Viessmann VITOFLAME 200 Istruzioni operative

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

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

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

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

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

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

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

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

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

FGAD

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

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