Viessmann VITOCROSSAL 200 Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 200
Type CM2
Gas condensing boiler with MatriX radiant burner
For applicability, see the last page
VITOCROSSAL 200
5692 907 GB 12/2011 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 exclusively
designed for qualified personnel.
■ Work on gas equipment must only be
carried out by a qualified 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.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental 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,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical appli-
ances 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 build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
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3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the
living space.
Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which ful-
fil a safety function can compro-
mise 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 com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5692 907 GB

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Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 7
Troubleshooting
Diagnosis.............................................................................................................. 40
Start-up problems with 285 kW, open flue operation........................................... 46
Burner control unit flow chart........................................................................... 47
Burner control unit connection diagram.......................................................... 49
Component overview......................................................................................... 51
Control unit
Adjusting codes at the control unit....................................................................... 55
Parts lists............................................................................................................ 56
Report.................................................................................................................. 61
Specification....................................................................................................... 66
Certificates
Declaration of Conformity..................................................................................... 69
Certificates
Manufacturer’s certificate according to the 1st BImSchV..................................... 70
Keyword index.................................................................................................... 71
Index
Index
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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............. 7
•2. Filling the heating system with water and venting the
system............................................................................. 7
•3. Filling the siphon with water......................................... 7
••• 4. Commissioning the system........................................... 7
•5. Checking the gas type.................................................... 9
•6. Converting to natural gas LL......................................... 9
••• 7. Checking the static and the supply pressure.............. 12
••• 8. Checking the CO2 content............................................. 14
••• 9. Checking the CO content
••• 10. Checking the flue gas temperature
• • 11. Checking the ionisation current.................................... 19
• • 12. Shutting down the 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........................................................................... 20
• • 16. Checking gaskets and thermal insulation parts.......... 21
• • 17. Checking all connections on the heating water side
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
Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
• • 21. Checking the ignition electrodes and ionisation
electrode.......................................................................... 24
• • 22. Closing the boiler door.................................................. 25
• • 23. Cleaning the burner........................................................ 25
•24. Fitting the burner............................................................ 26
• • 25. Checking both gas train valves for tightness (for 115
to 311 kW)........................................................................ 27
• • 26. Checking the filter element (if fitted) in the gas line and
replacing it if required
••• 27. Checking all gas connections for tightness................ 27
• • 28. Checking the gaskets/seals on the flue gas side........ 28
•29. Implementing final tests................................................. 29
• • 30. Checking the water quality............................................ 29
••• 31. Checking the function of safety valves
• • 32. Checking the diaphragm expansion vessel and
system pressure............................................................. 30
• • 33. Checking the mixer for ease of operation and leaks... 31
••• 34. Checking the thermal insulation for firm seating
• • 35. Checking the ventilation air apertures in the
installation room (only for open flue operation)
•36. Instructing the system user........................................... 31
•37. Operating and service documents................................ 31
Commissioning, inspection, maintenance
Steps – commissioning, inspection and… (cont.)
5692 907 GB

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Checking the high limit safety cut-out setting
Never set the high limit safety cut-out
higher than 110 °C, set it to a maximum
of 110 °C if required.
Control unit installation and serv-
ice instructions
Filling the heating system with water and venting the system
Record the fill volume, water hardness
and pH value on page 29 and 30.
Note
Observe the "Water quality require-
ments" on page 62.
Filling the siphon with water
1. Undo the siphon and fill with water
(otherwise flue gas may escape).
2. Check that the condensate can drain
freely.
3. Refit the siphon.
Commissioning the system
Control unit operating and serv-
ice instructions, and neutralising
system operating instructions
1. Check the heating system pressure.
Permissible boiler operating pres-
sure: 4 bar
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 907 GB

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2. For open flue operation: Check that
the vents in the installation room are
open.
3. Check the gas supply pressure.
4. Open the gas line shut-off valves.
5. Switch ON the mains isolator (outside
the installation room).
A B
D
C
6. Switch ON system ON/OFF switch
B at the control unit. If fault indicator
lamp A on the control unit illumi-
nates and burner control unit display
C flashes, initially press reset button
D on the burner control unit.
Note
The system can enter a fault state
during commissioning if there is
insufficient gas in the supply line (the
fault indicator on the control unit illu-
minates). Vent the gas pipe again
and reset the burner control unit.
7. Set the code at the boiler control unit
according to the table on page 55.
Control unit installation and
service instructions
8. Check the function of the neutralising
system.
Neutralising system operating
instructions
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 907 GB

