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Viessmann Vitoflame 200 Service Instructions Manual

Pressure jet oil burner
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Service instructions
for heating engineers
Vitoflame 200
Pressure jet oil burner (type VEK)
H up to 40 kW with oil preheater
H from 50 kW without oil preheater
for Vitorond 200
See notes on applicability, page 2.
VITOFLAME 200
Please keep safe
5692 554 GB
2/2004

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Summary of Contents for Viessmann Vitoflame 200

  • Page 1 Service instructions for heating engineers Vitoflame 200 Pressure jet oil burner (type VEK) H up to 40 kW with oil preheater H from 50 kW without oil preheater for Vitorond 200 See notes on applicability, page 2. VITOFLAME 200 Please keep safe...

  • Page 2: General Information

    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. Applicability from serial no. 7159805 2 00001 kkk, 7159806 2 00001 kkk, 7159807 2 00001 kkk,...

  • Page 3: Table Of Contents

    Contents Index Page General information Safety instructions ........................Applicability .

  • Page 4: Initial Start−Up, Inspection And Maintenance

    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 1. System start−up ................2.

  • Page 5: Further Details Regarding The Individual Steps

    (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.

  • Page 6: Oil Pressure Adjustment And Vacuum Check

    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.
  • Page 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). ³ pressure rises Clockwise Anti−clockwise ³...

  • Page 8: Air Volume Adjustment

    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).

  • Page 9: Checking And Cleaning Flame Monitor

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Checking and cleaning flame monitor 1. Pull flame monitor A from flange C. 2. Clean flame monitor. Safety check Response Burner start with Fault shutdown darkened flame at end of safety monitor period 19.0...

  • Page 10: Cleaning Burner

    Initial start−up, inspection and maintenance Further details regarding the individual steps (cont.) Cleaning burner 1. Set burner to maintenance. Cleaning the combustion chamber and hot gas flues, 2. Clean casing, flame tube, sensor see boiler service plate A, ignition electrodes B, instructions.

  • Page 11: Nozzle Replacement

    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 C from the flange.

  • Page 12: Checking Or Adjusting Ignition Electrodes

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

  • Page 13: Cleaning And, If Required, Replacing Oil Pump Filter

    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 A Filter plug B O ring (replace) C Filter (replace) Suntec oil pump, type AL 35 A Filter (clean or replace)

  • Page 14: Oil Burner Control Unit

    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.
  • Page 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 Fault shutdown at end of pre−flush signal during pre−purge time t1 time t1 In case of premature, faulty flame Starting will be inhibited after a...
  • Page 16 Initial start−up, inspection and maintenance Oil burner control unit (cont.) Operating controls Reset button EK is the Both elements (EK and LED) are central control element located under the clear cover of the for resetting and for reset button. activating or de−activating Visual diagnostics diagnostics.
  • Page 17 Initial start−up, inspection and maintenance Oil burner control unit (cont.) Fault cause diagnostics The fault cause diagnostics are The red indicator stays on activated as follows: 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 >...

  • Page 18: Diagnostics

    Troubleshooting Diagnostics Fault/system Flashing Cause Remedy behaviour code red at LMO 14 Burner does No voltage Check fuse or connector aBÖ in control not start (no fault display), unit, electrical indicator connections, setting of does not heating system ON/OFF illuminate switch on control unit and mains electrical isolator...
  • Page 19 Troubleshooting Diagnostics (cont.) Fault/system Flashing Cause Remedy behaviour code red at LMO 14 Pump does 2 × Shut−off valves closed Open valves not supply oil at filter or in oil pipe 2 × Filter blocked Clean filter (pre−filter and pump filter) or replace if required 2 ×...
  • Page 20 Troubleshooting Diagnostics (cont.) Fault/system Flashing Cause Remedy behaviour code red at LMO 14 2 × Flame monitor Clean flame monitor Burner starts contaminated and flame is a d a e s formed, but d b t 2 × Flame monitor receives Clean sensor plate burner cuts insufficient light...
  • Page 21 Troubleshooting Diagnostics (cont.) Fault/system Flashing Cause Remedy behaviour code red at LMO 14 Burner sooty Too little or too much Correct setting. Check and clean impeller. Check boiler room ventilation. Insufficient chimney Check flue and flue gas draught baffles Nozzle faulty Replace nozzle, install correct nozzle (see page 35)

  • Page 22: Component Summary

    Component summary Component summary Legend A Air regulating valve P Flame tube B Blast tube connection set screw R Flame tube extension C Solenoid valve (only for 15 to 33 kW) D Electronic ignition unit S Sensor plate E Oil supply pipe T Oil burner nozzle F Fan motor U Flame monitor...
  • Page 23 Component summary Component summary (cont.)
  • Page 24 Component summary...

