Viessmann Vitocrossal 200 CM2 400 Service Instructions Manual
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Viessmann Vitocrossal 200 CM2 400 Service Instructions Manual

Cm2 series gas condensing boiler with cylinder burner
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See also: Instruction and Installation Manual
Service Instructions
for use by heating contractor
Vitocrossal 200
CM2 Series 400, 500, 620 and 620 TX
Gas condensing boiler with cylinder burner
Heating input:
1445 to 2245 MBH
(423 to 658 kW)
VITOCROSSAL 200
H
5584 071- 04
06/2015
Product may not be exactly as shown
IMPORTANT
Read and save these instructions
for future reference.
Please file in Service Binder

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Summary of Contents for Viessmann Vitocrossal 200 CM2 400

  • Page 1 Service Instructions for use by heating contractor Vitocrossal 200 CM2 Series 400, 500, 620 and 620 TX Gas condensing boiler with cylinder burner Heating input: 1445 to 2245 MBH (423 to 658 kW) VITOCROSSAL 200 Product may not be exactly as shown IMPORTANT Read and save these instructions for future reference.

  • Page 2: Vitocrossal 200, Cm2 400, 500, 620 And 620Tx Service

    Follow the ultimate owner with all equipment, as well as safety Viessmann maintenance schedule of the boiler contained precautions/requirements, shutdown procedure, and in this manual. the need for professional service annually before the...

  • Page 3: About These Installation Instructions

    Safety Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Safety, Installation and Warranty Requirements Safety, Installation and Warranty Requirements (continued) Suppliers of fiberglass wool products recommend the Fiberglass wool and ceramic fiber materials following precautions be taken when handling these materials: WARNING - Avoid breathing fiberglass dust and contact with...

  • Page 4: Table Of Contents

    Table of Contents Vitocrossal 200, CM2 400, 500, 620 and 620TX Service Page Safety Safety, Installation and Warranty Requirements....2 About these Installation Instructions......3 General Information Equipment..............6 Product Information.............6 Important Regulatory and Installation Requirements..7 Safety Instructions............8 Target group............8 Regulations.............8 If you smell gas............8 If you smell flue gas..........8 Working on the system..........8 Repair work............8...

  • Page 5: Commissioning, Inspection And Maintenance

    Table of Contents Vitocrossal 200, CM2 400, 500, 620 and 620TX Service Page Commissioning, Inspection and Checking the Flue Side Gaskets/Seals......29 Flue side gaskets/seals..........29 Maintenance Checking the Diaphragm Expansion Vessel and System Pressure............30 Check proper expansion tank and system pressure..30 Water quality............30 Burner Service Further Details Regarding the Individual Steps....31...

  • Page 6: General Information

    This boiler does not require a flow switch. The Vitocrossal 200, CM2 boilers are CSA certified with WARNING Viessmann burners which must be used in conjunction with this boiler series. Exposing the boiler to pressures and temperatures in The proper burner size must be verified and the burner...

  • Page 7: Important Regulatory And Installation Requirements

    Literature applicable to all aspects of the Vitocrossal 200,  L eave all literature at the installation site and advise CM2: the system operator/ultimate owner where the literature Technical Data Manual can be found. Contact Viessmann for additional copies. Installation Instructions Service Instructions Operating Instructions Wiring diagrams...

  • Page 8: Safety Instructions

    CSD-1 Field Testing of High Limit Switches for Vitocrossal 200 in serious injury. CM2 boilers (models 400 to 620) – where required by law. VIESSMANN IS NOT RESPONSIBLE FOR ANY DAMAGES ■ Do not smoke. Prevent naked flames and sparks. Do not THAT THE FOLLOWING TEST PROCEDURE MAY RESULT press any switches for lights or electrical appliances.

  • Page 9: Start-Up

    Start-up Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Safety Instructions (continued) Menu item “6“ is used to change the following operating parameters: (see page 49 for more detail) Sub-menu Parameter Units/Scale Delivered Item condition Maximum operational input % of rated input 100% Gas type...

