Viessmann VITOCROSSAL 200 Istruzioni operative
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.
2
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
Safety instructions
5692 908 GB
3
■ 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
4
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
5
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
Index
5692 908 GB
6
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
7
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
8
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
9
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
10
6.
A B
D
C
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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