Viessmann VITOCROSSAL 200 Instructions Manual
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Viessmann VITOCROSSAL 200 Instructions Manual

Viessmann VITOCROSSAL 200 Instructions Manual

Gas condensing boiler
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See also: Instruction and Installation Manual , Technical Data Manual
VIESMANN
Service instructions
for contractors
Vitocrossal 200
Type CM2
Gas condensing boiler
For applicability, see the last page
VITOCROSSAL 200
Please keep safe.
5692 681 GB
4/2009

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Summary of Contents for Viessmann VITOCROSSAL 200

  • Page 1 VIESMANN Service instructions for contractors Vitocrossal 200 Type CM2 Gas condensing boiler For applicability, see the last page VITOCROSSAL 200 Please keep safe. 5692 681 GB 4/2009...

  • Page 2: Safety Instructions

    Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate- rial losses. Safety instructions explained ■ all current safety regulations as defined by DIN, EN, DVGW, TRGI, Danger TRF, VDE and all locally applicable This symbol warns against the standards, risk of injury.
  • Page 3 Please note and may invalidate our warranty. Electronic modules can be dam- For replacements, use only orig- aged by electro-static dis- inal spare parts from Viessmann charges. or those which are approved by Touch earthed objects, such as Viessmann. heating or water pipes, to dis-...

  • Page 4: Table Of Contents

    Index Index Commissioning, inspection, maintenance Steps – commissioning, inspection and maintenance.......... Further details regarding the individual steps............Troubleshooting Diagnosis......................41 Burner control unit flow chart................47 Burner control unit connection diagram............49 Component overview..................51 Control unit Adjusting codes at the control unit............... 55 Parts lists......................
  • Page 5 Commissioning, inspection, maintenance Steps – commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page • 1. Checking the high limit safety cut-out setting..... • 2. Filling the heating system with water and venting the system................
  • Page 6 Commissioning, inspection, maintenance Steps – commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • • 21. Checking the ignition and ionisation electrodes..24 • • 22. Closing the boiler door..........25 • • 23. Cleaning the burner............25 •...

  • Page 7: Further Details Regarding The Individual Steps

    Commissioning, inspection, maintenance Further details regarding the individual steps Checking the high limit safety cut-out setting The high limit safety cut-out must not be Control unit installation and serv- set higher than 110 °C; if required, set it ice instructions to a maximum of 110 °C.
  • Page 8 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. For open flue operation: Check that the installation room ventilation aper- ture is open. 3. Check the gas supply pressure. 4. Open the gas supply pipe shut-off valves. 5. Switch ON the main isolator (outside the installation room).

  • Page 9: Checking The Gas Type

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 9. Check all gaskets/seals and plugs, and retighten if necessary. Note We recommend you check all heating water connections for leaks after approx. 500 hours (see page 22). 10. Check the boiler door and clean-out cover a few days after commission- ing and retighten all screws.
  • Page 10 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 10. Secure and tighten fitting A. 11. Affix enclosed label "Adjusted to ..." F above the existing label. 12. Start the burner (see page 7). Danger Escaping gas leads to a risk of explosion.
  • Page 11 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 04. Undo fitting A. 08. Secure the gas train (without restric- tor C and without rubber cork gas- ket D, but including O-ring B) at flange E; replace the factory-fitted screws M 5 ×...

  • Page 12: Open The Gas Shut-Off Valve

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the static and the supply pressure Static pressure 115 to 311 kW 87 kW 1. Close the gas shut-off valve. 2. Undo the screw inside test connector A, but do not remove. 3.

  • Page 13: Start The Burner

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Supply pressure 3. Record the actual value in the report (on page 61). 1. Start the burner. 4. Close the gas shut-off valve. Note For commissioning, see page 7. 5. Remove the pressure tester and close test connector A.
  • Page 14 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the CO content Preparing the test 1. Open the gas shut-off valve. 2. Start the burner. 3. Press "S" E and "-" D simultane- ously. Display C will then show the follow- ing: ■...
  • Page 15 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. If the CO content must be adjusted: Turn adjusting screw A in small increments until the CO content rea- ches the specified range. ■ Turning clockwise → CO content falls ■...

