Viessmann Vitoflame 100 Service Instructions Manual
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Viessmann Vitoflame 100 Service Instructions Manual

Pressure−jet gas burner. for vitoplex 100, 200 and 300. rated output 80 to 225 kw. for vitorond 200. rated output 125 to 195 kw
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Service instructions
for heating contractors
Vitoflame 100
Pressure−jet gas burner (type VG III)
H for Vitoplex 100, 200 and 300
Rated output 80 to 225 kW
H for Vitorond 200
Rated output 125 to 195 kW
For applicability, see the last page.
VITOFLAME 100
5692 622 GB
7/2005
Please keep safe

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Summary of Contents for Viessmann Vitoflame 100

  • Page 1 Service instructions for heating contractors Vitoflame 100 Pressure−jet gas burner (type VG III) H for Vitoplex 100, 200 and 300 Rated output 80 to 225 kW H for Vitorond 200 Rated output 125 to 195 kW For applicability, see the last page.

  • Page 2: General Information

    General information Safety instructions ¨ Follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained Regulations ¨ Danger Observe the following when working This symbol warns against on this system H all legal requirements regarding personal injuries. the prevention of accidents, H all legal instructions regarding Please note...
  • Page 3 For replacements, use only original spare parts from Viessmann or those which are approved by Viessmann.

  • Page 4: Table Of Contents

    Index Index Page General information Safety instructions ........................Initial start−up, inspection and maintenance Steps initial start−up, inspection and maintenance .

  • Page 5: Initial Start−Up, Inspection And Maintenance

    Initial start−up, inspection and maintenance Steps Initial start−up, inspection and maintenance For further instructions on individual steps, see pages indicated. Commissioning steps Inspection steps Maintenance steps Page 1. Preparing for commissioning ..........2.

  • Page 6: Further Details Regarding The Individual Steps

    Initial start−up, inspection and maintenance Further details regarding the individual steps Preparing for commissioning Soundness test 1. Close the gas shut−off valve. 2. Release the screw in test port A, but do not remove. 3. Connect the soundness test set at test port A.
  • Page 7 Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Function test without gas supply H Check the function sequence (see The burner control unit program program sequence on page 25). sequence is started with the H Switch ON the mains isolator following functions: H The burner motor starts and the (outside the installation room).

  • Page 8: Starting The Heating System

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) To obtain optimum combustion values, it is essential to adjust the burner with the boiler at operating temperature (min. 60 ºC). Also carry out measurements at base load. Starting the heating system Service instructions Boiler control unit...
  • Page 9 Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the adjustment of the air damper servomotor The switch cams are located under the cover of the air damper servomotor. A scale ring is positioned adjacent to each switch cam, which enables the selected positioning angle of the air damper to be checked.

  • Page 10: Checking The Static And The Supply Pressure

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the static and the supply pressure Check the gas type with your local gas supplier. The burner is factory−adjusted for natural gas E. Adjust the nozzle pressure for operation with natural gas LL according to the table on pages 44 to 46.
  • Page 11 Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Supply pressure 7. Start up the burner. Note Start up the burner at stage 2; for this set the emissions test switch at the control unit to ON. Service switch B must be in position II.

  • Page 12: Checking The Nozzle Pressure

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the nozzle pressure 1. Release the screw in test port A, but do not remove. 2. Connect the U−shaped pressure gauge to the test port A. 3. Open the gas shut−off valve. 4.
  • Page 13 Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Note Never turn the pressure regulator outside its setting range. Turn set screw F only as long as the nozzle pressure noticeably changes. Main volume butterfly D should be turned fully to "+".

  • Page 14: Adjusting The Volume Of Starting Gas

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Adjusting the volume of starting gas The opening characteristics of the gas solenoid valve has been matched to the boiler and been preset at the factory. Generally you never need to change this setting; continue with point 3. 1.

  • Page 15: Adjusting The Air Volume

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) 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. Fine adjusting stage 2 Regulate the air volume at set screw A to adjust the mixing...
  • Page 16 Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Fine adjusting stage 1 1. Bring service switch B into position II (automatic mode) and close the cover flap. 2. Change the burner to stage 1 by pulling plug lÖ off. 3.

  • Page 17: Checking The Ionisation Current

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the ionisation current 1. Switch system ON/OFF switch OFF . 2. Separate the plug connection of the ionisation current cable (red ). Note Test cable no. 1 is required when checking with Testomatik−Gas.

