Gas condensing boiler with cylinder burner (12 pages)
Summary of Contents for Viessmann Vitocrossal 200
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VIESMANN Service instructions for contractors Vitocrossal 200 Type CM2B, 87 to 311 kW Gas condensing boiler with MatriX radiant burner Permissible operating pressure 6 bar (0.6 MPa) For applicability, see the last page VITOCROSSAL 200 Please keep safe. 5812086 GB/en 9/2017...
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Hot surfaces can cause burns. Replace faulty components only with genuine ■ Before maintenance and service work, switch Viessmann spare parts. OFF the appliance and let it cool down. Never touch hot surfaces on the boiler, burner, ■ flue system or pipework.
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For replacements, use only original spare parts supplied or approved by Viessmann. Safety instructions for operating the system If you smell gas Condensate Danger...
Index Index 1. Information Symbols ....................Intended use ..................Product information ................2. Commissioning, inspec- Steps - commissioning, inspection and maintenance ......tion, maintenance 3. Vitotronic control unit Setting the codes at the control unit ............33 codes 4. Burner control unit Burner control unit VUC 310 ..............
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...
Information Product information Vitocrossal 200, type CM2B 87 to 311 kW with permis- Gas condensing boiler for natural gas E and LL, with sible operating pressure 6 bar (0.6 MPa). modulating MatriX radiant burner.
Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance 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............• 3. Filling the trap with water....................•...
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Commissioning, inspection, maintenance Steps - commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • • • 38. Checking the installation room ventilation air apertures..........31 • 39. Instructing the system user....................32 • 40. Operating and service documents................... 32...
Commissioning, inspection, maintenance Checking the high limit safety cut-out setting The high limit safety cut-out must not be set higher Control unit installation and service instructions than 110 °C; if required, set it to a maximum of 110 °C. Filling the heating system with water and venting Record the volume filled, water hardness and pH value Note on page 72.
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Commissioning, inspection, maintenance Commissioning the system (cont.) 01. Check the heating system pressure. Permiss. operating 6 bar (0.6 MPa) pressure Minimum operating 0.5 bar (50 kPa) pressure Danger If the operating pressure is too low, excess temperatures in the flue system can cause leaks.
Commissioning, inspection, maintenance Commissioning the system (cont.) 10. Check all gaskets and plugs, and retighten if nec- essary. Note We recommend checking all connections on the heating water side for leaks approx. every 500 hours run. See page 21. 11. Check the boiler door and flue gas cover a few days after commissioning.
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Commissioning, inspection, maintenance Converting to natural gas LL (cont.) Conversion for 87 kW 01. Close the gas shut-off valve. 02. Turn off the system ON/OFF switch at the user interface of the control unit. 03. Switch OFF the mains isolator (outside the instal- lation room) or isolate the mains power and secure against unintentional reconnection.
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Commissioning, inspection, maintenance Converting to natural gas LL (cont.) Conversion for 115 to 311 kW 01. Close the gas shut-off valve. 02. Switch OFF the system ON/OFF switch on the control unit. 03. Switch OFF the mains isolator (outside the instal- lation room) or isolate the mains power and secure against unintentional reconnection.
Commissioning, inspection, maintenance Reducing the heating output (if required) The maximum heating output of the burner can be reduced if required. 1. Press S and hold for longer than 2 s. Status Service flashes. 2. Press until the display shows "6" under Service. 3.
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Commissioning, inspection, maintenance Checking static pressure and supply pressure (cont.) Supply pressure Note 3. Record the actual value in the report (on See type plate for supply pressures for operation with page 73). other country-specific gas types. 4. Close the gas shut-off valve. 1.
Commissioning, inspection, maintenance Checking the rotary damper setting For 246 and 311 kW rated heating output only Fig. 8 1. Open the gas shut-off valve. 4. Start the burner. 2. Check the position of the rotary damper with the 5. Check the position of the rotary damper during the burner in idle mode.
