Viessmann VITOCROSSAL 200 Service Instructions Manual
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Viessmann VITOCROSSAL 200 Service Instructions Manual

Viessmann VITOCROSSAL 200 Service Instructions Manual

Type ct2, gas fired condensing boiler with matrix cylinder burner for natural gas e and ll
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See also: Instruction Manual , Instruction and Service Manual
VIESMANN

Service instructions

for contractors
Vitocrossal 200
Type CT2
Gas fired condensing boiler with MatriX cylinder burner
for natural gas E and LL
For applicability, see the last page
VITOCROSSAL 200
Please keep safe.
5692 759 GB
5/2008

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Summary of Contents for Viessmann VITOCROSSAL 200

  • Page 1: Service Instructions

    VIESMANN Service instructions for contractors Vitocrossal 200 Type CT2 Gas fired condensing boiler with MatriX cylinder burner for natural gas E and LL For applicability, see the last page VITOCROSSAL 200 Please keep safe. 5692 759 GB 5/2008...

  • Page 2: Safety Instructions

    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 Instal- charge static loads. ling non-authorised compo- nents and non-approved modifications/conversion can compromise safety and may invalidate our warranty. For replacements, use only ori- ginal spare parts from Viessmann or those which are approved by Viessmann.

  • Page 4: Table Of Contents

    Index Index Commissioning, inspection, maintenance Steps – commissioning, inspection and maintenance ........Further details regarding the individual steps ..........Troubleshooting Diagnosis ....................40 Gas burner control unit flow chart Burner control unit flow diagram ..............48 Connection diagrams Burner control unit connection diagram ............50 Mains filter unit connection diagram ............

  • Page 5: Commissioning, Inspection, Maintenance

    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 ... •...
  • Page 6 Commissioning, inspection, maintenance Steps – commissioning, inspection and . . . (cont.) Commissioning steps Inspection steps Maintenance steps Page • • 21. Checking the ignition and ionisation electrodes ..• • 22. Closing the boiler door .

  • 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 Control unit installation and be set higher than 110 °C; if required, service instructions set it to a maximum of 110 °C. Filling the heating system with water and venting the system Note Record the fill volume, water hard-...

  • Page 8: Starting The Heating System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Starting the heating system Control unit operating and service instructions, and neutralising system operating instructions 1. Check the heating system pres- sure. Permissible boiler operating pres- sure: 5.5 bar 2. For open flue operation: Check that the installation room ventila- tion is unobstructed.
  • Page 9 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Switch ON system ON/OFF 7. Match the coding at the boiler switch B at the control unit. If control unit according to the table fault indicator A at the control on page 54.

  • Page 10: Checking The Gas Type

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the gas type 1. Determine the gas type and Wobbe 2. In the delivered condition, the burn- index (Wo) from your gas supplier. er is set up for natural gas E. If &...

  • Page 11: Checking The Static And The Supply Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 7. Release the gas train from flange 12. Affix enclosed label "Adjusted to ..." F above the existing label. 8. Remove restrictor C with rubber 13. Start the burner (see page 8). cork gasket D.
  • Page 12 Commissioning, 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 61). Note For commissioning, see page 8. 4. Close the gas shut-off valve. Switch the burner to maximum out- put.

  • Page 13: Checking The Co 2 Content

    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 simulta- neously. Display C will then show the fol- lowing: &...
  • Page 14 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 spe- cified range: –...
  • Page 15 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 content reaches the stipu- lated range: –...

  • Page 16: Checking The Ionisation Current

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

  • Page 17: Shutting Down The System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Shutting down the system 2. Pull connecting plugs fÖ, fA, lÖ 1. Switch OFF the main isolator or the and fÖ/aBH from the burner. power supply and safeguard against unauthorised reconnection. 3.
  • Page 18 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 5. Undo six screws on the boiler door Please note E and open the door. Scratches inside the combus- tion chamber can lead to corro- sion. Never put tools or other objects into the combustion chamber.

  • Page 19: Separating The Neutralising System (If Installed) From The Boiler And Connecting The Drain Hose

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Separating the neutralising system (if installed) from the boiler and connecting the drain hose 1. Separate hose A to the neutralis- ing system from siphon B. 2. Connect drain or cleaning hose C to the siphon and run it into a sewer.