  • Page 10: Removing Covers

    Start-up Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Removing Covers Removing the front covers 1. Remove the M5 screw and set aside. 2. Lift and remove the top front panel. 3. Lift and remove the lower front panel. Removing the side covers 1.

  • Page 11: Burner Overview

    Start-up Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Overview CM2 400 burner Legend A Compensating tube CM2 500 burner Legend A Compensating tube CM2 620/620 TX burner Legend A Compensating tube Model CM2 620 TX 30 o 20 o 20 o Rotary damper position...

  • Page 12: Steps - Commissioning, Inspection And Maintenance

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance Commissioning the system 6. Match the coding card at the burner control unit WARNING according to the chart on this page. Also refer to page 55.

  • Page 13: Conversion To Liquid Propane Gas (Lpg)

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) Conversion to liquid propane gas (LPG) (The LPG conversion kit is supplied with the burner) 1. Close the gas shut-off valve. 2.

  • Page 14: Conversion To Natural Gas (Ng)

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) Conversion to natural gas (NG) 10.Push compensation hose G on to the gas valve. 1. Close the gas shut-off valve. 11.

  • Page 15: Converting Gas Type On Burner Control Unit

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) Converting gas type on burner control unit Altitude adjustment To implement the changes the burner has to be in To implement the changes the burner has to be in stand-by, Status “0”, Service “C”.

  • Page 16: Reducing Operational Input (If Required)

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) Checking the static and the supply pressure Reducing operational input (if required) To implement the changes the burner has to be in stand-by, Status “0”, Service “C”.

  • Page 17: Supply Pressure For Ng And Lpg

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) Supply pressure for NG and LPG. 1. Start the burner Note: The supply pressure should be between 4“w.c. and 14”w.c. The gas pressure switch for the inlet Note: For commissioning, see page 12.

  • Page 18: Checking The Co Level

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) Checking the CO level Test at the upper heating input Preparing the test 1. Press button E until the service display B has incremented to “100“(= 100%).

  • Page 19: Co Test At The Lower Heating Output

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) Test at the lower heating output Displaying the ionization current 1. Press button G until the service display B has counted down to “0“...

  • Page 20: Shutting Down The System

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) Shutting down the system 1. Close the gas shut-off valve. 2. Switch OFF the main circuit breaker or the power supply and safeguard against unauthorized reconnection.

  • Page 21: Separating The Neutralizing System (If Installed) From The Boiler And Connecting The Drain Hose

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) Separating the neutralizing system (if installed) from the boiler and connecting the drain hose 1. Separate hose A to the neutralizing system from siphon B.

  • Page 22: Cleaning And Reconnecting The Condensate Drain System

    See Neutralization System Operating Instructions. Note: You can obtain the neutralizing granulate from Viessmann. 4. Release and flush lower part D of siphon B. 5. Fill lower part D of siphon B with water and reassemble.

  • Page 23: Checking The Cylinder Burner Assembly

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) Checking the cylinder burner assembly WARNING Escaping gas leads to a risk of explosion. Close the gas shut-off valve. 1. Undo fitting on the gas supply pipe A. 2.

  • Page 24: Checking The Ignition And Ionization Electrodes

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) Checking the ignition and ionization electrodes Ionization electrode Check the ignition electrodes and the ionization electrode for correct gap towards the cylinder burner assembly and damage (replace if required).

  • Page 25: Checking The 15A And 15B Flue Gas Sensor

    Steps – Commissioning, Inspection and Maintenance (continued) Checking the 15A and 15B flue gas sensor Viessmann NTC 10 kΩ (blue identification) Note: The sensor is located on the flue gas collector and the connecting plug is located at the burner control unit.

