Viessmann Vitocrossal 200 Series Service Instructions Manual
  1. Manuals
  2. Brands
  3. Viessmann Manuals
  4. Boiler
  5. Vitocrossal 200 Series
  6. Service instructions manual

Viessmann Vitocrossal 200 Series Service Instructions Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

VIESMANN
Service instructions
for contractors
Vitocrossal 200
Type CM2C, 75 to 311 kW
Gas condensing boiler
for open flue and room sealed operation
Permissible operating pressure 6 bar
VITOCROSSAL 200
Please keep safe.
5831036 GB
7/2019

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Vitocrossal 200 Series and is the answer not in the manual?

Questions and answers

Related Manuals for Viessmann Vitocrossal 200 Series

Summary of Contents for Viessmann Vitocrossal 200 Series

  • Page 1 VIESMANN Service instructions for contractors Vitocrossal 200 Type CM2C, 75 to 311 kW Gas condensing boiler for open flue and room sealed operation Permissible operating pressure 6 bar VITOCROSSAL 200 Please keep safe. 5831036 GB 7/2019...
  • Page 2 Never touch hot surfaces on the boiler, burner, lidate our warranty. ■ flue system or pipework. For replacements, use only original spare parts supplied or approved by Viessmann. Please note Electronic assemblies can be damaged by elec- trostatic discharge. Prior to commencing work, touch earthed objects such as heating or water pipes to dis- charge static loads.
  • Page 3 Safety instructions Safety instructions (cont.) Safety instructions for operating the system If you smell gas Flue systems and combustion air Danger Ensure that flue systems are clear and cannot be Escaping gas can lead to explosions which may sealed, for instance due to accumulation of conden- result in serious injury.
  • Page 4 Index Index 1. Information Symbols ....................Intended use ..................Product information ................System examples .................. Spare parts lists ..................2. Commissioning, inspec- Steps - commissioning, inspection and maintenance ......tion, maintenance 3. Burner control unit Burner control unit VUC 310 ..............35 Display and programming unit ............
  • Page 5 Information Symbols The steps in connection with commissioning, inspec- Symbol Meaning tion and maintenance are found in the "Commission- Reference to other document containing ing, inspection and maintenance" section and identified further information as follows: Step in a diagram: Symbol Meaning The numbers correspond to the order in Steps required during commissioning...
  • Page 6 MatriX cylinder burner for natural gas E, LL and LPG P (not CH) Permissible operating pressure 6 bar. ■ System examples Available system examples: See www.viessmann- schemes.com. Spare parts lists Information about spare parts can be found on the Viessmann spare parts app.

  • Page 7: Table Of Contents

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • 1. Filling the heating system with water and venting............• 2. Filling the trap with water....................• • • 3. Commissioning the system....................•...
  • Page 8 Commissioning, inspection, maintenance Steps - commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • 39. Instructing the system user....................33 • 40. Operating and service documents................... 34...

  • Page 9: Filling The Heating System With Water And Venting

    Commissioning, inspection, maintenance Filling the heating system with water and venting Record the volume filled, water hardness and pH value Note on page 55. Observe the "Water quality requirements" on page 53. Filling the trap with water Fig. 1 1. Fill the trap with water. To do this, pour water into 2.

  • Page 10: Where Present: Check Motorised Flue Gas Damper (Flue Gas Cascade Accessory)

    Commissioning, inspection, maintenance Commissioning the system (cont.) 01. Check the heating system pressure. 08. Check the function of the neutralising system. Neutralising system operating instructions Permiss. operating 6 bar (0.6 MPa) pressure Minimum operating 0.5 bar (50 kPa) 09. Check all gaskets and plugs, and retighten if nec- pressure essary.

  • Page 11: Checking The Gas Type

    Commissioning, inspection, maintenance Checking the gas type 1. Check with your gas supply utility regarding the 2. In the delivered condition, the burner is set up for gas type and Wobbe index Ws (0 °C). natural gas H/E. If necessary, convert the burner to ■...

