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

Type cm2 gas condensing boiler with matrix radiant burner
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See also: Instruction Manual , Instruction and Service Manual
VIESMANN
Service instructions
for contractors
Vitocrossal 200
Type CM2
Gas condensing boiler with MatriX radiant burner
For applicability, see the last page
VITOCROSSAL 200
Please keep safe.
5692 907 GB
12/2011

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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 with MatriX radiant burner For applicability, see the last page VITOCROSSAL 200 Please keep safe. 5692 907 GB 12/2011...

  • 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 ■ When using gas as fuel, also close the For replacements, use only orig- main gas shut-off valve and safeguard inal spare parts from Viessmann against unauthorised reopening. or those which are approved by ■ Isolate the system from the power sup- 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 Start-up problems with 285 kW, open flue operation........... 46 Burner control unit flow chart................47 Burner control unit connection diagram............49 Component overview..................
  • 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 electrodes and ionisation electrode................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 Never set the high limit safety cut-out Control unit installation and serv- higher than 110 °C, set it to a maximum ice instructions of 110 °C if required. Filling the heating system with water and venting the system Record the fill volume, water hardness Note...
  • Page 8 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. For open flue operation: Check that the vents in the installation room are open. 3. Check the gas supply pressure. 4. Open the gas line shut-off valves. 5. Switch ON the mains 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 and plugs, and retighten if necessary. Note We recommend you check all con- nections on the heating water side for leaks after approx. 500 hours run (see page 22).
  • Page 10 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 09. Secure Venturi mixing pipe H at 03. Switch OFF the mains isolator (out- side the installation room) or the the gas fan. power supply and prevent unauthor- Connect compensation line E ised reconnection.
  • 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) to flange E; replace the factory-fitted M 5 ×...

  • Page 12: Checking The Static And The Supply Pressure

    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 in test nipple A, but do not remove.
  • Page 13 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 nipple 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 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 heat-...
  • Page 17 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. If the CO content must be adjusted: ■ Remove cap B. ■ Turn setting screw A in small increments (3 mm Allen key) until the CO content lies within the specified 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 falls within 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 mains isolator. 07. Switch the mains isolator ON and press reset. 02. Pull ionisation cable plug C. 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 mains isolator or the 2. Pull plug-in connector 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: Checking Gaskets And Thermal Insulation Parts

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

  • Page 22: And The Sensor Well For Leaks

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking all connections on the heating water side and the sen- sor 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.

  • Page 23: System (If Installed)

    Neutralising system operating instructions Note You can obtain the 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 Information regarding the door lock Tighten the boiler door screws evenly Before commissioning, check that the across with a torque of approx. 18 Nm. boiler door is seated correctly and has no leaks.

  • Page 26: Fitting The Burner

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

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

    1 mbar within 5 min. Otherwise it leaks. In that case, return the gas train to your local Viessmann sales office for tests. 7. After the test, close both test nipples 1. Close the gas shut-off valve.

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

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the gaskets/seals on the flue gas side 1. Check flue gas collector C and 2. Check the lip seal B of the boiler flue boiler body A for tightness. connection for tightness.

  • Page 29: Implementing Final Tests

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. If required, retighten the flue gas col- lector at clamping clips D. Replace lip seal B if it leaks. Implementing final tests 1. Carry out the final tests according to 2.

  • Page 30: 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 2.

  • Page 31: Checking The Mixer For Ease Of Operation And Leaks

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the mixer for ease of operation and leaks 1. Remove the motorised lever from the 3. Check the mixer for leaks. Replace mixer handle. the O-ring gaskets if the mixer is leak- ing.

  • Page 32: Air Pressure Switch

    Air pressure switch Function The air pressure switch A signal will be interpreted 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 33 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 34 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 35 Burner control unit (cont.) Display Status Service (single digit) (two digits) Operating display in Current operating Display "FL" if a flame Page 34 standard mode condition, see signal is present page 33 and 34 Operating display for Message code "A" or —...
  • Page 36 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 heating output of the burner. A change to this factory setting is only required for operation with reduced heating output.
  • Page 37 Burner control unit (cont.) Setting Setting Rated burner heating output Reduced burner heating 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 38: Fault Display

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

  • Page 39: 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. The operating display will then be shown again. Fault memory The most recent six faults are saved and may be called up.

