Viessmann Vitocrossal 200 CM2 186 Service Instruction Download

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Service Instructions

VITOCROSSAL 200

5584 109 - 10 12/2015

for use by heating contractor

Vitocrossal 200

CM2 Series 186 to 311

Gas condensing boiler with Pre-mix cylinder burner

Read and save these instructions

for future reference.

Please file in Service Binder

Heating input: 663 to 1112 MBH

194 to 326 kW

Product may not be exactly as shown

IMPORTANT

Summary of Contents for Vitocrossal 200 CM2 186

Page 1: ... contractor Vitocrossal 200 CM2 Series 186 to 311 Gas condensing boiler with Pre mix cylinder burner Read and save these instructions for future reference Please file in Service Binder Heating input 663 to 1112 MBH 194 to 326 kW Product may not be exactly as shown H IMPORTANT ...

Page 2: ...hemicals can cause by products in the combustion process which are poisonous to inhabitants and destructive to Viessmann equipment For a listing of chemicals which cannot be stored in or near the boiler room please see subsection entitled Mechanical room in the Installation Instructions Advice to owner Once the installation work is complete the heating contractor must familiarize the system operat...

Page 3: ...rect fired hot water storage tank s Installation Instructions for burner and accessories Replacement parts For a complete listing of replacement components please see Parts List starting on page 50 of these instructions Order replacement components from your Viessmann distributor CAUTION Use only original Viessmann recommended components when replacing defective parts Installation of incorrect rep...

Page 4: ... Checking the static and the supply pressure 14 Supply pressure for NG and LPG 15 Checking the Rotary Damper Setting CM2 246 311only 15 Checking the CO2 level 16 Preparing the test 16 CO2 test at the upper heating input 16 CO2 test at the lower heating output 17 Displaying the ionization current 17 Shutting down the system 18 Opening the boiler door 18 Separating the neutralizing system if install...

Page 5: ...e Boiler 30 Burner Control 30 Burner Control Coding Card 31 Burner Control Programming Unit 32 Gas Valve NG 32 Gas Valve LPG 33 Air Pressure Switch 34 2 2 Way Solenoid Valve choke valve for CM2 186 burner only 34 Ignition Unit 35 Ignition Cable 35 Ignition Electrode Block 36 Ionization Electrode Block 36 Motorized Burner Inlet Damper 37 Inlet Damper Servomotor 37 Inlet Damper Linkage 38 Plug Conso...

Page 6: ... safety clothing respirators and equipment when servicing or working nearby the appliance The state of California has listed the airborne fibers of these materials as a possible cancer hazard through inhalation When handling these materials special care must be applied First aid measures If eye contact occurs flush eyes with water to remove dust If symptoms persist seek medical attention If skin c...

Page 7: ...tallation Instructions Service Instructions Operating Instructions Wiring diagrams Additional applicable literature Viessmann boiler controls manuals The following topics must be covered Proper system operation sequence Explain the equipment as well as the need for combustion air Demonstrate an emergency shut down what to do and what not Explain that there is no substitute for proper maintenance t...

Page 8: ...ection Codes of practice of the relevant trade associations Safety Instructions If you smell gas 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 t...

Page 9: ...n activated on temperature rise high fixed limit of 210 F 99 C disable the burner to operate The fixed high limit when tripped produces a fault that will require manual reset of the boiler control Fixed High Limit test procedure 1 Install a jumper switch in GW6B control on terminals 2 3 of 146 plug this will simulate a call for heat for multi boiler systems using the GW6B cascade lead boiler and l...

Page 10: ...s purge burner or vent outdoors 6 Match the coding card at the burner control unit according to the chart on this page Also refer to page 31 See the control section of the Installation Instructions and neutralizing system Operating Instructions 7 Check the function of the neutralizing system Note Refer to neutralizing system operating instructions 8 Check all gaskets and plugs and retighten if nec...

Page 11: ...orized reconnection 4 Remove boiler front cover 9 Secure gas valve orifice D and rubberized cork gaskets E to the flange of the mixing system C Torque nuts diagonally with 17 7 lb in 2 0 Nm 10 Secure and tighten gas supply fitting A 11 Reconnect the compensation tubing B connected between the venturi tube and the gas valve 12 Apply Partial rating plate above CSA rating plate located on top panel b...