  • Page 26: 3A And 3B Boiler Temperature Sensor Description

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) 3A and 3B boiler temperature sensor description 3A sensor (NTC 10k ) terminals 1 & 2  3B sensor (NTC 20k ) terminals 3 &...

  • Page 27: Making The Electrical Burner Connection

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) Making the electrical burner connection Note: Never allow cables/leads to come into contact with hot components. Secure all cables with cable ties if required.

  • Page 28: Cleaning The Burner

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance (continued) Cleaning the burner 1. Undo fitting C on gas supply pipe B. 2. Undo Venturi mixing pipe D from fan E. 3.

  • Page 29: Checking All Gas Connections For Leaks

    Commissioning, Inspection, Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Steps – Commissioning, Inspection and Maintenance Checking all gas connections for leaks The burner control unit automatically checks the valves for tightness when the burner is started. If the valves are gas tight, the burner enters standard mode and the burner starts.

  • Page 30: Checking The Diaphragm Expansion Vessel And System Pressure

    If in any doubt about the water quality, please have a be properly sized for the system. proper water analysis done. Check with regional chemical suppliers for boiler water treatment or with Viessmann Manufacturing Company Inc. directly. CAUTION Total output (MBH) Total Hardness (ppm as CaCO Damage on boiler or other system components may >...

  • Page 31: Further Details Regarding The Individual Steps

    Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Further Details Regarding the Individual Steps Fan pressure monitoring function (air pressure switch 1) Combustion chamber pressure monitoring (air pressure switch 2) The switching threshold of air pressure switch 1 (APS1) is monitored in all fan ramp-up phases and checked in modulating burner operation.

  • Page 32: Gas Inlet Pressure Monitoring Switch - Gdw1

    Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Further Details Regarding the Individual Steps (continued) Gas inlet pressure monitoring switch - GDW1 The factory default setting for the gas inlet pressure switch is 10 mbar (4” w.c.). This is the minimum gas pressure required for the burner to operate with natural gas fuel.

  • Page 33: Burner Component Overview

    Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Component Overview CM2 pre-mix cylinder burner 400/500/620/620 TX Legend A Burner frame J Manual shut-off valve B Air pressure switch 1 K Venturi mixing pipe C Air pressure switch 2 L Gas fan D Display and programming unit M Burner gauze assembly...

  • Page 34: Accessing The Burner

    Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Accessing the Burner 1. Close main gas supply valve. 2. Switch off main power switch. Ensure that main power to equipment being serviced is off. 3. Remove front panel and front side panels. Refer to the boiler Installation Instructions.

  • Page 35: Burner Control Coding Card

    Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Control (continued) 4. Remove coding card from burner control sub-base and set aside. Note: Ensure there is no power to the burner control when replacing the coding card. 5.

  • Page 36: Burner Control Programming Unit

    Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Control Programming Unit 1. Loosen the two programming unit screws. 2. Lift the programming unit off the burner control sub-base and disconnect the cable plug and replace. 3.

  • Page 37: Ignition Unit

    Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Ignition Unit 1. Remove plug from ignition unit. 2. Remove ignition cables from ignition unit. 3. Loosen screws of ignition unit. 4. Remove ignition unit. 5. Reinstall in reverse order. Ignition Cable 1.

  • Page 38: Motorized Burner Inlet Damper

    Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Motorized Burner Inlet Damper 1. Remove the four M6 (5 mm hex) bolts and nuts from the burner inlet damper and set aside. 2. Remove the burner inlet damper from the burner along with the servomotor and linkage.

  • Page 39: Inlet Damper Linkage

    Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Inlet Damper Linkage 1. Remove the M4 (8 mm hex) nut connecting the linkage to the inlet damper bracket. 2. Loosen the M5 (4 mm hex key) set screw connecting the linkage to the servomotor.

