Viessmann VITOCROSSAL 200 Operating instructions

VIESMANN
Service instructions
for heating engineers
Vitocrossal 200
Type CM2
Gas fired condensing boiler
For applicability, see the last page
VITOCROSSAL 200
5692 599 GB 7/2005 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 exclusively
designed for qualified personnel.
&Work on gas appliances 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.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&the Code of Practice of relevant
trade associations,
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
Danger
Escaping gas can lead to
explosions which may lead to
serious injury.
&Never smoke. Prevent naked
flames and sparks.
&Never switch lights or electri-
cal appliances ON or OFF.
&Close the gas shut‐off valve.
&Open windows and doors.
&Remove all people from the
danger zone.
&Notify your gas or electricity
supplier 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‐threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Close doors to the living
space.
Safety instructions
2
Safety instructions
5692 599 GB

Working on the system
&Isolate the system from the power
supply and check that it is no longer
'live', e.g. by removing a separate
fuse or by means of a mains isola-
tor.
&Safeguard the system against
unauthorised reconnection.
&When using gas as fuel, also close
the main gas shut‐off valve and
safeguard against unauthorised
reopening.
Repair work
!Please note
Repairing components which
fulfil a safety function can com-
promise the safe operation of
your heating system.
Replace faulty components
only with original Viessmann
spare parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can
compromise its function. Instal-
ling non‐authorised compo-
nents and non‐approved
modifications or conversions
can compromise safety and
may invalidate our warranty.
For replacements, use only ori-
ginal spare parts supplied or
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 599 GB

Initial start-up, inspection, maintenance
Steps –initial startup, inspection and maintenance ..................................... 5
Further details regarding the individual steps .............................................. 7
Air pressure switch ..................................................................................... 31
Burner control unit ...................................................................................... 32
Troubleshooting
Diagnosis ................................................................................................... 40
Gas burner control unit flow chart ........................................................... 46
Burner control unit connection diagram .................................................. 48
Component overview................................................................................ 50
Control unit
Adjusting codes at the control unit............................................................... 54
Parts lists .................................................................................................. 55
Report ....................................................................................................... 60
Water quality requirements ......................................................................... 60
Specification............................................................................................. 62
Certificates
Declaration of conformity ............................................................................ 65
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 66
Keyword index .......................................................................................... 67
Index
4
Index
5692 599 GB

For further information regarding individual steps, see the pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
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•01. Checking the high limit safety cut‐out setting ........... 7
•02. Filling the heating system with water and venting
the system ............................................................................... 7
•03. Filling the siphon with water............................................. 7
••• 04. Starting the heating system .............................................. 7
•05. Checking the gas type......................................................... 9
•06. Conversion to natural gas LL ........................................... 9
••• 07. Checking the static and the supply pressure............. 12
••• 08. Checking the CO2content ................................................. 14
••• 09. Checking the CO content
••• 10. Checking the flue gas temperature
• • 11. Checking the ionisation current ..................................... 19
• • 12. Shutting down the heating system................................. 20
• • 13. Opening the boiler door...................................................... 20
• • 14. Separating the neutralising system (if installed)
from the boiler and connecting the drain hose.......... 20
• • 15. Cleaning the combustion chamber and heating
surfaces.................................................................................... 21
• • 16. Checking gaskets and thermal insulation
components ............................................................................ 21
• • 17. Checking all primary connections and the sensor
well for leaks........................................................................... 22
• • 18. Cleaning and reconnecting the condensate drain
system....................................................................................... 22
• • 19. Checking the condensate drain and the
neutralising system (if installed) .................................... 23
• • 20. Checking the burner gauze assembly........................... 24
Steps –initial start‐up, inspection and maintenance
5
Initial start-up, inspection, maintenance
5692 599 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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• • 21. Checking the ignition and ionisation electrodes ...... 24
• • 22. Closing the boiler door ....................................................... 25
• • 23. Cleaning the burner ............................................................. 25
•24. Burner installation................................................................ 26
• • 25. Checking both gas train valves for soundness (for
115 to 311 kW)......................................................................... 27
• • 26. Checking and replacing (if required) the filter
elements in the gas pipe
••• 27. Checking all gas connections for soundness............ 27
•28. Implementing final tests..................................................... 28
• • 29. Checking the water quality................................................ 28
••• 30. Checking the function of all safety valves
• • 31. Checking the diaphragm expansion vessel and
system pressure.................................................................... 29
• • 32. Checking the mixer for obstructions and leaks ........ 30
••• 33. Checking the thermal insulation for tight fit
• • 34. Checking the ventilation apertures in the
installation room (only for open flue operation)
•35. Instructing the system user .............................................. 30
•36. Operating and service documents ................................. 30
Steps –initial start‐up, inspection and . . . (cont.)
6
Initial start-up, inspection, maintenance
5692 599 GB

