Viessmann Vitocrossal 200 Service Instructions Manual
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Viessmann Vitocrossal 200 Service Instructions Manual

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VIESMANN
Service instructions
for heating engineers
Vitocrossal 200
Type CM2
Gas fired condensing boiler
For applicability, see the last page
VITOCROSSAL 200
Please keep safe
5692 599 GB
7/2005

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Summary of Contents for Viessmann Vitocrossal 200

  • Page 1 VIESMANN Service instructions for heating engineers Vitocrossal 200 Type CM2 Gas fired condensing boiler For applicability, see the last page VITOCROSSAL 200 Please keep safe 5692 599 GB 7/2005...
  • Page 2 Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained the Code of Practice of relevant trade associations, Danger all current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury.
  • Page 3 For replacements, use only ori- Repair work ginal spare parts supplied or approved by Viessmann. Please note Repairing components which fulfil a safety function can com- promise the safe operation of your heating system. Replace faulty components only with original Viessmann spare parts.
  • Page 4 Index Index Initial start-up, inspection, maintenance Steps initial startup, inspection and maintenance ........Further details regarding the individual steps ..........Air pressure switch ..................31 Burner control unit ..................32 Troubleshooting Diagnosis ....................40 Gas burner control unit flow chart ............46 Burner control unit connection diagram ..........

  • Page 5: Table Of Contents

    Initial start-up, inspection, maintenance Steps initial start up, inspection and maintenance For further information regarding individual steps, see the pages indicated. Commissioning steps Inspection steps Maintenance steps Page 1. Checking the high limit safety cut out setting ... 2.
  • Page 6 Initial start-up, inspection, maintenance Steps initial start up, inspection and . . . (cont.) Commissioning steps Inspection steps Maintenance steps Page 21. Checking the ignition and ionisation electrodes ..22. Closing the boiler door ............23.
  • Page 7 Initial start-up, inspection, maintenance Further details regarding the individual steps Checking the high limit safety cut out setting The high limit safety cut out must not Control unit installation and be set higher than 110 °C; if required, service instructions set it to a maximum of 110 °C.
  • Page 8 Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 1. Check the heating system pres- sure. Permissible boiler operating pres- sure: 4 bar 2. For open flue operation: Check that the boiler room ventilation aperture is open. 3. Check the gas supply pressure. 4.
  • Page 9 Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 9. Check the function of the neutra- lising system. Neutralising system oper- ating instructions 10. Check all gaskets/seals and plugs and retighten, if necessary. Note We recommend you check all heating water connections after approx.
  • Page 10 Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 3. Switch OFF the mains isolator 6. Release the gas combination (outside the installation room) or valve from flange G. the power supply and prevent unauthorised reconnection. 7. Remove restrictor C with gasket D from venturi mixer tube H.
  • Page 11 Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 4. Undo fitting A. 7. Remove restrictor C with rubber cork gasket D. 8. Secure the gas combination valve (without restrictor C and without rubber cork gasket D, but includ- ing O ring B) at flange E;...
  • Page 12 Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Checking the static and the supply pressure Static pressure 87 kW 115 to 311 kW 1. Close the gas shut off valve. 2. Undo the screw inside test connector A, but do not remove. 3.
  • Page 13 Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Supply pressure 1. Start the burner. 3. Record the actual value in the report (on page 60). Note For commissioning, see page 7. 4. Close the gas shut off valve. Switch the burner to maximum out- put.
  • Page 14 Initial start-up, 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 simulta- neously. Display C will then show the fol- lowing: under status: "d"...
  • Page 15 Initial start-up, 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 reaches the stipulated range. Turning clockwise content drops Turning anti clockwise content rises Note The adjusting screw has no end...
  • Page 16 Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 2. Check the CO content at the flue 4. Record the actual value in the pipe. For permissible CO content, report (on page 60). see the table on page 14. Recheck the values 3.
  • Page 17 Initial start-up, 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 sti- pulated range: Turning clockwise content drops...
  • Page 18 Initial start-up, 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 content reaches the stipu- lated range: Turning clockwise content rises Turning anti clockwise content drops...

  • Page 19: Checking The Ionisation Current

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Checking the ionisation current 1. Switch OFF the mains isolator. 6. Push test cable socket A onto the ionisation electrode. 2. Pull ionisation current cable plug 7. Switch the mains isolator ON and press the reset button.

  • Page 20: Shutting Down The Heating System

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Shutting down the heating system 1. Switch OFF the mains isolator or 2. Pull plug connector fA and lÖ the power supply and safeguard from the burner. against unauthorised reconnection. 3.

  • Page 21: Cleaning The Combustion Chamber And Heating Surfaces

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the combustion chamber and heating surfaces Thoroughly clean the combustion Remove coatings and surface dis- chamber and heating surfaces with a colouration (yellow brown) with water jet. slightly acidic, chloride free clean- ing agents based on phosphoric Please note acid (e.g.

