Viessmann VITOCROSSAL 200 Operating instructions

VIESMANN
Service instructions
for contractors
Vitocrossal 200
Type CT2
Gas fired condensing boiler with MatriX cylinder burner
for natural gas E and LL
For applicability, see the last page
VITOCROSSAL 200
5692 759 GB 5/2008 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 equipment must only
be carried out by a qualified gas fit-
ter.
&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,
&theCodeofPracticeofrelevant
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 result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
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.
&Closealldoorsleadingtothe
living space.
Safety instructions
2
Safety instructions
5692 759 GB

Workingonthesystem
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
&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 main isolator.
&Safeguard the system against
unauthorised reconnection.
!Please note
Electronic modules can be
damaged 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
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/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 759 GB

Commissioning, inspection, maintenance
Steps –commissioning, inspection and maintenance .................................. 5
Further details regarding the individual steps .............................................. 7
Troubleshooting
Diagnosis ................................................................................................... 40
Gas burner control unit flow chart
Burner control unit flow diagram.................................................................. 48
Connection diagrams
Burner control unit connection diagram ....................................................... 50
Mains filter unit connection diagram ............................................................ 51
Component overview................................................................................ 52
Control unit
Adjusting codes at the control unit............................................................... 54
Parts lists .................................................................................................. 55
Commissioning /service report ................................................................ 61
Specification............................................................................................. 66
Certificates
Declaration of conformity ............................................................................ 68
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 69
Keyword index .......................................................................................... 70
Index
4
Index
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
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•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. Starting the heating system .............................................. 8
•5. Checking the gas type......................................................... 10
•6. Conversion to natural gas LL ........................................... 10
••• 7. Checking the static and the supply pressure............. 11
••• 8. Checking the CO2content ................................................. 13
••• 9. Checking the CO content
••• 10. Checking the flue gas temperature
•• 11. Checking the ionisation current ...................................... 16
•• 12. Shutting down the system ................................................. 17
•• 13. Opening the boiler door...................................................... 17
•• 14. Separating the neutralising system (if installed)
from the boiler and connecting the drain hose.......... 19
•• 15. Cleaning the combustion chamber and heating
surfaces.................................................................................... 19
•• 16. Checking gaskets and thermal insulation
components ............................................................................ 20
•• 17. Checking all connections on the heating water
side for leaks .......................................................................... 20
•• 18. Cleaning and reconnecting the condensate drain
system....................................................................................... 21
•• 19. Checking the condensate drain and the
neutralising system (if installed) .................................... 22
•• 20. Checking the burner gauze assembly........................... 22
Steps –commissioning, inspection and maintenance
5
Commissioning, inspection, maintenance
5692 759 GB

Commissioning steps
Inspection steps
Maintenance steps Page
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•• 21. Checking the ignition and ionisation electrodes ...... 23
•• 22. Closing the boiler door ....................................................... 23
•• 23. Cleaning the burner ............................................................. 23
•24. Installing the burner............................................................. 24
•• 25. Checking both gas train valves automatically for
gas-tightness ......................................................................... 25
•• 26. Checking and replacing (if required) the filter
elements in the gas pipe
••• 27. Checking all gas connections for tightness ............... 25
••• 28. Checking the rotary damper setting .............................. 26
•29. Implementing final tests..................................................... 27
•• 30. Checking the water quality................................................ 27
••• 31. Checking the function of all safety valves
•• 32. Expansion vessel and system pressure check ......... 29
•• 33. Checking the flue gas header for tightness................ 30
•• 34. Checking the mixer for obstructions and leaks ........ 30
••• 35. Checking the thermal insulation for tight fit
•36. Checking the function of the flue gas system
•• 37. Checking the ventilation apertures in the
installation room (only for open flue operation)
•38. Instructing the system user .............................................. 30
•39. Operating and service documents ................................. 31
Steps –commissioning, inspection and . . . (cont.)
6
Commissioning, inspection, maintenance
5692 759 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,
setittoamaximumof110°C.
Control unit installation and
service instructions
Filling the heating system with water and venting the system
Record the fill volume, water hard-
ness and pH value on page 28
and 29.
Note
Observe the "Water quality require-
ments" on page 62.
Filling the 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.
Further details regarding the individual steps
7
Commissioning, inspection, maintenance
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Starting the heating system
Control unit operating and service instructions, and neutralising system
operating instructions
1. Check the heating system pres-
sure.
Permissible boiler operating pres-
sure: 5.5 bar
2. For open flue operation: Check
that the installation room ventila-
tion is unobstructed.
3. Check the gas supply pressure.
4. Open the gas supply line shut-off
valves.
5. Switch ON the main isolator (out-
side the installation room).
Further details regarding the individual steps (cont.)
8
Commissioning, inspection, maintenance
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6. Switch ON system ON/OFF
switch Bat the control unit. If
fault indicator Aat the control
unit illuminates and burner control
unit display Cflashes, first press
reset Dat the burner control
unit.
Note
The system can enter a fault state
during commissioning, if the sup-
ply line carries insufficient gas
(the fault indicator at the control
unit illuminates). Ventilate the gas
supply line again and reset the
burner control unit.
7. Match the coding at the boiler
control unit according to the table
on page 54.
Control unit installation
and service instructions
8. Check the function of the neutra-
lising system, including the
hydraulic seal in the siphon.
Neutralising system oper-
ating instructions
9. 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 20).
10. A few days after commissioning,
check the boiler door and flue gas
box lid, and retighten all screws.
Further details regarding the individual steps (cont.)
9
Commissioning, inspection, maintenance
5692 759 GB

