Viessmann VITOCROSSAL 200 Manuel utilisateur

Service instructions

for contractors

VIESMANN

Vitocrossal 200

Type CM2

Gas condensing boiler

For applicability, see the last page

VITOCROSSAL 200

5692 681 GB 4/2009 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 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 681 GB

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 681 GB

Commissioning, inspection, maintenance

Steps – commissioning, inspection and maintenance.......................................... 5

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

Troubleshooting

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

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

Commissioning/service report.......................................................................... 61

Specification....................................................................................................... 66

Certificates

Declaration of conformity...................................................................................... 69

Manufacturer's certificate according to the 1st BImSchV [Germany]................... 69

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

Index

5692 681 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............. 7

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

system............................................................................. 7

•3. Filling siphon with water................................................ 7

••• 4. Starting the heating system........................................... 7

•5. Checking the gas type.................................................... 9

•6. Conversion 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

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

• • 17. Checking all heating water 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

Commissioning, inspection, maintenance

Steps – commissioning, inspection and maintenance

5692 681 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. Installing the burner....................................................... 26

• • 25. Checking both gas train valves for tightness (for 115

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

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

elements in the gas supply pipe.

••• 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............................................ 30

••• 31. Checking the function of safety valves

• • 32. Checking the diaphragm expansion vessel and

system pressure............................................................. 31

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

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

• • 35. Checking the ventilation apertures in the installation

room (only for open flue operation)

•36. Instructing the system user........................................... 32

•37. Operating and service documents................................ 32

Commissioning, inspection, maintenance

Steps – commissioning, inspection and… (cont.)

5692 681 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 serv-

ice instructions

Filling the heating system with water and venting the system

Record the fill volume, water hardness

and pH value on page 30 and 31.

Note

Observe the "Water quality require-

ments" on page 62.

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: 4 bar

Commissioning, inspection, maintenance

Further details regarding the individual steps

5692 681 GB

2. For open flue operation: Check that

the installation room ventilation aper-

ture is open.

3. Check the gas supply pressure.

4. Open the gas supply pipe shut-off

valves.

5. Switch ON the main isolator (outside

the installation room).

A B

6. Switch ON system ON/OFF switch

B at the control unit. If fault indicator

lamp A at the control unit illuminates

and burner control unit display C

flashes, first press reset button D 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). Vent 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 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 681 GB

9. Check all gaskets/seals and plugs,

and retighten if necessary.

Note

We recommend you check all heating

water connections for leaks after

approx. 500 hours (see page 22).

10. Check the boiler door and clean-out

cover a few days after commission-

ing 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/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 in accordance with

details provided by your gas supply

utility to a different gas type (see

page 9).

3. Record the gas type in the service

report (on page 61).

Conversion to natural gas LL

Conversion for 87 kW

01. Close the gas shut-off valve.

02. Switch OFF the control unit ON/OFF

switch.

03. Switch OFF the main isolator (out-

side the installation room) or the

power supply and prevent unauthor-

ised reconnection.

04. Undo fitting A.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 681 GB

05. Remove the venturi mixer tube H

from the gas fan.

Pull off the compensation line E

when operating the boiler in bal-

anced flue mode.

06. Release the gas train from flange

07. Remove restrictor C with gasket

D from venturi mixer tube 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 mixer tube H at the

gas fan.

Push compensation line E onto the

mixer tube when operating the

boiler in balanced flue mode.

10. Secure and tighten fitting A.

11. Affix enclosed label "Adjusted to ..."

F above 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 control unit ON/OFF

switch.

03. Switch OFF the main 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 681 GB

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