  • Page 22: Checking All Primary Connections And The Sensor Well For Leaks

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Checking all primary connections and the sensor well for leaks A Sensor well Note Also check the connections to control equipment and to the minimum pres- sure switch (low water indicator) for leaks.

  • Page 23: Checking The Condensate Drain And The Neutralising System (If Installed)

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

  • Page 24: Checking The Burner Gauze Assembly

    Initial start-up, 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

    Initial start-up, 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 gas fan A.

  • Page 26: Burner Installation

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Burner installation 87 kW 1. Install fan A. Note Ensure the gasket between the fan housing and the boiler door is cor- rectly positioned. 2. Push the connecting cables "100" and "100a"...

  • Page 27: Checking Both Gas Train Valves For Soundness (For 115 To 311 Kw)

    Otherwise it leaks. In that case, return the gas combination valve to Viessmann Werke for tests. 1. Close the gas shut off valve. 7. After the test, close both test con- nectors by tightening the respec- 2.

  • Page 28: Implementing Final Tests

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 4. Start the burner (see page 7). 5. Check the outlet seals of the gas combination valve and fittings between the fan and the boiler door and between the fan and the ven- turi pipe for soundness.

  • Page 29: Checking The Diaphragm Expansion Vessel And System Pressure

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) Fill Top up Coun- Total Concentra- Water treatment Date water water water tion [Ca volume (HCO mol/m Med- Meter- ing vo- lume Max. fill volume: ........m Checking the diaphragm expansion vessel and system pres- sure Note 2.

