Viessmann Vitoflame 100 Betriebsanleitung

Service instructions

for heating engineers

Vitoflame100

Pressure−jet oil burner (typeVEIII)

Hfor Vitoplex100, 200 and 300

Rated output 80 to 225kW

Hfor Vitorond200

Rated output 125 to 195kW

For applicability, see the last page.

VITOFLAME 100

5692623GB9/2005 Please keep safe

General information

Safety instructions

¨Please follow these safety instructions 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

environmental pollution.

Note

Details identified by the word "Note"

contain additional information.

Target group

These instructions are exclusively

designed for qualified personnel.

HWork on gas equipment must only

be carried out by a registered gas

fitter.

HElectrical work must only be

carried out by a qualified

electrician.

HThe system must be

commissioned by the system

installer or a qualified person

authorised by the installer.

Regulations

Observe the following when working

on this system

Hall legal instructions regarding the

prevention of accidents,

Hall legal instructions regarding

environmental protection,

Hregulations issued by professional

bodies,

Hall current safety regulations as

defined by DIN, EN, DVGW, TRGI,

TRF, VDE and all locally applicable

standards.

If you smell gas

¨Danger

Escaping gas can lead to

explosions which may lead to

serious injury.

HDo not smoke! Prevent

naked flames and sparks.

Never switch on electrical

lights or equipment.

HClose the gas shut−off valve.

HOpen windows and doors.

HRemove all people from the

danger zone.

HNotify your gas and

electricity supplier from

outside the building.

HShut off the electricity supply

to the building from a safe

place (outside the building).

5692623GB

General information

Safety instructions (cont.)

If you smell flue gas

¨Danger

Flue gas can lead to

life−threatening poisoning.

HShut down the heating

system.

HVentilate the boiler room.

HClose the gas shut−off valve.

Working on the heating system

HIsolate the system from the power

supply and check that it is no

longer ’live’, e.g. by removing a

separate fuse or by means of a

mains isolator.

HSafeguard the system against

unauthorised reconnection.

HWhen using gas as fuel, also close

the main gas shut−off valve and

safeguard against unauthorised

reopening.

Repair work

!Please note

Repairing components which

fulfil a safety function can

compromise 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

compromise its function.

Installing non−authorised

components and non−approved

modifications or conversions

can compromise safety and

may invalidate our warranty.

For replacements, use only

original spare parts from or

those approved by Viessmann.

5692623GB

Capacity

Index

Page

General information

Safety instructions 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial start−up, inspection and maintenance

StepsInitial start−up, inspection and maintenance 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Further details regarding the individual steps 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Burner control unit 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting

Diagnostics 19

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Components overview22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection and wiring diagrams24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HFlame monitoring through photo resistance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HFlame monitoring through light flicker detector 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts list27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix

Specification 35

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard burner settings 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning/service report 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Keyword index 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicability 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5692623GB

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

C I M 1. Starting the heating system 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I M 2. Checking the adjustment of the air damper servomotor 7

C M 3. Adjusting the oil pressure and checking the vacuum 8

C M 4. Adjusting the air volume 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C M 5. Checking the burner

(record values in the service report from page41)

I M 6. Cleaning and checking the flame monitor 12. . . . . . . . . . . . . . . . . . . . . .

I M 7. Shutting down the heating system

I M 8. Checking the tightness of electrical connections

M9. Cleaning the burner 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 10. Checking the impeller fixings

I M 11. Checking the flame tube fixings

M12. Replacing the nozzle 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 13. Checking and adjusting the ignition electrodes 15. . . . . . . . . . .

M14. Installing the burner lid on the burner housing

M15. Cleaning and replacing the oil pump filter, if required 16. .

M16. Replacing pre−filter elements

I M 17. Starting the heating system

I M 18. Checking the oil pipes and connections for leaks

M19. Checking the burner again and entering the

actual values into the service report

C20. Operating and service documents 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5692623GB

Initial start−up, inspection and maintenance

Further details regarding the individual steps

To obtain optimum combustion values, the burner must be adjusted with the

boiler heated to operating temperature (min. 60ºC).

Also carry out measurements at base load.

Starting the heating system

Boiler control unit service

instructions

1. Check the heating system pressure

and the oil level in the tank.

2. Open the shut−off valves in the oil

supply 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 switch

(outside of the boiler room).

5. Switch ON the system ON/OFF

switchBat the control unit.

If fault indicator lampAon the

control unit illuminates, press

reset buttonCon the burner.

5692623GB

Initial start−up, inspection and maintenance

Further details regarding the individual steps (cont.)

Checking the adjustment of the air damper servomotor

The burner is equipped with an air

damper servomotor with adjustable

switch cams used to position the air

damper plus a solenoid valve

control.

During a controlled shutdown, the

burner air damper moves to the

"closed" position, which reduces

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

function:

ST0 Air damper closed (0º)

Never alter the factory

settings of ST0.

ST1 Air damper position stage1

ST2 Air damper position stage2

MV Solenoid valve stage2

The switch cams for stage1 and 2

are set at the factory.

For factory setting values, see

page38.

The switch cams are adjusted via the

slotted screws in the cams.

5692623GB

ST1 MV ST2 STO

90 10305070

120

90 10

5070

120

90 10305070

120

90 10

5070

120

Initial start−up, inspection and maintenance

Further details regarding the individual steps (cont.)

Adjusting the oil pressure and checking the vacuum

The oil pressure is preset at the factory according to the oil throughput.

Readjust the oil pressure, if required.

1. Switch OFF the mains isolator and

safeguard against unauthorised

reconnection.

2. Unscrew plug"P"Afrom the oil

pump.

3. Unscrew plug"V"Bfrom the oil

pump.

This allows the oil to drain from

the oil pump.

4. Insert a pressure gauge (range

040bar) and a vacuum gauge

(range 01bar).

Seal the pressure and vacuum

gauges only with copper or

aluminium gaskets or Orings.

Never use tape to seal these

joints.

5. Start up the burner.

The solenoid valve opens.

6. Read off the oil and vacuum

pressures 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).

Where vacuum measures higher

than 0.35bar, check the filter for

contamination or check the pipe

run.

5692623GB

Danfoss oil pump, typeBFP52

Suntec oil pump, typeAT255

Initial start−up, inspection and maintenance

Further details regarding the individual steps (cont.)

7. If required, adjust the oil

pressure at pressure adjusting

screwCfor stage1 andDfor

stage2.

Clockwise ³pressure rises

Anti−clockwise ³pressure falls.

For standard burner settings,

see page38.

8. Check the emission values by

taking an actual measurement

after adjusting the oil pressure.

9. Switch OFF the mains isolator

and safeguard against

unauthorised reconnection.

10. Remove the pressure and

vacuum gauges.

11. Insert plug"P"Aand "V"B.

Check the plug seals for damage

and replace, if required.

12. Start the burner and check the

plugs for leaks.

5692623GB

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, first adjust the air volume for stage2 at the blast tube connection.

Starting up the burner may require a fine adjustment.

Readjusting stage2

1. Release locking screwB.

2. Change the position of sensor

plateDinside flame tubeC; for

this, turn knurled nutA:

HClockwise

³greater cross−section

³more air,

HAnti−clockwise

³smaller cross−section

³less air.

Note

For standard burner settings, see

page38.

3. Tighten locking screwB.

5692623GB

DC BA

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