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

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.)
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.)
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9
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.)
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11
08. Secure the gas train (without restric-
tor C and without rubber cork gas-
ket D) with inserted O-ring B to
flange E; for this, replace the fac-
tory-fitted screws M 5 x 16 with
M 5 x 12 (see separate pack).
09. Tighten screws M 5 x 12 diago-
nally.
Torque: 1.5 Nm.
10. Secure fitting A.
11. Push compensation hose G on to
the gas train.
12. Affix the enclosed label "Set to ..."
over existing label F.
13. Start the burner (see page 13).
Danger
Escaping gas leads to a risk of
explosion.
Check all fittings for gas tight-
ness.
!Please note
The use of leak detection spray
can lead to malfunctioning.
Leak detection spray must not
come into contact with electrical
contacts.
Converting to LPG P
Installing the restrictor
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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07. Position O-ring B, LPG restrictor
C and rubber cork gasket D.
Note
Bevel on the LPG restrictor must
face the gas train.
08. Tighten screws M 5 x 16 diago-
nally.
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 lead to malfunc-
tioning.
Leak detection spray must
not come into contact with
electrical contacts.
13. Start the burner (see page 13).
LPG 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 shows
the current gas type under Service (0
= natural gas or 1 = LPG).
5. Use button F or D to select
number "1" for LPG.
6. Press button S E to confirm. If
applied successfully, display C will
briefly show "1" under Service, or
"0" will appear if it failed.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5683 757 GB

13
Status Service
S
R
D
C
EF
G
7. Press button S E to switch to the
operating display.
8. Press button R G.
The system will be restarted.
Note
Each time the system is restarted, the
setting parameters will be shown.
1 Max. output (70-100 %)
The output setting is unrestricted.
Base load can also be set (CS con-
figuration).
2 Gas type (NG = natural gas or LPG
= liquid gas)
3 Installation height (LA (low alti-
tude) or HA (high altitude))
(not available)
4 Temperature of the temperature
limiter
5 Integral value for minimum pause
time
6 Cycling protection method
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 flue gas
components can be checked with an
inspection mirror during operation.
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 a leak.
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.)
5683 757 GB

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CD
AB
1. Check the heating system pressure.
Permiss. operating pressure: 6 bar
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 17).
4. Open the gas line shut-off valves.
5. Switch ON the mains isolator (outside
the installation room).
6. Turn on system 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, re-close the gas line
shut-off valves.
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.)
5683 757 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.
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.
8. Press button R G.
The system will be restarted.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5683 757 GB

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Checking static pressure and supply pressure
A
Static pressure
1. Close the gas shut-off valve.
2. Undo the screw in test nipple A, but
do not remove.
3. Connect the pressure tester at test
nipple 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 74).
Supply pressure
1. Start the burner.
Note
For commissioning, see page 13.
Switch the burner to maximum heat-
ing output. For this, activate the emis-
sions test switch at the control unit.
2. Check the supply pressure (flow
pressure), see table on page 17.
Note
The supply pressure (flow pressure)
must be between 18 and 50 mbar for
natural gas and between 42.5 and
57.5 mbar for LPG.
Nominal supply pressure for natural
gas: 20 mbar
Nominal supply pressure for LPG:
50 mbar
The boiler is factory-fitted with two
gas pressure switches. The gas pres-
sure switches are set to 10 mbar. For
LPG, set both gas pressure switches
to 20 mbar.
3. Record the actual value in the report
(on page 74).
4. Close the gas shut-off valve.
5. Remove the pressure tester and
close test nipple A.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5683 757 GB

17
Supply pressure (flow pressure) Action
Natural gas LPG
Less than 15
mbar
Less than 20 mbar Make no adjustments. Notify your gas supply
utility or LPG supplier.
15 to 18 mbar 20 to 42.5 mbar Please note: The boiler may only be operat-
ed temporarily with these settings (emergen-
cy mode).
Notify your gas supply utility or LPG suppli-
er.
18 to 50 mbar 42.5 to 57.5 mbar Commission the boiler.
Above 50 mbar Above 57.5 mbar Install a separate gas pressure governor with
zero off upstream of the boiler system and
regulate the pressure to 20 mbar for natural
gas or 50 mbar for LPG.
Notify your gas supply utility or LPG suppli-
er.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5683 757 GB

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Checking the rotary damper setting
0
0
A C D
B
1. Open the gas shut-off valve.
2. Check the position of the rotary
damper in burner idle mode. Rotary
damper window B must be fully
opened and scale ring D on the air
damper servomotor must be set to
"0", relative to marking C.
3. Check whether compensation cable
A has been connected between the
gas train and distributor pipe.
4. Start the burner.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5683 757 GB

19
5. Check the position of the rotary
damper during the start-up phase.
Rotary damper windows B must be
almost closed for approx. 5 s. During
this time, scale ring D is at the fol-
lowing settings:
Rated
heating
output
Rated
heat input
Rotary
damper
setting
Pmax
(50/30 °C)
Qmax (Hi)
in kW in kW in °
400 381 30
500 474 35
620 593 30
Checking the CO2 content
Test preparations
AB
C
D
E
F
1. Open the gas shut-off valve.
2. Start the burner with the emissions
test switch on the control unit ena-
bled.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5683 757 GB

20
3. Simultaneously hold down S E and
D for longer than 2 s.
Display C will then show the follow-
ing:
■ Under Status: "P" (= controlled
stop)
■ Under Service: Modulation level in
% ("100" = 100 % = upper heating
output, "0" = 0 % = lower heating
output)
CO2 test at upper heating output
1. Press F until the service indicator
has incremented to "100" (= 100 %).
2. Check the CO2 content at the flue
pipe.
Rated heating
output
Rated heat input Permissible CO2 content
Pmax (50/30 °C) Qmax (Hi) Natural gas E and
LL
LPG P
in kW in kW in % in %
400 381
8.8 ±0.2 10.5 ±0.2
500 474
620 593
3. If the CO2 content must be adjusted:
Remove cap B and turn setting
screw A in small steps (Allen key
3 mm) until the CO2 content is within
the specified range:
■ Turning clockwise → CO2 content
drops,
■ Turning anticlockwise → CO2 con-
tent increases.
4. Record the actual value in the report
(on page 74).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5683 757 GB