Viessmann VITOCROSSAL 200 Betriebsanleitung

VIESMANN

Service instructions

for heating engineers

Vitocrossal 200

Type CM2

Gas fired condensing boiler

For applicability, see the last page

VITOCROSSAL 200

5692 599 GB 7/2005 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 appliances must only

be carried out by a registered gas

fitter.

&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,

&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.

If you smell gas

Danger

Escaping gas can lead to

explosions which may lead to

serious injury.

&Never smoke. Prevent naked

flames and sparks.

&Never switch lights or electri-

cal 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.

&Close doors to the living

space.

Safety instructions

5692 599 GB

Working on the system

&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 mains isola-

tor.

&Safeguard the system against

unauthorised reconnection.

&When using gas as fuel, also close

the main gas shut‐off valve and

safeguard against unauthorised

reopening.

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 or conversions

can compromise safety and

may invalidate our warranty.

For replacements, use only ori-

ginal spare parts supplied or

approved by Viessmann.

Safety instructions (cont.)

Safety instructions

5692 599 GB

Initial start-up, inspection, maintenance

Steps –initial startup, inspection and maintenance ..................................... 5

Further details regarding the individual steps .............................................. 7

Air pressure switch ..................................................................................... 31

Burner control unit ...................................................................................... 32

Troubleshooting

Diagnosis ................................................................................................... 40

Gas burner control unit flow chart ........................................................... 46

Burner control unit connection diagram .................................................. 48

Component overview................................................................................ 50

Control unit

Adjusting codes at the control unit............................................................... 54

Parts lists .................................................................................................. 55

Report ....................................................................................................... 60

Water quality requirements ......................................................................... 60

Specification............................................................................................. 62

Certificates

Declaration of conformity ............................................................................ 65

Manufacturer's certificate according to the 1st BImSchV [Germany]............. 66

Keyword index .......................................................................................... 67

Index

5692 599 GB

For further information regarding individual steps, see the pages indicated.

Commissioning steps

Inspection steps

Maintenance steps Page

!!!



•01. Checking the high limit safety cut‐out setting ........... 7

•02. Filling the heating system with water and venting

the system ............................................................................... 7

•03. Filling the siphon with water............................................. 7

••• 04. Starting the heating system .............................................. 7

•05. Checking the gas type......................................................... 9

•06. Conversion to natural gas LL ........................................... 9

••• 07. Checking the static and the supply pressure............. 12

••• 08. Checking the CO2content ................................................. 14

••• 09. Checking the CO content

••• 10. Checking the flue gas temperature

• • 11. Checking the ionisation current ..................................... 19

• • 12. Shutting down the heating 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.................................................................................... 21

• • 16. Checking gaskets and thermal insulation

components ............................................................................ 21

• • 17. Checking all primary 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

Steps –initial start‐up, inspection and maintenance

Initial start-up, inspection, maintenance

5692 599 GB

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. Burner installation................................................................ 26

• • 25. Checking both gas train valves for soundness (for

115 to 311 kW)......................................................................... 27

• • 26. Checking and replacing (if required) the filter

elements in the gas pipe

••• 27. Checking all gas connections for soundness............ 27

•28. Implementing final tests..................................................... 28

• • 29. Checking the water quality................................................ 28

••• 30. Checking the function of all safety valves

• • 31. Checking the diaphragm expansion vessel and

system pressure.................................................................... 29

• • 32. Checking the mixer for obstructions and leaks ........ 30

••• 33. Checking the thermal insulation for tight fit

• • 34. Checking the ventilation apertures in the

installation room (only for open flue operation)

•35. Instructing the system user .............................................. 30

•36. Operating and service documents ................................. 30

Steps –initial start‐up, inspection and . . . (cont.)

Initial start-up, inspection, maintenance

5692 599 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,

set it to a maximum of 110 °C.

Control unit installation and

service instructions

Filling the heating system with water and venting the system

Record the fill volume and concentra-

tion of calcium hydrogen carbonate on

page 29.

Note

Observe the "water quality require-

ments" on page 61.

Filling the siphon with water

1. Release the siphon and fill with

water (otherwise flue gas may

escape).

2. Check that the condensate can

freely drain.

3. Refit the siphon.

Starting the heating system

Control unit operating and ser-

vice instructions, and neutralis-

ing system operating

instructions

Further details regarding the individual steps

Initial start-up, inspection, maintenance

5692 599 GB

1. Check the heating system pres-

sure.

Permissible boiler operating pres-

sure: 4 bar

2. For open flue operation: Check

that the boiler room ventilation

aperture is open.

3. Check the gas supply pressure.

4. Check that the cleaning aperture

on the flue outlet is closed.

5. Open the gas supply line shut‐off

valves.

6. Switch ON the mains isolator (out-

side the installation room).

7. Switch ON the system ON/OFF

switch Bat the control unit. If

fault indicator lamp Aat the con-

trol unit illuminates and burner

control unit display Cflashes,

first press reset button Dat the

burner control unit.

Note

The system can enter a fault state

during commissioning, if insuffi-

cient gas is in the supply line (the

fault indicator at the control unit

illuminates). Vent the gas supply

line again and reset the burner

control unit.

8. Match the coding at the boiler

control unit according to the table

on page 54.

Control unit installation and

service instructions

Further details regarding the individual steps (cont.)

Initial start-up, inspection, maintenance

5692 599 GB

9. Check the function of the neutra-

lising system.

Neutralising system oper-

ating instructions

10. 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 22).

11. Check the boiler door and clean‐

out cover a few days after com-

missioning 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/m

(43.2 to 58.0 MJ/m

&With the natural gas LL setting,

the boiler can be operated in the

Wobbe index range 10.0 to 13.1

kWh/m

(36.0 to 47.2 MJ/m

2. The burner is set up in the factory

for natural gas E. If required, con-

vert the burner in accordance with

details provided by your gas sup-

plier to a different gas type (see

page 9).

3. Record the gas type in the service

report (on page 60).

Conversion to natural gas LL

Conversion for 87 kW

1. Close the gas shut‐off valve. 2. Switch OFF the system ON/OFF

switch at the control unit.

Further details regarding the individual steps (cont.)

Initial start-up, inspection, maintenance

5692 599 GB

3. Switch OFF the mains isolator

(outside the installation room) or

the power supply and prevent

unauthorised reconnection.

4. Undo fitting A.

5. Remove the venturi mixer tube H

from the gas fan.

Pull off the compensation line E

when operating the boiler in

balanced flue mode.

6. Release the gas combination

valve from flange G.

7. Remove restrictor Cwith gasket

Dfrom venturi mixer tube H.

8. Secure the gas combination valve

(without restrictor Cand without

gasket D, but including O‐ring

B) at flange G.

9. Secure venturi mixer tube Hat

the gas fan.

Push compensation line Eonto

the mixer tube when operating the

boiler in balanced flue mode.

10. Fit and tighten fitting A.

11. Affix enclosed label "Adjusted to

..." Fabove the existing label.

12. Start the burner (see page 7).

Danger

Escaping gas leads to a risk of

explosions.

Check all fittings for sound-

ness.

Conversion for 115 to 311 kW

1. Close the gas shut‐off valve.

2. Switch OFF the system ON/OFF

switch at the control unit.

3. Switch OFF the mains isolator

(outside the installation room) or

the power supply and prevent

unauthorised reconnection.

Further details regarding the individual steps (cont.)

Initial start-up, inspection, maintenance

5692 599 GB

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