  • Page 12: Conversion To Lpg P

    Commissioning, inspection, maintenance Conversion to natural gas L (cont.) Conversion with 115 to 311 kW rated heating output 07. Remove restrictor with rubber cork gasket 08. Secure the gas train to flange ■ with O-ring without restrictor ■ ■ without rubber cork gasket Torque for M 5 nuts: 1.5 Nm 09.
  • Page 13 Commissioning, inspection, maintenance Conversion to LPG P (cont.) 13. Affix the label "Set to ..." supplied over existing label. 14. Start the burner. 15. Check for gas tightness. Danger Escaping gas leads to a risk of explosion. Check gas routing components for leaks. Please note The use of leak detection spray can result in faulty operation.

  • Page 14: Reducing Heating Output (If Required)

    Commissioning, inspection, maintenance Reducing heating output (if required) The maximum heating output of the burner can be Service instructions of the control unit reduced if required. 1. Keep S depressed for longer than 2 s. Status Service flashes. 2. Press until the display shows "6"...

  • Page 15: Checking Static Pressure And Supply Pressure

    Commissioning, inspection, maintenance Checking static pressure and supply pressure Static pressure Rated heating output 75 and 87 kW Rated heating output 115 to 311 kW Fig. 8 1. Close the gas shut-off valve. Fig. 7 2. Undo the screw in test connector , but do not remove.

  • Page 16: Checking The Co 2 Content

    Commissioning, inspection, maintenance Checking static pressure and supply pressure (cont.) 2. Check the supply pressure (flow pressure); see the 3. Record the actual value in the report (on following table. page 56). Note 4. Close the gas shut-off valve. Set supply pressure (flow pressure): Natural gas 18 to 50 mbar (1.8 to 5 kPa) 5.
  • Page 17 Commissioning, inspection, maintenance Checking the CO content (cont.) Relationship between CO value and Wobbe index Gas type Wobbe index setting kWh/m MJ/m Natural gas 16.10 58.00 11.0 15.00 54.00 14.00 50.40 13.00 46.80 12.00 43.20 Permissible CO content (depending on the Wobbe index of the gas type) Gas type con- Rated heating output in kW...
  • Page 18 Commissioning, inspection, maintenance Checking the CO content (cont.) Checking the CO level at upper heating output (75 and 87 kW) 1. Press until the service indicator has counted up to "100" (= 100 %). 2. Check the CO content at the flue pipe. For permissible CO content, see above table.
  • Page 19 Commissioning, inspection, maintenance Checking the CO content (cont.) 5. Check the CO content at the upper and lower heating output again. If the CO content is not within the specified range: Repeat steps for upper and lower heating output. 6. Hold down buttons and S simultaneously for lon- ger than 2 s.

  • Page 20: Checking The Co Content

    Commissioning, inspection, maintenance Checking the CO content (cont.) 5. Check the CO content at the upper and lower heating output again. If the CO content is not within the specified range: Repeat steps for upper and lower heating output. 6. Hold down buttons and S simultaneously for lon- ger than 2 s.

  • Page 21: Shutting Down The System

    Commissioning, inspection, maintenance Shutting down the system 1. Switch OFF the mains isolator or the power supply, 2. Close the gas shut-off valve. and safeguard against unauthorised reconnection. Danger Mains voltage can be life threatening. Ensure that the system is not 'live' during maintenance work.

  • Page 22: Checking All Connections And The Sensor Well On The Heating Water Side For Tightness

    Commissioning, inspection, maintenance Checking all connections and the sensor well on the heating water side for tightness SA/KR2 Fig. 14 Fitting assembly connection Boiler return Safety valve or safety equipment block KR2 Boiler return 2 (depending on version) Boiler flow 2nd boiler return Drain and expansion vessel connection Safety connection...

  • Page 23: Cleaning The Condensate Drain Pipe And Trap

    Commissioning, inspection, maintenance Cleaning the condensate drain pipe and trap Note Clean the condensate drain pipe and trap at least once a year. 1. Disconnect drain hose to neutralising system from trap 2. Connect cleaning hose to the trap and route it to the drainage system.

