Инструкция по сервисному обслуживанию vitoflame 100

Appr. nr. B98.01 A — CE 0063 AT 4967INSTALLATION, SERVICE AND USER INSTRUCTIONSFERROLI F24gas combination boiler for central heatingand hot water production, wall mounted,copper heat exchanger, fan assisted,room sealed, electronic fl ame ignition and controlcod. 3544015/2 — 05/2005G.C. NO: 47-267-31 …

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When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.For the very latest copy of literature for specification and maintenance practices visit our website www.id …

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NBE PELLET SYSTEMS RTB Ready to Burn EN303-5 2012 Class 5 approved by DTI. Approved for expansion vessel. Energy class AA. Manufacturer: NBE Production A/S Brinken 6-10 Øster Vrå Denmark www.nbe.dk …

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A MP+ 1.115 — 1.130 — 1.150it CALDAIA MURALE A GAS A CONDENSAZIONEManuale per l’uso destinato all’utente e all’installatoreen CONDENSING GAS WALL-HUNG BOILERS,QVWUXFWLRQVPDQXDOIRUXVHUVDQG¿WWHUVde (AT) KONDENSATIONS-WANDGASHEIZKESSEL Gebrauchsanleitung für den Benutzer und Installateures CALDERA MURAL DE GAS A CONDENSACIÓNManu …

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Installation, Operation and Maintenance Instructions Document 1187BInstallation,Operation andMaintenanceInstructions forEnduranceEBP Series Modulating Combination Boiler(natural or propane gas)EDP Series Modulating Hydronic Boiler(natural or propane gas)EDN Series Modulating Boiler, non ferrous(natural or propane gas)WARNINGIf the information in this manual …

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To be retained by householderUSER, INSTALLATIONCOMMISSIONING & SERVICINGINSTRUCTIONSBALANCED FLUEOIL FIRED CENTRAL HEATING BOILERSTRIANCOEuroStar WM 50/65In The Wall BoilerBED 92/42 EECEMC 89/336 EEC …

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Viessmann Vitoflame 100 3 Contents Index Page General information Safety instructionsĂ 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ApplicabilityĂ 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 Appendix Maint./service Maint./service Maint./service Maint./service 5692Ă534ĂGB

Viessmann Vitoflame 100 48 Appendix Standard values for burner settings (cont.) Mixer setting Rated output range from kW to kW 90 100 125 140 150 165 190 210 Boiler output kW 90 100 125 140 150 165 190 210 Standard values for mixer setting mm 8.0 10.5 14.0 17.0 18.5 21.0 18.0 22.0 Gas throughput subject to the operational net calorific value (H uB ) Gas type Gas group Operational net calorific value H UB G as t ype G as group O pera ti ona l ne t ca l or ifi c va l ue H UB kWh/m 3 MJ/m 3 Natural gas E 9.45 34.02 Natural gas LL 8.13 29.25 Gas Gas Rated boiler output G as G as R a t e d b o il er ou t pu t type grou

Viessmann Vitoflame 100 55 Appendix Maint./service Maint./service Maint./service Maint./service 5692Ă534ĂGB

38 Connection and wiring diagrams Connection and wiring diagram (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

9 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Checking adjustment of air damper actuator The burner is equipped with an air damper actuator motor with adjustable switching cams for setting the air damper position and for switching the solenoid valves. During a regular shutdown, the burner air damper will drive into the «closed» position. This reduces cooldown losses. The switching cams are located below the air damper actuator motor cover. A scaling ring is locat

Viessmann Vitoflame 100 60 Appendix Commissioning/service report (cont.) Setting and test values Date: By: Set value Maint./service Output located kW set kW Switch cam ii h i ST 1 located º position at the air damper actuator set º d amper ac t ua t or 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

Viessmann Vitoflame 100 64 Appendix Commissioning/service report (cont.) Setting and test values Date: By: Set value Maint./service Oxygen content O Stage 1 located % by vol. yg O 2 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

