Viessmann VITOCROSSAL 200 User manual

Service instructions
for contractors
VIESMANN
Vitocrossal 200
Type CM2
Gas condensing boiler
For applicability, see the last page
VITOCROSSAL 200
5692 681 GB 4/2009 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
5692 681 GB

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 681 GB

4
Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 7
Troubleshooting
Diagnosis.............................................................................................................. 41
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
Commissioning/service report.......................................................................... 61
Specification....................................................................................................... 66
Certificates
Declaration of conformity...................................................................................... 69
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 69
Keyword index.................................................................................................... 71
Index
Index
5692 681 GB

5
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 siphon with water................................................ 7
••• 4. Starting the heating system........................................... 7
•5. Checking the gas type.................................................... 9
•6. Conversion 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
components.................................................................... 21
• • 17. Checking all heating water connections 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
5692 681 GB

6
Commissioning steps
Inspection steps
Maintenance steps Page
• • 21. Checking the ignition and ionisation electrodes......... 24
• • 22. Closing the boiler door.................................................. 25
• • 23. Cleaning the burner........................................................ 25
•24. Installing the burner....................................................... 26
• • 25. Checking both gas train valves for tightness (for 115
to 311 kW)........................................................................ 27
• • 26. Checking and replacing (if required) the filter
elements in the gas supply pipe.
••• 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............................................ 30
••• 31. Checking the function of safety valves
• • 32. Checking the diaphragm expansion vessel and
system pressure............................................................. 31
• • 33. Checking the mixer for obstructions and leaks........... 32
••• 34. Checking the thermal insulation for tight fit
• • 35. Checking the ventilation apertures in the installation
room (only for open flue operation)
•36. Instructing the system user........................................... 32
•37. Operating and service documents................................ 32
Commissioning, inspection, maintenance
Steps – commissioning, inspection and… (cont.)
5692 681 GB

7
Checking the high limit safety cut-out setting
The high limit safety cut-out must not be
set higher than 110 °C; if required, set it
to a maximum of 110 °C.
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 30 and 31.
Note
Observe the "Water quality require-
ments" on page 62.
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: 4 bar
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 681 GB

8
2. For open flue operation: Check that
the installation room ventilation aper-
ture is open.
3. Check the gas supply pressure.
4. Open the gas supply pipe shut-off
valves.
5. Switch ON the main 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 at the control unit illuminates
and burner control unit display C
flashes, first press reset button D 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). Vent 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 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 681 GB

9
9. Check all gaskets/seals and plugs,
and retighten if necessary.
Note
We recommend you check all heating
water connections for leaks after
approx. 500 hours (see page 22).
10. Check the boiler door and clean-out
cover a few days after commission-
ing and retighten all screws.
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/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 in accordance with
details provided by your gas supply
utility to a different gas type (see
page 9).
3. Record the gas type in the service
report (on page 61).
Conversion to natural gas LL
Conversion for 87 kW
01. Close the gas shut-off valve.
02. Switch OFF the control unit ON/OFF
switch.
03. Switch OFF the main isolator (out-
side the installation room) or the
power supply and prevent unauthor-
ised reconnection.
04. Undo fitting A.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 681 GB

10
05. Remove the venturi mixer tube H
from the gas fan.
Pull off the compensation line E
when operating the boiler in bal-
anced flue mode.
06. Release the gas train from flange
G.
07. Remove restrictor C with gasket
D from venturi mixer tube 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 mixer tube H at the
gas fan.
Push compensation line E onto the
mixer tube when operating the
boiler in balanced flue mode.
10. Secure and tighten fitting A.
11. Affix enclosed label "Adjusted to ..."
F above 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 control unit ON/OFF
switch.
03. Switch OFF the main 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.)
5692 681 GB

11
04. Undo fitting A.
05. Except for 115 kW: Pull compensa-
tion hose G from 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) at
flange E; replace the factory-fitted
screws M 5 × 16 with M 5 × 12 (in
the pack).
09. Secure and tighten fitting A.
10. Except for 115 kW: Push compen-
sation hose G onto the gas train.
11. Affix enclosed label "Adjusted to ..."
F above 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 681 GB

12
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 inside test connector
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).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 681 GB

13
Supply pressure
1. Start the burner.
Note
For commissioning, see page 7.
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)
should be between 20 and 50 mbar.
The gas pressure limiter 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)
Measures
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 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 681 GB

14
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: Level of modulation
in % ("00." = 100 % = upper output
"00" = 0 % = lower output)
CO2 test at the upper 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 output
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 681 GB

15
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 four turns.
4. Record the actual value in the report
(on page 61).
CO2 test at the lower output (87 kW)
1. Press "-" D until the service display
has decremented to "00" (lower out-
put).
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 681 GB

16
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 61).
Rechecking the values
Regulate to the upper and lower out-
put 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. Press "S" E and "-" D simultane-
ously. The burner is now in operating
mode.
CO2 test at the upper 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 681 GB

17
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 61).
CO2 test at the lower output (115 kW
to 311 kW)
1. Press "-" D until the service display
has decremented to "00" (lower out-
put).
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 681 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 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 61).
Rechecking the values
Regulate to the upper and lower out-
put using 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 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 681 GB

19
Checking the ionisation current
A
B
CD
01. Switch OFF the main isolator.
02. Pull ionisation current cable plug
C.
03. Switch ON the main isolator.
There must be a fault shutdown
after the burner has tried to start.
The fault code "F 25" flashes in dis-
play B.
04. 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.
05. Push ionisation current cable plug
C into adaptor D.
06. Push test cable socket A onto the
ionisation electrode.
07. Switch the main isolator ON and
press reset.
08. Check the ionisation current.
Note
Approx. 2 to 3 s after the gas valve
has been opened and during oper-
ation, the ionisation current should
be at least 3 µA.
09. Record the actual value in the report
(on page 61).
10. Switch the main isolator OFF,
remove the test equipment and
reconnect the ionisation cable plug-
in connectors.
11. Switch ON the main isolator.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 681 GB

20
Shutting down the system
1. Switch OFF the main isolator or the
power supply and safeguard against
unauthorised reconnection.
2. Pull plug-in connectors 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 into a sewer.
Cleaning the combustion chamber and heating surfaces
Thoroughly clean the combustion cham-
ber and heating surfaces thoroughly 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 681 GB