Page 12: ...C Note No separate orifice is necessary for Natural Gas 9 Secure gas valve to the flange of the mixing system C Torque nuts diagonally with 17 7 lb in 2 0 Nm 10 Secure and tighten gas supply fitting A 11 Reconnect the compensation tubing B connected between the venturi tube and the gas valve 12 Apply Partial rating plate above CSA rating plate located on top panel behind the boiler control Label F...

Page 13: ...on Level Gas Type 2 nG Natural Gas or 2 LPG Liquid Propane Gas Altitude 3 LA Low Altitude 3 HA High Altitude Converting gas type on burner control unit To implement the changes the burner has to be in stand by Status 0 Service 0 1 Press button S F hold for more than 2 seconds and the in the display area D will flash 2 Press button Y E until 6 appears in the Service display B 3 Press button S F unt...

Page 14: ...e room WARNING Never purge a gas line into a combustion chamber Never use matches candles flame or other sources of ignition for purpose of checking leakage Use a soap and water solution to check for leakage Failure to follow this warning could result in fire explosion personal injury or death IMPORTANT The burner is automatically ignited and starts operation after a safety time has elapsed During...

Page 15: ...e between 4 w c and 14 w c The gas pressure switch for the inlet pressure test check is factory set to 4 w c Never alter this setting 3 Record the actual value in the report on page 53 4 Close the gas shut off valve 5 Remove the pressure tester and close test nipple A shown on page 14 The electro mechanical inlet air damper reduces the amount of air during ignition timing for a smoother ignition o...

Page 16: ...ord the actual value in the report on page 64 Steps Commissioning Inspection and Maintenance continued Checking the CO2 level Preparing the test 1 Open the gas shut off valve 2 Start the burner with the emissions test switch enabled at the boiler control unit 3 At the same time press button S F and button B G and hold for longer than 2 seconds The display will then show the following Under Status ...

Page 17: ... ionization current must be called up via the burner control unit It is not possible to measure the ionization current using a multimeter 1 Press button S F hold for more than 2 seconds and the in the display area D will flash 2 Press button YE until 5 appears in the service display B 3 Press button S F and 5 will appear in the status display A 4 Press button YE until 3 appears in the service disp...

Page 18: ...er door for damage 2 Check the thermal insulation components of the boiler door for possible damage 3 Replace any damaged parts Checking all connections for leaks 1 Check all connections on the heating water side and sensor well A for leaks Note Also check the connections to control equipment and to the minimum pressure switch low water indicator for leaks Shutting down the system 1 Switch OFF the...

Page 19: ...tap water 3 Add granulate as marked IMPORTANT The granulate is consumed as it neutralizes the condensate The red marking indicates the minimum filling level See Neutralization Unit Installation Instructions Note For maintenance purposes route the gas supply pipe A on the opposite side of the burner D door hinges Cleaning and reconnecting the condensate drain system Note Clean the inside of the con...

Page 20: ...ng clamp and disconnect the combustion air flex hose A 2 Visually inspect the combustion air hose A and venturi mixing pipe B 3 If cleaning is required remove the venturi B refer to page 35 for burner fan removal procedures and clean the venturi pipe fan casing and impeller with low pressure compressed air 4 To clean the burner vacuum the inside and outside of the burner tube C refer to page 39 fo...

Page 21: ...e Installation Instructions for details 2 Check that the flue gas collector C is tight to the boiler A If required retighten the flue gas collector mounting fasteners D 3 Reconnect the venting system with the flue gas pipe adaptor and tighten with gear clamps Note The seals gaskets can also be checked under full load with an inspection mirror If required remove the thermal insulation components Tr...

Page 22: ...r control The burner control is factory set to open at 230 F 110 C During boiler operation the flue gas temperature sensor sends a signal to the burner control and will disable the burner operation when the flue gas temperature reaches 230 F 110 C The temperature switch will reset once the temperature drops approximately 20 F 10 C from the factory set point Check the burner control for fault F F1 ...