  • Page 40: Burner Fan

    Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Fan 1. Loosen the retaining clamp and disconnect the combustion air flex hose and set aside. 2. Disconnect the gas line. 3. Disconnect electrical plugs 100 and 100A from the fan. 4.
  • Page 41 Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Tube (continued) The electrodes 1. Disconnect both the ignition and ionization plugs from the electrodes and remove the nuts, retaining brackets and electrodes and set aside. 2. Once the burner is installed to the burner door (see page 39), install the electrodes in reverse order.
  • Page 42 Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Tube (continued) The burner 1. Install the burner with frame to the boiler door with six M12 nuts and washers. Torque nuts to 177 lb/in (20 Nm). 2.

  • Page 43: Burner Door

    Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Door 1. Loosen the retaining clamp and disconnect the combustion air flex hose and set aside. 2. Disconnect the gas line. 3. Disconnect electrical plugs 35, 36, 87, 111 and 122 from the burner control.

  • Page 44: Burner Door Refractory

    Burner Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Door Refractory 1. Loosen the retaining clamp and disconnect the combustion air flex hose and set aside. 2. Disconnect the gas line. 3. Remove ionization electrode block. 4.

  • Page 45: Boiler Service

    Boiler Service Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Boiler Water Temperature Sensor Note: The boiler water temperature sensor is located on the boiler supply connection. 1. Remove spring clip (set aside). 2. Insert 6 in. (150 mm) temperature sensor. 3.

  • Page 46: Burner Control Unit

    Burner Control Unit Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Control Unit Display and programming unit Standby 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.
  • Page 47 Burner Control Unit Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Control Unit (continued) Operating display (continued) Maintenance program Pre-ignition no air pressure Ignition Maintenance program Safety time no gas pressure or Flame established mains undervoltage Flame stabilization Forced ventilation when no flame was recognized...

  • Page 48: Information Configuration Display

    Burner Control Unit Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Control Unit (continued) Scroll through Status until “6“ is shown under Information and configuration display Status: The information display and the configuration display are activated from the operating display. The menu selection Status Description is activated by pressing button S for longer than 2 seconds.
  • Page 49 Burner Control Unit Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Control Unit (continued) Configurations: Menu item Description Changeover from the operating display of the burner control unit phase to other process information Configuration of control function operating parameters Menu item “5“...

  • Page 50: Resetting Operating Parameters To Their Factory Setting

    Burner Control Unit Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Control Unit (continued) Example: to set the maximum operational burner input to between 0 and 100%, press the following buttons: for required maximum operational output. 1. S longer than 2 seconds “ “ flashes. Note: Observe the modulation range.

  • Page 51: Burner Control Unit Flow Diagram

    Flow Diagram Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Control Unit Flow Diagram...
  • Page 52 Flow Diagram Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Control Unit Flow Diagram (continued) State description: Phase Display Description Duration System start “A” System start 10 seconds Fan ramp-up, system start max. 20 seconds Forced ventilation, system start 20 seconds Relay test ”P“...

  • Page 53: Burner Control Unit Connection Diagram

    Connection Diagram Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Burner Control Unit Connection Diagram WARNING Disconnect power inside the boiler junction box, before CAUTION * servicing boiler. Provide disconnect means and overload protection as A Burner control unit interface VUC 310/base required.

  • Page 54: Faults

    Troubleshooting Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Faults Fault display Fault memory The fault display is activated automatically if the burner The ten most recent faults are saved and may be called up. control unit switches to a fault state. The most recent The order of scans ranges from the most recent to the fault will then be displayed.

  • Page 55: Fault Codes

    Troubleshooting Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Fault Codes General process errors Fault display on the display interface and programming unit on the burner. Note: Carry out measures in the described order. All fault codes are saved to the fault memory and the last 10 can be called up.
  • Page 56 Troubleshooting Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Fault Codes (continued) Displayed System Characteristics Cause Measures Fault Code F EE Burner control unit in a fault Internal error in feedback from Reset burner control unit; replace state gas safety valves;...
  • Page 57 Troubleshooting Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Fault Codes (continued) Displayed System Characteristics Cause Measures Fault Code F F4 No flame builds during safety Combustion characteristics not Adjust the burner (see from page time; ionization flame monitor ideal 15, if necessary, also adjust the reports no signal...

