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
5692 759 GB

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
5692 759 GB

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
5692 759 GB

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.)
10
Commissioning, inspection, maintenance
5692 759 GB