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Commissioning, inspection, maintenance Checking the CO content (cont.) Permissible CO content Gas type con- Rated heating output in kW tent Natural gas Upper heat- 7.1 - 10.2 % 7.0 - 10.1 % 7.0 - 10.1 % 7.1 - 10.2 % 7.1 - 10.2 % 7.1 - 10.2 % ing output (100 %)
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Commissioning, inspection, maintenance Checking the CO content (cont.) 4. If the CO content needs adjusting: Turn adjusting screw in small increments. Con- tinue turning until CO content falls within the specified range. Turning clockwise ■ content falls → ■ Turning anti-clockwise content rises →...
Commissioning, inspection, maintenance Checking the CO content (cont.) test at the upper heating output (115 to 311 kW) 1. Press until the service display has counted up to "100" (= 100 %). 2. Check the CO content at the flue pipe. For permissible CO content, see above table.
Commissioning, inspection, maintenance Checking the flue gas temperature Enter actual value into the report in the appendix. Displaying the ionisation current Note 08. Record the actual value in the report. The ionisation current must be called up via the burner control unit.
Commissioning, inspection, maintenance Cleaning the combustion chamber and heating surfaces Thoroughly clean the combustion chamber and heat- Remove coatings and surface discolouration (yellow- ■ ing surfaces with a water jet. brown) with slightly acidic, chloride-free cleaning agents based on phosphoric acid (e.g. Antox 75 E). Please note ■...
4. Clean the neutralising system (if installed) in accordance with the manufacturer's instructions. Neutralising system operating instructions Note Neutralising agent can be obtained from Viessmann by quoting part no. 9521702. Fig. 15 5. Undo and flush lower section of trap 6. Fill lower section with water and secure.
Commissioning, inspection, maintenance Checking the burner gauze assembly Danger Escaping gas leads to a risk of explosion. Close the gas shut-off valve. Undo fitting on the gas supply pipe. 2. Undo the screws on the boiler door and open the door.
Commissioning, inspection, maintenance Cleaning the burner 1. Release clamps and disconnect control cables. 87 kW 2. Undo fitting on gas supply pipe 3. Remove Venturi mixing pipe from fan 4. Remove all connecting cables from the gas train. 5. Remove Venturi mixing pipe with gas train and gas supply pipe Note...
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Commissioning, inspection, maintenance Fitting the burner (cont.) 115 to 311 kW 5. Reinstall control cables using clamps. For connec- tion diagrams, see following pages. Please note Incorrectly connected control cables can cause malfunctions. Ensure that control cables are connected correctly. 6.
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Commissioning, inspection, maintenance Fitting the burner (cont.) Gas train Enriching nozzle in hose 87 kW 2 mm Hose dimensions Hose dimensions Length in mm Length in mm Pressure-jet gas burners 115 to 186 kW Fig. 24 Air pressure switch 2 Boiler door Choke valve Air pressure switch 1...
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Commissioning, inspection, maintenance Fitting the burner (cont.) Venturi mixing pipe Enriching nozzle in hose 115/142 kW 1 mm 186 kW 1.6 mm Hose dimensions Hose dimensions Length in mm Length in mm Pressure-jet gas burners 246 to 311 kW Fig. 25 Air pressure switch 2 Boiler door Air pressure switch 1...
Commissioning, inspection, maintenance Closing the boiler door 18 Nm Fig. 26 1. If the burner has been removed, hook the burner 3. To ensure that the boiler door closes tightly, adjust onto the hinge bracket and secure it with a split the clearance between the front panel and hinge pin.
1 mbar (0.1 kPa) within 5 min. Otherwise there is a leak. In this case, return the gas train to your local Viessmann sales office for tests. 7. After testing, close both test connectors by tighten- ing the respective screws.
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.
