Viessmann VITOCROSSAL 200 Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 200
Type CT2
Gas condensing boiler with MatriX cylinder burner
for natural gas E and LL
For applicability, see the last page
VITOCROSSAL 200
5692 908 GB 3/2011 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 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
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■ 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.)
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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.)
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5
Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance.......................................... 6
Further details regarding the individual steps....................................................... 8
Troubleshooting
Diagnosis.............................................................................................................. 41
Burner control unit flow diagram...................................................................... 51
Connection diagrams
Burner control unit connection diagram................................................................ 53
Mains filter unit connection diagram..................................................................... 54
Component overview......................................................................................... 56
Control unit
Adjusting codes at the control unit....................................................................... 58
Parts lists............................................................................................................ 59
Commissioning/service report.......................................................................... 65
Water quality requirements............................................................................... 67
Specification....................................................................................................... 71
Certificates
Declaration of conformity...................................................................................... 73
Manufacturer's certificate according to the first BImSchV [Germany].................. 74
Keyword index.................................................................................................... 75
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. Information regarding maintenance work.................... 8
•2. Checking the high limit safety cut-out setting............. 8
•3. Filling the heating system with water and venting the
system............................................................................. 8
•4. Filling siphon with water................................................ 9
••• 5. Starting the heating system........................................... 9
•6. Checking the gas type.................................................... 11
•7. Conversion to natural gas LL........................................ 11
••• 8. Checking the static and the supply pressure.............. 12
••• 9. Checking the CO2 content............................................. 14
••• 10. Checking the CO content
••• 11. Checking the flue gas temperature
• • 12. Checking the ionisation current.................................... 17
• • 13. Shutting down the system............................................. 18
• • 14. Opening the boiler door................................................. 18
• • 15. Separating the neutralising system (if installed) from
the boiler and connecting the drain hose.................... 20
• • 16. Cleaning the combustion chamber and heating
surfaces........................................................................... 20
• • 17. Checking gaskets and thermal insulation parts.......... 21
• • 18. Checking all connections on the heating water side
for leaks........................................................................... 22
• • 19. Cleaning and reconnecting the condensate drain
system............................................................................. 22
• • 20. Checking the condensate drain and the neutralising
system (if installed)........................................................ 23
• • 21. 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
• • 22. Checking the ignition and ionisation electrodes......... 24
• • 23. Closing the boiler door.................................................. 25
• • 24. Cleaning the burner........................................................ 25
•25. Installing the burner....................................................... 26
• • 26. Checking both gas train valves automatically for gas
tightness.......................................................................... 26
• • 27. Checking and replacing (if required) the filter
elements in the gas line
••• 28. Checking all gas connections for tightness................ 26
••• 29. Checking the rotary damper setting............................. 27
•30. Implementing final tests................................................. 28
• • 31. Checking the water quality............................................ 29
••• 32. Checking the function of safety valves
• • 33. Expansion vessel and system pressure....................... 30
• • 34. Checking the gaskets/seals on the flue gas side........ 31
• • 35. Checking the mixer for ease of operation and leaks... 32
••• 36. Checking the thermal insulation for firm seating
•37. Checking the flue gas system for leaks
• • 38. Checking the ventilation air apertures in the
installation room (only for open flue operation)
•39. Instructing the system user........................................... 32
•40. Operating and service instructions.............................. 32
Commissioning, inspection, maintenance
Steps – commissioning, inspection and… (cont.)
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Information regarding maintenance work
Danger
The product contains ceramic fibres. If handled incorrectly, fibre dust may be
released.
Observe the stipulations of the Technical Guideline for the Handling of Haz-
ardous Materials (TRGS) 521.
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" from page 67.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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Filling siphon with water
1. Release the siphon and fill with water
(otherwise flue gas may escape).
2. Check that the condensate can drain
freely.
3. Refit the siphon.
Starting the heating system
Control unit operating and serv-
ice instructions, and neutralising
system operating instructions
1. Check the heating system pressure.
Permissible boiler operating pres-
sure: 5.5 bar.
2. For open flue operation: Check that
the installation room ventilation is
unobstructed.
3. Check the gas supply pressure.
4. Open the gas line shut-off valves.
5. Switch ON the mains isolator (outside
the installation room).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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6.
A B
D
C
Switch ON system ON/OFF switch
B at the control unit. If fault indicator
A at the control unit illuminates and
burner control unit display C flashes,
first press reset buttonD at the
burner control unit.
Note
The system can enter a fault state
during commissioning if the supply
pipe carries insufficient gas (the fault
indicator at the control unit illumi-
nates). Ventilate the gas supply pipe
again and reset the burner control
unit.
7. Match the coding at the boiler control
unit according to the table on
page 58.
Control unit installation and
service instructions
8. Check the function of the neutralising
system, including the hydraulic seal
in the siphon.
Neutralising system operating
instructions
9. Check all gaskets/seals and plugs,
and retighten if necessary.
Note
We recommend you check all heating
water side connections for leaks after
approx. 500 hours run (see
page 22).
10. Check the boiler door and flue gas
collector cover a few days after
commissioning and retighten all
screws.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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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)
(not in a and c).
