Viessmann VITOCROSSAL 200 Betriebsanleitung

Service instructions

for contractors

VIESMANN

Vitocrossal 200

Type CM2B, 87 to 311 kW

Gas condensing boiler with MatriX radiant burner

6 bar

For applicability, see the last page

VITOCROSSAL 200

5677 612 GB 10/2016 Please keep safe.

Please follow these safety instructions closely to

prevent accidents and material losses.

Safety instructions explained

Danger

This symbol warns against the risk of injury.

!Please note

This symbol warns against the risk of material

losses and environmental pollution.

Note

Details identified by the word "Note" contain additional

information.

Target group

These instructions are intended exclusively for quali-

fied contractors.

■Work on gas installations must only be carried out by

a registered gas fitter.

■Work on electrical equipment must only be carried

out by a qualified electrician.

■The system must be commissioned by the system

installer or a qualified person authorised by the

installer.

■This appliance has not been designed to be oper-

ated by individuals (including children) with limited

physical, sensory or mental capacities or who are

lacking in the appropriate experience and/or knowl-

edge, unless they are supervised by a person with

responsibility for their safety or were instructed by

that person in the operation of this appliance.

!Please note

Children should be supervised.

Ensure that children never play with the appli-

ance.

Regulations

Observe the following when working on this system:

■Statutory regulations regarding the prevention of

accidents

■Statutory regulations regarding environmental pro-

tection

■Codes of practice of the relevant trade associations.

■All current safety regulations as defined by DIN, EN,

DVGW, TRGI, TRF, VDE and all locally applicable

standards.

aÖNORM, EN, ÖVGW-TR Gas, ÖVGW-TRF and

ÖVE

cSEV, SUVA, SVGW, SVTI, SWKI, VKF and

EKAS Directive 1942: LPG, part 2

If you smell gas

Danger

Escaping gas can lead to explosions which may

result in serious injury.

■Do not smoke. Prevent naked flames and

sparks. Do not press any switches for lights or

electrical appliances.

■Close the gas shut-off valve.

■Open windows and doors.

■Remove all people from the danger zone.

■Notify your gas or electricity supply utility from

outside the building.

■Shut off the electricity supply to the building

from a safe place (outside the building).

If you smell flue gas

Danger

Flue gas can lead to life-threatening poisoning.

■Shut down the heating system.

■Ventilate boiler room.

■Close all doors in the living space.

Working on the system

■Where gas is used as the fuel, close the main gas

shut-off valve and safeguard it against unintentional

reopening.

■Isolate the system from the power supply (e.g. at the

separate fuse or a main switch) and check that it is

de-energised.

■Safeguard the system against reconnection.

!Please note

Electronic assemblies can be damaged by elec-

trostatic discharges.

Before beginning work, touch earthed objects,

such as heating or water pipes, to discharge

static loads.

Repair work

!Please note

Repairing components that fulfil a safety func-

tion can compromise the safe operation of your

system.

Replace faulty components only with original

Viessmann spare parts.

Safety instructions

5677 612 GB

Auxiliary components, spare and wearing parts

!Please note

Spare and wearing parts that have not been tes-

ted together with the system can compromise its

function. Installing non-authorised components

and making non-approved modifications or con-

versions can compromise safety and may inva-

lidate our warranty.

For replacements, use only original spare parts

supplied or approved by Viessmann.

Safety instructions

Safety instructions (cont.)

5677 612 GB

1. Information Symbols ................................................................................................. 5

Intended use .......................................................................................... 5

Product information ................................................................................ 6

2. Commissioning, inspec-

tion, maintenance

Steps - commissioning, inspection and maintenance ............................ 7

3. Vitotronic control unit

codes

Setting the codes at the control unit ...................................................... 30

4. Burner control unit Burner control unit VUC 310 .................................................................. 31

■Display and programming unit ............................................................ 31

■Operating display ................................................................................ 31

■Info display/configuration display ........................................................ 32

■Resetting operating parameters to their delivered condition .............. 33

■Manual operation and service display ................................................ 34

Burner control unit flow chart ................................................................. 35

