Viessmann VITOCROSSAL 200 Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 200
Type CM2, 400 to 620 kW
Gas condensing boiler with MatriX cylinder burner
For applicability, see the last page
VITOCROSSAL 200
5794 780 GB 4/2013 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are intended exclu-
sively for qualified 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 elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
■ This appliance has not been designed
to be operated by individuals (includ-
ing children) with limited physical, sen-
sory or mental capacities or who are
lacking in the appropriate experience
and/or knowledge, unless they are
supervised by a person with responsi-
bility for their safety or were instructed
by that person in the operation of this
appliance.
!Please note
Children should be super-
vised.
Ensure that children never play
with the appliance.
Regulations
Observe the following when working on
this system:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental protection
Safety instructions
Safety instructions
5794 780 GB

3
■ 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 explo-
sions 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-threat-
ening 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 safe-
guard it against unintentional reopen-
ing.
■ Isolate the system from the power sup-
ply (e.g. at the separate fuse or a main
switch) and check that it is de-ener-
gised.
■ Safeguard the system against recon-
nection.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charges.
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 function can compromise
the safe operation of your sys-
tem.
Replace faulty components only
with original Viessmann spare
parts.
Safety instructions
Safety instructions (cont.)
5794 780 GB

4
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5794 780 GB

5
Product information
Intended use......................................................................................................... 6
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 7
Further details regarding the individual steps....................................................... 9
Air pressure switch............................................................................................ 46
Burner control unit............................................................................................. 48
Troubleshooting
Fault display......................................................................................................... 56
Fault codes........................................................................................................... 57
Faults without fault display................................................................................... 64
Burner control unit flow chart........................................................................... 65
Connection diagrams
Burner control unit connection diagram................................................................ 67
Mains filter unit connection diagram..................................................................... 71
Component overview......................................................................................... 73
Control unit
Adjusting codes at the control unit....................................................................... 75
Parts lists
Ordering parts...................................................................................................... 76
Overview of the assemblies................................................................................. 76
Parts not shown.................................................................................................... 76
Boiler assembly.................................................................................................... 77
Thermal insulation assembly................................................................................ 77
Burner assembly, 400 kW.................................................................................... 80
Burner assembly, 500 kW.................................................................................... 81
Burner assembly, 620 kW.................................................................................... 84
Report.................................................................................................................. 86
Specification....................................................................................................... 91
Keyword index.................................................................................................... 93
Index
Index
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The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions 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 pur-
pose other than the heating up of heating
water shall be deemed inappropriate.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble components designed for this pur-
pose has been carried out.
Every other use will be deemed to be
inappropriate. Any resulting losses are
excluded from the manufacturer's liabil-
ity.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Intended use also includes the adher-
ence to maintenance and inspection
intervals.
Product information
Intended use
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For further information regarding the individual steps, see the page indicated
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 siphon with water......................................... 9
•4. Checking the gas type.................................................... 10
•5. Conversion to natural gas E.......................................... 11
•6. Conversion to LPG P...................................................... 14
•7. Height adjustment.......................................................... 16
• • 8. Configuring the motorised flue gas damper (flue gas
cascade).......................................................................... 18
••• 9. Commissioning the system........................................... 18
•10. Reducing operational output (if necessary)................. 20
••• 11. Checking static pressure and supply pressure........... 21
••• 12. Checking the rotary damper setting (for 400 and 620
kW)................................................................................... 23
