Viessmann VITOCROSSAL 200 Betriebsanleitung

Service instructions

for contractors

VIESMANN

Vitocrossal 200

Type CM2, 400 to 620 kW

Gas condensing boiler with MatriX cylinder burner

For applicability, see the last page

VITOCROSSAL 200

5794 780 GB 4/2013 Please keep safe.

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 intended exclu-

sively for qualified contractors.

■ Work on gas installations must only be

carried out by a registered 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.

■ This appliance has not been designed

to be operated by individuals (includ-

ing children) with limited physical, sen-

sory or mental capacities or who are

lacking in the appropriate experience

and/or knowledge, unless they are

supervised by a person with responsi-

bility for their safety or were instructed

by that person in the operation of this

appliance.

!Please note

Children should be super-

vised.

Ensure that children never play

with the appliance.

Regulations

Observe the following when working on

this system:

■ Statutory regulations regarding the

prevention of accidents

■ Statutory regulations regarding envi-

ronmental protection

Safety instructions

5794 780 GB

■ 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-TR Gas,

ÖVGW-TRF and ÖVE

cSEV, SUVA, SVGW, SVTI,

SWKI, VKF and EKAS Directive

1942: LPG, part 2

If you smell gas

Danger

Escaping gas can lead to explo-

sions which may result in serious

injury.

■ Do not smoke. Prevent naked

flames and sparks. Do not

press any switches for lights or

electrical appliances.

■ Close the gas shut-off valve.

■ Open windows and doors.

■ Remove all people from the

danger zone.

■ Notify your gas or electricity

supply utility 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-threat-

ening poisoning.

■ Shut down the heating system.

■ Ventilate boiler room.

■ Close all doors in the living

space.

Working on the system

■ Where gas is used as the fuel, close

the main gas shut-off valve and safe-

guard it against unintentional reopen-

ing.

■ Isolate the system from the power sup-

ply (e.g. at the separate fuse or a main

switch) and check that it is de-ener-

gised.

■ Safeguard the system against recon-

nection.

!Please note

Electronic assemblies can be

damaged by electrostatic dis-

charges.

Before beginning work, touch

earthed objects, such as heating

or water pipes, to discharge static

loads.

Repair work

!Please note

Repairing components that fulfil a

safety function can compromise

the safe operation of your sys-

tem.

Replace faulty components only

with original Viessmann spare

parts.

Safety instructions

Safety instructions (cont.)

5794 780 GB

Auxiliary components, spare and

wearing parts

!Please note

Spare and wearing parts that

have not been tested together

with the system can compromise

its function. Installing non-author-

ised components and making

non-approved modifications or

conversions can compromise

safety and may invalidate our

warranty.

For replacements, use only orig-

inal spare parts supplied or

approved by Viessmann.

Safety instructions

Safety instructions (cont.)

5794 780 GB

Product information

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

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance.......................................... 7

Further details regarding the individual steps....................................................... 9

Air pressure switch............................................................................................ 46

Burner control unit............................................................................................. 48

Troubleshooting

Fault display......................................................................................................... 56

Fault codes........................................................................................................... 57

Faults without fault display................................................................................... 64

Burner control unit flow chart........................................................................... 65

Connection diagrams

Burner control unit connection diagram................................................................ 67

Mains filter unit connection diagram..................................................................... 71

Component overview......................................................................................... 73

Control unit

Adjusting codes at the control unit....................................................................... 75

Parts lists

Ordering parts...................................................................................................... 76

Overview of the assemblies................................................................................. 76

Parts not shown.................................................................................................... 76

Boiler assembly.................................................................................................... 77

Thermal insulation assembly................................................................................ 77

Burner assembly, 400 kW.................................................................................... 80

Burner assembly, 500 kW.................................................................................... 81

Burner assembly, 620 kW.................................................................................... 84

Report.................................................................................................................. 86

Specification....................................................................................................... 91

Keyword index.................................................................................................... 93

Index

5794 780 GB

The appliance is only intended to be

installed and operated in sealed unven-

ted heating systems that comply with

EN 12828, with due attention paid to the

associated installation, service and

operating instructions 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 pur-

pose other than the heating up of heating

water shall be deemed inappropriate.

Intended use presupposes that a fixed

installation in conjunction with permissi-

ble components designed for this pur-

pose has been carried out.

