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Viessmann VITOCROSSAL 200 CM2 Service Instructions For Contractors

400 to 620 kw gas condensing boiler with matrix cylinder burner, for open flue and room sealed operation, permissible operating pressure 6 bar
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VIESMANN
Service instructions
for contractors
Vitocrossal 200
Type CM2, 400 to 620 kW
Gas condensing boiler with MatriX cylinder burner
For open flue and room sealed operation
Permissible operating pressure 6 bar
VITOCROSSAL 200
Please keep safe.
5833544 GB
6/2018

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Summary of Contents for Viessmann VITOCROSSAL 200 CM2

  • Page 1 VIESMANN Service instructions for contractors Vitocrossal 200 Type CM2, 400 to 620 kW Gas condensing boiler with MatriX cylinder burner For open flue and room sealed operation Permissible operating pressure 6 bar VITOCROSSAL 200 Please keep safe. 5833544 GB 6/2018...
  • Page 2 Danger system. Hot surfaces and fluids can lead to burns or Replace faulty components only with genuine scalding. Viessmann spare parts. Before maintenance and service work, switch ■ OFF the appliance and let it cool down. ■ Never touch hot surfaces on the boiler, burner,...
  • Page 3 For replacements, use only original spare parts supplied or approved by Viessmann. Safety instructions for operating the system If you smell gas Condensate Danger...
  • Page 4 Index Index 1. Information Disposal of packaging ................Key to date of manufacture ..............Symbols ....................Intended use ..................■ 2. Commissioning, inspec- Steps – commissioning, inspection and maintenance ......tion, maintenance 3. Control unit Adjusting codes at the control unit ............33 4.
  • Page 5 Key to date of manufacture Year Week Fig. 1 Digits Internal Viessmann information Digits 0 and 5 = calendar week 05 = 5th calendar week 1 and 5 = year 2015 Digits Digit 2 = 2nd day of the working week (Monday = 1, Tuesday = 2, etc.)
  • Page 6 Information Symbols Symbol Meaning Reference to other document containing further information Step in a diagram: The numbers correspond to the order in which the steps are carried out. Warning of material losses and environ- mental pollution Live electrical area Pay particular attention. Component must audibly click into place.
  • Page 7 Information Symbols (cont.) Every other use will be deemed to be inappropriate. Permissible operating temperature up to 95 °C. Per- ■ Any resulting losses are excluded from the manufac- missible safety temperature up to 110 °C turer's liability. ■ Delivery: Boiler body on pallet Any usage beyond this must be approved by the man- Thermal insulation, burner, electronics unit with cable...

  • Page 8: Table Of Contents

    Commissioning, inspection, maintenance Steps – commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • 1. Checking the high limit safety cut-out setting..............10 • 2. Filling the heating system with water and venting............10 • 3. Filling the trap with water....................10 •...
  • Page 9 Commissioning, inspection, maintenance Steps – commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • • • 39. Checking the thermal insulation for firm seating • • 40. Checking the ventilation air aperture in the installation room (only for open flue operation) •...

  • Page 10: Checking The High Limit Safety Cut-Out Setting

    Commissioning, inspection, maintenance Checking the high limit safety cut-out setting The high limit safety cut-out is preset to 110 °C and, if required, can only be adjusted by changing the coding card. Filling the heating system with water and venting Record the volume filled, water hardness and pH value Note on page 62.
  • Page 11 Commissioning, inspection, maintenance Opening the boiler (cont.) 2. Remove front panels and, if necessary, the front of the top panel and the side panel (on the side where the boiler door is hinged). For this, undo the M5 screw from the top of the front panel. Disengage the location studs from the side panels, tip the front panel slightly forward and lift away from the lower front panel.

  • Page 12: Checking The Gas Type

    Commissioning, inspection, maintenance Opening the boiler (cont.) 4. To remove the side panel and top panel, undo the M6 screws on the top rail and on the lower support. 5. Close the gas shut-off valve. Fig. 5 Checking the gas type 1.

  • Page 13: Converting To Natural Gas Ll

    Commissioning, inspection, maintenance Converting to natural gas LL 07. Remove restrictor (Not in with rubber cork gasket 08. Secure the gas train (without restrictor without rubber cork gasket ) with inserted O- B C D ring to flange . For this, replace the factory- fitted M5 x 16 screws with the M5 x 12 ones sup- plied.

