Viessmann VITOCROSSAL 200 User guide

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

5692 907 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 907 GB

4

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

5692 907 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 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

5692 907 GB

6

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

7

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

8

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

10

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.)

5692 907 GB

11

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

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 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

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: 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

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 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

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 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

17

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.)

5692 907 GB

20

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

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Viessmann VITOCROSSAL 200, Vitocrossal 200 CM2 Series User guide

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