  • Page 20: Checking Gaskets And Thermal Insulation Components

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) For normal cleaning, flush the heating & Remove coatings and surface dis- surfaces with a water jet. However, colouration (yellow-brown) with you may use cleaning agents if you slightly acidic, chloride-free clean- notice stubborn residues, surface dis- ing agents based on phosphoric colouration or soot deposits.

  • Page 21: Cleaning And Reconnecting The Condensate Drain System

    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 siphon B. 5. Fill lower part A of siphon B with water and reassemble.

  • Page 22: Checking The Condensate Drain And The Neutralising System (If Installed)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the condensate drain and the neutralising system (if installed) Fill water into the combustion cham- If necessary, clean the condensate ber. drain again. Note The water must flow from the conden- sate drain without back pressure.

  • Page 23: Checking The Ignition And Ionisation Electrodes

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the ignition and ionisation electrodes Ignition electrodes Ionisation electrode Check the ignition electrodes and the ionisation electrode for correct gap towards the burner gauze assembly and damage (replace, if required). Closing the boiler door Note Tighten the boiler door screws evenly...

  • Page 24: Installing The Burner

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Pull the connecting cables from fan 5. Clean the fan casing and impeller E and remove fan. with compressed air. Danger 6. If required, vacuum the inside of burner gauze assembly F. Mains voltage can be extre- mely dangerous.

  • Page 25: Checking Both Gas Train Valves Automatically For Gas-Tightness

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking both gas train valves automatically for gas-tight- ness The burner control unit automatically In either case, the gas train must be checks the valves for tightness when replaced. the burner is started. If the valves are gas-tight, the burner enters standard Danger mode and the burner starts.

  • Page 26: Checking The Rotary Damper Setting

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the rotary damper setting 1. Open the gas shut-off valve. 3. Check whether the compensation cable A has been connected 2. Check the position of the rotary between the gas train and distribu- damper in burner idle mode.

  • Page 27: Implementing Final Tests

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 5. Check the position of the rotary damper during the start-up phase. The rotary damper windows B must be almost closed for approx. 5 s, during which time the gradu- ated collar D is set as follows: Rated output in Rotary valve dam-...
  • Page 28 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Fill water Top-up water Meter reading Total water Date volume — — — — — — — — — — — — — — — — — — Max. fill volume: ......m...

  • Page 29: Expansion Vessel And System Pressure Check

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Total hardness pH value Water treatment Date Feedwater Boiler Boiler Medium Metering water water volume The pH value should be between 8.2 and 9.5. Expansion vessel and system pressure check Note 2.

  • Page 30: Checking The Flue Gas Header For Tightness

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the flue gas header for tightness 1. Visually inspect gasket A on the 2. If required, retighten the gasket at clamping clips B. flue gas collector. Traces of con- densate on the outside of the flue gas header indicate a leak.

  • Page 31: Operating And Service Documents

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Operating and service documents 1. Complete and detach the customer 2. File all parts lists, operating and registration card: service instructions in the folder & Hand the system user this part and hand this over to the system for safekeeping.
  • Page 32 Commissioning, inspection, maintenance Air pressure switch (cont.) & if the idle state check is not suc- The fault shutdown is indicated with cessful after 5 attempts (anti-cycling the fault codes "F AA" and "F AB" in function) (i.e the air pressure switch the burner control unit display.

  • Page 33: Operating Display

    Commissioning, inspection, maintenance Burner control unit (cont.) Operating display In standard mode, the display shows the current operating conditions. The same applies after pressing reset following a fault display. The following displays are scrolled through automatically. In case of faults, see the fault codes from page 40.
  • Page 34 Commissioning, inspection, maintenance Burner control unit (cont.) Flame stabilisation Operation with flame Post-purge Maintenance program Lack of gas Standby...

  • Page 35: Information Display

    Commissioning, inspection, maintenance Burner control unit (cont.) Display Status Service (single digit) (two digits) Operating display in For current operating Display "FL" if a Page 34 standard mode condition/status, see flame signal is pre- pages 33 and 34 sent — Operating display for For message code Table on...
  • Page 36 Commissioning, inspection, maintenance Burner control unit (cont.) Start counter with reset, 1 digit Start counter with reset, 100 digit Start counter with reset, 1000 digit Hours run meter with reset, 1 digit Hours run meter with reset, 100 digit Hours run meter with reset, 1000 digit Manual mode and service display To call up the service display and for manual mode, a heat demand must be issued by the control unit.

