Viessmann Vitocrossal 200 CM2 Series Betriebsanleitung

Service instructions

for contractors

VIESMANN

Vitocrossal 200

Type CM2, 400 to 620 kW

Gas condensing boiler with MatriX cylinder burner

For open flue and room sealed operation

Permissible operating pressure 6 bar

VITOCROSSAL 200

5833544 GB 6/2018 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 intended for quali-

fied contractors.

■Work on gas installations may only be carried out by

a registered gas fitter.

■Work on electrical equipment may 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 to be observed

■National installation regulations

■Statutory regulations for the prevention of accidents

■Statutory regulations for environmental protection

■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 G K directives,

ÖVGW-TRF and ÖVE

cSEV, SUVA, SVGW, SVTI, SWKI, VKF and

EKAS guideline 1942: LPG, part 2

Safety instructions for working on the system

Working on the system

■Where gas is used as the fuel, close the main gas

shut-off valve and safeguard it against unintentional

reopening.

■Isolate the system from the power supply, e.g. by

removing the separate fuse or by means of a mains

isolator, and check that it is no longer live.

■Safeguard the system against reconnection.

■Wear suitable personal protective equipment when

carrying out any work.

Danger

Hot surfaces and fluids can lead to burns or

scalding.

■Before maintenance and service work, switch

OFF the appliance and let it cool down.

■Never touch hot surfaces on the boiler, burner,

flue system or pipework.

!Please note

Electronic assemblies can be damaged by elec-

trostatic discharge.

Prior to commencing work, touch earthed

objects such as heating or water pipes to dis-

charge static loads.

Repair work

!Please note

Repairing components that fulfil a safety func-

tion can compromise the safe operation of the

system.

Replace faulty components only with genuine

Viessmann spare parts.

Safety instructions

5833544

Auxiliary components, spare and wearing parts

!Please note

Spare and wearing parts that have not been tes-

ted together with the system can compromise its

function. Installing non-authorised components

and making non-approved modifications or con-

versions can compromise safety and may inva-

lidate our warranty.

For replacements, use only original spare parts

supplied or approved by Viessmann.

Safety instructions for operating the system

If you smell gas

Danger

Escaping gas can lead to explosions which may

result in serious injury.

■Do not 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.

■Evacuate any people from the danger zone.

■Notify your gas or electricity supply utility from

outside the building.

■Have the power supply to the building shut off

from a safe place (outside the building).

If you smell flue gas

Danger

Flue gas can lead to life threatening poisoning.

■Shut down the heating system.

■Ventilate the installation site.

■Close doors to living spaces to prevent flue

gases from spreading.

What to do if water escapes from the appliance

Danger

If water escapes from the appliance there is a

risk of electrocution.

Switch OFF the heating system at the external

isolator (e.g. fuse box, domestic distribution

board).

Danger

If water escapes from the appliance there is a

risk of scalding.

Never touch hot heating water.

Condensate

Danger

Contact with condensate can be harmful to

health.

Never let condensate touch your skin or eyes

and do not swallow it.

Flue systems and combustion air

Ensure that flue systems are clear and cannot be

sealed, for instance due to accumulation of conden-

sate or other external causes.

Avoid continuous condensate disposal with a wind pro-

tector.

Ensure an adequate supply of combustion air.

Inform system users that subsequent modifications to

the building characteristics are not permissible (e.g.

cable/pipework routing, cladding or partitions).

Danger

Leaking or blocked flue systems, or an inade-

quate supply of combustion air can cause life

threatening poisoning from carbon monoxide in

the flue gas.

Ensure the flue system is in good working order.

Vents for supplying combustion air must be non-

sealable.

Extractors

Operating appliances that exhaust air to the outside

(extractor hoods, extractors, air conditioning units, etc.)

can create negative pressure. If the boiler is operated

at the same time, this can lead to a reverse flow of flue

gas.

Danger

The simultaneous operation of the boiler and

appliances that exhausts air to the outside can

result in life threatening poisoning due to a

reverse flow of flue gas.

Fit an interlock circuit or take suitable steps to

ensure an adequate supply of combustion air.