■Description of state: ............................................................................ 35

5. Troubleshooting Fault display ........................................................................................... 37

■Fault memory ...................................................................................... 37

Fault codes ............................................................................................ 37

■General process errors ....................................................................... 37

■Internal system faults .......................................................................... 40

Faults without fault display ..................................................................... 40

6. Parts lists Overview of assemblies ......................................................................... 41

Boiler assembly ..................................................................................... 42

Thermal insulation assembly ................................................................. 44

Miscellaneous assembly ........................................................................ 46

7. Component overview Overview of burner components ............................................................ 48

■Pressure-jet gas burner, type VMA III, 87 kW .................................... 48

■Pressure-jet gas burner, type VMA III, 115 to 311 kW ........................ 49

8. Function description Air pressure switch ................................................................................ 50

■Fan pressure monitoring function (LDW1) .......................................... 50

■Combustion chamber pressure monitoring function (LDW2) .............. 50

■Fan for burner 115 to 311 kW ............................................................. 51

9. Connection diagrams Burner control unit connection diagram ................................................. 52

10. Reports ................................................................................................................ 56

11. Specification ................................................................................................................ 58

12. Final decommissioning Final decommissioning and disposal ..................................................... 61

13. Certificates Declaration of Conformity ...................................................................... 62

Manufacturer’s certificate according to the 1st German Immissions

Order (BImSchV) ................................................................................... 62

14. Keyword index ................................................................................................................ 64

Index

5677 612 GB

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.

■Acoustic signal

■Fit new component.

■In conjunction with a tool: Clean the sur-

face.

Dispose of component correctly.

Dispose of component at a suitable collec-

tion point. Do not dispose of component in

domestic waste.

The steps in connection with commissioning, inspec-

tion and maintenance are found in the "Commission-

ing, inspection and maintenance" section and identified

as follows:

Symbol Meaning

Steps required during commissioning

Not required during commissioning

Steps required during inspection

Not required during inspection

Steps required during maintenance

Not required during maintenance

Intended use

The appliance is only intended to be installed and

operated in sealed unvented heating systems that

comply with EN 12828, with due attention paid to the

associated installation, service and operating instruc-

tions as well as the details in the datasheet.

It is only designed for the heating up of heating water.

Commercial or industrial usage for a purpose other

than the heating up of heating water shall be deemed

inappropriate.

Intended use presupposes that a fixed installation in

conjunction with permissible components designed for

this purpose has been carried out.

Every other use will be deemed to be inappropriate.

Any resulting losses are excluded from the manufac-

turer's liability.

Any usage beyond this must be approved by the man-

ufacturer for the individual case.

Intended use also includes the adherence to mainte-

nance and inspection intervals.

Information

Symbols

5677 612 GB

Information

Vitocrossal 200 CM2B 87 to 311 kW with permissible

operating pressure 6 bar (0.6 MPa).

Gas condensing boiler for natural gas E and LL, with

modulating MatriX radiant burner

Information

Product information

5677 612 GB

Information

Commissioning steps

Inspection steps

Maintenance steps Page

•1. Checking the high limit safety cut-out setting................................................................ 9

•2. Filling the heating system with water and venting......................................................... 9

•3. Filling the trap with water.................................................................................................. 9

••• 4. Commissioning the system............................................................................................... 9

•5. Checking the gas type....................................................................................................... 11

•6. Converting to natural gas LL............................................................................................ 11

•7. Reducing the operational output (if required)................................................................. 12

••• 8. Checking static pressure and supply pressure.............................................................. 13

••• 9. Checking the rotary damper setting................................................................................. 15

••• 10. Checking the CO2 content................................................................................................. 16

••• 11. Checking the CO content

••• 12. Checking the flue gas temperature

• • 13. Displaying the ionisation current..................................................................................... 19

• • 14. Shutting down the system................................................................................................. 20

• • 15. Opening the boiler door..................................................................................................... 20

• • 16. Cleaning the combustion chamber and heating surfaces............................................. 20

• • 17. Checking the gaskets and thermal insulation sections................................................. 20

