Viessmann Vitoflame 100 Service Instructions For Contractors
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Viessmann Vitoflame 100 Service Instructions For Contractors

Viessmann Vitoflame 100 Service Instructions For Contractors

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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VIESMANN
Service instructions
for contractors
Vitoflame 100
Type VGIII
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
For applicability, see the last page
VITOFLAME 100
Please keep safe.
5692 678 GB
11/2006

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Summary of Contents for Viessmann Vitoflame 100

  • Page 1 VIESMANN Service instructions for contractors Vitoflame 100 Type VGIII 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 For applicability, see the last page VITOFLAME 100 Please keep safe.
  • Page 2 Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained the Code of Practice of relevant trade associations, Danger all current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury.
  • Page 3 Instal- charge static loads. ling non-authorised compo- nents and non-approved modifications/conversion can compromise safety and may invalidate our warranty. For replacements, use only ori- ginal spare parts from Viessmann or those which are approved by Viessmann.

  • Page 4: Table Of Contents

    Index Index Commissioning, inspection, maintenance Steps commissioning, inspection and maintenance ........Further details regarding the individual steps ..........Burner control unit Burner control unit LME 21................25 Troubleshooting Diagnosis ....................28 Component overview ................34 Connection and wiring diagram ............... 36 Parts list ....................
  • Page 5 Commissioning, inspection, maintenance Steps commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page 1. Commissioning preparations ......... . . 2.

  • Page 6: Commissioning, Inspection, Maintenance

    Commissioning, inspection, maintenance Further details regarding the individual steps Commissioning preparations 5. Wait approx. 5 minutes for the tem- perature to level out and then observe the display on the pres- sure gauge: The tested area is sound if, within a further 5 minutes, the displayed pressure does not drop by more than 1 mbar.

  • Page 7: Commissioning The Heating System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) The following program must now run The gas solenoid valve for stage 1 (see also program sequence on opens. page 25): The pressure inside the valves When there is a heat demand (control drops.

  • Page 8: Checking The Adjustment Of The Air Damper Servomotor

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Open the gas shut off valve. 3. Check the supply pressure (see page 10). 4. Switch ON the main isolator (out- side the installation room). 5. Switch ON system ON/OFF switch B at the control unit.

  • Page 9: Checking The Static And Supply Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) The switch cams are located under Never alter the setting of ST 0. the cover of the air damper servomo- ST1 Air damper position stage 1 tor. A scale ring is located adjacent to ST2 Air damper position stage 2 each switch cam, where the selected MV Solenoid valve stage 2...
  • Page 10 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Static pressure Supply pressure 1. Close the gas shut off valve. 2. Undo the screw inside test connec- 1. Start the burner. tor A, but do not remove. Note 3. Connect the U shaped pressure Start the burner at stage 2;...
  • Page 11 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Check the supply pressure (flow 3. Record the actual value in the ser- pressure), see the following table. vice report (see from page 44). Note 4. Close the gas shut off valve. The supply pressure (flow pres- sure) should be between 20 and 5.

  • Page 12: Checking The Nozzle Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the nozzle pressure 5. Check the nozzle pressure in accordance with the Wobbe index and the output in the nozzle pres- sure table from page 48. Note During the adjustment, also check the gas throughput by means of a volumetric test.

  • Page 13: Adjusting The Volume Of Starting Gas

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Setting stage 2 Start up the burner at stage 2; for this set the emissions test switch at the control unit to ON. Service switch must be in position II. 1.

  • Page 14: Adjusting The Air Volume

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Adjust the quick action (opening characteristics) with protective cap G positioned in reverse. Note The quick action is set at the fac- tory fully to "+". Ionisation current min. 8 A. Checking the ionisation current, see page 16.
  • Page 15 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Readjusting stage 2 Regulate the air volume at set screw Readjusting stage 1 A to adjust the mixing assembly: Turning anti clockwise larger cross section more air, Turning clockwise smaller cross section less air.

  • Page 16: Checking The Ionisation Current

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Change service switch B to posi- 4. Change the air volume by turning tion II (automatic mode) and close the adjusting screw at switch cam the cover flap. ST1 (see Fig. on page 9): Turning clockwise more air, 2.

  • Page 17: Checking The Air Pressure Switch

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Press the reset button at the burner 7. Record the actual value in the ser- control unit and switch OFF the vice report (see from page 44). system ON/OFF switch. 8.