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
(43.2to58.0MJ/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
(36.0to47.2MJ/m
3
).
2. In the delivered condition, the burn-
er is set up for natural gas E. If
required, convert the burner in
accordance with details provided
by your gas supply utility to a differ-
ent gas type (see page 10).
3. Record the gas type in the service
report (on page 61).
Conversion to natural gas LL
(not in aand c)
1. Close the gas shut-off valve.
2. Switch OFF the control unit ON/
OFF switch.
3. Switch OFF the main isolator (out-
side the installation room) or the
power supply and prevent
unauthorised reconnection.
4. Pull cables from gas train.
5. Undo fitting A.
6. Pull compensation hose Gfrom
gas train.
Further details regarding the individual steps (cont.)
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Commissioning, inspection, maintenance
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7. Release the gas train from flange
E.
8. Remove restrictor Cwith rubber
cork gasket D.
9. Secure the gas train (without
restrictor Cand without rubber
cork gasket D, but including O-
ring B) at flange E;replacethe
factory-fitted screws M 5 × 16 with
M5×12(inthepack).
10. Secure and tighten fitting A.
11. Push compensation hose Gonto
the gas train.
12. Affix enclosed label "Adjusted to
..." Fabove the existing label.
13. Start the burner (see page 8).
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 func-
tions.
Leak detection spray must not
come into contact with electri-
cal contacts.
Checking the static and the supply pressure
Static pressure
1. Close the gas shut-off valve.
2. Undo the screw inside test connec-
tor 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 61).
Further details regarding the individual steps (cont.)
11
Commissioning, inspection, maintenance
5692 759 GB

Supply pressure
1. Start the burner.
Note
For commissioning, see page 8.
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 12.
Note
The supply pressure (flow pres-
sure) should be between 20 and 50
mbar. The gas pressure limiter
minimum (GDW 1) 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 connector A.
Supply pressure
(flow pressure)
Remedy
below 15 mbar Make no adjustments and contact 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 up-
stream in the boiler system, and regulate the pressure to 20
mbar.
Notify your gas supply utility.
Further details regarding the individual steps (cont.)
12
Commissioning, inspection, maintenance
5692 759 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, "0" = 0 % = lower output)
CO2test at the upper output
1. Press "+" Funtil the service dis-
play has incremented to "00" (=100
%).
2. Check the CO2contentattheflue
pipe.
Burner output in
kW
Permissible CO2
content in %
404 8.6 ± 0.3
503 8.6 ± 0.3
628 8.6 ± 0.3
Further details regarding the individual steps (cont.)
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Commissioning, inspection, maintenance
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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 spe-
cified range:
–Turning clockwise
→CO2content falls
–Turning anti-clockwise
→CO2content rises
4. Record the actual value in the
report (on page 61).
CO2test at the lower output
1. Press "-" Duntil the service dis-
play has decremented to "0" (lower
output).
2. Check the CO2contentattheflue
pipe. For permissible CO2content,
seethetableonpage13.
Further details regarding the individual steps (cont.)
14
Commissioning, inspection, maintenance
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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 falls
4. Record the actual value in the
report (on page 61).
Rechecking 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 13, repeat the
steps for the upper and lower out-
put.
5. Briefly press "S" Eand "-" D
simultaneously. The burner con-
tinues to the original modulation
level, at which the status "d" (= con-
trol stop) was initiated. The burner
then returns to operating mode.
Further details regarding the individual steps (cont.)
15
Commissioning, inspection, maintenance
5692 759 GB