Viessmann Vitoflame 100 8 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) To obtain the optimum combustion values, it is essential to adjust the burner with the boiler heated to operating temperature (min. 60ĂºC). Also carry out measurements at base load. System start-up Service instructions Boiler control unit. 1. Check the heating system pressure. 2. Open the gas shut-off valve. 3. Check the supply pressure (see page 11). 4. Switch ON the mains electrical isolator (outside the boiler ro

18 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Checking air pressure switch At the factory, the air pressure switch is adjusted to the corresponding switching point, so that readjustment is generally not required. However, should an adjustment nevertheless be required, check the air pressure switch setting and correct, if required, in accordance with the details below by rotating black scaled ring B. A Adjustment ma

Viessmann Vitoflame 100 11 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Supply pressure ĂĂ7. Start the burner. Please note: Initial start-up, see pageĂ8. Switch the burner to stage 2. To do this, activate the emissions test switch on the control unit. ĂĂ8. Check the supply pressure (flow pressure), see the table below. Please note: The supply pressure (flow pressure) should be between 20 and 25Ămbar. The gas governor is factory-set to 12.5 mbar. Do not change this setting. ĂĂ9. Record the actual values in the commissioning report on page 50. 10. Close the gas shut-off valve. 11. Remove the

44 Parts list Parts list (cont.) 5692Ă534ĂGB

Viessmann Vitoflame 100 20 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Cleaning gas orifices in sensor plate (if necessary) 1. Pull the leads from electrodesĂH andĂG. 2. Loosen electrode 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). 5692Ă534Ă

17 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Checking ionisation current 1. Switch OFF the system ON/OFF switch. 2. Separate the plug connection of the ionisation current cable (red cable). Please note: When checking with a TestomatikĆGas, test cable no.Ă1 is required. You can also carry out this check with a multimeter. 3. Switch ON the system 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

Viessmann Vitoflame 100 39 Connection and wiring diagrams Connection and wiring diagram (cont.) 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 1Gas governor

Viessmann Vitoflame 100 6 Initial start-up, inspection and maintenance Further details regarding the individual steps Commissioning preparations Leak test 1. Close the gas shut-off valve. 2. Loosen the screw in test nipple A but do not remove. 3. Connect the pressure test equipment to test nipple A. 4. By gently activating the manual pump, create a test pressure of approx. 100 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 Chec

Viessmann Vitoflame 100 22 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Checking both valves of the gas train for leaks Please note: Only a function test is required for gas trains with leak test device. 1. Close the gas shut-off valve. 2. Release the screw in test nippleĂA but do not remove. 3. Release the screw in test nippleĂB but do not remove. 4. Connect the U-shaped pressure gauge 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 minu

Viessmann Vitoflame 100 45 Parts list Parts list (cont.) 5692Ă534ĂGB

Viessmann Vitoflame 100 32 Troubleshooting Diagnostics (cont.) Fault/behaviour of the system Flashing code red Cause Remedy Combustion errors through pulsation Start gas volume too large or too small Adjust start gas volume or opening characteristics (see page 14) p Flue gas draught incorrect Check flue gas draught (chimney) CO is formed or burner is very sooty Too little or too much air Correct setting. Check boiler room ventilation. CO 2 content too low or O 2 content too high Incorrect setting Adjust nozzle pressure in accordance with type of gas used. Correct air damper setting. Infiltrating ai

23 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Checking 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

Viessmann Vitoflame 100 25 Troubleshooting Diagnostics Function sequence (see diagram on page 38 and 39): A Start command Startup by thermostat tw Delay: approx. 8 s Air pressure switch and flame relay are checked for correct contact position. t10 Default time for air pressure signal: min. 5 s After expiry of this delay, the set air pressure should be established, otherwise there will be a fault shutdown. t1 Pre-purge time: min. 30 s Purging the combustion chamber and the secondary heating surfaces. t3 Pre-ignition time: approx. 2 s During the pre-ignition time until the expiry of safety time t2, the flame relay is forcibly pulled up. Fuel is released afte