  • Page 30: Checking The Mixer For Obstructions And Leaks

    Initial start-up, inspection, maintenance Further details regarding the individual steps (cont.) 3. Top up your heating system with water and vent until the filling pres- sure of a cool system is 0.1 to 0.2 bar higher than the inlet pressure of the diaphragm expansion ves- sel.
  • Page 31 Initial start-up, inspection, maintenance Air pressure switch Function The air pressure switch A signal is assessed under the following operat- ing conditions: prior to the fan start (idle state check) in the pre purge phase in control mode, as far as at least a starting output is produced.
  • Page 32 Initial start-up, inspection, maintenance Burner control unit Display and programming unit Function A display and programming unit is integrated into the burner control unit. The display indicates the respective operating conditions, the service and parameter conditions as well as all fault and error messages. The display comprises three elements of seven segments each.
  • Page 33 Initial start-up, inspection, maintenance Burner control unit (cont.) Idle state check Fan spin Pre purge Pre ignition Safety time Flame established Operation with flame Post purge Standby...
  • Page 34 Initial start-up, inspection, maintenance Burner control unit (cont.) Display Status Service (single digit) (two digit) Operating display in Current operating Display "FL" if a Page 33 standard mode condition, see flame signal is pre- pages 32 and 33 sent Operating display for Message code "A"...
  • Page 35 Initial start-up, inspection, maintenance 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 operation with reduced output.
  • Page 36 Initial start-up, inspection, maintenance Burner control unit (cont.) Setting Setting Rated burner output Reduced burner output Parameter set 4 Parameter set 10 246 kW 173 kW Parameter set 5 Parameter set 11 311 kW 218 kW Acknowledging a parameter set A flashing "P"...
  • Page 37 Initial start-up, inspection, maintenance Burner control unit (cont.) 2. Press b and a simultaneously 3. Press the reset button. for approx. 2 s. Then the operating display will be The selected parameter setting has shown again. been accepted when "P" no longer flashes and the memory LED illumi- nates.
  • Page 38 Initial start-up, inspection, maintenance Burner control unit (cont.) 1. Press a. The operating phase, under which the fault has occurred, is displayed under "Service" as long as this key is held down. (value "01" to "21". See flow chart on page 46). 2.
  • Page 39 Initial start-up, inspection, maintenance Burner control unit (cont.) 2. Press S to scan the penultimate to the sixth from last fault. Display under Fault "Status" most recent fault sixth from last fault The relevant fault code is displayed under "Service". 3.
  • Page 40 Troubleshooting Diagnosis Faults with indication on the display and programming unit Message codes Message System character- Cause Remedy code istics Burner OFF Gas pressure Check the gas pressure switch fault switch Burner OFF Lack of gas Notify your gas supply company Burner is in a fault See fault code...
  • Page 41 Troubleshooting Diagnosis (cont.) Fault code System character- Cause Remedy istics The gas pressure Gas shut off valve Open the gas shut off switch signals no closed, gas pres- valve and check the gas gas pressure during sure switch faulty supply pressure; clean the safety period the gas filter, if required.
  • Page 42 Troubleshooting Diagnosis (cont.) Fault code System character- Cause Remedy istics No flame signal Incorrect para- Adjust the parameter set after the safety peri- meter set se- (see page 35 to 36). od; the ionisation lected flame monitor re- ports no flame sig- The ionisation flame Ignition cables Remove the short cir-...
  • Page 43 Troubleshooting Diagnosis (cont.) Fault code System character- Cause Remedy istics Burner control unit Internal fault of Replace the burner con- fault the gas pressure trol unit. switch input Burner control unit Internal flame Replace the burner con- fault monitor fault trol unit.
  • Page 44 Troubleshooting Diagnosis (cont.) Fault code System character- Cause Remedy istics The fan does not The fan is faulty; Check cable "100" or reach its set speed cable "100" or "100a"; if required, re- "100a" is faulty or place the cable or fan or broken;...
  • Page 45 Troubleshooting Diagnosis (cont.) Faults without fault display Fault Cause Measures Combustion fault through Excessive gas through- Adjust the gas throughput pulsation in accordance with the rated boiler output Air shortage or excess Adjust the gas throughput in accordance with the rated boiler output.
  • Page 46 Gas burner control unit flow chart Gas burner control unit flow chart After the controller issues a heat demand, the following program sequence will be run:...
  • Page 47 Gas burner control unit flow chart Gas burner control unit flow chart (cont.) Phase Duration Test for heat demand Checking the idle state of the air pressure switch and 1 to 30 s the fan Fan ramps up to speed (a fault shutdown will be in- 1 to 30 s itiated if the air pressure switch does not signal within this time scale, that the air pressure has reached a...
  • Page 48 Burner control unit connection diagram Burner control unit connection diagram A1 Burner control unit MPA 51 F4 Minimum pressure, gas pressure A2 Display unit with reset function switch B1 Flame monitoring via an ionisa- F6 Air pressure switch tion current H1 Hours run counter, total B2 Safety chain jumper H2 Fault indication...
  • Page 49 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 dam- feedback per (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 186...
  • Page 50 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 51 Component overview Component overview (cont.) E Gas supply pipe M Ignition unit F Gas shut off valve N Inlet adaptor for balanced flue G Flame body operation (option) H Ignition electrodes P Gas pressure switch I Ionisation electrode Q Gas combination valve K Thermal insulation block R Venturi mixing pipe L Burner control unit...
  • Page 52 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 53 Component overview Component overview (cont.) E Gas combination valve M Burner control unit F Gas supply pipe N Ignition unit G Gas shut off valve P Suppressor box H Flame body Q Inlet adaptor for balanced flue I Ignition electrodes operation (for 115, 142 and 186 K Ionisation electrode L Thermal insulation block...
  • Page 54 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 radiant burner in kW Coding address card...
  • Page 55 116 Cable harness (servomotor, fan 211 Front insulating mat and ignition transformer) for 246 212 R.h. and l.h. cover panel and 311 kW 213 Vitocrossal 200 logo Ignition unit connecting cable for 214 Edge protector 87, 115, 142 and 186 kW Wearing parts...
  • Page 56 Parts lists Parts lists (cont.) Parts not shown 133 Enriching nozzle 103 Small parts comprising: 300 Thermal insulation pack a Threaded connector 301 Touch up spray, Vitosilver b Cheese head screw M6 x 10 302 Touch up paint stick, Vitosilver c 6.4 mm washer 303 Installation instructions d Hexagon screw M5 x 16...
  • Page 57 Parts lists Parts lists (cont.) MatriX burner 87 kW...
  • Page 58 Parts lists Parts lists (cont.) MatriX burner 115 to 311 kW...
  • Page 59 Parts lists Parts lists (cont.) Vitocrossal 200, type CM2, 87 to 311 kW...
  • Page 60 Report Report Setting and test values Initial start up Service Static pressure mbar Supply pressure (flow pres- sure) = for natural gas E mbar = for natural gas LL mbar Tick gas type Carbon dioxide content CO at the upper actual % vol.
  • Page 61 Report Water quality requirements (cont.) Boiler water requirements Total rated output of the Calcium hydrogen car- Maximum permissible fill heating system [ ] bonate concentration and top up water volume [Ca(HCO of the fill and top up water 100 kW no requirements no requirements 100 kW <...
  • Page 62 Specification Specification Gas fired boiler, category I 2ELL Rated output = 40/30 °C = 80/60 °C Rated output Product ID CE 0085 BQ 0021 Connection values Relative to the max. load with gas with H Natural 9.45 kWh/m 10.3 gas E (34.01 MJ/m 11.5 14.2...
  • Page 63 Specification Specification (cont.) MatriX radiant burner Rated output of the boiler = 40/30 °C = 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...
  • Page 64 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 65 Condensing boilers. 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 66 Certificates Manufacturer's certificate according to the 1st BImSchV [Germany] We, Viessmann Werke GmbH&Co KG, D 35107 Allendorf, confirm that the fol- lowing product meets the NO limits specified by the 1st BImSchV paragraph 7 (2) [Germany]: Vitocrossal 200, type CM2 incl. MatriX radiant burner Allendorf 05.07.05...
  • Page 67 Keyword index Keyword index Acknowledging a parameter set Fault code ........Adjusting the DIP switch Fault display .
  • Page 68 7185 861 5 00001 7185 862 5 00001 7185 863 5 00001 7185 864 5 00001 7185 865 5 00001 7185 866 5 00001 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telefon: +49 6452 70-0 Shropshire, TF1 7YP, GB...

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