  • Page 18: Shutting Down The Heating System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) In conjunction with the Vitoplex 200 Rated output Air pressure switch setting mbar 4.5 5.0 3.8 4.3 3.8 4.3 5.0 5.5 In conjunction with the Vitorond 200 Rated output Air pressure switch setting mbar 3.8 4.3 4.9 5.4...

  • Page 19: Cleaning The Gas Outlet Holes In The Sensor Plate (If Required)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Set the burner into its maintenance 3. Check the gas outlet holes in the position. sensor plate for contamination, if required (see page 19). 2. Clean casing C, flame tube A, mixer assembly B (together with 4.

  • Page 20: Checking The Ignition And Ionisation Electrodes

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 5. Remove and clean sensor plate Note E, spring washer D and cover Ensure the correct orientation of the C from the mixer assembly B. gas outlet holes in the end panel (see page 20).
  • Page 21 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 120 to 225 kW A Earth electrode G Slightly turn the ionisation elec- B Sensor plate trode towards the earth electrode C Ionisation electrode in accordance with the actual gap D Cover H Point the tip of the ignition elec- E Ignition electrode...

  • Page 22: Checking Both Valves Of The Combination Valve For Soundness

    1 mbar continue with point 7. Otherwise, the system leaks. In that case, return the combination valve to Viessmann Werke for tests. Note 7. After the test, close both test con- Only implement a function test on...

  • Page 23: Checking The Filter Insert In The Combination Valve Made By Dungs

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the filter insert in the combination valve made by Dungs 1. Close the gas shut off valve. 2. Unscrew filter lid D. 3. Pull out filter insert B. 4. If necessary, clean or replace the filter mats.

  • Page 24: Operating And Service Documents

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Operating and service documents 1. Complete and detach the customer 2. File all parts lists, operating and registration card: service instructions in the folder Hand the system user this part and hand this over to the system for safekeeping.

  • Page 25: Burner Control Unit

    Burner control unit Burner control unit LME 21..Program sequence during commissioning Start command Gas pressure switch B B' Interval before the flame has Electronic ignition built Burner motor Burner operation Fuel valve 1 Controlled shutdown Fuel valve 2 1 qW Plug in terminals on the burn- Air pressure switch er control unit Flame monitoring...
  • Page 26 Burner control unit Burner control unit LME 21..(cont.) 1. Press reset button B for approx. 5 s (longer than 3 s). 2. A flashing code will then be dis- played. The number of flashing sig- nals in a sequence will indicate the type of fault.

  • Page 27: Burner Control Unit Lme 21

    Burner control unit Burner control unit LME 21..(cont.) Burner fault sequence diagram...
  • Page 28 Troubleshooting Diagnosis Fault Flash- Cause Measures code Burner does not No voltage Check the fuses in the start; demand indi- control unit and the cator does not illu- connection panel; minate check the electrical connections, the posi- tion of the ON/OFF switch at the control unit and at the main isolator...
  • Page 29 Troubleshooting Diagnosis (cont.) Fault Flash- Cause Measures code Burner does not Gas supply pressure Check the gas supply start; demand indi- too low; gas pressure pressure. The gas flow cator illuminates switch switches OFF pressure should be at least 20 mbar. Clean gas filter, if required.

  • Page 30: Troubleshooting Diagnosis

    Troubleshooting Diagnosis (cont.) Fault Flash- Cause Measures code Burner starts, but 2 × Ignition electrode in- Adjust correctly (see no flame builds correctly adjusted page 20) 2 × Ignition electrode Clean ignition elec- damp and contami- trode nated 2 × Insulation body of the Replace ignition elec- ignition electrode...
  • Page 31 Troubleshooting Diagnosis (cont.) Fault Flash- Cause Measures code Burner starts, Lack of gas Clean or replace gas flame builds, but filter. Check the gas the system shuts pressure switch set- down after a short tings. Check the gas while (not a fault supply pressure.
  • Page 32 Troubleshooting Diagnosis (cont.) Fault Flash- Cause Measures code Combustion fault 7 × Excessive gas Adjust the gas through- through pulsation throughput put in accordance with rated boiler output 7 × Mixer assembly (stage Change the mixer as- 2) incorrectly adjusted sembly adjustment (see from page 48) 7 ×...
  • Page 33 Troubleshooting Diagnosis (cont.) Fault Flash- Cause Measures code Flue gas tempera- Gas throughput too low Match gas throughput ture too low to the rated boiler out-...