• • 18. Checking all connections and the sensor well on the heating water side for

tightness............................................................................................................................. 21

• • 19. Removing the neutralising system, connecting the drain hose.................................... 21

• • 20. Cleaning and reconnecting the condensate drain system............................................. 22

• • 21. Checking the condensate drain and neutralising system (if installed)......................... 22

• • 22. Checking the burner gauze assembly.............................................................................. 23

• • 23. Checking the ignition electrodes and ionisation electrode........................................... 23

• • 24. Closing the boiler door...................................................................................................... 24

• • 25. Cleaning the burner........................................................................................................... 24

•26. Fitting the burner................................................................................................................ 25

• • 27. Checking the gas train valves for tightness.................................................................... 26

• • 28. Checking the filter element in the gas line...................................................................... 26

••• 29. Checking gas connections for tightness......................................................................... 26

• • 30. Checking the gaskets on the flue gas side...................................................................... 27

•31. Performing final checks..................................................................................................... 28

• • 32. Checking the water quality................................................................................................ 28

••• 33. Checking the safety valve function

• • 34. Expansion vessel .............................................................................................................. 28

• • 35. Checking the mixer for ease of operation and leaks...................................................... 28

••• 36. Checking the thermal insulation for firm seating

••• 37. Checking the installation room ventilation air apertures............................................... 29

•38. Instructing the system user.............................................................................................. 29

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5677 612 GB

Commissioning steps

Inspection steps

Maintenance steps Page

•39. Operating and service documents................................................................................... 29

Commissioning, inspection, maintenance

Steps - commissioning, inspection and… (cont.)

5677 612 GB

The high limit safety cut-out must not be set higher

than 110 °C; if required, set it to a maximum of 110 °C.

Control unit installation and service instructions

Filling the heating system with water and venting

Record the volume filled, water hardness and pH value

on page 56.

Note

Observe section "Water quality requirements" on

page 54.

Filling the trap with water

Fig. 1

1. Undo the trap and fill it with water. Otherwise flue

gas may escape.

2. Check that the condensate can drain freely.

3. Refit the trap.

Commissioning the system

Danger

CO build-up as a result of incorrect burner

adjustment can have serious health implications.

Always carry out a CO test before and after

work on gas appliances.

Control unit operating and service instructions,

and neutralising system operating instructions

Commissioning, inspection, maintenance

Checking the high limit safety cut-out setting

5677 612 GB

A B

Fig. 2

01. Check the heating system pressure.

Permiss. operating

pressure

6 bar (0.6 MPa)

Minimum operating

pressure

0.5 bar (50 kPa)

Danger

If the operating pressure is too low, excess

temperatures in the flue system can cause

leaks. Escaping flue gas can cause life

threatening carbon monoxide poisoning.

Ensure the minimum operating pressure

with a minimum pressure switch.

02. For open flue operation: check that the ventilation

facility in the installation room is open.

03. Check the gas supply pressure.

04. Open the gas line shut-off valves.

05. Switch ON the mains isolator (outside the installa-

tion room).

06. Switch ON system ON/OFF switch B at the con-

trol unit. If fault indicator A on the control unit illu-

minates and display C on the burner control unit

flashes, first reset the system. To do this, press

reset button D on the burner control unit.

Note

The boiler can enter a fault state during commis-

sioning if the gas line carries insufficient gas. The

fault indicator on the control unit illuminates. Purge

the gas line again and reset the burner control

unit.

07. Adjust the codes on the boiler control unit in

accordance with the table on page 30.

Note

If the codes are not set, the boiler’s service life

and efficiency may be adversely affected.

Control unit installation and service instruc-

tions

08. Check the function of the neutralising system.

Neutralising system operating instructions

09. Check all gaskets and plugs, and retighten if nec-

essary.

Note

We recommend you check all connections on the

heating water side for leaks approx. every

500 hours run. See page 21.

10. Check the boiler door and flue gas cover a few

days after commissioning. In the case of leaks,

tighten the screws in the boiler door and flue gas

collector with 30 Nm.

Commissioning, inspection, maintenance

Commissioning the system (cont.)

5677 612 GB

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