41 Parts list Parts list Parts not shown 051 Allen key SWĂ5 052 Burner housing pack 053 Installation instructions 054 Operating instructions 055 Service instructions Wear parts 029 Ionisation electrode 030 Ignition electrode 037 Filter element 072 Earth electrode 003 Small parts comprising: 3a Cheese-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 Coun

Viessmann Vitoflame 100 13 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Please 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 «+». Adjusting stage 2 Please note: Start the burner in stage 2. To do this, activate 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

Viessmann Vitoflame 100 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 function diagram on page 25). H Switch ON the mains electrical isolator (outside the boiler room). H Start the burner. To do this, switch ON the ON/OFF switch at the control unit. H With the leak test equipment still connected, build the pressure to approx. 20Ămbar (gas shut-off valve closed). The following program must now run (see also the function diagram on page 25): If a heat demand is present (Ă»demand» lamp at the plug-in

Viessmann Vitoflame 100 59 Appendix Maint./service Maint./service Maint./service Maint./service 5692Ă534ĂGB

12 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Checking nozzle pressure 1. Release the screw in test nippleĂA but do not remove. 2. Connect the U-shaped pressure gauge to test nippleĂA. 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,

Viessmann Vitoflame 100 46 Appendix Specification Rated output range from kW to kW 90 100 125 140 150 165 190 210 Boiler output kW 90 100 125 140 150 165 190 210 Burner output 1 st /2 nd Ăstage* 1 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″ 1¼» *1 Corresponds to the boiler rated thermal load. 5692Ă534ĂGB

54 Appendix Commissioning/service report (cont.) Setting and test values Date: By: Set value Initial start-up Output located kW set kW Switch cam ii h i ST 1 located º position at the air damper actuator set º d amper ac t ua t or 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

Viessmann Vitoflame 100 49 Appendix Standard values for burner settings (cont.) Gas throughput subject to the operational net calorific value (H uB ) (cont.) Gas Gas Rated boiler output G as G as R a t e d b o il er ou t pu t type group 150 to 165 kW 190 to 210 kW yp gp Boiler output 150 kW 165 kW 190 kW 210 kW m 3 /h l/min m 3 /h l/min m 3 /h l/min m 3 /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

Viessmann Vitoflame 100 66 Appendix Commissioning/service report (cont.) Setting and test values Date: By: Set value Maint./service Output located kW set kW Switch cam ii h i ST 1 located º position at the air damper actuator set º d amper ac t ua t or 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

Viessmann Vitoflame 100 2 General information Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Work on the equipment Installation, initial start-up, inspection, maintenance and repairs must only be carried out by a competent person (heating engineer/installation contractor). Before working on the equipment/ heating system, isolate the mains electrical supply (e.g. by removing a separate mains fuse or by means of a mains electrical isolator) and safeguard against unauthorised reconnection. Close the main gas shut-off valve and safeguard against unauthorised reopening. Work

Viessmann Vitoflame 100 50 Appendix Commissioning/service report Setting and test values Date: By: Set value Initial start-up Static pressure mbar max.Ă50Ămbar Supply pressure (flow pressure) 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 5 µA set mA min. 5 µA Carbon dioxide CO Stage 1 located % by vol. content CO 2 set % by vol. Stage 2 located % by vol. set % by vol. 5692Ă534ĂGB

Viessmann Werke GmbHĂ&ĂCo DĆ35107 Allendorf Tel: +49 6452 70Ć0 Fax: +49 6452 70Ć27Ă80 www.viessmann.de Viessmann Limited Hortonwood 30, Telford Shropshire, TF1 7YP, GB Tel: +44 1952 675000 Fax: +44 1952 675040 email: [email protected] 68 Appendix Keyword index A Air damper actuator (checking settings),ă9 Air volume adjustment,ă15 Applicability,ă2 B Burner cleaning,ă19 Burner control unit,ă26 C Commissioning preparations,ă6 Commissioning/service report,ă50 Component summary,ă34 Connection and wiring diagrams,ă37 Conversion to natural

14 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Adjusting start-up gas volume The opening characteristics of the gas solenoid valve have been matched to the boiler and been preset at the factory. Generally 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

