Viessmann VITOFLAME 200 Operating instructions

Service instructions
for heating engineers
Vitoflame200
Pressure jet oil burner (typeVEK)
Hup to 40kW with oil preheater
Hfrom50kW without oil preheater
for Vitorond200 and Vitorond222
See applicability on the last page.
VITOFLAME 200
5692589GB2/2005 Please keep safe

2
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 notice a smell of gas
¨Danger
Escaping gas can lead to
explosions which may lead to
serious injury.
HDo not smoke! Prevent
naked flames and sparks.
Never switch electrical lights
or equipment.
HOpen windows and doors.
HClose the gas shut−off valve.
HShut down the heating
system.
HRemove all people from the
danger zone.
HObserve the safety regulations
of your local gas supplier
found on the gas meter.
5692589GB

3
Safety instructions
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 all doors leading to the
living space.
Working on the heating system
HIsolate the system from the mains
power supply and check that it is
no longer ’live’, e.g. by removing a
separate fuse or by means of a
mains electrical 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/conversion can
compromise safety and may
infringe our warranty
conditions.
For replacements, use only
original spare parts from
Viessmann or those which are
approved by Viessmann.
5692589GB

4
Index
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 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Diagnosis (burner control unit LMO14. ...) 20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component summary26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection and wiring diagram28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts list30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Specification 35
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard values for burner adjustment 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service report 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyword index 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692589GB

5
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
C1. System start−up 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 2. Oil pressure adjustment and vacuum check 7. . . . . . . . . . . . . . . . . .
C M 3. Air volume adjustment 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 4. Fully checking burner
(Record actual values in service report from page38)
C5. Operating and service instructions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 6. System shutdown
I M 7. Checking tightness of electrical connections
M8. Cleaning burner 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 9. Checking impeller fixings
I M 10. Checking flame tube fixings
M11. Nozzle replacement 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 12. Checking and, if required,
adjusting ignition electrodes 13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 13. Checking and cleaning flame monitor 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M14. Checking the 0−point adjustment of
blast tube connection 15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M15. Mounting burner lid on burner housing
M16. Cleaning and, if required, replacing
oil pump filter 16
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M17. Replacing pre−filter element
I M 18. System start−up
I M 19. Checking oil supply pipes and connections for leaks
M20. Checking burner again and entering actual values in
commissioning/service report
5692589GB

6
Initial start−up, inspection and maintenance
Further details regarding the individual steps
To obtain the optimum combustion values, it is essential to adjust the burner
with the boiler heated to operating temperature (min. 60ºC).
System start−up
Note
For Vitorond222:
For balanced flue operation, the air
supply duct should be fitted before
setting the burner up. Observe the
following values during this step:
HPressure drop in the air supply line
max. 35Pa,
HAir inlet temperature in the inlet
connection min. 5ºC/max. 30ºC.
Boiler control unit
service instructions
Note
The Vitoflame200 oil burner features
very good combustion values which
are achieved without the use of fuel
oil additives (combustion
improvers). We do not therefore
recommend the use of such
combustion improvers.
1. Check whether the flame tube
extension (for 15 to 33kW) has
been fitted.
2. Check the heating system pressure
and the oil level in the tank.
3. Open the shut−off valves in the oil
supply lines on the oil tank and on
the filter.
4. Fill the oil suction line and the
filter with fuel oil using a manual
oil suction pump before switching
ON the burner.
5. Switch ON the mains electrical
isolator (outside the installation
room).
6. Switch ON system ON/OFF
switchBon the control unit.
If fault indicator lampAon the
control unit illuminates, press
reset buttonCon the burner.
5692589GB
A
B
C

7
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Oil pressure adjustment and vacuum check
The oil pressure is preset at the factory according to the oil throughput.
Adjust the oil pressure, if necessary.
1. Isolate the mains electricity supply
and safeguard against
unauthorised reconnection.
2. Unscrew drain plugPAfrom the
oil pump.
3. Unscrew drain plugVBfrom the
oil pump.
Note
This allows the oil to drain from
the oil pump.
4. Insert a pressure gauge (range
025bar) and a vacuum gauge
(range 01bar).
Note
Seal the pressure and vacuum
gauges only with copper or
aluminium gaskets or O rings.
Never use PTFE tape.
5. Start up the burner.
Note
The solenoid valve opens.
6. Read off the oil and vacuum
pressures of the pump on the
relevant gauges (vacuum should
be max. 0.35bar given a head of
3m between the oil pump and the
bottom of the tank).
Note
Where vacuum measures higher
than 0.35bar, check filter for
cleanliness or pipe run.
5692589GB
Danfoss oil pump, typeBFP31
Suntec oil pump, typeALE35
C
A
B
A
B
C