Checking the ionisation current
1. Switch OFF the main isolator.
2. Pull ionisation current cable plug
C.
3. SwitchONthemainisolator.
There must be a fault shutdown
after the burner has tried to start.
Fault code "F A7" flashes in dis-
play B.
4. Switch OFF the main isolator.
Note
Test cable no.1 is required when
checking with the Testomatik-
Gas. You can also carry out this
test with a multimeter.
5. Push ionisation current cable plug
Cinto adaptor D.
6. Push test cable socket Aonto
the ionisation electrode.
7. SwitchthemainisolatorONand
press reset.
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 3 µA.
9. Record the actual value in the
report (on page 61).
10. SwitchthemainisolatorOFF,
remove the test equipment and
reconnect the ionisation cable
plug-in connectors.
11. SwitchONthemainisolator.
Further details regarding the individual steps (cont.)
16
Commissioning, inspection, maintenance
5692 759 GB

Shutting down the system
1. Switch OFF the main isolator or the
power supply and safeguard
against unauthorised reconnection.
Danger
Mains voltage can be extre-
mely dangerous.
For maintenance work, the
gas fan must be isolated
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
1. Remove the burner hoodA.
2. Release burner cables Cwith
plug fA and lÖ from the burner
control unit and route them out of
the burner casing.
3. Release power cable Dwith plug
fÖ and control unit cable Fwith
plug fÖ/aBH from the burner and
strain relief, and route them out of
the burner casing.
4. Remove gas supply pipe B.
Further details regarding the individual steps (cont.)
17
Commissioning, inspection, maintenance
5692 759 GB

5. Undo six screws on the boiler door
Eand open the door. !Please note Scratches inside the combus-
tion chamber can lead to corro-
sion.
Neverputtoolsorotherobjects
into the combustion chamber.
Further details regarding the individual steps (cont.)
18
Commissioning, inspection, maintenance
5692 759 GB

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.
Cleaning the combustion chamber and heating surfaces
Thoroughly clean the combustion
chamber and heating surfaces with a
water jet. !Please note
Scratches on parts that are in
contactwithfluegascanlead
to corrosion.
Only use plastic brushes, NOT
wire brushes or sharp objects.
Further details regarding the individual steps (cont.)
19
Commissioning, inspection, maintenance
5692 759 GB

For normal cleaning, flush the heating
surfaces with a water jet. However,
you may use cleaning agents if you
notice stubborn residues, surface dis-
colouration or soot deposits.
For this, observe the following:
&Only use solvent-free cleaning
agents. Ensure that no cleaning
agents enter between the boiler
body and the thermal insulation.
&Remove soot deposits with alkaline
cleaning agents with additional sur-
factants (e.g. Fauch 600).
&Remove coatings and surface dis-
colouration (yellow-brown) with
slightly acidic, chloride-free clean-
ing agents based on phosphoric
acid (e.g. Antox 75 E).
&Remove loose deposits from the
boiler; flush the heating surfaces
and the flue gas header thoroughly
with a water jet.
Cleaning agent manufacturer's
details.
Note
"Fauch 600" and "Antox 75 E"
Manufacturer:
Hebro Chemie GmbH
Rostocker Straße 40
D -41199 Mönchengladbach
Checking gaskets and thermal insulation components
1. Check gaskets and the packing
cord in the boiler door for damage.
2. Check the thermal insulation com-
ponents of the boiler door for possi-
ble damage.
3. Replace all faulty parts.
Checking all connections on the heating water side for leaks
Danger
There is a risk of injury when
workingonpressurisedcompo-
nents.
Only open the connections on
the heating water side after the
boiler has been de-pres-
surised.
Only drain the boiler with a
vacuum pump when the boiler
air vent valve is open.
Note
Also check the connections to control
equipment and to the minimum pres-
sure switch (low water indicator) for
leaks.
Further details regarding the individual steps (cont.)
20
Commissioning, inspection, maintenance
5692 759 GB