  • Page 34: Component Overview

    Component overview Component overview A Combination valve F Air pressure switch B Service switch for burner adjust- G Fan motor ment H Reset button C Hood adaptor K Burner control unit D Quick acting closure L Electronic ignition E Servomotor M Ball shut off valve...
  • Page 35 Component overview Component overview (cont.) C Hood adaptor R Impeller F Air pressure switch S Inlet air silencer G Fan motor T Blast tube H Reset button U Ignition electrode N Flange V Sensor plate O Air regulating valve W Ionisation electrode P Burner housing X Mixer assembly...

  • Page 36: Connection And Wiring Diagram

    Connection and wiring diagram Connection and wiring diagram...
  • Page 37 (cont.) Note A Burner control unit (for program This wiring diagram only applies in sequence, see page 25) conjunction with Viessmann products. B External fault indicator C Gas pressure switch Burner plug at the control unit D Electronic ignition External fuse...

  • Page 38: Parts List

    Parts list Parts list When ordering spare parts: 028 Sensor plate Quote the part and serial no. (see 031 Fuse type plate) and the item no. of the 032 Ignition transformer required part (as per this parts list). 033 Burner control unit Obtain standard parts from your local 034 Connection panel supplier.
  • Page 39 Parts list Parts list (cont.) Wearing parts Parts not shown 029 Ionisation electrode 051 Allen key SW 5 030 Ignition electrode 052 Burner casing pack 037 Filter mat 053 Installation instructions 072 Earth electrode 054 Operating instructions 055 Service instructions A Type plate...
  • Page 40 Parts list Parts list (cont.)
  • Page 41 Parts list Parts list (cont.)
  • Page 42 Parts list Parts list (cont.)
  • Page 43 Parts list Parts list (cont.)

  • Page 44: Report

    Report Report Setting and test values Commission- Service Static pressure mbar Supply pressure (flow pres- sure) Tick gas type = for nat. gas E mbar = for nat. gas LL mbar Nozzle pressure Stage 1 actual mbar mbar Stage 2 actual mbar mbar...
  • Page 45 Report Report (cont.) Setting and test values Commission- Service Draught (at the actual back of the boil- Output actual Position of the switch cams at the air damper servomotor actual ° ° actual ° ° actual ° ° Static burner pressure Stage 1 actual mbar...

  • Page 46: Specification

    Specification Specification In conjunction with the Vitoplex 100 and the Vitoplex 300 Rated boiler output Burner output stage 52/87 69/115 85/142 112/186 147/ Burner type VG III VG III VG III VG III VG III 1 CH 2 CH 3 CH 4 CH 5 CH Product ID...

  • Page 47: Standard Values For Burner Settings

    Specification Specification (cont.) Rated boiler output Voltage Frequency Power consumption Motor speed 2800 Version Two stage Gas supply pressure mbar Gas connection R (cyl. 1" 1" 1¼" fem. thread) Standard values for burner settings Note Check that the service instructions are valid for the burner concerned (see notes on applicability, page 56 and the serial no.
  • Page 48 Specification Standard values for burner settings (cont.) Wobbe Supply Rated boiler output grou- index Wo pres- sure kWh/ mbar Gas throughput subject to the net calorific value during operation (H Operational net Rated boiler output group calorific value kWh/m MJ/m Natural 9.45 34.02...
  • Page 49 Specification Standard values for burner settings (cont.) In conjunction with the Vitoplex 200 Nozzle pressure table and mixing assembly settings Wobbe Supply Rated boiler output group index Wo pres- sure kWh/ mbar Natural 15.00 54.00 20.0 Nozzle Stage gas E pres- sure Stage...
  • Page 50 Specification Standard values for burner settings (cont.) Operational net Rated boiler output group calorific value kWh/m MJ/m 90 kW Natural 8.13 29.25 12.0 16.0 20.0 26.7 gas LL throu- ghput litres/ Note Partial load gas throughput equals 60 % of the full load gas throughput. In conjunction with the Vitorond 200 Nozzle pressure table and mixing assembly settings Wobbe...
  • Page 51 Specification Standard values for burner settings (cont.) Gas throughput subject to the net calorific value during operation (H Operational net Rated boiler output group calorific value kWh/m MJ/m 125 kW 160 kW 195 kW Natural 9.45 34.02 14.4 18.4 22.4 gas E through- litres/min...

  • Page 52: Keyword Index

    Keyword index Keyword index Adjusting the air volume Implementing final tests ....... Adjusting the volume of starting gas .
  • Page 56 In conjunction with the Vitoplex 200 Burner serial no. 7188847 5 00001 7188848 5 00001 7188849 5 00001 7188850 5 00001 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB...

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