8
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
7. If necessary, set the oil pressure
on oil pump pressure setting
screwC(for Danfoss pumps,
subject to type, either at the front
or the side).
Clockwise ³pressure rises
Anti−clockwise ³pressure falls.
Note
For standard values for burner
adjustment, see page36.
8. Check the actual emission values
after adjusting the oil pressure.
9. Isolate the mains electricity
supply and safeguard against
unauthorised reconnection.
10. Remove the pressure and
vacuum gauges.
11. Note
Check the plug seals for damage
and replace if necessary.
Insert drain plugsPAand VB.
12. Start the burner and check the
plugs for leaks.
5692589GB

9
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Air volume adjustment
The air volume is preset at the factory. Re−adjust the air volume if necessary.
Starting up the burner may require a fine adjustment.
Before changing the setting, check whether the air supply route (inside the
housing, item no.022 on page34) is set to position7.5 (factory setting).
ABlast tube connection set screw
BTest nipple
CAir damper
DBlast tube connection
EClamping screw
FSensor plate
GFlame tube
Note
Do not release clamping screwE,
otherwise the 0−point setting of the
blast tube connection will be
affected.
1. Modify the sensor plate position
inside the flame tube. For this,
turn blast tube connection set
screwA:
HAnti−clockwise
³larger cross−section
³more air,
HClockwise
³smaller cross−section
³less air.
Note
For standard values for burner
adjustment, see page36.
2. Check static burner pressure at
test nippleB.
3. Check the emissions.
5692589GB
A ECD
BA
FGAD

10
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Operating and service instructions
1. Complete and detach the
customer registration card:
HGive the system user this part
for safe−keeping.
HRetain the heating engineer part.
2. Keep all parts lists, operating and
service instructions in the folder
and hand this over to the system
user.
5692589GB

11
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Cleaning the burner
1. Set burner to maintenance.
2. Clean the housing, the flame tube,
sensor plateA, ignition
electrodesB, flame monitorC
and impellerD.
For cleaning the combustion
chamber and hot gas flues,
see the boiler service
instructions.
5692589GB
A
B
C
D

12
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Nozzle replacement
1. Plug the burner lid into the burner
housing, with the blast tube
connection pointing upwards.
Note
This avoids air−locks being created
when replacing nozzles.
2. Pull flame monitorCfrom the
flange.
3. Release fixing screwDby two
full turns.
4. Remove sensor plateAfrom the
blast tube connection.
6. Replace the nozzle (whilst holding
the blast tube connection).
Note
For make and type of nozzle, see
standard values for burner
adjustment on page36.
7. Only for 15 to 33kW:
Check seal washerBon
deflectorEof the sensor plate
and apply instrument grease;
replace the seal ring if necessary.
8. Push sensor plateAonto the
blast tube connection up to the
end−stop of the oil preheater and
retighten fixing screwD.
9. Push flame monitorCinto the
flange, until the strap audibly clicks
into place (see page14, Fig. above).
Note
The flame monitor, typeQRB,
should be positioned at the sensor
plate (see page14).
5692589GB
A
F
BE
CD
15 to 33kW
40kW
AF
CD
50 and 63kW
AF
CD

13
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking and, if required, adjusting ignition electrodes
Check ignition electrodesAfor
wear, contamination and size (see
fig.) and replace if necessary.
5692589GB
+0.3
1.5
A
15 to 33kW
.
.
.
.
40 to 63kW
1.5
A
.
.
.

14
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking and cleaning the flame monitor
DStrap centring tab
EFlame monitor sight glass
1. Pull flame monitorAfrom
flangeC.
2. Clean the flame monitor.
Safety check Response
Burner start with
darkened flame
monitor
Fault shutdown
at the end of the
safety period
Burner start with
flame monitor lit
from an outside
source
Fault shutdown
after max. 40s
3. Push flame monitorAinto
flangeC, until strapBaudibly
clicks into place.
Note
Observe the angle and distance.
Safety check Response
Burner operation
with simulated
flame blow−off:
for this, pull
plugFfrom the
solenoid valve
during operation
and leave in this
condition
Restart followed
by fault
shutdown at the
end of the safety
period
5692589GB
6.0
19.0
B
A
CD E
0
F

15
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the 0−point adjustment of the blast tube connection
This adjustment is only required if optimum combustion characteristics
cannot be achieved with the standard burner adjustment values (see
page36).
1. Fit the burner lid on the burner
housing.
2. Set the scale for blast tube
connection adjustment with
blast tube connection adjusting
screwAto 0.
3. Release clamping screwE.
4. Push blast tube connectionD
forward up to its end stop.
5. Retighten clamping screwE.
6. Adjust the blast tube connection
in accordance with the burner
adjustment guide values on
page36.
5692589GB
A ECD
BA
FGAD

16
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Cleaning and, if required, replacing the oil pump filter
Danfoss oil pump, typeBFP31
AFilter plug
BO−ring
(replace)
CFilter
(replace)
Suntec oil pump, typeALE35
AFilter
(clean or
replace)
BFlat gasket
(replace)
COrings
(replace)
DLid
5692589GB
A
B
C
A B C D