  • Page 37: Fault Display

    Commissioning, inspection, maintenance Burner control unit (cont.) 1. Press b and S simultaneously; the burner enters manual mode. The display shows "d" = control stop under status. 2. Adjust the lower output: Press b until "d 0" is shown. 3. Adjust the upper output: Press a until "d 00"...

  • Page 38: Fault Memory

    Commissioning, inspection, maintenance Burner control unit (cont.) A Fault code of the most recent fault (see table on page 40) 1. Press a. The status number / operating phase under which the fault has occurred is displayed under "Ser- vice" as long as this key is held down (values "01"...
  • Page 39 Commissioning, inspection, maintenance 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. Calling up the fault 1. Press the reset button and a simultaneously. The most recent fault will be dis- played: First, "0"...

  • Page 40: Troubleshooting Diagnosis

    Troubleshooting Diagnosis Faults with indication on the display and programming unit (fault codes) Message codes Message System character- Cause Measures code istics Burner OFF Gas pressure lim- Check the gas pressure iter fault limiter Burner OFF Lack of gas Notify your gas supply company Burner OFF Data transfer from...
  • Page 41 Troubleshooting Diagnosis (cont.) Fault code System character- Cause Measures istics F AB Fan does not run Fan faulty; cables Check cables and re- are faulty or bro- place the fan if required F AD The gas pressure Gas shut-off valve Open the gas shut-off limiter signals no closed, gas pres-...
  • Page 42 Troubleshooting Diagnosis (cont.) Fault code System character- Cause Measures istics F A6 The ionisation flame Gas train not gas- Replace the gas train monitor reports ex- tight; gas is es- ternal light ingress caping and burn- during the start or after the post-purge F A6 The ionisation flame...
  • Page 43 Troubleshooting Diagnosis (cont.) Fault code System character- Cause Measures istics F A7 No flame signal dur- Connections "L1" Check core allocations ing the safety time; and "N" at the and alter if required the ionisation flame power supply monitor reports no terminals of the flame signal control unit or...
  • Page 44 Troubleshooting Diagnosis (cont.) Fault code System character- Cause Measures istics F A9 Flame extinguishes Burner gauze as- Replace the burner during stabilising sembly faulty gauze assembly time F A9 Flame extinguishes Incorrect para- Set parameters during stabilising meter set time F A9 Flame extinguishes Combustion char-...
  • Page 45 Troubleshooting Diagnosis (cont.) Fault code System character- Cause Measures istics F 4F Type of parameter Memory stick Replace stick or burner memory stick does not match control unit burner control unit F 40 Burner control unit Set default value Replace memory stick in fault state for fan in para- meter set incor-...

  • Page 46: Faults Without Fault Display

    Troubleshooting Diagnosis (cont.) Fault code System character- Cause Measures istics F 54 PWM values incor- EEPROM of Replace memory stick rect memory stick modified or de- leted; stick faulty F 55 Parameter memory Memory stick Replace memory stick stick fault faulty Internal system fault Internal system faults are created if a perfect program sequence can no longer...
  • Page 47 Troubleshooting Diagnosis (cont.) Fault Cause Remedy Whining noises Incorrect CO settings; Adjust the burner in ac- air shortage or excess cordance with the details on page 13. content too low Incorrect setting Check that burner has been adjusted for the cor- rect gas type and change the gas restrictor, if re- quired (see from...

  • Page 48: Gas Burner Control Unit Flow Chart

    Gas burner control unit flow chart Burner control unit flow diagram...
  • Page 49 Gas burner control unit flow chart Burner control unit flow diagram (cont.) After the controller issues a heat demand, the following program sequence will be run: Phase Duration Fault 0 ... Waiting for heat demand 0 ... Fan idle state max.

  • Page 50: Connection Diagrams

    Connection diagrams Burner control unit connection diagram A Burner control unit MPA 5113 L Ignition unit B Vitotronic control unit M Solenoid valve stage 2 (BV 2) C Fan motor with PWM control and N Solenoid valve stage 1 (BV 1) O Servomotorfor rotary valve feedback D Flame monitoring via an ionisation...

