G Gas connections leak testing ă24 Gas type checking ă10 I Ignition and ionisation electrodes checking ă21 Ionisation current checking ă17 L Leak test commissioning ă6 Leak testing ...

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Viessmann Vitoflame 100, Service Instructions Manual

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