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
5683 757 GB 9/2012 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
5683 757 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.)
5683 757 GB

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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.)
5683 757 GB

5
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 7
Further details regarding the individual steps....................................................... 9
Air pressure switch............................................................................................ 38
Burner control unit............................................................................................. 40
Troubleshooting
Fault display......................................................................................................... 47
Fault codes........................................................................................................... 48
Faults without fault display................................................................................... 54
Burner control unit flow chart........................................................................... 55
Connection diagrams
Burner control unit connection diagram................................................................ 57
Connection diagram for mains filter unit............................................................... 61
Component overview......................................................................................... 63
Control unit
Adjusting codes at the control unit....................................................................... 65
Parts lists
Ordering parts...................................................................................................... 66
Overview of the assemblies................................................................................. 67
Boiler body assembly........................................................................................... 68
Thermal insulation assembly................................................................................ 69
Cable kit assembly............................................................................................... 70
Burner assembly.................................................................................................. 71
Report.................................................................................................................. 74
Specification....................................................................................................... 79
Certificates
Declaration of conformity for boiler ≤400 kW....................................................... 81
Declaration of conformity for boiler >400 kW....................................................... 82
Certificates
Manufacturer's certificate..................................................................................... 83
Index
Index
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Keyword index.................................................................................................... 84
Index
Index (cont.)
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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. Converting to natural gas LL......................................... 10
•6. Converting to LPG P....................................................... 11
••• 7. Commissioning the system........................................... 13
•8. Reducing operational output (if necessary)................. 15
••• 9. Checking static pressure and supply pressure........... 16
••• 10. Checking the rotary damper setting............................. 18
••• 11. Checking the CO2 content............................................. 19
••• 12. Checking the CO content
••• 13. Checking the flue gas temperature
• • 14. Displaying the ionisation current.................................. 22
• • 15. Shutting down the system............................................. 23
• • 16. Opening the boiler door................................................. 26
• • 17. Cleaning the combustion chamber and heating
surfaces........................................................................... 27
• • 18. Checking gaskets and thermal insulation parts.......... 27
• • 19. Checking all connections on the heating water side
for leaks........................................................................... 28
• • 20. Cleaning and reconnecting the condensate drain
system............................................................................. 28
• • 21. Checking for tightness on the flue side....................... 30
• • 22. Checking the condensate drain and the neutralising
system (if installed)........................................................ 31
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
• • 23. Checking the burner gauze assembly.......................... 31
• • 24. Checking the ignition electrodes and ionisation
electrode.......................................................................... 32
• • 25. Cleaning the burner........................................................ 33
•26. Fitting the fan.................................................................. 33
•27. Making the electrical burner connection...................... 34
• • 28. Checking both gas train valves automatically for gas
tightness.......................................................................... 35
• • 29. Checking the filter element in the gas line (if installed)
and replacing if required
••• 30. Checking all gas connections for tightness................ 35
•31. Implementing final checks............................................. 35
• • 32. Checking the water quality............................................ 36
••• 33. Checking the function of safety valves
• • 34. Checking the expansion vessel and system pressure 36
• • 35. Checking the mixer for ease of operation and leaks... 37
••• 36. Checking the thermal insulation for firm seating
• • 37. Checking the ventilation air apertures in the
installation room (only for open flue operation)
•38. Instructing the system user........................................... 37
•39. Operating and service documents................................ 37
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
5683 757 GB

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Checking the high limit safety cut-out setting
The high limit safety cut-out is preset to
110 °C. If this temperature needs to be
changed, this can only be done by swap-
ping the coding card.
Filling the heating system with water and venting
Record the charge volume, water hard-
ness and pH value on page 36.
Note
Observe the "Water quality require-
ments" on page 75.
Filling the siphon with water
1. Undo four screws and from the back
remove the centre and bottom back
panels.
2. Undo the siphon and fill with water
(otherwise flue gas may escape).
3. Check that the condensate can drain
freely.
4. Refit 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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10
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).
■ The natural gas LL setting ena-
bles boilers to be operated in the
Wobbe index range 10.0 to
13.1 kWh/m3 (36.0 to 47.2 MJ/m3)
(not in a and c).
■ 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 in accordance with details provi-
ded by your gas supply utility (see
from page 10).
3. Record the gas type in the report (on
page 74).
Converting to natural gas LL
(not in a and c)
B
C
D
EG
F
A
01. Close the gas shut-off valve.
02. Switch 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.
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. Remove restrictor C with rubber
cork gasket D.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5683 757 GB