17
Initial start−up, inspection and maintenance
Burner control unit
Program sequence during commissioning
A’ Start of oil pre−heat time
A Start−up
B Time of flame formation
C Operating position
D Controlled switch−off
3qW Plug−in terminals on the
burner control unit
CSolenoid valve on the oil pump
EIgnition transformer
FFlame monitor
GBurner motor
KOil preheater
Burner control unitLOA14....
tw Oil preheat time up to 12min.*1
t1 Pre−purge time approx. 13s
t2 Safety time max. 10s
t3 Pre−ignition time approx. 13s
t3n Post−ignition time
after flame builds approx. 15s
Burner control unitLMO14....
tw Oil preheat time up to 12min.*1
t1 Pre−purge time approx. 16s
t2 Safety time max. 10s
t3 Pre−ignition time approx. 15s
t3n Post−ignition time
after flame builds approx. 13s
*1Subject to the temperature of the oil supply.
5692589GB
F
C
E
G
K
t2
tw
t1
qQ
qW
4
6
3
8
PTC
M
~
t3 t3n

18
Initial start−up, inspection and maintenance
Burner control unit (cont.)
You may use the following burner control units with this burner:
Burner control unitLOA14....
Program sequence see page17.
Sensor current:
Hmin. requirement 50ĂmA
Hmax. permiss. without flame 5.5ĂmA
Undervoltage
When the mains voltage falls below
165V~, the burner will be prevented
from starting or the oil flow will be
interrupted; simultaneously the
system will initiate a fault shutdown.
Fault position
A lamp in the reset button also
indicates the fault shutdown of the
burner control unit.
Burner control unitLMO14....
Program sequence see page17.
Sensor current:
Hmin. requirement 40ĂmA
Hmax. permiss. without flame 5.5ĂmA
Undervoltage
The burner control unit initiates a
safety shutdown if the mains voltage
drops below 165V~.
The system restarts when the mains
voltage rises again above approx.
175V~.
If the power supply is 2×127V and
red flashing code: 10×flashing
(see page22) contact your local
Viessmann sales office.
Controlled intermittent operation
After a maximum of 24h non−stop
operation, the burner control unit
implements an automatic safety
shutdown with subsequent restart.
Control sequence in case of faults
The fuel valve outputs and the
ignition system are immediately shut
down (<1s) if the system shuts
down because of faults.
5692589GB

19
Initial start−up, inspection and maintenance
Burner control unit (cont.)
Burner control unitLMO14.... (cont.)
Cause Response
After mains power failure Restart
After falling below the undervoltage
level
Restart
In case of premature, faulty flame
signal during the pre−purge timet1
Fault shutdown at the end of the
pre−purge timet1
in case of premature, faulty flame
signal during the oil pre−heat timetw
Starting will be inhibited after a
maximum of 40s fault shutdown
If the burner does not light within the
safety timet2
Fault shutdown at the end of the
safety timet2
If the flame fails during operation Max. 3 re−starts, then fault shutdown
No heating or oil preheater enabling
within 10min
Fault shutdown
Fault shutdown
After a fault shutdown, the burner
control unit remains locked out
(non−modifiable fault shutdown) and
the red lamp lights up.
This state is also maintained after
the mains power supply has failed.
Resetting the burner control unit
The system can be immediately reset
after a fault shutdown. Hold down the
reset button for approx.1s (<3s).
Ignition sequence
If the flame fails within the safety
time, the system re−ignites but no
longer than up to the end of the max.
safety time. This allows several
ignition attempts within the safety
period; see program sequence on
page17.
Repeat restriction
For flame failure during operation,
up to three re−ignition attempts can
be made. The fourth flame failure
during operation triggers a fault
shutdown. The count of these
repeats begins with every controlled
start−up (through temperature or
pressure regulators, thermostat or
pressure limiters or safety limiters).
5692589GB

20
Troubleshooting
Diagnosis (burner control unit LMO14. ...)
Function and fault indications by the indicator lamp (LED)
In standard mode, operating states are displayed by colour code through LED
indicator lampA(see the following table).
The red indicator lamp stays on permanently after a fault shutdown. In this
state, the optical cause display may be activated (see flow chart on page21).
1. Press reset buttonBfor approx.
5s (longer than 3s).
2. Then a flashing code appears.
The number of signal flashes
in one sequence indicates the
type of fault.
For explanations, see the table
on page22.
3. To reset the burner and exit the
fault display, press the reset
button approx. 1s. (less than 3s.).
Colour of the LEDs Operating condition
Constant yellow light Oil preheater active, oil pre−heat time tw
Yellow flashing Ignition phase pre−purge, ignition activated
Constant green light Operation, flame steady
Green flashing Operation, poor flame
Alternating flashing
yellowred
Undervoltage (t165V)
Constant red light Fault, burner locked out
Red flashing Fault display (for explanations see page22)
Alternating greenred Extraneous light before burner start
Red flickering light Interface diagnosis
For diagnostic with interface adaptor (accessory)
5692589GB
AB