Safety instructions

Safety instructions (cont.)

5833544

1. Information Disposal of packaging ............................................................................ 5

Key to date of manufacture .................................................................... 5

Symbols ................................................................................................. 6

■Intended use ....................................................................................... 6

2. Commissioning, inspec-

tion, maintenance

Steps – commissioning, inspection and maintenance ........................... 8

3. Control unit Adjusting codes at the control unit ......................................................... 33

4. Burner control unit ................................................................................................................ 34

5. Flow diagram for burner

control unit

................................................................................................................ 38

6. Troubleshooting Fault indicator ........................................................................................ 40

■Fault display ....................................................................................... 40

■Fault memory ...................................................................................... 40

Fault codes ............................................................................................ 40

■General process errors ....................................................................... 40

■Internal system faults .......................................................................... 43

Faults without fault display ..................................................................... 45

7. Parts lists Overview of assemblies ......................................................................... 47

Boiler assembly ..................................................................................... 48

Thermal insulation assembly ................................................................. 50

Cable set assembly ............................................................................... 52

Burner assembly .................................................................................... 54

Parts not shown ..................................................................................... 56

8. Component overview ................................................................................................................ 57

9. Functions Air pressure switch ................................................................................ 58

■Fan pressure monitoring function (LDW1) .......................................... 58

■Combustion chamber pressure monitoring function (LDW2) .............. 58

10. Connection diagrams Burner control unit connection diagrams ............................................... 59

■Mains filter unit connection diagram ................................................... 61

11. Reports Water quality .......................................................................................... 62

Settings and test values ......................................................................... 62

12. Specification ................................................................................................................ 66

13. Final decommissioning

and disposal

................................................................................................................ 69

14. Certificates EU Declaration of Conformity ................................................................ 70

Manufacturer's certificate ....................................................................... 70

15. Keyword index ................................................................................................................ 71

Index

5833544

Please dispose of packaging waste in line with statu-

tory regulations.

DE: Use the disposal system organised by

Viessmann.

AT: Use the ARA statutory disposal system (Altstoff

Recycling Austria AG, licence number 5766).

CH: Packaging waste is disposed of by the HVAC

contractor.

Key to date of manufacture

1 2 43 5 6 7

X X 0 1 2 5 5

Day

Year

Week

Fig. 1

Digits 1 and 2Internal Viessmann information

Digits 3 and 70 and 5 = calendar week 05 = 5th calendar week

Digits 4 and 61 and 5 = year 2015

Digit 52 = 2nd day of the working week

(Monday = 1, Tuesday = 2, etc.)

Example 0501255 corresponds to date of manufacture: 27 January 2015

Information

Disposal of packaging

5833544

Information

Symbol Meaning

Reference to other document containing

further information

Step in a diagram:

The numbers correspond to the order in

which the steps are carried out.

Warning of material losses and environ-

mental pollution

Live electrical area

Pay particular attention.

■Component must audibly click into place.

■Acoustic signal

■Fit new component.

■In conjunction with a tool: Clean the sur-

face.

Dispose of component correctly.

Dispose of component at a suitable collec-

tion point. Do not dispose of component in

domestic waste.

The steps in connection with commissioning, inspec-

tion and maintenance are found in the "Commission-

ing, inspection and maintenance" section and identified

as follows:

Symbol Meaning

Steps required during commissioning

Not required during commissioning

Symbol Meaning

Steps required during inspection

Not required during inspection

Steps required during maintenance

Not required during maintenance

Intended use

The appliance is only intended to be installed and

operated in sealed unvented heating systems that

comply with EN 12828, with due attention paid to the

associated installation, service and operating instruc-

tions as well as the details in the datasheet.

It is only designed for the heating up of heating water.

Commercial or industrial usage for a purpose other

than the heating up of heating water shall be deemed

inappropriate.

Intended use presupposes that a fixed installation in

conjunction with permissible components designed for

this purpose has been carried out.

Information

Symbols

5833544

Information

Every other use will be deemed to be inappropriate.

Any resulting losses are excluded from the manufac-

turer's liability.

Any usage beyond this must be approved by the man-

ufacturer for the individual case.