Viessmann Vitoflame 100 63 Appendix Maint./service Maint./service Maint./service Maint./service 5692Ă534ĂGB

Viessmann Vitoflame 100 30 Troubleshooting Diagnostics (cont.) Fault/behaviour of the system Flashing code red Cause Remedy Burner starts up, but no flame is formed 2Ă× Insufficient combustible gas mixture available Vent gas supply line to the outside. Check with a test burner, whether sufficient combustible gas is available. 2Ă× Gas solenoid valves fail to open Check electrical connection, voltage across gas train (230 V). Replace gas train if voltage is present at valve. Burner starts up and ignition is OK, but burner enters a fault 2Ă× Start gas volume poorly adjusted Adjust start gas volume or opening character

Viessmann Vitoflame 100 15 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Air volume adjustment 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

43 Parts list Parts list (cont.) 5692Ă534ĂGB

58 Appendix Commissioning/service report (cont.) Setting and test values Date: By: Set value Maint./service Oxygen content O Stage 1 located % by vol. yg O 2 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

61 Appendix Maint./service Maint./service Maint./service Maint./service 5692Ă534ĂGB

Viessmann Vitoflame 100 56 Appendix Commissioning/service report (cont.) Setting and test values Date: By: Set value Maint./service Static pressure mbar max.Ă50Ămbar Supply pressure (flow pressure) 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 CO 2 set % by vol. Stage 2 located % by vol. set % by vol. 5692Ă534ĂGB

67 Appendix Maint./service Maint./service Maint./service Maint./service 5692Ă534ĂGB

Viessmann Vitoflame 100 28 Troubleshooting Diagnostics (cont.) Fault/behaviour of the system Flashing code red Cause Remedy Burner does not start, demand lamp does not illuminate No voltage present Check fuse in control unit and in plug-in terminal block, check electrical connections, position of the ON/OFF switch on control unit and mains electrical isolator High limit safety cut-out activated Press reset button on boiler control 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

33 Troubleshooting 5692Ă534ĂGB

Viessmann Vitoflame 100 26 Troubleshooting Diagnostics (cont.) Burner control unit H in fault state, red fault lamp C illuminates constantly — Diagnosis of fault causes: — wait at least 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

Viessmann Vitoflame 100 37 Connection and wiring diagrams Connection and wiring diagram Legend 11 Ionisation monitoring 36 Fuel valve 2 54 Ignition transformer 100 Burner motor 111 Strapping plug 122 Actuator 123 Actuator 126 Service switch 129 Fuel valve 1 130 Gas governor 131 Air pressure switch fA Burner plug on control unit 90 D Internal connection inside plug-in connector lÖ F Ă1 Fuse in plug-in module TR/STB Safety equipment inside control unit K.. Burner relay contact 1 Ć qW Plug-in terminals on burner control unit A Start command B — B` Interval for flame to be established C Burner operating position achiev

36 Component summary 5692Ă534ĂGB

40 Parts list Parts list When ordering spare parts Quote the type and serial no. (see type plate) and the item no. of the required part (as per parts list). Obtain common parts from your local supplier. Parts 002 Blast tube 003 Small parts comprising: see below 004 Blast tube fixing screw 005 Mixer assembly 006 Burner flange seal ring 007 Air pressure switch 008 Fan motor 009 Hose 010 Impeller 011 Seal ring 012 Gasket set 016 Air regulating damper 017 Burner hood 018 Cover 028 Sensor plate 031 Fuse 032 Ignition transformer 033 Burner control unit 034 Plug-in terminal block

47 Appendix Standard values for burner settings Please note: Check that the service instructions are valid for the burner concerned (see notes on applicability, pageĂ2 and serial no. on the burner type plate). Nozzle pressure table Gas type Gas group Wobbe index Supply pressure yp gp Wo pp y p kWh/m 3 MJ/m 3 mbar *1 Natural gas E 15.00 54.00 20.0 Natural gas LL 12.40 44.60 20.0 Gas Gas Rated boiler output in kW G as G as R a t e d b o il er ou t pu t i n kW type group 90 ć 100 125 ć 140 150 ć 165 190 ć 210 Boiler output

