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
See notes on applicability, page2.
VITOFLAME 200
5692 554 GB2/2004 Please keep safe

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 it from 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.
Repair work
It is not permitted to carry out
repairs on parts that fulfil a safety
function.
Use only original Viessmann spare
parts, or equivalent parts that have
been approved by Viessmann.
Initial start−up
The initial start−up must be carried
out by the system installer or a
designated commissioning engineer.
All actual values should be recorded
in a commissioning/service report.
Instructing the system user
The system installer must hand the
operating instructions to the system
user and instruct him/her in the
operation of the system.
Applicability
from serial no.
7159805200001kkk, 7159806200001kkk, 7159807200001kkk,
7159810200001kkk, 7170760200001kkk, 7170761200001kkk,
7170762200001kkk, 7170763200001kkk
Operating and service documents
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.
The installation instructions will
not be required after the
installation is completed, and may
therefore be discarded.
5692 554 GB

3
Contents
Index
Page
General information
Safety instructions 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicability 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating and service documents 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start−up, inspection and maintenance
Stepsinitial start−up, inspection and maintenance 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further details regarding the individual steps 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil burner control unit 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Diagnostics 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component summary22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection and wiring diagram25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts list29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Specification 34
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard values for burner settings 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service report 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyword index 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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. System start−up 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 2. Oil pressure adjustment and vacuum check 6. . . . . . . . . . . . . . . . . .
C M 3. Air volume adjustment 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 4. Checking burner
(record values in service report from page36)
I M 5. Checking and cleaning flame monitor 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 6. System shutdown
I M 7. Checking tightness of electrical connections
M8. Cleaning burner 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 9. Checking impeller fixings
I M 10. Checking flame tube fixings
M11. Nozzle replacement 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 12. Checking or adjusting ignition electrodes 12. . . . . . . . . . . . . . . . . . . . . .
M13. Burner chassis installation on burner housing
M14. Cleaning and, if required, replacing oil pump filter 13. . . . .
M15. Replacing pre−filter element
I M 16. System start−up
I M 17. Checking oil supply pipes and
connections for leaks
M18. Checking burner again and
entering actual values in commissioning report
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5
Initial start−up, inspection and maintenance
Further details regarding the individual steps
To obtain optimum combustion values, it is essential to adjust the burner with
the boiler heated to operating temperature (min. 60ºC).
System start−up
Boiler control unit service
instructions
Please note:
The Vitoflame200 oil burner features
very good combustion values, which
are achieved without the use of fuel
oil additives (combustion
improvers). The use of combustion
improvers, which leave residues, is
not acceptable.
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
the burner ON.
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 554 GB
A
B
C

6
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 mains electricity supply
and safeguard against
unauthorised reconnection.
2. Unscrew drain plugPAfrom oil
pump.
3. Unscrew drain plugVBfrom oil
pump.
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).
Seal pressure and vacuum gauges
only with copper or aluminium
gaskets or Orings.Never use
sealing tape.
5. Start up burner.
Solenoid valve opens.
6. Read off 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 oil pump and bottom of
tank).
Where vacuum measures higher
than 0.35bar, check filter for
cleanliness or pipe run.
5692 554 GB
Danfoss oil pump, typeBFP31
Suntec oil pump, typeAL35
C
A
B
C
A
B

7
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
7. If necessary, set oil pressure on
oil pump pressure setting
screwC(for Danfoss pumps,
subject to type, either at front or
side).
Clockwise ³pressure rises
Anti−clockwise ³pressure falls.
For standard values for burner
settings, see page35.
8. Check the actual emission values
after adjusting the oil pressure.
9. Isolate mains electricity supply
and safeguard against
unauthorised reconnection.
10. Remove pressure and vacuum
gauges.
11. Insert drain plugsPAand VB.
Check plug seals for damage and
replace if necessary.
12. Start burner and check plugs for
leaks.
5692 554 GB

8
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Air volume adjustment
The air volume is preset at the factory. Readjust the air volume if necessary.
Starting up the burner may require a fine adjustment.
Before changing any setting, check whether the air supply route (inside the
housing) is set to position7.5 (factory setting).
ABlast tube connection set screw
BTest nipple
CAir damper
DBlast tube connection
ETerminal screw
FSensor plate
GFlame tube
1. Modify sensor plate position
inside the flame tube:
Turn blast tube connection set
screwA:
HAnti−clockwise
³larger cross−section
³more air,
HClockwise
³smaller cross−section
³less air.
For standard values for burner
settings, see page35.
2. Check static burner pressure at
test nippleB.
3. Check emission values by
measurement.
Do not release sealed clamping
screwE, otherwise the zero point of
the blast tube connection will be
altered.
5692 554 GB
A ECD
BA
FGAD