Page 23: ...r Temperature Resistance in k ohms 3A sensor NTC 10k Temperature Resistance in k ohms 3B sensor NTC 20k Checking the 3A and 3B boiler temperature sensor Note The sensor is located on the boiler supply connection and the connecting plug is located at the burner control unit Note Check the burner control for fault F FZ on the display ...

Page 24: ... Replacing the Boiler Temperature Sensor Commissioning Inspection and Maintenance Note The boiler water temperature sensor is located at the boiler supply connection 1 Remove spring clip set aside 2 Insert 6 in 150 mm temperature sensor 3 Observe the inserted depth 4 Secure sensor lead with spring clip 5 Insert the 3A and 3B plug to the burner electrical connector ...

Page 25: ...r treatment system will protect against damages caused by corrosion and lime formation Hard water conditions i e calcium carbonate must be avoided as it will cause deposits to accumulate on the heat exchanger surfaces If in any doubt about the water quality please have a proper water analysis done Check with regional chemical suppliers for boiler water treatment or with Viessmann Manufacturing Com...

Page 26: ...fault setting for valve seat gas pressure switch is 10 mbar 4 w c The switch will trigger an E1 pressure or E2 open circuit during control self diagnostics faults on the burner control if activated IMPORTANT Do not adjust this switch Legend A GDW1 gas inlet pressure monitoring switch B GDW2 valve seat gas pressure monitoring switch Combustion chamber pressure monitoring air pressure switch 2 To mo...

Page 27: ...to the boiler Note External vent line is not required If necessary the d NPT vent opening on the Honeywell low gas pressure switch can be used Legend 1 Low gas pressure switch cable CM2 Boiler connection Low pressure gas switch connection Wire color G Green 26 L COM White 27 L NO Black Legend A DIN rail junction box B Auxiliary low gas pressure switch or external shut off dry contact Operation Whe...

Page 28: ...educing tee kit part D Short nipple kit field supplied E Manual gas shutoff valve supplied with boiler F Ground joint union recommended field supplied G Reducing bushing kit only for 7842159 H Short nipple kit part I Low gas pressure switch the switch can be installed in the gas line anywhere near the boiler Gas Piping Components Note Typical gas piping shown ...

Page 29: ...switch F Gas supply pipe G Burner test firing valve H Cylinder burner assembly I Ignition electrodes Note Solenoid valve choke valve for CM2 model 186 not shown J Ionization electrode K Gas pipe L AC EMI suppression filter device M Ignition unit N Thermal insulation block O Manual shut off valve P Venturi mixing pipe Q Air pressure switch 2 R Burner control sub base S Servomotor and burner inlet d...

Page 30: ...er control sub base Burner Service 1 Close main gas supply valve 2 Switch off main power switch Ensure that main power to equipment being serviced is off 3 Remove front panel and front side panels Refer to the boiler Installation Instructions 4 Remove plugs 41 and 90 from the burner control and plug 40 156 40 and 53 from the burner bracket 5 Remove plugs from electrodes 6 Remove air intake adaptor...

Page 31: ...he burner control sub base 6 Remove burner control sub base 7 Reinstall in reverse order 1 Loosen the two programming unit screws 2 Lift the programming unit off the burner control sub base and disconnect the cable plug and set aside 3 Remove the coding card from burner control sub base and replace Note Ensure there is no power to the burner control when replacing the coding card Note If error cod...

Page 32: ...from the lower gas valve flange and set aside 5 Disconnect gas supply line 6 Disconnect compensation tubing from gas valve 7 Remove tube support from gas valve and set aside 8 Remove four M5 8 mm hex nuts from the gas manifold and set aside Note Clean surface area of manifold and replace O ring 9 Replace gas valve Note Install M5 studs to the gas valve to reconnect the manifold and torque to 17 lb...

Page 33: ...disconnect the electrical plug white from the gas pressure switch 4 Remove the four M5 4 mm hex key screws from the lower gas valve flange and set aside 5 Disconnect gas supply line 6 Disconnect compensation tubing from gas valve 7 Remove tube support from gas valve and set aside 8 Remove four M5 8 mm hex nuts from the gas manifold and set aside 9 Remove LPG orifice and set aside 10 Remove both LP...