4 Initial start-up, inspection and maintenance StepsĂćĂinitial start-up, inspection and maintenance For further instructions on individual steps, see pages indicated. Commissioning steps Inspection steps Maintenance steps Page C 1. Commissioning preparationsĂ 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C I M 2. System start-upĂ 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C I M 3. Checking adjustment of the air dampe

Viessmann Vitoflame 100 19 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Cleaning burner 1. Set the burner 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

Viessmann Vitoflame 100 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

Viessmann Vitoflame 100 34 Component summary Component summary A Gas train B Service switch for burner settings C Hood adaptor D Quick-action fastener 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

Viessmann Vitoflame 100 24 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Checking all gas unions for leaks 1. Insert new gaskets in all gas unions that have been opened. 2. Open the gas shut-off 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

10 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Checking static and supply pressure Check the type of gas with your local gas supplier. The burner is factory-set to natural gas E. Adjust 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 t

Viessmann Vitoflame 100 51 Appendix Maint./service Maint./service Maint./service Maint./service 5692Ă534ĂGB

Viessmann Vitoflame 100 16 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Fine adjustment stageĂ1 1. Set service switchĂB to positionĂII (automatic mode), and close the cover flap. 2. Change the burner over to stageĂ1 by pulling plug lÖ. 3. Remove the actuator motor cover. 4. Modify the air volume by turning the adjusting screw on switching camsĂSTĂ1 (see fig. on pageĂ9): H ClockwiseĂĂmore air, H Anti-clockwiseĂĂless air. Please note: Adjust switching camsĂSTĂ1

35 Component summary Component summary (cont.) 5692Ă534ĂGB

Viessmann Vitoflame 100 57 Appendix Maint./service Maint./service Maint./service Maint./service 5692Ă534ĂGB

Viessmann Vitoflame 100 65 Appendix Maint./service Maint./service Maint./service Maint./service 5692Ă534ĂGB

Viessmann Vitoflame 100 29 Troubleshooting Diagnostics (cont.) Fault/behaviour of the system Flashing code red Cause Remedy Burner does not start (demand 3Ă× Burner motor faulty Replace burner motor ( lamp illuminates) Actuator faulty (zero volt at terminal 4) Replace actuator Burner does not run and goes into a fault state after approx. 65 s 4Ă× Air pressure switch Check air pressure switch settings and replace switch if necessary pp 4Ă× Earth connection at ionisation cable or electrode Remedy short-circuit Burner motor starts, but a fault 3Ă× Dirty air pressure switch connection Clean connection , shutdown occurs during pre-purge phase 3Ă× A

62 Appendix Commissioning/service report (cont.) Setting and test values Date: By: Set value Maint./service Static pressure mbar max.Ă50Ămbar Supply pressure (flow pressure) 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 CO 2 set % by vol. Stage 2 located % by vol. set % by vol. 5692

Viessmann Vitoflame 100 5 Initial start-up, inspection and maintenance StepsĂćĂinitial 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

42 Parts list Parts list (cont.) 5692Ă534ĂGB

Viessmann Vitoflame 100 27 Troubleshooting Diagnostics (cont.) Diagnosis of fault causes Fault code table (red fault lamp) Fault Possible cause 2 x flashing The flame is not established at the end of the safety period 3 x flashing Air pressure switch does not close during pre-purge 4 x flashing Air pressure switch does not open or external light at burner start (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 voltag

31 Troubleshooting Diagnostics (cont.) Fault/behaviour of the system Flashing code red Cause Remedy Burner goes from operation into a fault state, when 7Ă× Ionisation current too low (<4 µA) Check position or condition of sensor electrode and change or replace if necessary , flame is already established 7Ă× Electrode body faulty Measure ionisation current and replace ionisation electrode or earth electrode if necessary Burner goes from operation into a fault state, when 7Ă× Ionisation current too low because of incorrect burner settings Correct burner settings

Viessmann Vitoflame 100 21 Initial start-up, inspection and maintenance Further details regarding the individual steps (cont.) Checking ignition and ionisation electrodes 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