9
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking and cleaning flame monitor
DStrap centring tab
EFlame monitor sight glass
1. Pull flame monitorAfrom
flangeC.
2. Clean flame monitor.
Safety check Response
Burner start with
darkened flame
monitor
Fault shutdown
at end of 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.
Observe angle and distance (see
fig.).
Safety check Response
Burner operation
with simulated
flame blow−off:
for this, pull
plugFfrom
solenoid valve
during operation
and leave in this
condition
Restart followed
by fault
shutdown at end
of safety period
5692 554 GB
6.0
19.0
B
A
CD E
.
F

10
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Cleaning burner
1. Set burner to maintenance.
2. Clean casing, flame tube, sensor
plateA, ignition electrodesB,
flame monitorCand fan
impellerD.
Cleaning the combustion
chamber and hot gas flues,
see boiler service
instructions.
5692 554 GB
A
B
C
D

11
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Nozzle replacement
1. Plug burner lid into burner
housing, with blast tube
connection pointing upwards.
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.
5. Replace nozzleF(whilst holding
blast tube connection).
For make and type of nozzle, see
standard values for burner
settings on page35.
6. Only for 15 to 33kW:
Check seal washerBon sensor
plate deflectorEand apply
instrument grease; replace seal
ring if necessary.
7. Push sensor plateAonto the
blast tube connection up to the
end−stop of the oil preheater and
retighten fixing screwD.
8. Push flame monitorC into flange,
until the strap audibly clicks into
place (see page9, fig. above).
The flame monitor, typeQRB,
should be positioned at the sensor
plate (see Fig. on page9).
5692 554 GB
A
F
BE
CD
15 to 33kW
40kW
AF
CD
50 and 63kW
AF
CD

12
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking or adjusting ignition electrodes
Check ignition electrodesAfor
wear, contamination and size (see
fig.) and replace if necessary.
5692 554 GB
+0.3
1.5
A
15 to 33kW
40 to 63kW
1.5
A

13
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Cleaning and, if required, replacing oil pump filter
Danfoss oil pump, typeBFP31
AFilter plug
BOring
(replace)
CFilter
(replace)
Suntec oil pump, typeAL35
AFilter
(clean or
replace)
BFlat gasket
(replace)
COrings
(replace)
DLid
5692 554 GB
A
B
C
A B DC

14
Initial start−up, inspection and maintenance
Oil burner control unit
You may use the following oil burner control units with this burner:
Oil burner control unitLOA14.171B2V
For operating sequence, see wiring
diagram on page25.
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
oil burner control unit.
Oil burner control unitLMO14.113A2
For operating sequence, see wiring
diagram on page25.
Sensor current:
Hmin. requirement 40ĂmA
Hmax. permiss. without flame 5.5ĂmA
Undervoltage
The oil 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 power supply is 2×127V with red
flashing code: 10×flashing (see
page18), contact your local
Viessmann sales office.
Controlled intermittent operation
After a maximum of 24h non−stop
operation, the oil 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.
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15
Initial start−up, inspection and maintenance
Oil burner control unit (cont.)
Cause Response
After mains power failure Restart
After falling below undervoltage level Restart and fault shutdown
In case of premature, faulty flame
signal during pre−purge timet1
Fault shutdown at end of pre−flush
timet1
In case of premature, faulty flame
signal during oil preheat timet0
Starting will be inhibited after a
maximum of 40s fault shutdown
If burner does not light within safety
timet2
Fault shutdown at end of safety
timet2
If flame fails during operation max. 3 restarts, then fault shutdown
No heating or oil preheater enabling
within 10min
Fault shutdown
Fault shutdown
After a fault shutdown, the oil burner
control unit remains locked out
(non−modifiable fault shutdown) and
the red indicator illuminates.
This state is also maintained after
the mains power supply has failed.
Resetting the oil 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25.
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).
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16
Initial start−up, inspection and maintenance
Oil burner control unit (cont.)
Operating controls
Reset buttonEK is the
central control element
for resetting and for
activating or
de−activating
diagnostics.
Multi−coloured
indicatorLED is the
central indicator for
visual diagnostics as
well as interface
diagnostics.
Both elements (EK and LED) are
located under the clear cover of the
reset button.
Visual diagnostics
Operational display or fault cause
diagnostics
During standard mode, the various
conditions are indicated by colour
code acc. to the following colour
code table.
Colour code table
Condition Colour code Colour
Oil preheater active, oil
preheat time t0
FFFFFFFFFFFFF yellow
Ignition phase, ignition
activated
FfFfFfFfFfFfF yellow−off
Operation, flame OK JJJJJJJJJJJJJ green
Operation, poor flame JfJfJfJfJfJfJ green−off
Undervoltage F|F|F|F|F|F|Fyellow−red
Fault, alarm ||||||||||||| red
Fault code output |f|f|f|f|f|f|red−off
Extraneous light before
burner start
J|J|J|J|J|J|Jgreen−red
Interface diagnostic ||||||||||||| red flickering
Legend
fOFFFyellowJgreen|red
5692 554 GB
EK
red
yellow
green
LED