  • Page 14: Conversion To Lpg P

    Commissioning, inspection, maintenance Conversion to LPG P Restrictor installation 07. Insert O-ring , LPG restrictor and rubber cork gasket B C D Note The bevel on the LPG restrictor must point towards the gas train. 08. Tighten the M5 x 16 screws diagonally. Torque: 1.5 Nm.

  • Page 15: Commissioning The System

    Commissioning, inspection, maintenance Conversion to LPG P (cont.) 6. Use to select "1" for LPG and confirm with "S". If applied successfully, "1" will be shown briefly on the display under "Service", or "0" will be shown if unsuccessful. 7. Press "S" again to switch to the operating display. 8.

  • Page 16: Reducing Operational Output (If Necessary)

    Commissioning, inspection, maintenance Commissioning the system (cont.) 07. Turn ON the system ON/OFF switch on the control 08. Adjust the codes at the boiler control unit. unit. Control unit installation and service instruc- Note tions The burner will start with a delay of approx. 3 min. 09.

  • Page 17: Checking The Static Pressure And Supply Pressure

    Commissioning, inspection, maintenance Checking the static pressure and supply pressure Fig. 11 Static pressure 1. Close the gas shut-off valve. 4. Open the gas shut-off valve. 2. Undo the screw in test connector . Do not 5. Check the static pressure (max. 60 mbar/6 kPa). remove.

  • Page 18: Checking The Rotary Damper Setting

    Commissioning, inspection, maintenance Checking the static pressure and supply pressure (cont.) Supply pressure (flow pressure) Measure Natural gas < 15 mbar < 20 mbar Do not adjust any settings. Notify your gas supply utility or < 1.5 kPa < 2 kPa LPG supplier.
  • Page 19 Commissioning, inspection, maintenance Checking the rotary damper setting (cont.) 5. Check the position of the rotary damper during the start-up phase. Rotary damper windows must be almost closed for approx. 5 s. During this time, scale ring must be at the following settings: Rated heating Rated heat in- Rotary damper...
  • Page 20 Commissioning, inspection, maintenance Checking the rotary damper setting (cont.) Burner 500 kW Fig. 14 Control cable between LDW2 Plus and combustion chamber Control cable between LDW1 Minus and Venturi Control cable between LDW1 Plus, gas train and rotary damper mounting plate Burner 620 kW Fig.

  • Page 21: Checking The Co2 Content

    Commissioning, inspection, maintenance Checking the CO2 content Preparing the test 1. Open the gas shut-off valve. 2. Start the burner via menu point "Emissions test mode" at the control unit. 3. Simultaneously press S and for longer than 2 s. The display will then show the following: Under Status: "P"...
  • Page 22 Commissioning, inspection, maintenance Checking the CO content (cont.) Gas type content Rated heating output in kW lower heating output 1.6 - 2.0 % 1.6 - 2.0 % 1.6 - 2.0 % (0 %) Natural gas K upper heating output 7.3 - 9.7 % 7.3 - 9.7 % 7.3 - 9.7 % (G25.3) NL only...

  • Page 23: Checking The Co Content

    Commissioning, inspection, maintenance Checking the CO content (cont.) 3. If the CO content needs adjusting: 6. Hold down S and simultaneously for longer than 2 s. Burner switches to operating mode. Undo cover and turn setting screw in small steps (Torx 40) until the CO content lies within the Note specified range:...

  • Page 24: Opening The Boiler Door

    Commissioning, inspection, maintenance Opening the boiler door 1. Disconnect power cable with plug fÖ , then discon- nect the burner cables with plugs plug , as well as plug , from the burner control lÖ unit and guide them out of the burner casing. 40/156 15A/15B Fig.

  • Page 25: Checking Gaskets And Thermal Insulation Sections

    Commissioning, inspection, maintenance Cleaning the combustion chamber and heating… (cont.) Cleaning agent manufacturer's instructions Recommendation: "Fauch 600" and "Antox 75 E" Manufacturer: Hebro Chemie GmbH Rostocker Strasse 40 D-41199 Mönchengladbach Checking gaskets and thermal insulation sections 1. Check the gaskets and packing cords in the boiler 3.