•13. Overview of differences between the three burner
sizes................................................................................. 24
••• 14. Checking the CO2 content............................................. 27
••• 15. Checking the CO content
••• 16. Checking the flue gas temperature
• • 17. Displaying the ionisation current.................................. 29
• • 18. Shutting down the system............................................. 30
• • 19. Opening the boiler door................................................. 34
• • 20. Cleaning the combustion chamber and heating
surfaces........................................................................... 34
• • 21. Checking the gaskets and thermal insulation
components.................................................................... 35
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
• • 22. Checking all connections on the heating water side
for tightness.................................................................... 36
• • 23. Cleaning and reconnecting the condensate drain
system............................................................................. 36
• • 24. Checking for tightness on the flue side....................... 38
• • 25. Checking the condensate drain and the neutralising
system (if installed)........................................................ 38
• • 26. Checking the burner gauze assembly.......................... 39
• • 27. Checking the ignition electrodes and ionisation
electrode.......................................................................... 40
• • 28. Cleaning the burner........................................................ 40
•29. Fitting the fan.................................................................. 41
•30. Making the burner electrical connections.................... 41
• • 31. Checking both gas train valves automatically for
tightness.......................................................................... 42
• • 32. Checking the filter element in the gas line (if installed)
and replacing if required
••• 33. Checking all gas connections for tightness................ 42
•34. Implementing final checks............................................. 43
• • 35. Checking the water quality............................................ 44
••• 36. Checking the function of safety valves
• • 37. Checking the expansion vessel and system pressure 44
• • 38. Checking the mixer for ease of operation and leaks... 45
••• 39. Checking the thermal insulation for firm seating
• • 40. Checking the ventilation air apertures in the
installation room (only for open flue operation)
•41. Instructing the system user........................................... 45
•42. Operating and service documents................................ 45
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
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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 charge volume, water hard-
ness and pH value on page 44.
Note
Observe the "Water quality require-
ments" on page 87.
Filling the siphon with water
1. Undo four screws and remove the
rear centre and lower back panels.
2. Undo the siphon and fill with water
(otherwise flue gas may escape).
3. Check that the condensate can drain
freely.
4. Remount the siphon.
Note
The hose connection to the on-site
condensate system or to the neutral-
ising system must not be permitted to
sag; support with a pipe if neces-
sary.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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Checking the gas type
1. Check the gas type and Wobbe index
(Wo) with your gas supply utility.
■ With the natural gas E setting, the
boiler can be operated in the
Wobbe index range 12.0 to
16.1 kWh/m3 (43.2 to 58.0 MJ/m3).
■ With the LPG P setting, the boiler
can be operated in the Wobbe
index range 20.3 to 21.3 kWh/m3
(72.9 to 76.8 MJ/m3).
2. In the delivered condition, the burner
is set up for natural gas E. If required,
convert the burner to a different gas
type (see from page 11) in accord-
ance with details provided by your
gas supply utility.
Note
The 500 kW burner requires a natural
gas restrictor. A natural gas restrictor
is not required for the 400 and
620 kW burners.
Rated heating output kW 400 500 620
Restrictor for natural gas E 7 mm − 21.5 −
Restrictor for LPG P 7 mm 14.0 14.8 17.2
3. Record the gas type in the report (on
page 86).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Conversion to natural gas E
Restrictor installation
B
C
D
EG
F
A
01. Close the gas shut-off valve.
02. Turn off the ON/OFF switch on the
control unit.
03. Switch OFF the mains isolator (out-
side the installation room) or isolate
the mains power and secure against
unintentional reconnection.
Note
For removal of the front panels and
side panel, see from page 30
04. Undo fitting A from the gas supply
pipe.
05. Pull compensation hose G from
the gas train.
06. Release the gas train from flange
E.
07. In the case of a 500 kW burner:
Insert O-ring B, natural gas restric-
tor C and rubber cork gasket D.
Note
The bevel on the natural gas restric-
tor must point towards the gas
train.
In the case of a 400 and 620 kW
burner:
Remove natural gas restrictor C
with rubber cork gasket D.
08. Tighten screws M 5 x 16 cross-wise
(torque: 1.5 Nm).
09. Secure fitting A.
10. Push compensation hose G on to
the gas train.
11. Affix the enclosed label "Set to ..."
over existing label F.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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12. Check all fittings for tightness.
Danger
Escaping gas leads to a risk
of explosion.
Check all fittings for gas
tightness.
!Please note
The use of leak detection
spray can result in incorrect
functions.
Leak detection spray must
not come into contact with
electrical contacts.
13. Start the burner (see page 18).
Rated heating output kW 400 500 620
Restrictor for natural gas E 7 mm − 21.5 −
Natural gas settings on the burner control unit
C
D
E
F
1. Press button S E for longer than 2 s.
" " flashes.
2. Press button F until display C
shows "6" under Service.
3. Press button S E until display C
shows "6" under Status.
4. Press button F until display C
shows "2" under Status and the cur-
rent gas type is shown under Service
(0 = natural gas or 1 = LPG).
5. Use button F or D to select
"0" for natural gas.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5794 780 GB