  • Page 51: Mains Filter Unit Connection Diagram

    Connection diagrams Mains filter unit connection diagram fÖ Mains filter Power supply 230 V~/50 Hz fÖ/aBH Control unit Contactor To the fan (plug a-Ö) Flue gas damper Note The power cable must be protected. The maximum fuse rating is 16 A. Provide the power supply (230 V~/ 50 Hz) via a permanent connection.

  • Page 52: Component Overview

    Component overview Component overview MatriX cylinder burner A Burner frame F Rotary valve damper with servo- B Air pressure switch motor C Gas fan G Venturi mixing pipe D Display and programming unit H Mains filter unit with contactor E Gas train...
  • Page 53 Component overview Component overview (cont.) B Air pressure switch M Gas supply pipe D Display and programming unit N Burner control unit H Mains filter unit with contactor O Ignition unit K Ignition electrodes p Burner gauze assembly L Ionisation electrode...

  • Page 54: 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 ad- Rated output of the MatriX cylinder burner Coding card dress in kW...

  • Page 55: Parts Lists

    Parts lists Parts lists Spare parts information 026 Burner hood Quote the type and serial no. (see 027 Enriching nozzle type plate) and the item no. of the 028 Parameter memory stick required part (as per this parts list). 029 Compensation set Obtain standard parts from your local 030 VPS connecting cable for gas supplier.
  • Page 56 Parts lists Parts lists (cont.) 224 Top part, cable duct 304 Dirko-HT sealant 225 Strain relief 305 Installation instructions 226 Edge protector 306 Service instructions 227 Brace A MatriX burner type plate B Label "Adjusted to ..." Wearing parts C Burner cable (see parts list in the 005 Ignition electrodes 1 and 2 with O-rings service instructions of the boiler...
  • Page 57 Parts lists Parts lists (cont.) MatriX cylinder burner...
  • Page 58 Parts lists Parts lists (cont.) Vitocrossal 200, type CT2...
  • Page 59 Parts lists Parts lists (cont.)
  • Page 60 Parts lists Parts lists (cont.)

  • Page 61: Commissioning /Service Report

    Commissioning /service report Commissioning /service report Setting and test values Commission- 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 % by...

  • Page 62: Water Quality Requirements

    Commissioning /service report Water quality requirements Note Maintaining the following require- ments 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 guide- line 2035 sheet 1 "Prevention of heating system damage –...
  • Page 63 Commissioning /service report Water quality requirements (cont.) & In systems > 50 kW, install a water & Take the system into use step by meter to record the volume of the fill step, starting with the lowest boiler & top-up water. Enter the amount of output and at a high heating water fill water and the water hardness flow rate.
  • Page 64 Commissioning /service report 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 an expansion vessel, heating systems and boilers depends offer good protection against the on the absence of oxygen in the heat- ingress of airborne oxygen into the...
  • Page 65 Commissioning /service report Water quality requirements (cont.) Where chemicals are used as part of Further details can be found in the the corrosion protection, we recom- VDI Directive 2035-2 and in EN mend that the manufacturer of the 14868. chemicals issues a certificate of suit- ability of the additives with regard to the boiler materials and the materials of the other heating equipment com-...

  • Page 66: Specification

    Specification Specification Gas fired boiler, category I 2ELL Rated output = 50/30 °C 135-404 168-503 209-628 = 80/60 °C 123-370 153-460 192-575 Rated thermal load 127-381 158-474 198-593 Product ID CE-0085 BS 0399 Connection values relative to the max. load with &...
  • Page 67 Specification Specification (cont.) Gas restrictor dimensions (natural Rated output Dimension a gas E) 404 kW 17.8 503 kW 22.0 628 kW 24.0...

  • Page 68: Certificates

    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 69: Manufacturer's Certificate According To The 1St Bimschv [Germany]

    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): Vitocrossal 200, type CT2, with MatriX cylinder burner Allendorf, 09.05.08...

  • Page 70: Keyword Index

    Keyword index Keyword index Air pressure switch Gas connection tightness ........Applicability .
  • Page 72 7311 947 7 00001 ␣␣␣, 7311 545 7 00001 ␣␣␣, 7311 948 7 00001 ␣␣␣, 7311 546 7 00001 ␣␣␣, 7311 949 7 00001 ␣␣␣, Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0...

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