Viessmann VITOCROSSAL 200 Betriebsanleitung

Service instructions

for contractors

VIESMANN

Vitocrossal 200

Type CT2

Gas condensing boiler with MatriX cylinder burner

for natural gas E and LL

For applicability, see the last page

VITOCROSSAL 200

5692 908 GB 3/2011 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

5692 908 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.)

5692 908 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.)

5692 908 GB

Commissioning, inspection, maintenance

Steps – commissioning, inspection and maintenance.......................................... 6

Further details regarding the individual steps....................................................... 8

Troubleshooting

Diagnosis.............................................................................................................. 41

Burner control unit flow diagram...................................................................... 51

Connection diagrams

Burner control unit connection diagram................................................................ 53

Mains filter unit connection diagram..................................................................... 54

Component overview......................................................................................... 56

Control unit

Adjusting codes at the control unit....................................................................... 58

Parts lists............................................................................................................ 59

Commissioning/service report.......................................................................... 65

Water quality requirements............................................................................... 67

Specification....................................................................................................... 71

Certificates

Declaration of conformity...................................................................................... 73

Manufacturer's certificate according to the first BImSchV [Germany].................. 74

Keyword index.................................................................................................... 75

Index

5692 908 GB

For further information regarding the individual steps, see the page indicated

Commissioning steps

Inspection steps

Maintenance steps Page

• • 1. Information regarding maintenance work.................... 8

•2. Checking the high limit safety cut-out setting............. 8

•3. Filling the heating system with water and venting the

system............................................................................. 8

•4. Filling siphon with water................................................ 9

••• 5. Starting the heating system........................................... 9

•6. Checking the gas type.................................................... 11

•7. Conversion to natural gas LL........................................ 11

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

••• 9. Checking the CO2 content............................................. 14

••• 10. Checking the CO content

••• 11. Checking the flue gas temperature

• • 12. Checking the ionisation current.................................... 17

• • 13. Shutting down the system............................................. 18

• • 14. Opening the boiler door................................................. 18

• • 15. Separating the neutralising system (if installed) from

the boiler and connecting the drain hose.................... 20

• • 16. Cleaning the combustion chamber and heating

surfaces........................................................................... 20

• • 17. Checking gaskets and thermal insulation parts.......... 21

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

for leaks........................................................................... 22

• • 19. Cleaning and reconnecting the condensate drain

system............................................................................. 22

• • 20. Checking the condensate drain and the neutralising

system (if installed)........................................................ 23

• • 21. Checking the burner gauze assembly.......................... 24

Commissioning, inspection, maintenance

Steps – commissioning, inspection and maintenance

5692 908 GB

Commissioning steps

Inspection steps

Maintenance steps Page

• • 22. Checking the ignition and ionisation electrodes......... 24

• • 23. Closing the boiler door.................................................. 25

• • 24. Cleaning the burner........................................................ 25

•25. Installing the burner....................................................... 26

• • 26. Checking both gas train valves automatically for gas

tightness.......................................................................... 26

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

elements in the gas line

••• 28. Checking all gas connections for tightness................ 26

••• 29. Checking the rotary damper setting............................. 27

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

• • 31. Checking the water quality............................................ 29

••• 32. Checking the function of safety valves

• • 33. Expansion vessel and system pressure....................... 30

• • 34. Checking the gaskets/seals on the flue gas side........ 31

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

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

•37. Checking the flue gas system for leaks

• • 38. Checking the ventilation air apertures in the

installation room (only for open flue operation)

•39. Instructing the system user........................................... 32

•40. Operating and service instructions.............................. 32

Commissioning, inspection, maintenance

Steps – commissioning, inspection and… (cont.)

5692 908 GB

Information regarding maintenance work

Danger

The product contains ceramic fibres. If handled incorrectly, fibre dust may be

released.

Observe the stipulations of the Technical Guideline for the Handling of Haz-

ardous Materials (TRGS) 521.

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" from page 67.

Commissioning, inspection, maintenance

Further details regarding the individual steps

5692 908 GB

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: 5.5 bar.

2. For open flue operation: Check that

the installation room ventilation is

unobstructed.

3. Check the gas supply pressure.

4. Open the gas line shut-off valves.

5. Switch ON the mains isolator (outside

the installation room).

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 908 GB

A B

Switch ON system ON/OFF switch

B at the control unit. If fault indicator

A at the control unit illuminates and

burner control unit display C flashes,

first press reset buttonD 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). Ventilate 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 58.

Control unit installation and

service instructions

8. Check the function of the neutralising

system, including the hydraulic seal

in the siphon.

Neutralising system operating

instructions

9. Check all gaskets/seals and plugs,

and retighten if necessary.

Note

We recommend you check all heating

water side connections for leaks after

approx. 500 hours run (see

page 22).

10. Check the boiler door and flue gas

collector cover a few days after

commissioning and retighten all

screws.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 908 GB

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