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Status Service
S
R
D
C
EF
G
6. Press button S E to confirm. If
applied successfully, "1" will be
shown briefly in display C under
Service, or "0" will appear if it failed.
7. Press button S E to switch to the
operating display.
8. Press button R G.
The system will be restarted.
Note
The setting parameters are displayed
each time the system is restarted.
1 Max. output (70-100 %)
The output setting is not limited.
The base load can also be set (CS
configuration).
2 Gas type (NG = natural gas or LPG
= liquid gas)
3 Installation height (LA or HA)
4 Temperature of temperature lim-
iter
5 Integral for minimum pause time
6 Cycle protection method
Note
Once the gas type has been converted,
the CO2 values need to be checked for
full load and partial load and corrected if
necessary (see page 27 and 28).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5794 780 GB

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Conversion to LPG P
Restrictor installation
B
C
D
EG
F
A
01. Close the gas shut-off valve.
02. Turn off the ON/OFF switch on the
control unit.
03. Switch OFF the mains isolator (out-
side the installation room) or isolate
the mains power and secure against
unintentional reconnection.
Note
For removal of the front panels and
side panel, see from page 30
04. Undo fitting A from the gas supply
pipe.
05. Pull compensation hose G from
the gas train.
06. Release the gas train from flange
E.
07. Insert O-ring B, LPG restrictor C
and rubber cork gasket D.
Note
The bevel on the LPG restrictor
must point towards the gas train.
08. Tighten screws M 5 x 16 cross-wise
(torque: 1.5 Nm).
09. Secure fitting A.
10. Push compensation hose G on to
the gas train.
11. Affix the enclosed label "Set to ..."
over existing label F.
12. Check all fittings for tightness.
Danger
Escaping gas leads to a risk
of explosion.
Check all fittings for gas
tightness.
!Please note
The use of leak detection
spray can result in incorrect
functions.
Leak detection spray must
not come into contact with
electrical contacts.
13. Start the burner (see page 18).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5794 780 GB

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Rated heating output kW 400 500 620
Restrictor for LPG P 7 mm 14.0 14.8 17.2
LPG settings on the burner control unit
C
D
E
F
Status Service
S
R
D
C
EF
G
1. Press button S E for longer than 2 s.
" " flashes.
2. Press button F until display C
shows "6" under Service.
3. Press button S E until display C
shows "6" under Status.
4. Press button F until display C
shows "2" under Status and the cur-
rent gas type is shown under Service
(0 = natural gas or 1 = LPG).
5. Use button F or D to select
"1" for LPG.
6. Press button S E to confirm. If
applied successfully, "1" will be
shown briefly in display C under
Service, or "0" will appear if it failed.
7. Press button S E to switch to the
operating display.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5794 780 GB

16
8. Press button R G.
The system will be restarted.
Note
The setting parameters are displayed
each time the system is restarted.
1 Max. output (70-100 %)
The output setting is not limited.
The base load can also be set (CS
configuration).
2 Gas type (NG = natural gas or LPG
= liquid gas)
3 Installation height (LA or HA)
4 Temperature of temperature lim-
iter
5 Integral for minimum pause time
6 Cycle protection method
Note
Once the gas type has been converted,
the CO2 values need to be checked for
full load and partial load and corrected if
necessary (see page 27 and 28).
Height adjustment
Note
To be able to adjust the settings the
burner must be on standby (Status "0",
Service "C").
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5794 780 GB