Page 34: ... mm hex key screw to 5 lb in 0 6 Nm Note Ensure the ground wire is securely fastened Note Set new air pressure settings to the exact same settings as the old air pressure switch 8 Reinstall in reverse order During the ignition timing of the burner unit the solenoid is activated for approximately 5 seconds This will open the valve and allow fan positive pressure pneumatically linked to the gas pres...

Page 35: ...ug from ignition unit 2 Remove ignition cables from ignition unit 3 Loosen screws of ignition unit 4 Remove ignition unit 5 Reinstall in reverse order 1 Remove plug from ignition unit 2 Remove ignition cables from ignition unit 3 Remove ignition cables from the ignition electrodes 4 Reinstall in reverse order ...

Page 36: ...tion electrode block and gasket from burner door 8 Reinstall in reverse order use only new parts supplied in the kit 9 Check the dimension between the electrode and burner as shown Carefully adjust if necessary 10 Torque the M12 19 mm hex burner door bolts to 13 lb ft 18 Nm 11 Torque the M6 5 mm hex socket cap screws ionization electrode 35 lb in 4 Nm 1 Disconnect the ignition cables from the igni...

Page 37: ... setup of the servomotor Note Only CM2 models 246 and 311 are equipped with a inlet damper servomotor Motorized Burner Inlet Damper 1 Remove four screws from the venturi tube and remove damper 2 Remove the burner inlet damper from the burner along with the servomotor and linkage 3 Remove servomotor cover and set aside 4 Disconnect the servomotor electrical connection from the servomotor 5 Disconne...

Page 38: ...rew to 13 2 lb in 1 5 Nm Plug Console with Relay 1 Disconnect plugs 40 156 and 40 from the back of the plug console 2 Disconnect the two ground wires yellow green from the terminal block below the plug console 3 Disconnect wires T1 brown and T2 blue from the relay contactor 4 Remove the four 3 mm hex head screws and washers from the plug console mounting plate and set aside Replace the plug consol...

Page 39: ... Note Install the fan in the original orientation 10 When installing the fan assembly to the burner door torque the M8 13 mm hex bolts nuts to 53 lb in 6 Nm 11 Reinstall in reverse order Burner Tube Burner Fan WARNING Leak test the reconnected gas line WARNING Leak test the reconnected gas line 1 Loosen the retaining clamp and disconnect the combustion air flex hose and set aside 2 Disconnect the ...

Page 40: ...ner door and set aside Remove fan venturi assembly see page 39 for additional information 2 Remove the two M6 bolts and remove the burner control assembly 3 Remove the ignition and ionization electrode block see page 36 4 Remove the cotter pins and hinge pins from burner door and set aside 5 Remove the four M12 19 mm hex burner door bolts and washers and set aside Note To access the burner door di...

Page 41: ...ner Door Refractory 1 Loosen the retaining clamp and disconnect the combustion air flex hose and set aside 2 Disconnect the gas line 3 Remove ionization electrode block 4 Remove ignition electrode block 5 Remove the six M12 19 mm hex burner door bolts and washers and set aside 6 Remove burner tube see page 39 Note Replace burner tube gasket as required 7 Remove rope seal Note When reinstalling the...

Page 42: ...s display B Service display C Reset button D LEDs from left heat demand flame maintenance and fault F Selection key E G Cursor keys Operating display In standard mode the status display shows the current operating conditions The same applies in a fault state after pressing reset button R C The following displays are scrolled through automatically In case of faults see the fault codes from page 50 ...

Page 43: ...n Safety time Flame established Pre ignition Flame stabilization Operation with flame Reheat Post purge Maintenance program no air pressure Maintenance program no gas pressure or mains under voltage Forced ventilation when no flame was recognized Safety shutdown due to flame tear off Operating display continued ...

Page 44: ...tings of the burner control unit Note Only make adjustments when the burner control unit is on standby 4 Y Scroll through Status until 6 is shown under Status Status Description 1 Display of start up meter with reset 1 digit 2 Display of start up meter with reset 1000 digit 3 Menu item for deleting the start up meter reading 4 Display of hours run meter with reset 1 digit 5 Display of hours run me...