  • Page 24: Checking The Burner Gauze Assembly

    Commissioning, inspection, maintenance Checking the burner gauze assembly 142 kW 1. Check the wire mesh of burner gauze assembly ≤ and thermal protection ring for damage. 2. If required, replace burner gauze assembly thermal protection ring Installation instructions Replacing burner components Note If the specified rated heat input is not reached, the burner gauze assembly is probably contaminated.

  • Page 25: Checking The Ignition Electrodes And Ionisation Electrode

    Commissioning, inspection, maintenance Checking the ignition electrodes and ionisation electrode 142 kW ≤ Ignition electrodes Ionisation electrode Fig. 20 Check the ignition electrodes and ionisation electrode for the correct gap to the burner gauze assembly and for possible damage. Replace the electrodes if required.

  • Page 26: Cleaning The Burner

    Commissioning, inspection, maintenance Cleaning the burner 87 kW 1. Disconnect the connecting cables, release the clamps and disconnect the control cables. 2. Undo fitting on gas supply pipe 3. Undo fan . Remove Venturi mixing pipe , gas train and gas supply pipe 4.

  • Page 27: Control Cables Connection Diagram

    Commissioning, inspection, maintenance Fitting the burner (cont.) 1. Fit fan 6. Tighten fitting with Venturi mixing pipe , gas train on gas supply pipe and gas supply pipe Danger Note Escaping gas leads to a risk of explosion. Ensure the gasket between the fan housing and Check the fitting and gasket between the fan the boiler door is correctly seated.
  • Page 28 Commissioning, inspection, maintenance Control cables connection diagram (cont.) Note Replacement cables must be cut to length. For required length, see page 28 and 29 Hose Ø 6 mm: --------- Hose Ø 4 mm: – – – – 75 and 87 kW L=35 L=370 L=280...
  • Page 29 Commissioning, inspection, maintenance Control cables connection diagram (cont.) 115 to 311 kW L=50 L=300 L=209 L=120 L=260 L=326 L=255 L=490 L=105 L=400 Fig. 29 Gas train Enriching nozzle Air pressure switch 2 115/142 kW - 1 mm Air pressure switch 1 186 kW - 0.5 mm Solenoid valve 246/311 kW - 1 mm...

  • Page 30: Closing The Boiler Door

    Commissioning, inspection, maintenance Closing the boiler door 18 Nm Fig. 30 1. Close the boiler door. 3. To ensure that the boiler door closes tightly, adjust the clearance between front panel and hinge bolt 2. Tighten the boiler door screws crosswise to a tor- to 16 mm ±...

  • Page 31: Checking The Gas Train Valves For Tightness

    1 mbar (0.1 kPa) within 5 min. Otherwise there is a leak. In that case, return the gas train to your local Viessmann sales office for tests. If the gas train cannot be replaced immediately, switch off the boiler.

  • Page 32: Checking Gas Connections For Tightness

    Commissioning, inspection, maintenance Checking gas connections for tightness Danger 2. Open the gas shut-off valve. Escaping gas leads to a risk of explosion. Always carry out the following steps: 3. Check the inlet joints of the gas train for tightness. Please note 4.