Commissioning, inspection, maintenance Checking the water quality Enter the amount of top-up water, the total hardness and the pH value in the tables on page 72. For water quality requirements, see page 70. Checking the safety valve function Checking the temperature controller setting if a building management system is used (DCC system) Please note Shutting down from full load can result in high...
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Commissioning, inspection, maintenance Instructing the system user The system installer should hand the operating instruc- This includes all components installed as accessories, tions to the system user and instruct the user in oper- e.g. remote control units. In addition, the system instal- ating the system.
Vitotronic control unit codes Setting the codes at the control unit Vitotronic service instructions In conjunction with the following control units: ■ Vitotronic 100, type CC1E ■ Vitotronic 200, type CO1E Vitotronic 300, type CM1E ■ Parameters in the boiler group Rated heating output in kW Coding card Settings...
Burner control unit Burner control unit VUC 310 Display and programming unit A display and programming unit is integrated into the Note burner control unit. The display screen shows the rele- Depending on the system configuration, the display vant operating status, the service and parameter sta- and control functions can in part also be carried out on tus, as well as any fault or error messages.
Burner control unit Burner control unit VUC 310 (cont.) Display Meaning Status Service Fig. 30 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...
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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 Units/scale...
Burner control unit Burner control unit VUC 310 (cont.) Resetting operating parameters to their delivered condition 1. S longer than 2 s, " " flashes. 5. S "1" is shown under Status and "dEL" under Serv- ice. until "6" is shown under Service. 6.
Burner control unit Burner control unit flow chart Fig. 31 Description of state: Phase Display Description Duration System start "A" System start 10 s Initialisation of fault meter 0.1 s Mains test, gas pressure Fan ramp-up, system start max. 20 s Forced ventilation, system start 20 s...
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Burner control unit Burner control unit flow chart (cont.) Phase Display Description Duration Relay test "P" Fan ramp-up for test max. 20 s Safety relay test 0.9 s Disable relays BV1 and BV2. 0.9 s Relays test BV1 and BV2 0.9 s Ignition relay test 0.9 s...
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 40) recent fault is then displayed. The fault LED is also illu- minated in the case of a non-lockout fault, or flashes 1.
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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 required. burner control unit locked out.
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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 rotary damper does not connected, servomotor connections (see page 66), re- close, solenoid valve does faulty, servomotor power place connecting cables, replace not switch.
Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played F F9 No feedback from fan Fan faulty, external fan Check cable " A", check exter- a-Ö power supply not connec- nal power supply, replace cable or ted or faulty, cable " A"...
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) Fig. 33 Type plate Thermal insulation assembly Burner assembly...
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0010 Thermal insulation jacket 0011 Thermal insulation mat, back 0012 Thermal insulation mat, front 0013 Right and left cover panel 0014 Vitocrossal 200 logo 0015 Edge protection 0016 Fixing rail, top 0017 Fixing rail, bottom 0018 Side panel, right front...
Parts lists Burner control unit assembly, 87 kW 0001 0002 0004 0005 0003 0006 0007 0012 0014 0017 0016 Fig. 39...
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Parts lists Burner control unit assembly, 87 kW (cont.) Pos. Part 0001 Burner control unit VUC310 0002 Programming unit HI201-D01.001 0003 Connecting cable, 38 bypass 0004 Ionisation cable 11/earth 0005 Ignition transformer connecting cable 54 0006 Connecting cable, gas train/gas pressure switch 0007 Gas fan connecting cable 0012...
Parts lists Burner control unit assembly, 115, 142 and 186 kW 0001 0002 0005 0004 0003 0006 0007 0012 0016 0017 0014 Fig. 40...
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Parts lists Burner control unit assembly, 115, 142 and 186… (cont.) Pos. Part 0001 Burner control unit VUC310 0002 Programming unit HI201-D01.001 0003 Connecting cable, 38 bypass 0004 Ionisation cable 11/earth 0005 Ignition transformer connecting cable 54 0006 Gas train connecting cable 0007 Gas fan connecting cable 0012...