Page 45: ...eters Sub menu Item Parameter Units Scale Delivered condition 1 Maximum operational input of rated input 100 2 Gas type 0 NG natural gas 1 LPG liquid propane gas 3 Not assigned 4 Maximum boiler water temperature from 41 to 260 F 5 to 127 C 203 F 95 C 5 Integral threshold value of controller In Kmin from 1 to 255 30 Kmin 6 Runtime optimization 0 minimum pause 1 integral method 1 7 Motorized vent da...

Page 46: ...B S together for longer than 2 seconds The burner returns to modulating mode Resetting Operating Parameters to Factory Settings Manual Mode and Service Display Example to set the maximum operational burner input to between 0 and 100 press the following buttons 1 S longer than 2 seconds flashes 2 Y until 6 is shown under Service 3 S 6 will be displayed under Status 4 S 1 will be shown under Status ...

Page 47: ...47 5584 109 10Vitocrossal 200 CM2 186 to 311 Service Burner Control Unit Flow Diagram Flow Diagram ...

Page 48: ... Start up 1 Flame signal amplifier test max 50 seconds Gas fan and air pressure switch test max 20 seconds 2 Fan ramp up max 20 seconds 3 Pre purge 30 seconds Adjusting start up load test APS1 1 9 seconds 4 Pre ignition 2 seconds 5 Ignition safety time 2 3 seconds Flame detection safety time max 51 seconds Operation 6 Flame stabilizing time 15 seconds 7 Start up partial load 20 seconds Modulating ...

Page 49: ...ly if no key is pressed within 20 seconds Note If the burner does not start up due to a non lockout fault without displaying a fault code the fault memory may be able to indicate the cause To call up the fault codes press the following keys 1 S longer than 2 seconds flashes 2 Y until 4 is shown under Service 3 S 4 will be displayed under Status 4 Y B to scroll through the fault memory display Serv...

Page 50: ...d and sensors A and B replace sensor if required F b7 Burner control unit in a fault state system cools down burner control unit locked out Coding card not inserted in the burner control unit incorrect or faulty coding card Insert coding card check coding card replace if required F b7 Type of coding card Coding card does not match burner control unit Replace coding card or burner control unit Dang...

Page 51: ... check CO2 setting set gas throughput according to rated boiler heating output see connection values page 18 F F2 Burner control unit in a fault state system cools down Excessive boiler water temperature Wait until temperature falls below the permissible boiler water temperature reset burner control unit F F3 Ionization flame monitor reports faulty flame signal during start up or after the post pu...

Page 52: ...tch 1 connect or set correctly F F5 Air pressure switch 1 switches off during operation Flue gas back pressure condensate built up air pressure switch 1 hose faulty connecting hose leaking Remove flue gas back pressure check if condensate banked up reset burner control unit replace hose F F6 Gas pressure switch shows no gas pressure Gas shut off valve closed gas pressure switch faulty multiple pro...

Page 53: ...rol unit in a fault state Flue gas path or condensate path blocked off Check flue gas path or condensate path and clean if required Motorized vent damper not configured with control if used See flue gas damper setting common vent system Fault Cause Measures Combustion fault through pulsation Excessive gas input Adjust gas input in accordance with rated boiler heating output Insufficient or excessi...

Page 54: ...h gasket 0004 Gasket for connector 0005 Condensate siphon 0006 Flue gas sensor well 0007 Flue gas vent adaptor with clamps 0008 Boiler temperature sensor well 0009 Boiler inspection cup 3 0010 Leveling bolts accessory pack 0011 Boiler door hinge bracket Other Parts not illustrated 0400 Installation set 0420 Installation Instructions 0421 Operating Instructions 0422 Service Instructions 0423 Parts ...

Page 55: ...t 0006 Side panel front left 0007 Front panel top 0008 Front panel 0009 Nameplate Vitocrossal 200 0010 Cover strip 0011 Top shield panel 0012 Bottom panel 0013 Top panel right 0014 Top panel left 0015 Rear panel top with 0016 edge molding 0016 Cover edge molding 0017 Rear panel middle 0018 Rear panel bottom 0019 Guide rail top right 0020 Guide rail top left 0021 Guide rail bottom left 0022 Guide r...