Checking the high limit safety cut‐out setting
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 the system
Record the fill volume and concentra-
tion of calcium hydrogen carbonate on
page 29.
Note
Observe the "water quality require-
ments" on page 61.
Filling the siphon with water
1. Release the siphon and fill with
water (otherwise flue gas may
escape).
2. Check that the condensate can
freely drain.
3. Refit the siphon.
Starting the heating system
Control unit operating and ser-
vice instructions, and neutralis-
ing system operating
instructions
Further details regarding the individual steps
7
Initial start-up, inspection, maintenance
5692 599 GB

1. Check the heating system pres-
sure.
Permissible boiler operating pres-
sure: 4 bar
2. For open flue operation: Check
that the boiler room ventilation
aperture is open.
3. Check the gas supply pressure.
4. Check that the cleaning aperture
on the flue outlet is closed.
5. Open the gas supply line shut‐off
valves.
6. Switch ON the mains isolator (out-
side the installation room).
7. Switch ON the system ON/OFF
switch Bat the control unit. If
fault indicator lamp Aat the con-
trol unit illuminates and burner
control unit display Cflashes,
first press reset button Dat the
burner control unit.
Note
The system can enter a fault state
during commissioning, if insuffi-
cient gas is in the supply line (the
fault indicator at the control unit
illuminates). Vent the gas supply
line again and reset the burner
control unit.
8. Match the coding at the boiler
control unit according to the table
on page 54.
Control unit installation and
service instructions
Further details regarding the individual steps (cont.)
8
Initial start-up, inspection, maintenance
5692 599 GB

9. Check the function of the neutra-
lising system.
Neutralising system oper-
ating instructions
10. Check all gaskets/seals and plugs
and retighten, if necessary.
Note
We recommend you check all
heating water connections after
approx. 500 hours for leaks (see
page 22).
11. Check the boiler door and clean‐
out cover a few days after com-
missioning and retighten all
screws.
Checking the gas type
1. Determine the gas type and Wobbe
index (Wo) from your gas supplier.
&With the natural gas E setting,
the boiler can be operated in the
Wobbe index range 12.0 to 16.1
kWh/m
3
(43.2 to 58.0 MJ/m
3
).
&With the natural gas LL setting,
the boiler can be operated in the
Wobbe index range 10.0 to 13.1
kWh/m
3
(36.0 to 47.2 MJ/m
3
).
2. The burner is set up in the factory
for natural gas E. If required, con-
vert the burner in accordance with
details provided by your gas sup-
plier to a different gas type (see
page 9).
3. Record the gas type in the service
report (on page 60).
Conversion to natural gas LL
Conversion for 87 kW
1. Close the gas shut‐off valve. 2. Switch OFF the system ON/OFF
switch at the control unit.
Further details regarding the individual steps (cont.)
9
Initial start-up, inspection, maintenance
5692 599 GB

3. Switch OFF the mains isolator
(outside the installation room) or
the power supply and prevent
unauthorised reconnection.
4. Undo fitting A.
5. Remove the venturi mixer tube H
from the gas fan.
Pull off the compensation line E
when operating the boiler in
balanced flue mode.
6. Release the gas combination
valve from flange G.
7. Remove restrictor Cwith gasket
Dfrom venturi mixer tube H.
8. Secure the gas combination valve
(without restrictor Cand without
gasket D, but including O‐ring
B) at flange G.
9. Secure venturi mixer tube Hat
the gas fan.
Push compensation line Eonto
the mixer tube when operating the
boiler in balanced flue mode.
10. Fit and tighten fitting A.
11. Affix enclosed label "Adjusted to
..." Fabove the existing label.
12. Start the burner (see page 7).
Danger
Escaping gas leads to a risk of
explosions.
Check all fittings for sound-
ness.
Conversion for 115 to 311 kW
1. Close the gas shut‐off valve.
2. Switch OFF the system ON/OFF
switch at the control unit.
3. Switch OFF the mains isolator
(outside the installation room) or
the power supply and prevent
unauthorised reconnection.
Further details regarding the individual steps (cont.)
10
Initial start-up, inspection, maintenance
5692 599 GB