  • Page 33: Performing Final Checks

    Commissioning, inspection, maintenance Performing final checks 1. Carry out final checks in accordance with the 2. Record actual values in the report (on page 55). points on pages 16 to 20. Checking the water quality Enter the amount of top-up water, the total hardness and the pH value in the tables on page 55.
  • Page 34 Commissioning, inspection, maintenance Operating and service documents 1. Complete and detach the customer registration 2. File all parts lists, operating and service instruc- card: tions in the folder and hand this over to the system ■ Hand system users their section for safekeeping. user.
  • Page 35 Burner control unit Burner control unit VUC 310 Display and programming unit The burner control unit includes a display and pro- Note gramming unit, as well as the burner coding card. The Depending on the system configuration, the display display screen shows the relevant operating status, the and control functions can in part also be carried out on service and parameter status, as well as any fault or the boiler control unit.
  • Page 36 Burner control unit Burner control unit VUC 310 (cont.) Display Meaning Status Service Fig. 34 Example Status Service Operation with flame After flame post-purge Dwell program, no air pressure Dwell program, no gas pressure or mains undervoltage Forced ventilation if no flame formation has been detected. Safety shutdown due to flame tear-off Info display/configuration display The information display and the configuration display...
  • Page 37 Burner control unit Burner control unit VUC 310 (cont.) Configurations: Menu Description point Changeover from the operating display of the burner control unit phase to other proc- ess information Configuration of control function operating parameters Menu point "5" is used to display the following process information: Sub-menu point Process information Unit/scale...
  • Page 38 Burner control unit Burner control unit VUC 310 (cont.) Sub-menu Parameter Setting range/unit Delivered condition point Boiler controller start hysteresis (effec- 0 to 20 K tive during minimum pause) Boiler controller stop hysteresis (effec- 0 to 20 K tive during minimum pause) Reset all operating parameters to their delivered condition.
  • Page 39 Burner control unit Burner control unit flow chart Fig. 35...
  • Page 40 Burner control unit Burner control unit flow chart (cont.) Description of state: Phase Display Description Duration System start "A" System start 10 s Fan ramp-up, system start max. 20 s Forced ventilation, system start 20 s Relay test "P" Fan ramp-up for test max.
  • Page 41 Troubleshooting Fault display If the burner control unit switches to a fault state, the Fault code of the most recent fault (see table from fault display is automatically activated. The most page 41) recent fault is then displayed. The fault LED is also illu- minated in the case of a non-lockout fault, or flashes 1.
  • Page 42 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played F B7 Burner control unit in a fault Coding card not inserted Insert coding card. Check coding state; system cooling down; in the burner control unit; card. Replace if necessary. burner control unit locked out.
  • Page 43 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played F F4 Poor start-up characteristics Compensation lines not Check compensation lines and (start enrichment). Solenoid connected, solenoid valve connections (see page 50); re- valve not switching. or solenoid valve power place compensation lines.
  • Page 44 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played F F8 Flame tears off during opera- Burner gauze assembly Clean the burner gauze assembly tion. contaminated or faulty with compressed air. Replace the burner gauze assembly if it is dam- aged.
  • Page 45 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played F EB Burner blocked Burner not enabled via ex- Check components connected to ternal contact. TR/TR EIN at plug of the aBÖ Vitotronic. F EC Burner control unit in a fault Internal error in feedback Reset the burner control unit.
  • Page 46 Troubleshooting Fault codes (cont.) Detailed error codes for F FD Detailed er- Component/signal Cause of fault Measure ror code Reset button Programming unit faulty Replace programming unit. Wiring Check wiring. Fuel valve 2 feed- Incorrect return voltage Disconnect the plug from fuel valve 2, reset the back (e.g., DC voltage) burner control unit and check the fault messages.
  • Page 47 Troubleshooting Faults without fault display (cont.) Fault Cause of fault Measure content too low Incorrect setting Check whether the burner has been adjusted to the correct gas type; change gas restrictor if required (see page 11 onwards). Adjust burner in accordance with the details on page 16 onwards.