  • Page 16: Check The Co Content At The Flue Pipe

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. If the CO content must be adjusted: 4. Record the actual value in the report (on page 61). ■ Remove cover B. ■ Turn adjusting screw A in small Rechecking the values increments (Torx 40) until the CO Regulate to the upper and lower out-...
  • Page 17 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. If the CO content must be adjusted: ■ Remove cap B. ■ Turn adjusting screw A in small increments (3 mm Allen key) until the CO content reaches the speci- fied range: –...
  • Page 18 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. If the CO content must be adjusted: ■ Remove cover B. ■ Turn adjusting screw A in small increments (Torx 40) until the CO content reaches the specified range: –...

  • Page 19: Checking The Ionisation Current

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the ionisation current 01. Switch OFF the main isolator. 07. Switch the main isolator ON and press reset. 02. Pull ionisation current cable plug 08. Check the ionisation current. 03.

  • Page 20: Shutting Down The System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Shutting down the system 1. Switch OFF the main isolator or the 2. Pull plug-in connectors fA and lÖ power supply and safeguard against from the burner. unauthorised reconnection. 3. Close the gas shut-off valve. Opening the boiler door 1.

  • Page 21: Components

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Only use plastic brushes, NOT Cleaning agent manufacturer's wire brushes or sharp objects. details. For normal cleaning, flush the heating Note surfaces thoroughly with a water jet. "Fauch 600" and "Antox 75 E" However, you may use cleaning agents Manufacturer: if you notice stubborn residues, surface...

  • Page 22: Sensor Well For Leaks

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking all heating water connections and the sensor well for leaks A Sensor well Note Also check the connections to control equipment and to the minimum pressure switch (low water indicator) for leaks. Cleaning and reconnecting the condensate drain system Note Clean the inside of the condensate drain...

  • Page 23: System (If Installed)

    Neutralising system operating instructions Note You can obtain neutralising agent from Viessmann quoting part no. 9521 702. 4. Release and flush lower part A of siphon B. 5. Fill lower part A of siphon B with water and reassemble.

  • Page 24: Checking The Burner Gauze Assembly

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the burner gauze assembly 1. Undo fitting A on the gas supply pipe. 2. Undo the screws on the boiler door and open the door. 3. Check the wire mesh of burner gauze assembly B and thermal protection ring C for damage.

  • Page 25: Closing The Boiler Door

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Closing the boiler door Note Tighten the boiler door screws evenly across with a torque of approx. 18 Nm. Cleaning the burner 87 kW 2. Remove venturi mixer tube E from fan A.

  • Page 26: Installing The Burner

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Installing the burner 87 kW 2. Push the connecting cables "100" and "100a" onto the fan. 3. Secure venturi mixer tube E with gas train B and gas supply pipe D on fan A.

  • Page 27: Checking Both Gas Train Valves For Tightness (For

    1 mbar within 5 min, then the gas train is tight. Otherwise it leaks. In that case, return the gas train to Viessmann Werke for tests. 7. After the test, close both test connec- tors by tightening the respective screws.

  • Page 28: Checking The Gaskets/Seals On The Flue Gas Side

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 5. Check the outlet seals of the gas train and fittings between the fan and the boiler door and between the fan and the venturi pipe for tightness. Checking the gaskets/seals on the flue gas side 1.

  • Page 29: Implementing Final Tests

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Note 3. If required, retighten the flue gas col- The seals/gaskets can also be lector seal E at the tensioning tog- checked under full load with an gles D or replace. Replace lip seal inspection mirror.

  • Page 30: Checking The Water Quality

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the water quality Enter the volume of top-up water, the water hardness and the pH value in the tables. For water quality requirements, see page 62. Fill water Top-up water Meter reading Total water Date...