  • Page 26: Checking The Condensate Drain And The Neutralising System (If Installed)

    Commissioning, inspection, maintenance Cleaning and reconnecting the condensate drain… (cont.) 1. Undo 4 screws and remove the centre and bottom 7. Undo and flush lower part of trap back panels. 8. Fill lower part of trap with water and reas- 2.
  • Page 27 Commissioning, inspection, maintenance Checking the burner gauze assembly (cont.) Please note Incorrect replacement of the burner gauze assembly can result in contamination of the combustion chamber. Ensure that the combustion chamber is kept free of thermal insulation fibres at all times. 1.

  • Page 28: Checking The Ignition Electrodes And Ionisation Electrode

    Commissioning, inspection, maintenance Checking the ignition electrodes and ionisation electrode Ignition electrodes Ionisation electrode Fig. 27 Fig. 25 Check the ignition electrodes and ionisation electrode for the correct gap to the burner gauze assembly and ± for possible damage. Replace if necessary. Torque 10 Fig.

  • Page 29: Closing The Boiler Door

    Commissioning, inspection, maintenance Fitting the fan (cont.) Note If the burner frame has been detached from the boiler door, ensure that the gasket between the burner frame and the boiler door is seated correctly. Replace the gasket if damaged. Closing the boiler door 1.

  • Page 30: Checking For Tightness On The Flue Side

    Commissioning, inspection, maintenance Checking for tightness on the flue side 2. If necessary, tighten flue gas collector diago- nally to a torque of 10 Nm. Replace the lip seal in the case of leaks. Note We recommend checking for tightness after approx.

  • Page 31: Checking The Filter Element In The Gas Line

    Commissioning, inspection, maintenance Checking the gas train filter element (cont.) 3. Reassemble the gas train in reverse order. 4. Check for gas tightness. See page. Checking the filter element in the gas line If a filter element is fitted in the gas line, check the filter element and replace if necessary.