9
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 after approx. 500 hours run
(see page 22).
10. Check the boiler door and cleaning
cover a few days after commission-
ing and retighten all screws.
Danger
For safe operation, a minimum
operating pressure of 0.5 bar is
essential.
For this, a minimum pressure
switch can be used.
Checking the gas type
1. Determine the gas type and Wobbe
index (Wo) from your gas supply util-
ity.
■ 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 natural gas LL setting, the
boiler can be operated in the
Wobbe index range 10.0 to
13.1 kWh/m3 (36.0 to 47.2 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
page 9).
3. Record the gas type in the service
report (on page 61).
Converting to natural gas LL
(not in a and c)
Conversion for 87 kW
01. Close the gas shut-off valve.
02. Switch OFF the system ON/OFF
switch at the control unit.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 907 GB

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03. Switch OFF the mains isolator (out-
side the installation room) or the
power supply and prevent unauthor-
ised reconnection.
04. Undo fitting A.
05. Remove Venturi mixing pipe H
from the gas fan.
Pull off the compensation line E
when the boiler is in balanced flue
operation.
06. Undo the gas train from flange G.
07. Remove restrictor C with gasket
D from Venturi mixing pipe H.
08. Secure the gas train (without restric-
tor C and without gasket D, but
including O-ring B) at flange G.
09. Secure Venturi mixing pipe H at
the gas fan.
Connect compensation line E
when the boiler is in balanced flue
operation.
10. Secure fitting A.
11. Affix supplied label "Set to..." F
over the existing label.
12. Start the burner (see page 7).
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 result in incorrect functions.
Leak detection spray must not
come into contact with electrical
contacts.
Conversion for 115 to 311 kW
01. Close the gas shut-off valve.
02. Switch OFF the system ON/OFF
switch at the control unit.
03. Switch OFF the mains isolator (out-
side the installation room) or the
power supply and prevent unauthor-
ised reconnection.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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04. Undo fitting A.
05. Except for 115 kW: Pull compensa-
tion hose G from the gas train.
06. Release the gas train from flange
E.
07. Remove restrictor C with rubber
cork gasket D.
08. Secure the gas train (without restric-
tor C and without rubber cork gas-
ket D, but including O-ring B) to
flange E; replace the factory-fitted
M 5 × 16 screws with M 5 × 12 (in
the pack).
09. Secure fitting A.
10. Except for 115 kW: Push compen-
sation hose G on to the gas train.
11. Affix supplied label "Set to..." F
over the existing label.
12. Start the burner (see page 7).
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 result in incorrect functions.
Leak detection spray must not
come into contact with electrical
contacts.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 907 GB

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Checking the static and the supply pressure
Static pressure
87 kW
115 to 311 kW
A
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 61).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 907 GB

13
Supply pressure
1. Start the burner.
Note
For commissioning, see page 7.
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 13.
Note
The supply pressure (flow pressure)
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 61).
4. Close the gas shut-off valve.
5. Remove the pressure tester and
close test nipple A.
Supply pressure
(flow pressure)
Measure
Below 15 mbar Make no adjustments and notify the gas supply utility.
15 to 20 mbar Please note The boiler may only be operated temporarily with
these settings (emergency mode).
Notify your gas supply utility.
20 to 50 mbar Start the boiler
Above 50 mbar Install a separate gas pressure governor with zero off upstream
in the boiler system, and regulate the pressure to 20 mbar.
Notify your gas supply utility.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 907 GB

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Checking the CO2 content
Preparing the test 1. Open the gas shut-off valve.
2. Start the burner.
3. Press "S" E and "-" D simultane-
ously.
Display C will then show the follow-
ing:
■ Under Status: "d" (= control stop)
■ Under Service: Modulation level in
% ("00." = 100 % = upper heating
output, "00" = 0 % = lower heating
output)
CO2 test at the upper heating output (87 kW)
1. Press "+" F until the service display
has incremented to "00." (= 100 %).
2. Check the CO2 content at the flue
pipe.
Burner out-
put in kW
Permissible CO2
content in %
87 9.0 (±0.3)
Note
The unconnected end of the hose is
open in open flue operation. For bal-
anced flue operation, it is pushed
onto the inlet adaptor.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 907 GB