  • Page 31: System Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Total hardness pH value Water treatment Date Feedwater Boiler water Boiler Medium Metering water volume The pH value should be between 8.2 and 9.5. Checking the diaphragm expansion vessel and system pressure Note 3.

  • Page 32: Checking The Mixer For Obstructions And Leaks

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the mixer for obstructions and leaks 1. Remove the motorised lever from the 3. Check the mixer for leaks. Replace mixer handle. the O-rings if the mixer leaks. 2. Check the mixer for ease of opera- 4.

  • Page 33: Air Pressure Switch

    Air pressure switch Function The air pressure switch A signal is assessed under the following operating conditions: ■ prior to the fan start (idle state check) ■ in the pre-purge phase ■ in control mode, subject to at least a starting output being produced.
  • Page 34 Burner control unit Display and programming unit Function A display and programming unit is integrated into the burner control unit. The display indicates the relevant operating conditions, the service and parameter conditions as well as all fault and error messages. The display comprises three elements of Status Service seven segments each.
  • Page 35 Burner control unit (cont.) Idle state check Status Service Fan ramp-up Pre-purge Status Service Pre-ignition Status Service Safety time Status Service Flame established Status Service Operation with flame Status Service Post-purge Status Service Standby Status Service...
  • Page 36 Burner control unit (cont.) Display Status Service (single digit) (two digits) Operating display in Current operating Display "FL" if a flame Page 35 standard mode condition, see signal is present pages 34 and 35 Operating display for Message code "A" or —...
  • Page 37 Burner control unit (cont.) DIP switch setting or parameter set The DIP switch (at the back of the display and programming unit) is factory-set to the rated output of the burner. A change to this factory setting is only required for oper- ation with reduced output.
  • Page 38 Burner control unit (cont.) Setting Setting Rated burner output Reduced burner output Parameter set 4 Parameter set 10 ≙ 246 kW ≙ 173 kW 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Parameter set 5 Parameter set 11 ≙...

  • Page 39: Fault Display

    Burner control unit (cont.) 3. Press the reset button. Then the operating display will be shown again. Displaying the selected parameter set This display will be terminated if no key is pressed within 20 s. 1. Press S and a simultaneously. Status Service 2.

  • Page 40: Fault Memory

    Burner control unit (cont.) 2. Press b. The additional fault information will be displayed under "Service" for as long as this key is held down. 3. Press the reset button. Then the operating display will be shown again. Fault memory The most recent six faults are saved and may be called up.

  • Page 41: Diagnosis

    Troubleshooting Diagnosis Faults with indication on the display and programming unit Message codes Message System characteris- Cause Measures code tics Burner OFF Gas pressure lim- Check the gas pressure iter fault limiter Burner OFF Lack of gas Notify your gas supply util- Burner is in a fault See fault code See fault code steps...
  • Page 42 Troubleshooting Diagnosis (cont.) Fault code System characteris- Cause Measures tics The gas pressure lim- Gas shut-off valve Open the gas shut-off iter signals no gas closed, gas pres- valve and check the gas pressure during the sure limiter faulty supply pressure; clean safety time the gas filter if required No flame signal after...
  • Page 43 Troubleshooting Diagnosis (cont.) Fault code System characteris- Cause Measures tics Ionisation flame mon- Ignition cables Remove the short circuit itor reports external shorted out light ingress during the start or after the post-purge Ionisation flame mon- Ionisation cable or Remove the short circuit itor reports external electrode short cir- light ingress during...
  • Page 44 Troubleshooting Diagnosis (cont.) Fault code System characteris- Cause Measures tics Burner control unit Internal low volt- Replace the burner con- fault age monitor fault trol unit. Burner control unit Internal voltage Replace the burner con- fault failure monitor trol unit fault Burner control unit Internal heat...
  • Page 45 Troubleshooting Diagnosis (cont.) Fault code System characteris- Cause Measures tics Burner control unit Safety chain bro- Check jumper B2 (plug remains in start-up fJ) of the safety chain at position, no start in the burner control unit. spite of heat demand Burner control unit Internal fault Replace the burner con-...
  • Page 46 Troubleshooting Diagnosis (cont.) Fault Cause Measures Burner restarts and Cores "L1" and "N" at Check the power supply and inter- switches off after the the power supply ter- change the cores. safety time has minals of the control expired unit interchanged CO is formed or burner Air shortage or Adjust correctly.