  • Page 32: Checking The Expansion Vessel And System Pressure

    Commissioning, inspection, maintenance Checking the expansion vessel and system pressure Note 3. Top up with water until the charge pressure of the Observe the expansion vessel manufacturer's instruc- cooled system is 0.1 to 0.2 bar (10 to 20 kPa) tions. higher than the pre-charge pressure of the expan- Carry out this test on a cold system.
  • Page 33 Control unit Adjusting codes at the control unit Vitotronic service instructions...
  • Page 34 Burner control unit Burner control unit Display and programming unit A display and programming unit is integrated into the burner control unit. The display screen shows the rele- vant operating status, the service and parameter sta- tus, as well as any fault or error messages. The display comprises four elements of 7 segments Status Service...
  • Page 35 Burner control unit Burner control unit (cont.) Status Service Status Service Flame stabilisation Dwell program, no gas pressure or mains undervoltage Status Service Operation with flame Status Service Forced ventilation if no flame formation has been detected. Status Service Reheat Status Service Safety shutdown due to Post-purge...
  • Page 36 Burner control unit Burner control unit (cont.) Configurations: Menu Description point Changeover from the operating display of the burner control unit phase to other process in- formation Configuration of control function operating pa- rameters Menu point "5" is used to display the following process information: Sub-menu point Process information Unit/scale...
  • Page 37 Burner control unit Burner control unit (cont.) 5. / for required maximum operational output. 6. S to confirm. If adopted successfully, "1" appears under Service; if it failed, "0" will appear. Note Observe the modulation range. See page 66. 7. S to change to the operating display.
  • Page 38 Flow diagram for burner control unit Flow diagram for burner control unit Fig. 33...
  • Page 39 Flow diagram for burner control unit Flow diagram for burner control unit (cont.) Description of state: Phase Dis- Description Duration play System "A" System start 10 s start Fan ramp-up, system start max. 20 s Forced ventilation, system start 20 s Valve test "P"...
  • Page 40 Troubleshooting Fault indicator Fault display The fault display is activated automatically if the burner 1. Remedy the fault. For fault codes and measures, control unit switches to a fault state. The most recent see from page 40. Carry out measures in the fault is then displayed.
  • Page 41 Troubleshooting Fault codes (cont.) Displayed fault System characteristics Cause Measures code F 82 Burner control unit in a fault Short circuit, flue gas tem- Check connecting lead and sen- state; system cooling down; perature sensor (A or B), sors (A and B); replace sensor if burner control unit locked out.
  • Page 42 Troubleshooting Fault codes (cont.) Displayed fault System characteristics Cause Measures code F F1 Burner control unit in a fault Flue gas excess tempera- Wait until temperature falls below state; system cools down ture; excessive gas the permissible flue gas tempera- throughput ture.
  • Page 43 Troubleshooting Fault codes (cont.) Displayed fault System characteristics Cause Measures code F F6 Gas pressure switch reports Gas shut-off valve closed; Open the gas shut-off valve. Check no gas pressure. gas pressure switch faulty; gas flow pressure. Replace gas fil- multiple problems with gas ter if necessary.
  • Page 44 Troubleshooting Fault codes (cont.) Detailed fault code for fault F Fd Detailed fault code Component/signal Cause of fault Measure Reset button Programming unit faulty, wir- Replace programming unit Check wiring Fuel valve 2 feedback Incorrect return voltage (e.g. Disconnect the plug from fuel DC voltage), actuator faulty valve 2, reset the burner con- trol unit and check the fault...
  • Page 45 Troubleshooting Faults without fault display Fault Cause of fault Measure Combustion faults due to Excessive gas throughput Adjust gas throughput in accordance with the pulsation rated boiler heating output. Insufficient or excessive air Condensate backed up in flue Check condensate drain. system Flue outlet not installed correctly Check flue outlet and flue system.
  • Page 46 Troubleshooting Faults without fault display (cont.)
  • Page 47 Parts lists Overview of assemblies The following details are required when ordering parts: ■ Serial no. (see type plate ■ Assembly (from this parts list) Position number of the individual part within the ■ assembly (from this parts list) 0001 0002 Fig.
  • Page 48 Parts lists Boiler assembly 0001 0002 0009 0008 0003 0004 0005 0006 0006 0007 0007 0008 0009 Fig. 35...
  • Page 49 Parts lists Boiler assembly (cont.) Pos. Part 0001 Flue gas cover with gasket 0002 Sensor well 0003 Stench trap 0004 Adjusting screws 0005 Boiler door 0006 Bolts 12 H11 x 85 x 80 0007 Mounting bracket 0008 Packing GF 0009 Thermal insulation block and mat...
  • Page 50 Parts lists Thermal insulation assembly 0020 0018 0021 0019 0028 0030 0029 0006 0010 0016 0027 0003 0024 0009 0026 0025 0013 0008 0012 0011 0004 0023 0001 0024 0033 0015 0032 0031 0032 0033 0022 0008 0007 0003 0005 0014 0002 Fig.
  • Page 51 Mounting bracket rear panel 0026 Mounting bracket 0027 Mounting bracket fascia 0028 Trunking retainer 0029 Cable trunking FB 60 x 150, lower section 0030 Cable trunking FB 60 x 150, upper section 0031 Support, bottom 0032 Vitocrossal 200 logo 0033 Viessmann logo...
  • Page 52 Parts lists Cable set assembly 0001 0002 0003 0004 0005 0006 Fig. 37...
  • Page 53 Parts lists Cable set assembly (cont.) Pos. Part 0001 Burner cable lÖ 0002 Burner cable 0004 Power cable fÖ 0005 Cable fÖ 0006 Flue gas temperature sensor lead...