  • Page 18: Checking The Air Pressure Switch

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the air pressure switch The air pressure switch is factory−set to the relevant switching point, in other words, an adjustment is generally not required. However, should an adjustment nevertheless be required, check the air pressure switch setting and correct, as required, by turning black scale ring B in accordance with the following details.

  • Page 19: Shutting Down The Heating System

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Shutting down the heating system 2. Pull plug fA and lÖ off the burner. 1. Switch OFF/isolate the mains isolator, the system ON/OFF switch or the power supply and safeguard 3.
  • Page 20 Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Clean the gas outlet holes in the sensor plate (if necessary) 1. Pull the leads off electrodes H and G. 2. Release electrode retainers K and A and remove the ignition and ionisation electrodes.

  • Page 21: Checking The Ignition And Ionisation Electrodes

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking the ignition and ionisation electrodes 80 to 105 kW 120 to 225 kW A Earth electrode G Slightly turn the ionisation B Sensor plate electrode in accordance with the C Ionisation electrode gap towards the earth electrode D End plate...

  • Page 22: Checking Gas Combination Valves (2) For Soundness

    5 minutes by more than 1 mbar ³ continue with point 7. Otherwise, the system leaks in that case, return the gas combination valve to Viessmann Werke for tests. 7. After the test, close both test connectors by tightening the respective screws.

  • Page 23: Checking Gas Combination Valve Filter Insert (Make: Dungs)

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking gas combination valve filter insert (make: Dungs) 1. Close the gas shut−off valve. 2. Unscrew filter lid D. 3. Remove filter element B. 4. If required, clean or replace the filter element.

  • Page 24: Checking All Gas Connections For Soundness

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking all gas connections for soundness 1. Insert new gaskets in all gas 4. Start the burner fittings that have been opened. (see page 8). 2. Open the gas shut−off valve. 5.

  • Page 25: Burner Control Unit

    Initial start−up, inspection and maintenance Burner control unit Program sequence during commissioning 1 qW Plug−in terminals on the Start command B B’ Interval before the flame has burner control unit E Fuel valve 2 built G Gas pressure limiter Burner operating position H Fuel valve 1 reached K Air pressure switch...
  • Page 26 Initial start−up, inspection and maintenance Burner control unit (cont.) Indicators H in a fault state, red fault indicator C illuminates constantly Fault diagnosis: wait at least 10 s press reset button B for at least 3 s observe the flashing code of the fault indicator (see fault code table on page 27) after every flashing code, a break...

  • Page 27: Diagnostics

    Troubleshooting Diagnostics Fault code table (red fault indicator) Fault Possible cause 2 × flashes The flame is not established at the end of the safety period 3 × flashes The air pressure switch does not close during pre−purging 4 × flashes Air pressure switch does not open or external light during burner start (after 65 s) 5 ×...
  • Page 28 Troubleshooting Diagnostics (cont.) Fault/ Flash− Cause Measure characteristics code Burner does No voltage present Check the fuses in the control not start; unit and the connection panel; demand check the electrical indicator does connections, the position of the not illuminate ON/OFF switch at the control unit and at the mains isolator High limit safety...
  • Page 29 Troubleshooting Diagnostics (cont.) Fault/ Flash− Cause Measure characteristics code 4 × Air pressure limiter Check the setting of the air Burner does pressure switch; replace the not start and enters fault switch, if required state after 4 × Earth conn. at Remedy short circuit approx.
  • Page 30 Troubleshooting Diagnostics (cont.) Fault/ Flash− Cause Measure characteristics code 2 × Start gas volume Adjust start gas volume or Burner starts poorly adjusted opening characteristics (see and ignition is page 14) OK, but the burner enters 2 × Ionisation current Check the position of the a fault state too low (<...
  • Page 31 Troubleshooting Diagnostics (cont.) Fault/ Flash− Cause Measure characteristics code 7 × Mixer assembly Clean mixer assembly Flame tears contaminated off during operation 7 × Air damper Correct the switch cam incorrectly adjustment at the air damper positioned motor (see page 9) Gas throughput too Adjust the gas throughput in Combustion...

  • Page 32: Component Overview

    Component overview Component overview A Gas combination valve M Ball shut−off valve B Service switch N Flange O Air control damper for burner adjustment C Hood adaptor P Burner housing D Quick−acting closure R Impeller E Servomotor S Inlet air silencer F Air pressure switch T Blast tube G Fan motor...
  • Page 33 Component overview Component overview (cont.)