4. Undo fitting A.
5. Only for 246 and 311 kW: Pull
compensation hose Gfrom the
gas combination valve.
6. Release the gas combination
valve from flange E.
7. Remove restrictor Cwith rubber
cork gasket D.
8. Secure the gas combination valve
(without restrictor Cand without
rubber cork gasket D, but includ-
ing O‐ring B) at flange E;
replace the factory‐fitted screws
M 5 × 16 with M 5 × 12 (in the
pack).
9. Secure and tighten fitting A.
10. Only for 246 and 311 kW: Push
compensation hose Gonto the
gas combination valve.
11. Affix enclosed label "Adjusted to
..." Fabove the existing label.
12. Start the burner (see page 7).
Danger
Escaping gas leads to a risk of
explosions.
Check all fittings for sound-
ness.
Further details regarding the individual steps (cont.)
11
Initial start-up, inspection, maintenance
5692 599 GB

Checking the static and the supply pressure
Static pressure
87 kW 115 to 311 kW
1. Close the gas shut‐off valve.
2. Undo the screw inside test
connector A, but do not remove.
3. Connect the pressure tester at test
connector A.
4. Open the gas shut‐off valve.
5. Check the static pressure (max.
60 mbar).
6. Record the actual value in the
report (on page 60).
Further details regarding the individual steps (cont.)
12
Initial start-up, inspection, maintenance
5692 599 GB

Supply pressure
1. Start the burner.
Note
For commissioning, see page 7.
Switch the burner to maximum out-
put. For this, activate the emissions
test switch at the control unit.
2. Check the supply pressure (flow
pressure), see table on page 13.
Note
The supply pressure (flow pres-
sure) should be between 20 and 50
mbar. The gas pressure switch is
factory‐set to 10 mbar. Never alter
this setting.
3. Record the actual value in the
report (on page 60).
4. Close the gas shut‐off valve.
5. Remove the pressure tester and
close test connector A.
Supply pressure
(flow pressure)
Measures
below 15 mbar Make no adjustments and contact the gas supply company
15 to 20 mbar Please note: The boiler may only be operated temporarily
with these settings (emergency mode).
Notify your gas supply company.
20 to 50 mbar Start the boiler
above 50 mbar Install a separate gas pressure valve with zero off upstream
in the boiler system, and regulate the pressure to 20 mbar.
Notify your gas supply company.
Further details regarding the individual steps (cont.)
13
Initial start-up, inspection, maintenance
5692 599 GB

Checking the CO2content
Preparing the test
1. Open the gas shut‐off valve.
2. Start the burner.
3. Press "S"Eand "‐"Dsimulta-
neously.
Display Cwill then show the fol-
lowing:
&under status: "d" (= control stop)
&under service: Modulation level
in % ("00." = 100 % = upper out-
put, "00" = 0 % = lower output)
CO2test at the upper output (87 kW)
1. Press "+"Funtil the service dis-
play has incremented to "00." (=
100 %).
2. Check the CO2content at the flue
pipe.
Burner output in
kW
Permissible CO2
content in %
87 9.0 (±0.3)
Further details regarding the individual steps (cont.)
14
Initial start-up, inspection, maintenance
5692 599 GB

3. If the CO2content must be
adjusted:
Turn adjusting screw Ain small
increments until the CO2content
reaches the stipulated range.
&Turning clockwise
&→CO2content drops
&Turning anti‐clockwise
&→CO2content rises
Note
The adjusting screw has no end
stop. The starting postion will be
reached again after four turns.
4. Record the actual value in the
report (on page 60).
CO2test at the lower output (87 kW)
1. Press "‐"Duntil the service dis-
play has decremented to "00"
(lower output).
Further details regarding the individual steps (cont.)
15
Initial start-up, inspection, maintenance
5692 599 GB