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3. If the CO2 content must be adjusted:
Turn adjusting screw A in small
increments until the CO2 content rea-
ches the specified range.
■ Turning clockwise
→ CO2 content falls
■ Turning anti-clockwise
→ CO2 content rises
Note
The adjusting screw has no end-stop.
The starting position will be reached
again after 4 turns.
4. Record the actual value in the report
(on page 61).
CO2 test at the lower heating output
(87 kW)
1. Press "-" D until the service display
has decremented to "00" (lower heat-
ing output).
2. Check the CO2 content at the flue
pipe. For permissible CO2 content,
see the table on page 14.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 907 GB

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3. If the CO2 content must be adjusted:
■Remove cover B.
■Turn adjusting screw A in small
increments (Torx 40) until the CO2
content falls within the specified
range:
– Turning clockwise
→ CO2 content rises
– Turning anti-clockwise
→ CO2 content falls
4. Record the actual value in the report
(on page 61).
Rechecking the values
Regulate to the upper and lower heat-
ing output using the programming
unit in the burner control unit. If the
values do not match the permissible
CO2 content according to the table on
page 14, repeat the steps for the
upper and lower heating output.
5. Press "S" E and "-" D simultane-
ously. The burner is now in operating
mode.
CO2 test at the upper heating output (115 kW to 311 kW)
1. Press "+" F until the service display
has incremented to "00." (=100 %).
2. Check the CO2 content at the flue
pipe.
Burner out-
put 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)
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 907 GB

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3. If the CO2 content must be adjusted:
■Remove cap B.
■Turn setting screw A in small
increments (3 mm Allen key) until
the CO2 content lies within the
specified range:
– Turning clockwise
→ CO2 content falls
– Turning anti-clockwise
→ CO2 content rises
4. Record the actual value in the report
(on page 61).
CO2 test at the lower heating output
(115 kW to 311 kW)
1. Press "-" D until the service display
has decremented to "00" (lower heat-
ing output).
2. Check the CO2 content at the flue
pipe. For permissible CO2 content,
see the table on page 16.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 907 GB

18
3. If the CO2 content must be adjusted:
■Remove cover B.
■Turn adjusting screw A in small
increments (Torx 40) until the CO2
content falls within the specified
range:
– Turning clockwise
→ CO2 content rises
– Turning anti-clockwise
→ CO2 content falls
4. Record the actual value in the report
(on page 61).
Rechecking the values
Regulate to the upper and lower heat-
ing output using the programming
unit in the burner control unit. If the
values do not match the permissible
CO2 content according to the table on
page 16, repeat the steps for the
upper and lower heating output.
5. Press "S" E and "-" D simultane-
ously. The burner is now in operating
mode.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 907 GB

19
Checking the ionisation current
A
B
CD
01. Switch OFF the mains isolator.
02. Pull ionisation cable plug C.
03. Switch ON the mains isolator.
There must be a fault shutdown
after the burner has tried to start.
Display B flashes fault code "F
25".
04. Switch OFF the mains isolator.
Note
Test cable no.1 is required when
checking with the Testomatik-Gas.
You can also carry out this test with
a multimeter.
05. Join ionisation cable plug C and
adaptor D.
06. Push test cable socket A onto the
ionisation electrode.
07. Switch the mains isolator ON and
press reset.
08. Check the ionisation current.
Note
The ionisation current should be at
least 3 µA for approx. 2 to 3 s after
the gas valve has been opened and
during operation.
09. Record the actual value in the report
(on page 61).
10. Switch the mains isolator OFF,
remove the test equipment and
reconnect the ionisation cable con-
nectors.
11. Switch ON the mains isolator.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Shutting down the system
1. Switch OFF the mains isolator or the
power supply and safeguard against
unauthorised reconnection.
2. Pull plug-in 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 combustion
chamber can lead to corrosion.
Never put tools or other objects
into the combustion chamber.
Separating the neutralising system (if installed) from the boiler
and connecting the drain hose
C
BA
1. Separate hose A to the neutralising
system from siphon B.
2. Connect drain or cleaning hose C to
the siphon and run it to the drain.
Cleaning the combustion chamber and heating surfaces
Thoroughly clean the combustion cham-
ber and heating surfaces with a water
jet. !Please note
Scratches on parts that are in
contact with flue gas can lead to
corrosion.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 907 GB