17
Initial start−up, inspection and maintenance
Oil burner control unit (cont.)
Fault cause diagnostics
The red indicator stays on
permanently after a fault shutdown.
In this condition, you can activate the
visual fault cause diagnostics
according to the fault code table by
pressing reset >3s.
The fault cause diagnostics are
activated as follows:
5692 554 GB
EK
ON
Fault position
Flashing
Fault position
Fault code table
Reset
EK
1 s (< 3 s)
> 3 s
1 s (< 3 s)
Visual diagnostics

18
Troubleshooting
Diagnostics
Fault/system
behaviour
Flashing
code red
at LMO14
Cause Remedy
Burner does
not start (no
fault display),
indicator
does not
illuminate
No voltage Check fuse or
connectoraBÖ in control
unit, electrical
connections, setting of
heating system ON/OFF
switch on control unit
and mains electrical
isolator
High limit safety cut−out
activated
Press reset button on
boiler control unit
Burner does
not start (no
fault display),
indicator
illuminates
10× Faulty electrical
connection, wiresL1 and
N interchanged or faulty
oil burner control unit
Check electrical
connection. If phases
correctly connected,
replace oil burner
control unit.
Burner does 2× Motor faulty Replace motor
not start
(with fault) 2× Coupling between motor
and oil pump faulty
Replace coupling
2× Oil pump seized or stiff Clean or, if necessary,
replace oil pump
8× Oil preheater faulty Replace oil preheater
Burner starts,
but no flame
if d
2× Ignition electrodes
poorly adjusted
Adjust correctly (see
page12)
is formed 2× Ignition electrodes damp
and contaminated
Clean ignition electrode
block
2× Insulation of ignition
electrodes cracked
Replace ignition
electrode block
2× Ignition trans former
faulty
Replace ignition
transformer
2× Ignition cable faulty Replace ignition cable
2× Pump does not supply
oil
Install pressure and
vacuum gauges on pump
and check build−up of
pressure (see following
paragraph)
5692 554 GB

19
Troubleshooting
Diagnostics (cont.)
Fault/system
behaviour
Flashing
code red
at LMO14
Cause Remedy
Pump does
not supply oil
2× Shut−off valves closed
at filter or in oil pipe
Open valves
2× Filter blocked Clean filter (pre−filter
and pump filter) or
replace if required
2× Coupling between
motor and pump faulty
Replace coupling
2× Leak in suction line or
filter cup
Tighten connections.
Check oil pipes and
connections for leaks
and tighten if
necessary.
2× Oil flow and return
hoses interchanged
Connect correctly acc.
to instructions on
pump
2× Vacuum in suction line
too high (higher than
0.35bar)
Check size of oil pipe
cross−section.
Replace filter. Check
external oil valve.
2× External oil valve faulty Check and, if necessary,
replace external fuel oil
valve
Burner starts,
bil
2× Solenoid coil faulty Replace solenoid coil
,
but no oil
injected
2× Oil pump faulty Replace oil pump
injected
2× Nozzle blocked Replace nozzle
Extraneous
light during
pre purge
4× Oil pump solenoid
valve fails to close
Replace oil pump
pre−purge
phase 4× Flame monitor faulty Replace flame monitor
4× Ignition electrodes
poorly adjusted or worn
Check ignition
electrodes and replace
if necessary
5692 554 GB

20
Troubleshooting
Diagnostics (cont.)
Fault/system
behaviour
Flashing
code red
at LMO14
Cause Remedy
Burner starts
and flame is
fdbt
2× Flame monitor
contaminated
Clean flame monitor
ad a es
formed, but
burner cuts
out after safet
y
2× Flame monitor receives
insufficient light
Clean sensor plate
out
after
safety
time expires 2× Flame monitor faulty Replace flame monitor
2× Oil burner control unit
faulty
Replace oil burner
control unit
2× Carbon deposits on
flame tube or on sensor
plate
Cleaning flame tube
Flame
extin
g
uishes
7× Air in suction line Seal line and filter
extinguishes
during
operation 7× Nozzle faulty Nozzle replacement
7× Burner incorrectly
adjusted
Adjust pre−settings
correctly (see page35)
7× Sensor plate
contaminated
Clean sensor plate
Ignition
switches ON
di
7× Flame monitor
contaminated
Clean flame monitor
stcesO
during
operation 7× Sensor plate
contaminated
Clean sensor plate
7× Nozzle contaminated or
faulty
Nozzle replacement
Flame pulsates Fan pressure too high Check fan pressure via
test nipple on top of fan
housing (U−shaped
pressure gauge). Adjust
air valve or blast tube
connection to ensure
that lower value of
static burner pressure
(see standard values
for burner settings,
page35) is not
exceeded.
Oil consumption too
high
Adjust oil pressure
correctly (see page35)
5692 554 GB