  • Page 54 Parts lists Burner assembly 0037 0036 0025 0026 0039 0007 0010 0011 0003 0004 0012 0027 0004 0006 0027 0005 0001 0008 0009 0024 0015 0030 0021 0014 0031 0032 0033 0038 0019 0034 0018 0035 0022 0013 0002 0016 0017 Fig.
  • Page 55 Parts lists Burner assembly (cont.) Pos. Part 0001 Burner frame 0002 Small and fixing parts (control cables/retaining clips) 0003 Burner gauze assembly (wearing part) 0004 Gasket, burner gauze assembly (wearing part) 0005 Ignition electrodes with O-rings (wearing part) 0006 Ignition cable 0007 Ignition transformer 0008...
  • Page 56 Parts lists Parts not shown Pos. Part 0001 Touch-up spray paint, Vitosilver 0002 Touch-up paint stick, Vitosilver 0003 Installation instructions 0004 Service instructions...
  • Page 57 Component overview Component overview Fig. 39 Fig. 40 Burner frame Venturi mixing pipe Air pressure switch 1 Gas fan Air pressure switch 2 Burner gauze assembly Display and programming unit Ignition electrodes Gas train Ionisation electrode Gas supply pipe Ignition unit Gas pressure switch Burner control unit Rotary damper with servomotor...
  • Page 58 Functions Air pressure switch Fan pressure monitoring function (LDW1) If the static pressure check was unsuccessful after ■ approx. 5 minutes ■ If the air pressure is outside the permissible range during the pre-purge phase (tolerance time approx. 5 minutes) ■...
  • Page 59 Connection diagrams Burner control unit connection diagrams Fig. 43 Burner control unit VUC 310 Air pressure switch 2 Fan motor with PWM switching and feedback Flue gas temperature sensor 2 Gas pressure switch 2 Flue gas temperature sensor 1 Air pressure switch 1 Display and programming unit Gas pressure switch 1...
  • Page 60 Connection diagrams Burner control unit connection diagrams (cont.) Fig. 44 Burner control unit VUC 310 Plug 150, HLSC-HLSC Flame monitor through ionisation current F1 Backup fuse Vitotronic control unit F2 Backup fuse Servomotor for rotary damper H1 Hours run meter, modulation Ignition unit H2 Fault message Fuel valve BV1...
  • Page 61 Connection diagrams Burner control unit connection diagrams (cont.) Mains filter unit connection diagram Fig. 45 Mains filter To the fan a-Ö Contactor Power supply 230 V~/50 Hz fÖ Flue gas temperature sensor Control unit fÖ Air pressure switch 2 Flue gas damper to burner control unit a-Ö...
  • Page 62 Reports Water quality Meter reading Fill and top-up water Total water volume Total hardness pH value Date Feedwater Boiler water Settings and test values Settings and test values Commissioning Maintenance/Service Static pressure mbar Supply pressure (flow pressure) for natural gas E mbar for natural gas LL mbar...
  • Page 63 Reports Settings and test values (cont.) Settings and test values Commissioning Maintenance/Service Carbon monoxide con- actual tent CO Flue gas temperature actual °C (gross) °C Ionisation current At upper rated heating μ ■ output At the lower rated heat- μ ■...
  • Page 64 Water quality requirements Water quality requirements Note Prevention of damage due to scaling Observing the following requirements is necessary to safeguard your warranty rights. Prevent excessive scale build-up (calcium carbonate) The warranty excludes damage due to corrosion and on the heating surfaces. For heating systems with scaling.
  • Page 65 Water quality requirements (cont.) Failure to observe the requirements of VDI Guideline Correctly sized sealed unvented systems operating at 2035 can result in damaging limescale deposits. In the correct pressure, e.g. systems with expansion ves- such cases, the service life of the installed boilers will, sel, offer good protection against the ingress of air- most often, already have been reduced.
  • Page 66 Specification Specification Gas boiler, category II 2ELL3P Boiler Rated heating output P For natural gas = 50/30 °C 80 to 400 100 to 500 124 to 620 = 80/60 °C 74 to 370 92 to 460 115 to 575 For LPG = 50/30 °C 100 to 400 125 to 500...
  • Page 67 Specification Specification (cont.) Boiler Flue gas parameters Temperature (at a return temper- ature of 30 °C) At rated heating output °C ■ At partial load °C ■ Temperature (at a return temper- ature of 60 °C) At rated heating output °C ■...
  • Page 68 Specification Specification (cont.) Gas restrictor dimensions (natural gas E and LPG P) Fig. 46 Rated heating output Rated heat input Dim. a (50/30 °C) ) [net cv] Natural gas E (G20) LPG P (G31) in kW in kW in mm in mm 17.4 14.0...
  • Page 69 Final decommissioning and disposal Final decommissioning and disposal Viessmann products can be recycled. Components For decommissioning the system, isolate the system and substances from the system are not part of ordi- from the power supply and allow components to cool nary household waste.
  • Page 70 Manufacturer's certificate We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, confirm that the product Vitocrossal 200, type CM2, complies with the following conditions stipulated by the 1st German Immissions Order (BImSchV): ■ limits according to paragraph 6 (1).
  • Page 71 Keyword index Keyword index Gas train valves, checking......... 30 Air pressure switch Gas type check............12 – Combustion chamber pressure monitoring (LDW2)58 – Fan pressure monitoring (LDW1)......58 Heating surfaces, cleaning.........24 Heating water side connections, checking....25 Boiler, opening............10 Boiler door –...
  • Page 72 Keyword index (cont.) Water quality.............. 62 – Checking..............31 Water quality, requirements........64 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...

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