Every other use will be deemed to be

inappropriate. Any resulting losses are

excluded from the manufacturer's liabil-

ity.

Any usage beyond this must be

approved by the manufacturer for the

individual case.

Intended use also includes the adher-

ence to maintenance and inspection

intervals.

Product information

Intended use

5794 780 GB

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............. 9

•2. Filling the heating system with water and venting...... 9

•3. Filling the siphon with water......................................... 9

•4. Checking the gas type.................................................... 10

•5. Conversion to natural gas E.......................................... 11

•6. Conversion to LPG P...................................................... 14

•7. Height adjustment.......................................................... 16

• • 8. Configuring the motorised flue gas damper (flue gas

cascade).......................................................................... 18

••• 9. Commissioning the system........................................... 18

•10. Reducing operational output (if necessary)................. 20

••• 11. Checking static pressure and supply pressure........... 21

••• 12. Checking the rotary damper setting (for 400 and 620

kW)................................................................................... 23

•13. Overview of differences between the three burner

sizes................................................................................. 24

••• 14. Checking the CO2 content............................................. 27

••• 15. Checking the CO content

••• 16. Checking the flue gas temperature

• • 17. Displaying the ionisation current.................................. 29

• • 18. Shutting down the system............................................. 30

• • 19. Opening the boiler door................................................. 34

• • 20. Cleaning the combustion chamber and heating

surfaces........................................................................... 34

• • 21. Checking the gaskets and thermal insulation

components.................................................................... 35

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5794 780 GB

Commissioning steps

Inspection steps

Maintenance steps Page

• • 22. Checking all connections on the heating water side

for tightness.................................................................... 36

• • 23. Cleaning and reconnecting the condensate drain

system............................................................................. 36

• • 24. Checking for tightness on the flue side....................... 38

• • 25. Checking the condensate drain and the neutralising

system (if installed)........................................................ 38

• • 26. Checking the burner gauze assembly.......................... 39

• • 27. Checking the ignition electrodes and ionisation

electrode.......................................................................... 40

• • 28. Cleaning the burner........................................................ 40

•29. Fitting the fan.................................................................. 41

•30. Making the burner electrical connections.................... 41

• • 31. Checking both gas train valves automatically for

tightness.......................................................................... 42

• • 32. Checking the filter element in the gas line (if installed)

and replacing if required

••• 33. Checking all gas connections for tightness................ 42

•34. Implementing final checks............................................. 43

• • 35. Checking the water quality............................................ 44

••• 36. Checking the function of safety valves

• • 37. Checking the expansion vessel and system pressure 44

• • 38. Checking the mixer for ease of operation and leaks... 45

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

• • 40. Checking the ventilation air apertures in the

installation room (only for open flue operation)

•41. Instructing the system user........................................... 45

•42. Operating and service documents................................ 45

Commissioning, inspection, maintenance

Steps - commissioning, inspection and… (cont.)

5794 780 GB

Checking the high limit safety cut-out setting

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 charge volume, water hard-

ness and pH value on page 44.

Note

Observe the "Water quality require-

ments" on page 87.

Filling the siphon with water

1. Undo four screws and remove the

rear centre and lower back panels.

2. Undo the siphon and fill with water

(otherwise flue gas may escape).

3. Check that the condensate can drain

freely.

4. Remount the siphon.

Note

The hose connection to the on-site

condensate system or to the neutral-

ising system must not be permitted to

sag; support with a pipe if neces-

sary.

Commissioning, inspection, maintenance

Further details regarding the individual steps

5794 780 GB

Checking the gas type

1. Check the gas type and Wobbe index

(Wo) with your gas supply utility.

■ 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 LPG P setting, the boiler

can be operated in the Wobbe

index range 20.3 to 21.3 kWh/m3

(72.9 to 76.8 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 (see from page 11) in accord-

ance with details provided by your

gas supply utility.

Note

The 500 kW burner requires a natural

gas restrictor. A natural gas restrictor

is not required for the 400 and

620 kW burners.

Rated heating output kW 400 500 620

Restrictor for natural gas E 7 mm − 21.5 −

Restrictor for LPG P 7 mm 14.0 14.8 17.2

3. Record the gas type in the report (on

page 86).

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5794 780 GB

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