  • Page 40: Diagnosis

    Troubleshooting Diagnosis Faults with fault indicator on the display and programming unit Message codes Message System characteris- Cause Measures code tics Burner off Gas pressure Check the gas pressure switch fault switch Burner off Lack of gas Notify your gas supply util- Burner is in a fault See fault code See fault code steps...
  • Page 41 Troubleshooting Diagnosis (cont.) Fault code System characteris- Cause Measures tics No flame signal after Ionisation elec- Adjust ionisation elec- the safety time; the trode incorrectly trode (see page 24). ionisation flame mon- adjusted itor reports no flame signal No flame signal after Ignition electrodes Adjust ignition electrodes the safety time;...
  • Page 42 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 43 Troubleshooting Diagnosis (cont.) Fault code System characteris- Cause Measures tics Burner control unit Fault during test of Replace burner control fault safety inputs unit. Burner control unit Internal fault, low Replace burner control fault voltage recog- unit. nised Burner control unit Internal fault, volt- Replace burner control fault...
  • Page 44 Troubleshooting Diagnosis (cont.) Fault code System characteris- Cause Measures tics The fan does not The fan is faulty; Check cable "100" or reach its set speed cable "100" or "100a"; if required, "100a" is faulty or replace the cable or fan or broken;...
  • Page 45 Troubleshooting Diagnosis (cont.) Faults without fault display Fault Cause Measure Combustion fault Excessive gas Adjust gas throughput in accord- through pulsation throughput ance with rated boiler heating out- put. Too little or too much Adjust gas throughput in accord- ance with rated boiler heating out- put.

  • Page 46: Start-Up Problems With 285 Kw, Open Flue Operation

    Troubleshooting Start-up problems with 285 kW, open flue operation Application information Applies only to the MatriX radiant burner, type VMA III with 285 kW, for open flue operation. If the following problems are experienced with the burner: ■ Loud and irregular start-up characteristics. ■...

  • 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 A Burner control unit MPA 51 G Minimum pressure, gas pressure switch B Vitotronic control unit H Ignition unit C Fan motor with PWM control and feedback K Gas fuel safety valve D Flame monitoring via an ionisation L Choke valve (for 87, 142 and current...
  • Page 50 Burner control unit connection diagram Burner control unit connection diagram (cont.) B2 Safety chain jumper K1 Relay contact F1 Backup fuse S1 ON/OFF switch (inside the control F2 Backup fuse unit) F6 High limit safety cut-out S3 Output controller (inside the control F7 Temperature controller unit) H1 Hours run meter, total...

  • 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 switch H Ignition electrodes Q Gas train I Ionisation electrode R Venturi mixing pipe 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 Suppressor 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 pipe 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 GC1B ■ Vitotronic 200, type GW1B ■ Vitotronic 300, type GW2B Coding Rated heating output of the MatriX radiant burner in kW Coding address card 1041...

  • Page 56: Parts Lists

    109 Ignition cable 211 Thermal insulation mat, front 112 Ionisation cable 212 R.h. and l.h. cover panel 113 Burner control unit 213 Vitocrossal 200 logo 114 Display and programming unit for 214 Edge protector burner control unit 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 Spray paint, 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: Report

    Report 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 heating output...

  • Page 62: Water Quality Requirements

    Water quality requirements Note The manufacturer's warranty excludes Observing the following requirements is damage due to corrosion and scaling. necessary to safeguard your warranty rights. 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 Directive 2035 sheet 1 "Prevention of heating system damage –...
  • Page 63 Water quality requirements (cont.) ■ In systems > 50 kW, install a water ■ Commission the system step by step, meter to record the volume of the fill & starting with the lowest boiler output top-up water. Enter the volume of the and 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–...
  • 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 system components.

  • Page 66: Specification

    Specification Specification Gas boiler, category I 2ELL Rated heating out- = 50/30 °C 104- = 80/60 °C Rated heat input 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 heat- ing 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 consump- tion Motor speed 4832 4384 5088 5568 5952 6080 Modulation range 33-100 33-100 33-100 25-100 33-100 33-100 Gas restrictor dimensions (natural...
  • Page 68 Specification Specification (cont.) Gas restrictor dimensions (natural Rated heating 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, type CM2, as part of EC type testing according to the Efficiency Directive can be used to assess the energy consumption of heating and ventilation equipment to DIN V 4701-10, as specified by the EnEV [Germany] (see specification table).

  • Page 70: Manufacturer's Certificate According To The 1St Bimschv

    Manufacturer’s certificate according to the 1st BImSchV We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm that the product Vitocrossal 200, type CM2, 87 to 311 (80 to 285) kW with MatriX radiant burner complies with the following conditions stipulated by the first German Immissions Order (BImSchV): ■...

  • Page 71: Keyword Index

    Keyword index Keyword index Faults without fault display....45 Acknowledging a parameter set..37 Flow chart..........47 Air pressure switch......32 Flow pressure........13 Burner Gas connection tightness....27 ■ Cleaning.........25 ■ Fitting..........26 Burner control unit......33 Implementing final tests.....29 Burner gauze assembly, checking..24 Internal system fault......44 Checking the CO2content....14 Operating display.......33 Checking the gaskets/seals on the flue...
  • Page 72 7247423 7247424 7247425 7185861 7185862 7185863 7185864 7185865 7185866 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040...

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