Viessmann VITOFLAME 200 Mode d'emploi

Service instructions

for heating engineers

Vitoflame 200

Gas pressure jet burner (typeVGA)

for Vitola and Vitorond 200

rated output 15 to 63 kW

See notes on applicability, page2.

VITOFLAME 200

5692449 GB1/2002 File in: Service folder

General Information

Safety instructions

Please follow these safety instructions closely to prevent accidents and material losses.

Work on the equipment

Installation, initial start−up,

maintenance and repairs must only

be carried out by a competent

person (heating engineer/

installation contractor) (EN50110,

part1, and VDE1000, part10 or local

regulations).

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

re−connection.

Disconnect the system from the

mains electrical power by means of a

device which simultaneously isolates

all non−earthed conductors with at

least 3 mm contact separation.

When using gas as fuel, also close

the mains gas shut−off valve and

safeguard against unauthorised

re−opening.

Work requiring the control unit to be

opened must not subject internal

components to electrostatic

discharges.

Work on gas equipment

This must only be carried out by an

approved installer.

Observe all commissioning work for

gas installations specified by

TRGI’86/96 or TRF1996 or local

regulations.

Repairs

It is not permitted to carry out

repairs on components that fulfil a

safety function.

Use only original Viessmann spare

parts or equivalent, which have been

approved by Viessmann.

Initial start−up

This must be carried out by the

system installer or a commissioning

engineer designated by him; all

actual values should be recorded in a

commissioning/service report.

Instructing the system user

The system installer must hand the

operating instructions for this

system to the user and instruct

him/her in the operation of the

system.

¨Safety instructions

In this instruction manual, this

heading denotes information which

must be observed to prevent

accidents and material losses.

¨Caution

In this instruction manual, this

caption denotes actions that must be

avoided to prevent accidents and

material losses.

This symbol is a reference

to other instructions which

must be observed.

Applicability

Applicable to burners from serial no.:

7143681 100001kkk

7143682 100001kkk

7143683 100001kkk

7143684 100001kkk

7143685 100001kkk

7143686 100001kkk

7143687 100001kkk

7143688 100001kkk

Operating and service documents

1. Complete and separate the customer registration card:

HHand the system user this part

for safekeeping.

HKeep the heating engineer

portion.

2. Keep all parts lists, operating and

service instructions in the folder

and hand this over to the system

user.

5692449 GB

Contents

Page

General Information Safety instructions2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applicability2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating and service documents2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial start−up,

inspection and maintenance

Procedure summary4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Implementation5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Procedure summary16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnosis17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional information Specification21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard values for burner settings22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nozzle pressure table 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mixer setting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gas throughput subject to operational net calorific value (HuB) 22. . .

Ignition and ionisation electrode 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard values for sensor plate, restrictor and blast tube24. . . . . . . . . .

Component summary25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring diagram27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts list29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Declaration of conformity 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manufacturer’s certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NO TAG

Initial start−up/service report36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5692449 GB

Initial start−up, inspection and maintenance

Procedure summary

Initial start−up steps

Steps for twice annual inspection

Maintenance steps

I M 1. Initial start−up Page 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 2. Setting the rated output Page 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 3. Air volume fine adjustment Page 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M4. Checking the burner Page 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M5. Air pressure switch Page 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 6. Heating system shut−down Page 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 7. Checking the electrical connections Page 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IM8. Cleaning the burner Page 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IM9. Checking the blast tube fixings Page 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IM10. Checking the fan fixings Page 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 11. Cleaning the sensor plate (if necessary) Page 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 12. Checking, adjusting and replacing (if necessary) the ignition and ionisation

electrodes Page 12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M13. Burner installation on the burner housing Page 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IM14. Checking both gas train valves Page 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 15. Checking the gas train filter insert (manufacturer: Dungs),

and replacing, if necessary Page 14

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 16. Checking the gas train (manufacturer: Kromschröder) Page 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IIM17. Checking all gas connections for leaks Page 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I I M 18. Measuring the ionisation current Page 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5692449 GB

Initial start−up, inspection and maintenance

Implementation

To obtain optimum combustion values, it is essential that the burner is

adjusted with the boiler heated to operating temperature.

Check the CO content, CO2content, flue gas temperature, room temperature

and chimney draught after 2minutes operation and at 60ºC boiler water

temperature with fitted burner hood.

Remove the burner hood before commencing maintenance work.

1.Initial start−up

Maint.Initial start−up

Service instructions

boiler control unit

Please note:

Function sequence during initial

start−up, see page 17.

During the initial start−up the system

can enter a fault state, if it has

insufficient gas in the supply line

(fault lamps on the control unit and

on the burner illuminate).

Purge the gas line again and unlock

the burner control unit.

1. Check the heating system

pressure.

2. Open the gas shut−off valve.

3. Switch on the mains electrical

isolator (outside the installation

room).

4. Switch on the system On/Off

switchBon the control unit.

If the fault indicator lampAon

the control unit lights up, press the

reset button; press the reset

buttonCon the burner control

unit.

5692449 GB

Initial start−up, inspection and maintenance

Implementation (cont.)

2.Setting the rated output

Maint.Initial start−up

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

table22.

Record the type of gas in the commissioning/service report (you will find this

report on pages36 and37).

Idle pressure

1. Close the gas shut−off valve.

2. Loosen the screw in the test

nippleA but do not remove.