Intended use also includes the adherence to mainte-

nance and inspection intervals.

Product information

Vitocrossal 200, type CM2

■Gas condensing boiler:

–400 to 620 kW rated heating output with modulat-

ing MatriX radiant burner for natural gas E and LL

(also for room sealed operation; accessories

required)

■Permissible operating pressure 6 bar (0.6 MPa)

■Permissible operating temperature up to 95 °C. Per-

missible safety temperature up to 110 °C

■Delivery:

Boiler body on pallet

Thermal insulation, burner, electronics unit with cable

harnesses and programming unit packed separately

Information

Symbols (cont.)

5833544

Information

Commissioning steps

Inspection steps

Maintenance steps Page

•1. Checking the high limit safety cut-out setting................................................................ 10

•2. Filling the heating system with water and venting......................................................... 10

•3. Filling the trap with water.................................................................................................. 10

••• 4. Opening the boiler.............................................................................................................. 10

•5. Checking the gas type....................................................................................................... 12

•6. Converting to natural gas LL............................................................................................ 13

•7. Conversion to LPG P......................................................................................................... 14

••• 8. Commissioning the system............................................................................................... 15

•9. Reducing operational output (if necessary).................................................................... 16

••• 10. Checking the static pressure and supply pressure........................................................ 17

••• 11. Checking the rotary damper setting................................................................................. 18

••• 12. Checking the CO2 content................................................................................................. 21

• • 13. Checking the CO content.................................................................................................. 23

• • 14. Checking the flue gas temperature.................................................................................. 23

• • 15. Displaying the ionisation current..................................................................................... 23

• • 16. Opening the boiler door..................................................................................................... 24

• • 17. Cleaning the combustion chamber and heating surfaces............................................. 24

• • 18. Checking gaskets and thermal insulation sections........................................................ 25

• • 19. Checking all connections on the heating water side for tightness............................... 25

• • 20. Cleaning and reconnecting the condensate drain system............................................. 25

• • 21. Checking the condensate drain and the neutralising system (if installed).................. 26

• • 22. Checking the burner gauze assembly.............................................................................. 26

• • 23. Checking the ignition electrodes and ionisation electrode........................................... 28

• • 24. Cleaning the burner........................................................................................................... 28

•25. Fitting the fan...................................................................................................................... 28

•26. Closing the boiler door...................................................................................................... 29

•27. Burner electrical connection............................................................................................. 29

• • 28. Checking for tightness on the flue side........................................................................... 30

• • 29. Automatic tightness test of gas train valves................................................................... 30

• • 30. Checking the gas train filter element............................................................................... 30

• • 31. Checking the filter element in the gas line...................................................................... 31

••• 32. Checking the connections on the gas side for tightness............................................... 31

•33. Performing final checks..................................................................................................... 31

• • 34. Checking the water quality................................................................................................ 31

••• 35. Checking the safety valve function

••• 36. Checking the temperature controller setting if a building management system is

used (DCC system)............................................................................................................ 31

• • 37. Checking the expansion vessel and system pressure................................................... 32

• • 38. Checking the mixer for ease of operation and leaks...................................................... 32

Commissioning, inspection, maintenance

Steps – commissioning, inspection and maintenance

5833544

Commissioning steps

Inspection steps

Maintenance steps Page

••• 39. Checking the thermal insulation for firm seating

• • 40. Checking the ventilation air aperture in the installation room (only for open flue

operation)

•41. Instructing the system user.............................................................................................. 32

Commissioning, inspection, maintenance

Steps – commissioning, inspection and… (cont.)

5833544

The high limit safety cut-out is preset to 110 °C and, if

required, can only be adjusted by changing the coding

card.

Filling the heating system with water and venting

Record the volume filled, water hardness and pH value

on page 62.

Note

Observe the "Water quality requirements" on

page 64.

Filling the trap with water

Fig. 2

1. Undo 4 screws. Remove the centre and bottom

back panels.

2. Undo the siphon and fill with water so that no flue

gas can escape.

Danger

Flue gas escaping from the trap or conden-

sate drain can cause life threatening carbon

monoxide poisoning. To prevent flue gas

from escaping, always connect the conden-

sate drain with a trap. Always fill the trap

with water before commissioning.