  • Page 47: Burner Control Unit Flow Chart

    Burner control unit flow chart Burner control unit flow chart...
  • Page 48 Burner control unit flow chart Burner control unit flow chart (cont.) After the controller issues a heat demand, the following program sequence will be run: Phase Duration Test for heat demand Checking the idle state of the air pressure switch and the 1 to 30 s Fan ramps up to speed (a fault shutdown will be initiated 1 to 30 s...

  • Page 49: Burner Control Unit Connection Diagram

    Burner control unit connection diagram Burner control unit connection diagram Ignition Speed 6.3 A (slow) A1 Burner control unit MPA 51 F4 Minimum pressure, gas pressure A2 Display unit with reset function limiter B1 Flame monitoring via an ionisation F6 Air pressure switch current H1 Hours run counter, total B2 Safety chain jumper...
  • Page 50 Burner control unit connection diagram Burner control unit connection diagram (cont.) K1 Relay contact T1 Ignition unit M1 Fan motor with PWM control and X1 Servomotor for rotary valve damper feedback (for 246 and 311 kW) S1 ON/OFF switch (inside the control Y1 Gas fuel safety valve unit) Y2 Choke valve (for 87, 142 and...

  • Page 51: Component Overview

    Component overview Component overview Pressure-jet gas burner, type VMA III, 87 kW A Boiler door C Fan B Air pressure switch D Display and programming unit...

  • Page 52: Control Unit

    Component overview Component overview (cont.) E Gas supply pipe M Ignition unit F Gas shut-off valve N Inlet adaptor for balanced flue oper- ation (option) G Burner gauze assembly P Gas pressure limiter H Ignition electrodes Q Gas train I Ionisation electrode R Venturi mixing tube K Thermal insulation block S Choke valve...
  • Page 53 Component overview Component overview (cont.) Pressure-jet gas burner, type VMA III, 115 to 311 kW A Boiler door C Fan B Air pressure switch D Display and programming unit...

  • Page 54: Control Unit

    Component overview Component overview (cont.) E Gas train M Burner control unit F Gas supply pipe N Ignition unit G Gas shut-off valve P Choke box H Burner gauze assembly Q Inlet adaptor for balanced flue oper- I Ignition electrodes ation (for 115, 142 and 186 kW) R Venturi mixing tube K Ionisation electrode...

  • Page 55: Adjusting Codes At The Control Unit

    Control unit Adjusting codes at the control unit Vitotronic service instructions In conjunction with the following control units: ■ Vitotronic 100, type GC1 ■ Vitotronic 200, type GW1 ■ Vitotronic 300, type GW2 Coding Rated output of the MatriX cylinder burner in kW Coding address card 1041...

  • Page 56: Parts Lists

    108 Ignition unit 211 Front insulation mat 109 Ignition cable 212 R.h. and l.h. cover panel 112 Ionisation cable 213 Vitocrossal 200 logo 113 Burner control unit 214 Edge protector 114 Display and programming unit for 215 Top fixing rail...
  • Page 57 Parts lists Parts lists (cont.) Parts not shown 133 Enriching nozzle 103 Small parts comprising: 134 Compensation set (only for 115 a Threaded connector and 246 kW) b Cheese-head screw M6 x 10 300 Thermal insulation pack c Washer 6,4 mm 301 Touch-up spray, Vitosilver d Hexagon screw M5 x 16 302 Touch-up paint stick, Vitosilver...
  • Page 58 Parts lists Parts lists (cont.) MatriX burner 87 kW...
  • Page 59 Parts lists Parts lists (cont.) MatriX burner 115 to 311 kW...
  • Page 60 Parts lists Parts lists (cont.) Vitocrossal 200, type CM2, 87 to 311 kW...