2. In the delivered condition, the burner
is set up for natural gas E. If required,
convert the burner in accordance with
details provided by your gas supply
utility to a different gas type (see
page 11).
3. Record the gas type in the service
report (on page 65).
Conversion to natural gas LL
(not in a and c)
01. Close the gas shut-off valve.
02. Switch OFF the control unit ON/OFF
switch.
03. Switch OFF the mains isolator (out-
side the installation room) or the
power supply and prevent unauthor-
ised reconnection.
04. Pull cables from gas train.
05. Undo fitting A.
A
B
C
D
G
F
E
06. Pull compensation hose G from
gas train.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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07. Release the gas train from flange
E.
08. Remove restrictor C with rubber
cork gasket D.
09. Secure the gas train (without restric-
tor C or rubber cork gasket D, but
with O-ring B) at flange E; in
doing so, replace the factory-fitted
screws M 5 × 16 with M 5 × 12 (in
the pack).
10. Secure and tighten fitting A.
11. Push compensation hose G onto
the gas train.
12. Affix supplied label "Set to ..." F
over the existing label.
13. Start the burner (see page 9).
Danger
Escaping gas leads to a risk of
explosion.
Check all fittings for gas tight-
ness.
!Please note
The use of leak detecting spray
can result in incorrect functions.
Leak detecting spray must not
come into contact with electrical
contacts.
Checking the static and the supply pressure
Static pressure
A
1. Close the gas shut-off valve.
2. Undo the screw inside 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 65).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Supply pressure
1. Start the burner.
Note
For commissioning, see page 9.
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 pressure)
must be between 18 and 50 mbar
(nominal 20 mbar). The gas pressure
limiter minimum (GDW 1) is factory-
set to 10 mbar. Never alter this set-
ting.
3. Record the actual value in the report
(on page 65).
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 contact the gas supply utility.
15 to 18 mbar Please note: The boiler may only be operated temporarily with
these settings (emergency mode).
Notify your gas supply utility.
18 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.)
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Checking the CO2 content
Preparing the test
C
D
E
F
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 output,
"0" = 0% = lower output)
CO2 test at the upper output
C
D
E
F
1. Press "+" F until the service display
has incremented to "00" (= 100 %).
2. Note
The CO2 content for all natural gases
must be between 7.5 and 10.5 %.
Check the CO2 content at the flue
pipe.
Burner out-
put in kW
Permissible CO2
content in %
404 8.6 ± 0.3
503 8.6 ± 0.3
628 8.6 ± 0.3
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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AB
3. If the CO2 content must be adjusted:
■Remove cap B.
■Turn adjusting screw A in small
increments (3 mm Allen key) until
the CO2 content reaches the speci-
fied range:
– Turning clockwise
→ CO2 content falls
– Turning anti-clockwise
→ CO2 content rises
4. Record the actual value in the report
(on page 65).
!Please note
The CO2 content must always
be lower in partial load than it
is in full load.
CO2 test at the lower output
C
D
E
F
1. Press "-" D until the service display
has gone down to "0" (lower output).
2. Note
The CO2 content for all natural gases
must be between 7.5 and 10.5 %.
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.)
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B A
3. If the CO2 content must be adjusted:
■Remove cover B.
■Turn adjusting screw A in small
increments (Torx 40) until the CO2
content reaches the specified
range:
– Turning clockwise
→ CO2 content rises
– Turning anti-clockwise
→ CO2 content falls
4. Record the actual value in the report
(on page 65).
!Please note
The CO2 content must always
be lower in partial load than it
is in full load.
Rechecking the values
Regulate again to the upper and
lower output using 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 output.
5. Briefly press "S" E and "-" D simul-
taneously. The burner continues to
the original modulation level, at which
the status "d" (= control stop) was ini-
tiated. The burner then returns to
operating mode.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the ionisation current
A
CD
B
01. Switch OFF the mains isolator.
02. Pull ionisation current cable plug
C.
03. Switch ON the mains isolator.
There must be a fault shutdown
after the burner has tried to start.
Fault code "F A7" flashes on display
B.
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. Push ionisation current cable plug
C into 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 65).
10. Switch the mains isolator OFF,
remove the test equipment and
reconnect the ionisation cable plug-
in connectors.
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.
Danger
Mains voltage can be
extremely dangerous.
For maintenance work, isolate
the gas fan from the power
supply.
2. Pull connecting plugs fÖ, fA, lÖ and
fÖ/aBH from the burner.
3. Close the gas shut-off valve.
Opening the boiler door
A
C
B
E
D
F
1. Remove the burner hood A.
2. Release burner cables C with plug
fA and lÖ from the burner control
unit and route them out of the burner
casing.
3. Release power cable D with plug
fÖ and control unit cable F with plug
fÖ/aBH from the burner and strain
relief, and route them out of the
burner casing.
4. Remove gas supply pipe B.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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E
6x
5. Undo six screws on boiler door E
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Separating the neutralising system (if installed) from the boiler
and connecting the drain hose
C
A
B
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.
Only use plastic brushes, NOT
wire brushes nor sharp objects.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 908 GB