3. Check that the condensate can drain freely.

4. Refit the trap.

Note

The hose connection to the on-site condensate

system or to the neutralising system must not be

permitted to sag. Support the hose connection with

pipe if necessary.

Opening the boiler

1. Switch OFF the mains isolator or the power supply,

and safeguard against unauthorised reconnection.

Danger

Mains voltage can be life threatening.

For maintenance work, isolate the system

from the power supply.

Commissioning, inspection, maintenance

Checking the high limit safety cut-out setting

5833544

Andere Handbücher für Vitocrossal 200 CM2 Series

Inhaltsverzeichnis

Andere Viessmann Kessel Handbücher

Viessmann

Viessmann Vitodens 100-W Bedienungsanleitung

Viessmann

Viessmann VITOMAX 200-HS Kurzanleitung

Viessmann

Viessmann Vitodens 100-W Gebrauchsanweisung

Viessmann

Viessmann Vitodens 200-W B2HA series Bedienungsanleitung

Viessmann

Viessmann VITOFLEX 300-UF Betriebsanleitung

Viessmann

Viessmann VITOLADENS333-F Betriebsanleitung

Viessmann

Viessmann Vitodens 200-W System Kurzanleitung

Viessmann

Viessmann VITOPLEX 100 Bedienungsanleitung

Viessmann

Viessmann VITOLIGNO 300-C Betriebsanleitung

Viessmann

Viessmann VITOCELL 100-B Gebrauchsanweisung

Viessmann

Viessmann VITOTRONIC 300-K Bedienungsanleitung

Viessmann

Viessmann Vitoplex 100-LS SXD Service-Handbuch

Viessmann

Viessmann VITORONDENS 200-T Betriebsanleitung

Viessmann

Viessmann Vitogas 100 GS1 Series Bedienungsanleitung

Viessmann

Viessmann Vitocrossal CRU 800 Betriebsanleitung

Viessmann

Viessmann Vitodens 100-W Bedienungsanleitung

Viessmann

Viessmann VITOLADENS 300-T Betriebsanleitung

Viessmann

Viessmann Vitomax 200-LW M64A Schulungshandbuch

Viessmann

Viessmann VITOLIGNO 300-C Kurzanleitung

Viessmann

Viessmann VITOMAX 200-HS Schulungshandbuch

Viessmann

Viessmann VITOLADENS 300-W Kurzanleitung

Viessmann

Viessmann Vitodens 100 Service-Handbuch

Viessmann

Viessmann VITOGAS 100 Betriebsanleitung

Viessmann

Viessmann Vitotronic 100 GC1 Kurzanleitung

Beliebte Kessel Handbücher anderer Marken

Vaillant

Vaillant uniSTOR VIH SW GB 500 BES Bedienungsanleitung

Radijator

Radijator BIO max 23.1 Bedienungsanleitung

Brunner

Brunner BSV 20 Bedienungsanleitung

Buderus

Buderus Logamax GB062-24 KDE H V2 Bedienungsanleitung

Potterton

Potterton 50e Datenblatt

UTICA BOILERS

UTICA BOILERS TriFire Bedienungsanleitung

Joannes

Joannes LADY Series Handbuch

ECR International

ECR International UB90-125 Gebrauchsanweisung

Froling

Froling FHG Turbo 3000 Bedienungsanleitung

Froling

Froling P4 Pellet 8 - 105 Bedienungsanleitung

U.S. Boiler Company

U.S. Boiler Company K2 Bedienungsanleitung

Henrad

Henrad C95 FF Bedienungsanleitung

NeOvo

NeOvo EcoNox EF 36 Bedienungsanleitung

Potterton

Potterton PROMAX SL 12 Bedienungsanleitung

Eco Hometec

Eco Hometec EC 25 COMPACT Bedienungsanleitung

Baxi

Baxi Prime 1.24 Bedienungsanleitung

REXNOVA

REXNOVA ISA 20 BITHERMAL Bedienungsanleitung

Radiant

Radiant R2K 55 Handbuch