  • Page 58: Internal System Fault

    Troubleshooting Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Fault Codes (continued) Internal system fault Internal system faults are created if a perfect program sequence can no longer be guaranteed. Displayed Fault Code System Characteristics Cause Measures F E5, F EC, F ED, F Fault around burner Internal system fault and Reset burner control unit.

  • Page 59: Parts Lists

    Ordering Replacement Parts: Please provide Model and Serial Number from ASME rating plate A when ordering replacement parts. Order replacement components from your Viessmann distributor. Boiler Parts 0001 Flue gas collector 0002 Condensate trap 0003 Sensor well G1/2 L=150 mm with clip...
  • Page 60 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate A when ordering replacement parts. Order replacement components from your Viessmann distributor. Boiler Parts 0001 Front LH side panel 0002 Front RH side panel 0003 Middle side panel...
  • Page 61 Ordering Replacement Parts: Please provide Model and Serial Number from burner rating plate B when ordering replacement parts. Order replacement components from your Viessmann distributor. Burner Parts 400 kW 0001 Burner frame 0002 Small parts and hardware 0003 Burner gauze assembly...
  • Page 62 Ordering Replacement Parts: Please provide Model and Serial Number from burner rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor. Burner Parts 500 kW 0001 Burner frame 0002 Small parts and hardware 0003 Burner gauze assembly...
  • Page 63 Ordering Replacement Parts: Please provide Model and Serial Number from burner rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor. Burner Parts 620 kW 0001 Burner frame 0002 Small parts and hardware 0003 Burner gauze assembly...

  • Page 64: Technical Data

    Specifications Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Technical Data Boiler Model 620 TX 1445 1800 2245 1999* Input (kW) (423) (527) (658) (585) Minimum Input NG (kW) (84) (105) (132) (132) Minimum Input LPG (kW) (103) (129) (160) (160)
  • Page 65 Specifications Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Technical Data (continued) Boiler Model 620 TX Boiler Water Content (395) (425) (495) (495) Heat exchanger surface 166.6 208.6 water cooled (15.5) (19.4) (21.7) (21.7) Maximum Operating Temperature °F (°C) 210 (99) 210 (99) 210 (99)

  • Page 66: Cylinder Burner

    Specifications Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Cylinder Burner Specifications Boiler Model CM2 620 TX Voltage Frequency Power consumption NG at max. input at min. input Power consumption LPG at max. input at min. input modulating Version Dimensions ¾...

  • Page 67: Maintenance Record

    Inspection and Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Maintenance Record Setting and Test Values Commissioning Maintenance/Service Static Pressure mbar/”w.c. Supply Pressure (running pressure) mbar/”w.c.  for natural gas NG mbar/”w.c. .  for liquid propane gas LPG Tick gas type Carbon Dioxide Content CO ■...

  • Page 68: Maintenance Schedule

    Inspection and Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Maintenance Schedule The following is an overview of scheduled service steps. Regular service work ensures reliable, energy-efficient, and environmentally friendly operation. IMPORTANT Keep boiler and boiler room clear and free from combustible materials, gasoline and other flammable vapors and liquids.
  • Page 69 Inspection and Maintenance Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service Maintenance Schedule (continued) Frequency Performed by Service  Annually Owner / Ensure service work/test is conducted at least annually by qualified personnel, Operator and that any deficiencies are corrected immediately. Heating Test functionality of safety high limits.
  • Page 70 Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service...
  • Page 71 Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service...
  • Page 72 Vitocrossal 200, CM2 400, 500, 620 and 620 TX Service...

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Vitocrossal 200 cm2 500Vitocrossal 200 cm2 620Vitocrossal 200 cm2 620 txVitocrossal 200 cm2 400

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