3. Connect the U−shaped pressure

gauge.

4. Open the gas shut−off valve.

5. Measure the static pressure

(max. 50mbar).

6. Record the actual value in the

service report.

You will find the commissioning/

service report on pages36 and37.

5692449 GB

Gas train (make: Kromschröder)

Gas train (make: Dungs)

Initial start−up, inspection and maintenance

Implementation (cont.)

2.Setting the rated output (cont.)

Maint.Initial start−up

Supply pressure

7. Start up the burner.

8. Check the supply pressure (flow

pressure), see the table below.

9. Record the actual value in the

service report.

10. Close the gas shut−off valve.

11. Remove the U−shaped pressure

gauge and close test nippleA.

Initial start−up, see page5.

The supply pressure (flow

pressure) should be between

20and25mbar.

The gas governor is factory−set to

10 mbar.

Do not change this setting.

You will find the service report on

pages36 and37.

Supply pressure Check

less than 15 mbar Do not change the settings and contact the gas supply

company.

15 to 18 mbar Attention: The boiler may only be temporarily operated

with these settings (emergency operation).

Notify your gas supply company.

18 to 50 mbar Start up the boiler.

above 50 mbar Install a separate gas pressure valve with zero off

upstream in the boiler system, and regulate the pressure

to 20 mbar.

Notify your gas supply company.

5692449 GB

Gas train (make: Kromschröder)

Gas train (make: Dungs)

Initial start−up, inspection and maintenance

Implementation (cont.)

2.Setting the rated output (cont.)

Maint.Initial start−up

Nozzle pressure

13. Loosen the screw in the test

nippleBbut do not remove, and

connect the U−shaped pressure

gauge.

14. Open the gas shut−off valve and

start the burner.

15. Check the nozzle pressure in

accordance with the Wobbe

index and the output in the

nozzle pressure table on page22.

16. Check and, if necessary, adjust

the nozzle pressure.

17. Record the actual value in the

service report.

During the adjustment, check the

gas throughput by means of a

volumetric test.

You will find the service report on

pages36 and37.

Burner with gas train

(make: Kromschröder) type CG10:

The adjusted gas pressure will be

present approx. 30seconds after the

burner has started.

Adjust the nozzle pressure on the

setscrewCusing an Allen key (size

2.5). Continue with item19.

Please note:

+: more gas

³higher nozzle pressure

−: less gas

³lower nozzle pressure

Burner with gas train

(make: Dungs) type MBDLE405B01:

The adjusted gas pressure will be

present approx. 30seconds after the

burner has been started.

HMove the cover over the

setscrewCaside.

HAdjust the nozzle pressure on the

setscrewCusing a screwdriver.

Do not turn the pressure regulator

outside its setting range. Turn the

setscrewConly as long as the

nozzle pressure noticeably changes.

The main volume butterfly valveD

should be turned fully to "+".

Please note:

+: more gas

³higher nozzle pressure

−: less gas

³lower nozzle pressure

5692449 GB

Initial start−up, inspection and maintenance

Implementation (cont.)

2. Setting the rated output (cont.)

Maint.Initial start−up

Start gas volume

The opening characteristics of the gas solenoid valve have been matched to

the boiler and have been preset at the factory.

Generally, you do not need to change this setting.

Please note:

If you do not wish to change the start gas volume, continue with item19.

18. For gas trains by Dungs type

MBDLE405B01 (if required):

HSet the quick action (opening

characteristics) with protective

cap positioned upside downE.

For pulsating burner start:

Rotate to the right³reduced

quick action (less gas during the

burner start).

When the ionisation current

during the start−up phase is too

low:

Rotate to the left³increased

quick action (more gas during

the burner start).

HFit the protective cap.

19. Close the gas shut−off valve,

remove the U−shaped pressure

gauge and close test nipple A

(see page8).

20. Start up the burner.

Ionisation current at least 3 µA.

Checking the ionisation current see

page15.

Safety instructions

Check the test nipple for gas leaks.

3.Air volume fine adjustment

Maint.Initial start−up

The air valve for regulating the air volume for Vitola boilers is factory−set.

Only make one adjustment during the initial start−up to match the system to

local conditions or to Vitorond.

The CO2content in the flue gas should be approx. 9.5%.

Test port (approx. 10 mm ∅) at a distance of two to three times the diameter

of the flue pipe behind the boiler adaptor.

Record the final values in the service report (you will find this report on

pages36 and37).

Ensure that the flue pipe is sealed at the boiler adaptor; otherwise infiltrating

air will falsify the measuring results.

ATest nipple for the static burner pressure

BAir damper setting

5692449 GB

Initial start−up, inspection and maintenance

Implementation (cont.)

4.Fully check the burner

Maint.

Record the actual values in their true

sequence in the service report on the

last pages of this manual.

Safety instructions

Measure the CO value before and

after any work on gas appliances, to

prevent any health hazards and to

ensure perfect system conditions.

5.Air pressure switch

Maint.

The air pressure switch is factory−set to the respective switching point

(1.5mbar); generally, you do not need to adjust this setting.

6.System shut−down

Inspection Maint.

1. Isolate the mains electricity supply

and take measures to prevent

re−connection.

2. Pull the plug−connectorfA from

the burner.

3. Close the gas shut−off valve.

7.Checking the electrical connections

Inspection Maint.

Check the plug connectors on the

burner components and their cable

grommets for tightness.

5692449 GB

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