Parts lists Burner control unit assembly, 246 and 311 kW 0001 0002 0004 0005 0003 0006 0007 0008 0012 0017 0014 0016 Fig. 41...
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Parts lists Burner control unit assembly, 246 and 311 kW (cont.) Pos. Part 0001 Burner control unit VUC310 0002 Programming unit HI201-D01.001 0003 Connecting cable, 38 bypass 0004 Ionisation cable 11/earth 0005 Ignition transformer connecting cable 54 0006 Gas train connecting cable 0007 Gas fan connecting cable 0008...
Component overview Overview of burner components Pressure-jet gas burner 87 kW Fig. 43 Boiler door Gas train Gas pressure switch Display and programming unit Inlet adaptor for room sealed operation (optional) Gas supply pipe Burner gauze assembly Gas shut-off valve Ignition electrode Air pressure switch 2 Ionisation electrode...
Component overview Overview of burner components (cont.) Ignition electrode Suppressor choke box Ionisation electrode Ignition unit Thermal insulation block Burner control unit Pressure-jet gas burners 246 to 311 kW Fig. 45 Boiler door Rotary damper with drive Air pressure switch 1 Burner gauze assembly Ignition electrode Display and programming unit...
Function description Air pressure switch Fan pressure monitoring (air pressure switch 1 - 131) The switching threshold of air pressure switch 1 (131) Rated heating LDW1 setting value in mbar (Pa) is monitored in all fan ramp-up phases and checked output in kW during modulating burner operation.
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Function description Air pressure switch (cont.) For 115, 142 and 186 kW, remove screw and attach Check control cables: connecting cable. Check for tightness. ■ Connection and kink-free routing ■ Application and seating of retaining clips...
Connection diagrams Burner control unit connection diagram Fig. 47 Burner control unit VUC 310 Gas pressure switch 1 Fan motor with PWM control and feedback Air pressure switch 2 Air pressure switch 1 Display and programming unit...
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Connection diagrams Burner control unit connection diagram (cont.) Fig. 48 Burner control unit VUC 310 F1 Backup fuse Flame monitor with ionisation current F2 Backup fuse F6 High limit safety cut-out Vitotronic control unit F7 Temperature controller Servomotor for rotary damper or 2/2-way solenoid valve H1 Hours run meter, modulation Ignition unit...
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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.
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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.
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...
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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 Tick gas type. Carbon dioxide content CO At the upper rated heat- actual % by vol. ■...
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If using the Vitocrossal 200 with moisture-resistant chimneys, the draught must be no more than 0 Pa. Standard values resulting from sound pressure level testing cannot be guaranteed, as sound pressure level tests are al-...
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Specification Specification (cont.) Rated heat input Upper ■ Lower ■ Total weight (with burner hood 37.5 41.0 41.0 41.0 42.0 42.0 and combination valve) Gas supply pressure mbar 20 to 50 20 to 50 20 to 50 20 to 50 20 to 50 20 to 50 2 to 5...
Final decommissioning 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.
EU Declaration of Conformity Vitocrossal 200, type CM2B, 87 to 311 (80 to 285) kW, with Vitotronic boiler control unit and MatriX burner We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, declare as sole responsible body that the named...
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 CM2B, complies with the following conditions stipulated by the 1st German Immissions Order (BImSchV): ■...
Keyword index Keyword index Air pressure switch.............66 Heating surfaces, cleaning.........21 Heating system – Filling with water............9 Boiler door, closing.............28 High limit safety cut-out..........9 Boiler door, opening........... 20 Boiler water requirements.......... 70 Burner Ignition electrodes, checking........23 – Cleaning..............24 Instructing the system user........32 –...
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Keyword index Keyword index (cont.) Water quality – Checking..............31 – Report..............72 – Requirements............70 Water quality, requirements........70...
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