  • Page 48 Component overview Overview of burner components MatriX radiant burner 75 and 87 kW Fig. 37 Boiler door Burner gauze assembly Display and programming unit Ionisation electrode Ignition electrodes Gas supply pipe Thermal insulation block Gas pressure switch Air pressure switch 131A Gas train Air pressure switch 131 Venturi mixing pipe...
  • Page 49 Component overview Overview of burner components (cont.) MatriX cylinder burner 186 to 311 kW Fig. 39 Boiler door Ionisation electrode Display and programming unit Ignition electrodes Thermal insulation block Gas supply pipe Air pressure switch 131A Gas train Air pressure switch 131 Venturi mixing pipe Burner control unit Choke valve...
  • Page 50 Function description Air pressure switch Fan pressure monitoring (air pressure switch 1 - 131) The switching threshold of air pressure switch 1 (131) Burner output in kW Setting value in mbar (Pa) is monitored in all fan ramp-up phases and checked during modulating burner operation.
  • Page 51 Function description Boiler water temperature sensors and flue gas temperature sensors The temperature sensors are of a dual sensor design. NTC 10 k Ω Connection to burner control unit. 3A/3B Boiler water temperature sensors 15A/15B Flue gas temperature sensors Temperature in °C Fig.
  • Page 52 Connection diagrams Burner control unit connection diagram Fig. 42 Burner control unit VUC 310 Display and programming unit Flame monitor (ionisation current) Air pressure switch 1 Vitotronic control unit Gas pressure switch 2/2-way solenoid valve Air pressure switch 2 Flue gas damper Flue gas temperature sensor 1 Ignition unit Flue gas temperature sensor 2...
  • Page 53 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 54 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 55 Reports Reports Fill water report Fill water Top-up water Meter reading Total water volume Date — — — — — — — — — — — — — — — — — — — Max. fill volume: ......m Water quality report Total hardness pH value Water treatment...
  • Page 56 Reports Reports (cont.) Settings and measurement values Commissioning Maintenance/Service Static pressure mbar Supply pressure (flow pressure) for natural gas E mbar for natural gas LL mbar for LPG P mbar for gas _______ mbar Tick gas type. Carbon dioxide content CO at upper rated heating actual % by vol.
  • Page 57 Specification Specification Rated heating output TF/TR = 50/30 29 - 75 29 - 87 38 - 115 47 - 142 37 - 186 62 - 246 62 - 311 TF/TR = 80/60 26 - 69 26 - 80 35 - 105 43 - 130 34 - 170 56 - 225 57 - 285 Rated heat input Product ID...
  • Page 58 Specification Specification (cont.) Rated heating output TF/TR = 50/30 29 - 75 29 - 87 38 - 115 47 - 142 37 - 186 62 - 246 62 - 311 TF/TR = 80/60 26 - 69 26 - 80 35 - 105 43 - 130 34 - 170 56 - 225 57 - 285 Flue gas parameters Temperature...
  • Page 59 Specification Specification (cont.) Rated boiler heating output 50/30 °C MatriX radiant burner MatriX cylinder burner Power consumption At upper heating output At lower heating output Version Modulating Weight 35.7 35.7 41.0 41.0 38.8 41.8 41.8 Burner with combination valve Gas connection ¼...
  • Page 60 Specification Specification (cont.) Rated heating output Dim. a Natural gas E LPG P 10.7 – 10.7 – 13.4 – 13.4 – 13.4 17.1 11.3 17.9 12.4 Fig. 44 Rated heating output 115 to 311 kW...
  • Page 61 Final decommissioning Final decommissioning and disposal The products can be recycled. Components and sub- For decommissioning, isolate the system from the stances from the system are not part of ordinary power supply and allow components to cool down household waste. where appropriate.
  • Page 62 Manufacturer’s certificate according to the 1st German Immissions Order (BImSchV) We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, confirm that the product Vitocrossal 200, type CM2C, 75 to 311 kW complies with the following conditions stipulated by the 1st German Immissions Order (BImSchV): ■...
  • Page 63 Keyword index Keyword index Air pressure switch.............50 Heating surfaces, cleaning.........21 Heating system – Filling with water............9 Boiler door – Closing..............30 – Opening..............21 Ignition electrodes, checking........25 Boiler water requirements.......... 53 Instructing the system user........33 Burner Intended use..............5 – Cleaning..............26 Internal system faults..........
  • Page 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 Fax: +44 1952 675040 E-mail: info-uk@viessmann.com...

This manual is also suitable for:

Vitocrossal 200 cm2c 115Vitocrossal 200 cm2c 87Vitocrossal 200 cm2c 75Vitocrossal 200 cm2c 142Vitocrossal 200 cm2c 186Vitocrossal 200 cm2c 246 ... Show all

Table of Contents