Viessmann VITOCROSSAL 200 Istruzioni operative

VIESMANN

Service instructions

for contractors

Vitocrossal 200

Type CT2

Gas fired condensing boiler with MatriX cylinder burner

for natural gas E and LL

For applicability, see the last page

VITOCROSSAL 200

5692 759 GB 5/2008 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 equipment must only

be carried out by a qualified gas fit-

ter.

&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,

&theCodeofPracticeofrelevant

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 result in

serious injury.

&Never smoke. Prevent naked

flames and sparks. Never

switch lights or electrical

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.

&Closealldoorsleadingtothe

living space.

Safety instructions

5692 759 GB

Workingonthesystem

&When using gas as fuel, also close

the main gas shut-off valve and

safeguard against unauthorised

reopening.

&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 main isolator.

&Safeguard the system against

unauthorised reconnection.

!Please note

Electronic modules can be

damaged 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

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/conversion can

compromise safety and may

invalidate our warranty.

For replacements, use only ori-

ginal spare parts from

Viessmann or those which are

approved by Viessmann.

Safety instructions (cont.)

Safety instructions

5692 759 GB

Commissioning, inspection, maintenance

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

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

Troubleshooting

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

Gas burner control unit flow chart

Burner control unit flow diagram.................................................................. 48

Connection diagrams

Burner control unit connection diagram ....................................................... 50

Mains filter unit connection diagram ............................................................ 51

Component overview................................................................................ 52

Control unit

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

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

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

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

Certificates

Declaration of conformity ............................................................................ 68

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

Keyword index .......................................................................................... 70

Index

5692 759 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 the siphon with water............................................. 7

••• 4. Starting the heating system .............................................. 8

•5. Checking the gas type......................................................... 10

•6. Conversion to natural gas LL ........................................... 10

••• 7. Checking the static and the supply pressure............. 11

••• 8. Checking the CO2content ................................................. 13

••• 9. Checking the CO content

••• 10. Checking the flue gas temperature

•• 11. Checking the ionisation current ...................................... 16

•• 12. Shutting down the system ................................................. 17

•• 13. Opening the boiler door...................................................... 17

•• 14. Separating the neutralising system (if installed)

from the boiler and connecting the drain hose.......... 19

•• 15. Cleaning the combustion chamber and heating

surfaces.................................................................................... 19

•• 16. Checking gaskets and thermal insulation

components ............................................................................ 20

•• 17. Checking all connections on the heating water

side for leaks .......................................................................... 20

•• 18. Cleaning and reconnecting the condensate drain

system....................................................................................... 21

•• 19. Checking the condensate drain and the

neutralising system (if installed) .................................... 22

•• 20. Checking the burner gauze assembly........................... 22

Steps –commissioning, inspection and maintenance

Commissioning, inspection, maintenance

5692 759 GB

Commissioning steps

Inspection steps

Maintenance steps Page

!!!



•• 21. Checking the ignition and ionisation electrodes ...... 23

•• 22. Closing the boiler door ....................................................... 23

•• 23. Cleaning the burner ............................................................. 23

•24. Installing the burner............................................................. 24

•• 25. Checking both gas train valves automatically for

gas-tightness ......................................................................... 25

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

elements in the gas pipe

••• 27. Checking all gas connections for tightness ............... 25

••• 28. Checking the rotary damper setting .............................. 26

•29. Implementing final tests..................................................... 27

•• 30. Checking the water quality................................................ 27

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

•• 32. Expansion vessel and system pressure check ......... 29

•• 33. Checking the flue gas header for tightness................ 30

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

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

•36. Checking the function of the flue gas system

•• 37. Checking the ventilation apertures in the

installation room (only for open flue operation)

•38. Instructing the system user .............................................. 30

•39. Operating and service documents ................................. 31

Steps –commissioning, inspection and . . . (cont.)

Commissioning, inspection, maintenance

5692 759 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,

setittoamaximumof110°C.

Control unit installation and

service instructions

Filling the heating system with water and venting the system

Record the fill volume, water hard-

ness and pH value on page 28

and 29.

Note

Observe the "Water quality require-

ments" on page 62.

Filling the 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.

Further details regarding the individual steps

Commissioning, inspection, maintenance

5692 759 GB

Starting the heating system

Control unit operating and service instructions, and neutralising system

operating instructions

1. Check the heating system pres-

sure.

Permissible boiler operating pres-

sure: 5.5 bar

2. For open flue operation: Check

that the installation room ventila-

tion is unobstructed.

3. Check the gas supply pressure.

4. Open the gas supply line shut-off

valves.

5. Switch ON the main isolator (out-

side the installation room).

Further details regarding the individual steps (cont.)

Commissioning, inspection, maintenance

5692 759 GB

6. Switch ON system ON/OFF

switch Bat the control unit. If

fault indicator Aat the control

unit illuminates and burner control

unit display Cflashes, first press

reset Dat the burner control

unit.

Note

The system can enter a fault state

during commissioning, if the sup-

ply line carries insufficient gas

(the fault indicator at the control

unit illuminates). Ventilate the gas

supply line again and reset the

burner control unit.

7. Match the coding at the boiler

control unit according to the table

on page 54.

Control unit installation

and service instructions

8. Check the function of the neutra-

lising system, including the

hydraulic seal in the siphon.

Neutralising system oper-

ating instructions

9. 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 20).

10. A few days after commissioning,

check the boiler door and flue gas

box lid, and retighten all screws.

Further details regarding the individual steps (cont.)

Commissioning, inspection, maintenance

5692 759 GB

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

(43.2to58.0MJ/m

&With the natural gas LL setting,

the boiler can be operated in the

Wobbe index range 10.0 to 13.1

kWh/m

(36.0to47.2MJ/m

2. In the delivered condition, the burn-

er is set up for natural gas E. If

required, convert the burner in

accordance with details provided

by your gas supply utility to a differ-

ent gas type (see page 10).

3. Record the gas type in the service

report (on page 61).

Conversion to natural gas LL

(not in aand c)

1. Close the gas shut-off valve.

2. Switch OFF the control unit ON/

OFF switch.

3. Switch OFF the main isolator (out-

side the installation room) or the

power supply and prevent

unauthorised reconnection.

4. Pull cables from gas train.

5. Undo fitting A.

6. Pull compensation hose Gfrom

gas train.

Further details regarding the individual steps (cont.)

Commissioning, inspection, maintenance

5692 759 GB

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