2. Check the CO2content at the flue
pipe. For permissible CO2content,
see the table on page 14.
3. If the CO2content must be
adjusted:
&Remove cover B.
&Turn adjusting screw Ain small
increments (Torx 40) until the
CO2content reaches the stipu-
lated range:
––Turning clockwise
– – →CO2content rises
––Turning anti‐clockwise
– – →CO2content drops
4. Record the actual value in the
report (on page 60).
Recheck the values
Regulate to the upper and lower
output using the burner control
unit. If the values do not match the
permissible CO2content according
to the table on page 14, repeat the
steps for the upper and lower out-
put.
5. Press "S"Eand "‐"Dsimulta-
neously. The burner is now in oper-
ating mode.
CO2test at the upper output (115 kW to 311 kW)
1. Press "+"Funtil the service dis-
play has incremented to "00." (=
100 %).
2. Check the CO2content at the flue
pipe.
Burner output in
kW
Permissible CO2
content in %
115 9.0 (±0.3)
142 9.0 (±0.3)
186 9.0 (±0.3)
246 8.8 (±0.3)
311 8.8 (±0.3)
Further details regarding the individual steps (cont.)
16
Initial start-up, inspection, maintenance
5692 599 GB

3. If the CO2content must be
adjusted:
&Remove cap B.
&Turn adjusting screw Ain small
increments (3 mm Allen key ) until
the CO2content reaches the sti-
pulated range:
––Turning clockwise
– – →CO2content drops
––Turning anti‐clockwise
– – →CO2content rises
4. Record the actual value in the
report (on page 60).
CO2test at the lower output (115 kW to 311 kW)
1. Press "‐"Duntil the service display
has decremented to "00" (lower
output).
2. Check the CO2content at the flue
pipe. For permissible CO2content,
see the table on page 16.
Further details regarding the individual steps (cont.)
17
Initial start-up, inspection, maintenance
5692 599 GB

3. If the CO2content must be
adjusted:
&Remove cover B.
&Turn adjusting screw Ain small
increments (Torx 40) until the
CO2content reaches the stipu-
lated range:
––Turning clockwise
– – →CO2content rises
––Turning anti‐clockwise
– – →CO2content drops
4. Record the actual value in the
report (on page 60).
Recheck the values
Regulate to the upper and lower
output using the burner control unit.
If the values do not match the per-
missible CO2content according to
the table on page 16, repeat the
steps for the upper and lower out-
put.
5. Press "S"Eand "‐"Dsimulta-
neously. The burner is now in oper-
ating mode.
Further details regarding the individual steps (cont.)
18
Initial start-up, inspection, maintenance
5692 599 GB

Checking the ionisation current
1. Switch OFF the mains isolator.
2. Pull ionisation current cable plug
C.
3. Switch ON the mains isolator.
There must be a fault shutdown
after the burner has tried to start.
The fault code "F 25" flashes in
display B.
4. Switch OFF the mains isolator.
Note
Test cable no.1 is required when
checking with Testomatik‐Gas.
You can also carry out this test
with a megohmmeter.
5. Push ionisation current cable plug
Cinto adaptor D.
6. Push test cable socket Aonto
the ionisation electrode.
7. Switch the mains isolator ON and
press the reset button.
8. Check the ionisation current.
Note
Approx. 2 to 3 s after the gas
valve has been opened and dur-
ing operation, the ionisation cur-
rent should be at least 6 µA.
9. Record the actual value in the
report (on page 60).
10. Switch the mains isolator OFF,
remove the test equipment and
reconnect the ionisation cable
plug connections.
11. Switch ON the mains isolator.
Further details regarding the individual steps (cont.)
19
Initial start-up, inspection, maintenance
5692 599 GB

Shutting down the heating system
1. Switch OFF the mains isolator or
the power supply and safeguard
against unauthorised reconnection.
2. Pull plug‐connector fA and lÖ
from the burner.
3. Close the gas shut‐off valve.
Opening the boiler door
1. Remove the gas supply pipe.
2. Undo the four screws on the boiler
door and open the door.
!Please note
Scratches inside the combus-
tion chamber can lead to corro-
sion.
Never put tools or other objects
into the combustion chamber.
Separating the neutralising system (if installed) from the
boiler and connecting the drain hose
1. Separate hose Ato the neutralis-
ing system from siphon B.
2. Connect drain or cleaning hose C
to the siphon and run it into a
sewer.
Further details regarding the individual steps (cont.)
20
Initial start-up, inspection, maintenance
5692 599 GB