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C
D
E
F
Status Service
S
R
D
C
EF
G
01. Press button S E for longer than
2 s. " " flashes.
02. Press button F until display C
shows "6" under Service.
03. Press button S E until display C
shows "6" under Status.
04. Press button F until display C
shows "3" under Service.
05. Press button S E until display C
shows "3" under Status.
06. The current height is shown in dis-
play C under Service (0 = low
height or 1 = large height).
07. Press button F or D until dis-
play C shows "1" under Service for
large height.
"1" is displayed briefly under Serv-
ice.
08. Press button S E to confirm. Reset
to "1" if "0" appears.
09. Press button S E to quit adjust-
ment mode and return to the oper-
ating display.
10. Press button R G for more than
2 s; the system restarts and the
adjustments are adopted.
11. Complete the "height adjustment"
label and attach it next to the type
plate.
12. Complete the adjustment report and
send by fax.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5794 780 GB

18
Note
Each time the burner is restarted the set-
ting parameters (max. output, gas type
and height) are displayed as in the fol-
lowing table.
Maxi-
mum out-
put
1; 0 to 100
Gas type 2; NG = natural gas
2; LPG = liquid gas
Height 3; LA = low height
(0 to 1500 m)
3; HA = large height
(1500 to 3000 m)
Configuring the motorised flue gas damper (flue gas cascade)
See page 54
Commissioning the system
Danger
CO build-up as a result of incor-
rect burner adjustment can have
serious health implications.
Carry out a CO test before and
after work on gas appliances.
Tightness test
Gaskets on the boiler door and compo-
nents routing flue gas can be checked
during operation with an inspection mir-
ror.
If required, remove the thermal insula-
tion components.
Traces of condensate on the outside of
the flue gas collector or on thermal insu-
lation components also indicate leaks.
Note
An examination of the burner setting with
the boiler heated to operating tempera-
ture (min. 40 °C) is essential.
Also check in the partial load range.
Boiler control unit service instruc-
tions
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5794 780 GB

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CD
1. Check the heating system pressure.
Permiss. operating pressure: 5.2 bar
(520 kPa)
2. In open flue operation:
Check that the installation room ven-
tilation is unobstructed.
3. Check the gas supply pressure (for
set value, see page 22).
4. Open the gas line shut-off valves.
5. Switch ON the mains isolator (outside
the installation room).
6. Turn on the ON/OFF switch B at the
control unit.
Note
The burner will start with a delay of
approx. 3 min.
If fault indicator A on the control unit
illuminates and display C on the
burner control unit flashes, initially
reset the system. For this press reset
button D on the burner control unit.
Note
The appliance can enter a fault state
during commissioning if there is
insufficient gas in the gas line (the
fault indicator on the control unit illu-
minates). Purge the gas line again
and reset the burner control unit.
If the fault persists, the inlet strainer
of the gas train may have become
blocked by work carried out on the
gas line.
Danger
Escaping gas leads to a risk of
explosion.
First close the shut-off valves
in the gas line again.
Undo the flange on the gas train and
clean the strainer (blocked strainer is
not recognised by the gas pressure
test at the flange).
7. Adjust the codes at the boiler control
unit.
Control unit installation and
service instructions
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5794 780 GB

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8. Check the function of the neutralising
system (if installed), including the
hydraulic seal in the siphon.
Neutralising system operating
instructions
9. Check all gaskets and plugs, and
retighten if necessary.
Note
We recommend you check all con-
nections on the heating water side for
leaks approx. every 500 hours run.
Reducing operational output (if necessary)
The maximum operational output of the
burner can be set to between 70 and
100 % if necessary.
C
D
E
F
Status Service
S
R
D
C
EF
G
1. Press button S E for longer than 2 s.
" " flashes.
2. Press button F until display C
shows "6" under Service.
3. Press button S E. In display C,
"6" appears under Status.
4. Press button S E. "1" will be dis-
played under Status in display C
and the current value for the maxi-
mum operational output is shown in
% under Service.
5. Press button F or D for the
required maximum operational out-
put.
6. Press button S E to confirm. If
applied successfully, "1" will be
shown in display C under Service,
or "0" will appear if it failed.
7. Press button S E to switch to the
operating display.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5794 780 GB