  • Page 34: Connection And Wiring Diagram

    Connection and wiring diagram Connection and wiring diagram Link 6.3A (slow) (slow)
  • Page 35 Connection and wiring diagram Connection and wiring diagram (cont.) Note This wiring diagram only applies in conjunction with Viessmann products. A Control unit components Burner plug at the control B Burner control unit unit 90 D Internal connection inside (program sequence see page 25) plug−in connector lÖ...

  • Page 36: Parts List

    Parts list Parts list When ordering spare parts 067 Cable for solenoid valve, make Quote the type and serial no. (see Dungs, with plug−in connector aXL type plate) and the item no. of the 068 Strapping plug aXH required part (as per this parts list). 069 Strapping plug aYA Obtain standard parts from your local supplier.
  • Page 37 Parts list Parts list (cont.) 003 Small parts comprising: 3a Cheese−head screw M 6 × 16 3b Cheese−head screw M 6 × 10 3c Lock washer A 6.4 3d Cable clamp 3e Twin clip 12 × 12 mm Oval−head screw M 4 × 8 3g Lock washer A 4.3 3h Oval−head screw M 6 ×...
  • Page 38 Parts list Parts list (cont.)
  • Page 39 Parts list Parts list (cont.) 3D 008...
  • Page 40 Parts list Parts list (cont.)
  • Page 41 Parts list Parts list (cont.)

  • Page 42: Specification

    Appendix Specification In conjunction with Vitoplex 100 and 300 Rated boiler output Burner output 52/87 69/115 85/142 112/186 147/245 Stage 1/2 Burner type VG III VG III VG III VG III VG III 1−CH 2−CH 3−CH 4−CH 5−CH Product ID Product ID CE−0085 AQ 0222 CE−0085 AQ 0222...
  • Page 43 Appendix Specification (cont.) In conjunction with Vitoplex 200 Rated boiler output Burner output 59/98 78/130 98/163 130/217 Stage 1/2 Burner type VG III VG III VG III VG III 2−CH 3−CH 4−CH 5−CH Product ID CE−0085 AQ 0222 Voltage Frequency Power consumption Motor speed 2 800...

  • Page 44: Standard Values For Burner Adjustment

    Appendix Standard values for burner adjustment Note Check that the service instructions are valid for the relevant burner (see notes on applicability, page 52 and serial no. on the burner type plate). In conjunction with Vitoplex 100 and 300 Nozzle pressure table and mixing assembly settings Rated boiler output Wobbe index Supply...
  • Page 45 Appendix Standard values for burner settings (cont.) In conjunction with Vitoplex 200 Nozzle pressure table and mixing assembly settings Rated boiler output Wobbe index Supply group press. kWh/m MJ/m mbar Nat. 15.00 54.00 20.0 Nozzle Stg. 1 gas E press. Stg.
  • Page 46 Appendix Standard values for burner settings (cont.) In conjunction with Vitorond 200 Nozzle pressure table and mixing assembly settings Wobbe index Supply Rated boiler output group press. kWh/m MJ/m mbar 125 kW 160 kW 195 kW Nat. 15.00 54.00 20.0 Nozzle Stg.

  • Page 47: Commissioning/Service Report

    Appendix Commissioning/service report Setting and test values Initial start−up Maintenance/ service Static pressure mbar Supply pressure (flow pressure) Tick gas type j for natural gas E mbar j for natural gas LL mbar Nozzle pressure H Stage 1 actual mbar mbar H Stage 2 actual...
  • Page 48 Appendix Commissioning/service report (cont.) Setting and test values Initial start−up Maintenance/ service Flue gas loss H Stage 1 actual H Stage 2 actual Draught (at the end of the boiler) actual Output actual Position of the switch cams at the air damper servomotor H ST 1 º...

  • Page 49: Keyword Index

    Appendix Keyword index Adjusting the air volume, 15 Implementing a final test, 24 Air damper servomotor (checking settings), 9 Applicability, 52 Mixer assembly settings, 44, 45, 46 Burner cleaning, 19 Nozzle pressure table, 44, 45, 46 Burner control unit, 25 Operating and service Checking all gas connections for documents, 24...

  • Page 52: Applicability

    7143269 1 00001 kkk and 7143270 1 00001 kkk Vitoplex 200 from serial no. 7188847 5 00001 kkk, 7188848 5 00001 kkk, 7188849 5 00001 kkk and 7188850 5 00001 kkk Viessmann Werke GmbH & Co KG D 35107 Allendorf Tel: +49 6452 70 0 Fax: +49 6452 70 27 80 www.viessmann.de...

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