Page 56: ...90o Street elbow c in 0404 Hex bushing 1a in x c in 0405 Cross 1a in 0406 Tee 1 b x 1 b x c in 0407 Cross 1a in 0408 Nipple 1 x 2 1 0409 Sediment faucet c in 0410 Air vent with shut off base 0411 Hex bushing 1a in x 3 8 in 0412 Pressure gauge 0413 Hex bushing b in x a in 0414 Low water cut off 0415 Nipple 0416 Gas ball valve Other Parts not illustrated 0417 Thermometer Winters 5 0 250 F 2 0425 Par...

Page 57: ...ol VUC310 B10 003 0014 Programming unit HI201 B02 001 with LED display 0015 Ignition transformer harness 54 0016 Wiring harness for fan 0017 Wiring harness for gas valve 0018 Pressure switch for fan inlet with 131 harness 0019 2 2 way solenoid valve 0021 Fan G1G170 120 1 60 0022 AC EMI suppression filter device 0024 Linkage M5 only for models 246 and 311 0025 Venturi mixing pipe 0026 Orifice LPG s...

Page 58: ...VUC310 B10 003 0014 Programming unit HI201 B02 001 with LED display 0015 Ignition transformer harness 54 0016 Wiring harness for fan 0017 Wiring harness for gas valve 0018 Pressure switch for fan inlet with 131 harness 0020 Servomotor STA 120V 0021 Fan G1G170 120 1 60 0022 AC EMI suppression filter device 0023 Inlet damper 0024 Linkage M5 0025 Venturi mixing pipe 0026 Oriface LPG sold as a convers...

Page 59: ...2293 CM2 311 Burner 7542294 Ordering Replacement Parts Please provide Model and Serial Number from CSA rating plate when ordering replacement parts Order replacement components from your Viessmann distributor Junction Box 0001 Outside panels 0002 Accessory bag with sensors 0003 Accessory bag with burner cables 0004 Boiler control coding card ...

Page 60: ...e boiler base Length in 40 40 40 mm 1005 1005 1005 Width in 31 31 31 mm 800 800 800 Thickness in 4 4 4 mm 100 100 100 Weight Boiler body lb 503 536 564 Kg 228 243 256 Complete with the burner control lb 726 759 792 and thermal insulation Kg 329 344 359 1 Tested to AHRI BTS 2000 Testing Standard Method to Determine Efficiency of Commercial Heating Boilers 2 Add 1f in 40 mm when using seismic mounts...

Page 61: ...mbustion air Internal Diameter Flue Gas Values temperature at a return temperature of 86 F 30 C in mm 6 150 6 150 6 150 at rated input F 136 132 130 C 58 55 54 at partial load F 95 95 95 C 35 35 35 Temperature at a return temperature of 140 F 60 C at rated input F 167 167 167 C 75 75 75 Mass flow rate of flue gas at rated input lbs h 593 785 994 kg h 269 356 451 at partial load lbs h 198 262 331 k...

Page 62: ...c 450 17c 450 17c 450 Total length in mm 23b 595 23b 595 23b 595 Length with burner hood in mm 20 510 20 510 20 510 Width in mm 21f 550 21f 550 21f 550 Height in mm 19 480 19 480 19 480 Weight Burner with combination valve and burner hood lb kg 72 8 33 74 33 5 78 3 35 5 Min gas supply pressure Natural gas w c 4 4 4 Liquid propane gas w c 10 10 10 Max gas supply pressure Natural gas w c 14 14 14 Li...

Page 63: ...essure switch outlet pressure at first valve seat kJ GDW2 O Inlet fan pressure switch acA APS1 P Inlet gas pressure switch ayA GDW1 Q Flue gas temperature sensor 2 15B R Overfire pressure switch 131A APS2 WARNING Disconnect power inside the boiler junction box before servicing boiler CAUTION Provide disconnect means and overload protection as required F1 Fuse F2 Fuse H1 Hours run meter modulation ...

Page 64: ...iquid propane gas LPG mbar w c Tick gas type Carbon Dioxide Content CO2 at the upper rated heating output actual by vol set by vol at the lower rated heating output actual by vol set by vol Oxygen Content O2 at the upper rated heating output actual by vol set by vol at the lower rated heating output actual by vol set by vol Carbon Monoxide Content CO actual ppm set ppm Flue Gas Temperature gross a...

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