  • Page 25: Connection And Wiring Diagram

    Test button Connection for external burner ON Burner relay control. 1 qW Plug−in terminals on oil burner control unit Please note: The wiring diagrams on the following pages only apply in conjunction with Viessmann products.
  • Page 26 Connection and wiring diagram Connection and wiring diagram (cont.) 6.3A (slow) 250V Control unit components Oil burner control unit Power supply on site Op. lamp Oil preheater Solenoid Burner plug−in panel valve for motor External external fault indicator connection via separate connector...
  • Page 27 Connection and wiring diagram Connection and wiring diagram (cont.) Control program LOA X4 ..t0 Oil pre−heat time *5 up to 2min t1 Pre−flush time approx. 13s t2 Safety time max. t3 Pre−ignition time approx. 13s t3n Post−ignition time approx.
  • Page 28 Connection and wiring diagram...

  • Page 29: Parts List

    Parts list Parts list When ordering spare parts 080 Small parts comprising: Quote the type and serial no. (see 80a Plug spigot hexagon socket type plate) and the item no. of the 4 mm required part (as per parts list). 80b Plug spigot compression spring Obtain common parts from your 80c Plug spigot lockwasher...
  • Page 30 Parts list Parts list (cont.)
  • Page 31 Parts list Parts list (cont.) 028 80g...
  • Page 32 Parts list Parts list (cont.)
  • Page 33 Parts list Parts list (cont.)

  • Page 34: Appendix

    Appendix Specification Rated output Burner type VEKI 1 Type test no. to EN 267 5G971/2001S Voltage Frequency Power consumption comprising 4 ignition procedures per h Motor speed 2 800 Version single stage Oil pump throughput e" Connections R (female thread) Suction and return lines of oil hoses supplied Rated output...

  • Page 35: Standard Values For Burner Settings

    Appendix Standard values for burner settings Please note: Check that the service instructions are valid for the burner concerned (see notes on applicability, page 2 and serial no. on the burner type plate). Rated output Oil burner nozzle Make: Fluidics Type 60ºSF 60ºSF...

  • Page 36: Commissioning/Service Report

    Appendix Commissioning/service report Setting and test Initial start−up values Date: Oil pressure actual Vacuum actual after maintenance Soot indicator located after maintenance actual % by vol. Carbon dioxide content CO % by vol. Oxygen content O actual % by vol. % by vol.
  • Page 37 Appendix Maint./service Maint./service Maint./service Maint./service...
  • Page 38 Appendix Commissioning/service report (cont.) Setting and test Maint./service values Date: Oil pressure actual Vacuum actual after maintenance Soot indicator located after maintenance actual % by vol. Carbon dioxide content CO % by vol. Oxygen content O actual % by vol. % by vol.
  • Page 39 Appendix Maint./service Maint./service Maint./service Maint./service...
  • Page 40 Appendix Commissioning/service report (cont.) Setting and test Maint./service values Date: Oil pressure actual Vacuum actual after maintenance Soot indicator located after maintenance actual % by vol. Carbon dioxide content CO % by vol. Oxygen content O actual % by vol. % by vol.
  • Page 41 Appendix Maint./service Maint./service Maint./service Maint./service...
  • Page 42 Appendix...

  • Page 43: Keyword Index

    Appendix Keyword index Air volume adjustment, 8 Oil burner control unit, 14 Applicability, 2 Oil pressure adjustment, 6 Oil pump filter cleaning and replacement if required, 13 Burner cleaning, 10 Operating and service documents, 2 Commissioning/service report, 36 Component summary, 22 Parts list, 29 Connection and wiring diagrams, 25 Safety instructions, 2...
  • Page 44 Viessmann Werke GmbH & Co D 35107 Allendorf Tel: +49 6452 70 0 Fax: +49 6452 70 27 80 www.viessmann.de Viessmann Limited Hortonwood 30, Telford Shropshire, TF1 7YP , GB Tel: +44 1952 675000 Fax: +44 1952 675040 E−mail: info−uk@viessmann.com...

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