  • Page 61: Commissioning/Service Report

    Commissioning/service report Commissioning/service report Setting and test values Commission- Maintenance/ service Static pressure mbar Supply pressure (flow pressure) = for natural gas E mbar = for natural gas LL mbar Tick gas type Carbon dioxide content CO ■ at the upper rated actual % by output...

  • Page 62: Water Quality Requirements

    Water quality requirements Note Maintaining the following requirements is necessary to safeguard your warranty rights. The manufacturer's warranty excludes damage due to corrosion and scaling. Prevention of damage due to scaling Prevent excessive scale build-up (calcium carbonate) on the heating surfaces. For heating systems with operating temperatures up to 100 °C, the VDI guideline 2035 sheet 1 "Prevention of heating system damage –...
  • Page 63 Water quality requirements (cont.) ■ In systems > 50 kW, install a water ■ Take the system into use step by step, meter to record the volume of the fill & starting with the lowest boiler output top-up water. Enter the amount of fill and at a high heating water flow rate.
  • Page 64 Water quality requirements (cont.) Prevention of damage due to corrosion on the water side The corrosion resistance of ferrous Sealed unvented systems, e.g. those materials on the heating water side of equipped with a diaphragm expansion heating systems and boilers depends on vessel, offer good protection against the the absence of oxygen in the heating ingress of airborne oxygen into the sys-...
  • Page 65 Water quality requirements (cont.) Where chemicals are used as part of the corrosion protection, we recommend that the manufacturer of the chemicals issues a certificate of suitability of the additives with regard to the boiler mate- rials and the materials of the other heat- ing equipment components.

  • Page 66: Specification

    Specification Specification Gas boiler, category I 2ELL Rated output = 50/30 °C 104- = 80/60 °C Rated thermal load kW Product ID CE-0085 BQ 0021 Connection val- relative to the max. load with ■ natural gas E 2.8- 3.8- 4.7- 4.6- 8.1- 10.3-...
  • Page 67 Specification Specification (cont.) MatriX radiant burner Rated boiler output = 50/30 °C 104- = 80/60 °C Burner type III-1 III-2 III-3 III-4 III-5 III-6 Voltage Frequency Power consumption Motor speed 4832 4384 5088 5568 5952 6080 Modulation range 33-10 33-10 33-10 25-10 33-10...
  • Page 68 Specification Specification (cont.) Gas restrictor dimensions (natural Rated output Dimension a gas E) for 115 to 311 kW 115 kW 12.9 142 kW 12.9 186 kW 16.0 246 kW 15.7 311 kW 16.8...

  • Page 69: Declaration Of Conformity

    The product characteristics determined as system values for the product Vitocrossal 200 as part of EC type testing according to the Efficiency Directive (see specification table), can be utilised to assess the energy consumption of heating and ventilation equipment to DIN V 4701–10 which is specified by the EnEV [Germany].
  • Page 70 Certificates Manufacturer's certificate according to the 1st… (cont.) Vitocrossal 200, type CM2 incl. MatriX radiant burner Allendorf, 16 February 2009 Viessmann Werke GmbH&Co KG pp. Manfred Sommer...

  • Page 71: Keyword Index

    Keyword index Keyword index Fault memory........40 Acknowledging a parameter set..38 Faults without fault display....45 Air pressure switch......33 Flow chart..........47 Applicability........72 Flow pressure........13 Boiler water quality requirements..62 Gas connection tightness....27 Burner control unit......34 Burner gauze assembly, checking..24 Implementing final tests.....29 Installing the burner......26 Checking the CO2 content....14 Internal system fault......45 Checking the gaskets/seals on the flue...
  • Page 72 7185 864 5 00001 ␣␣␣, 7247 424 6 00001 ␣␣␣, 7185 865 5 00001 ␣␣␣, 7247 425 6 00001 ␣␣␣, 7185 866 5 00001 ␣␣␣ Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0...

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