Viessmann Vitocrossal CRU 1000 Service Instructions For Contractors

Service instructions

for contractors

Vitocrossal

Type CRU, 800 and 1000 kW

Gas condensing boiler

For open flue and room sealed operation

Permissible operating pressure 6 bar

VITOCROSSAL

VIESMANN

5833296 GB 6/2018 Please keep safe.

2

Safety instructions

Safety instructions

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.

Target group

These instructions are exclusively intended for qualified contractors.

Note

Details identified by the word "Note" contain additional information.

■

■

■

Work on gas installations may only be carried out by a registered gas fitter.

Work on electrical equipment may 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 to be observed

■

■

■

■

■

National installation regulations

Statutory regulations for the prevention of accidents

Statutory regulations for environmental protection

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 a ÖNORM, EN, ÖVGW G K directives, c

ÖVGW-TRF and ÖVE

SEV, SUVA, SVGW, SVTI, SWKI, VKF and

EKAS guideline 1942: LPG, part 2

Safety instructions for working on the system

Working on the system

■

■

■

■

Where gas is used as the fuel, close the main gas shut-off valve and safeguard it against unintentional reopening.

Isolate the system from the power supply, e.g. by removing the separate fuse or by means of a mains isolator, and check that it is no longer live.

Safeguard the system against reconnection.

Wear suitable personal protective equipment when carrying out any work.

Danger

Hot surfaces and fluids can lead to burns or scalding.

■ Before maintenance and service work, switch

■

OFF the appliance and let it cool down.

Never touch hot surfaces on the boiler, burner, flue system or pipework.

!

Please note

Electronic assemblies can be damaged by electrostatic discharge.

Prior to commencing 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 the system.

Replace faulty components only with genuine

Viessmann spare parts.

Safety instructions

Safety instructions

(cont.)

!

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-authorised components and making non-approved modifications or conversions can compromise safety and may invalidate our warranty.

For replacements, use only original spare parts supplied or approved by Viessmann.

Safety instructions for operating the system

If you smell gas

Danger

Escaping gas can lead to explosions which may result in serious injury.

■ Do not 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.

■

■

■

Evacuate any people from the danger zone.

Notify your gas or electricity supply utility from outside the building.

Have the power supply to the building shut off from a safe place (outside the building).

If you smell flue gas

Danger

Flue gas can lead to life threatening poisoning.

■

■

Shut down the heating system.

Ventilate the installation site.

■ Close doors to living spaces to prevent flue gases from spreading.

What to do if water escapes from the appliance

Danger

If water escapes from the appliance there is a risk of electrocution.

Switch OFF the heating system at the external isolator (e.g. fuse box, domestic distribution board).

Danger

If water escapes from the appliance there is a risk of scalding.

Never touch hot heating water.

Condensate

Danger

Contact with condensate can be harmful to health.

Never let condensate touch your skin or eyes and do not swallow it.

Flue systems and combustion air

Ensure that flue systems are clear and cannot be sealed, for instance due to accumulation of condensate or other external causes.

Avoid continuous condensate disposal with a wind protector.

Ensure an adequate supply of combustion air.

Inform system users that subsequent modifications to the building characteristics are not permissible (e.g.

cable/pipework routing, cladding or partitions).

Danger

Leaking or blocked flue systems, or an inadequate supply of combustion air can cause life threatening poisoning from carbon monoxide in the flue gas.

Ensure the flue system is in good working order.

Vents for supplying combustion air must be nonsealable.

Extractors

Operating appliances that exhaust air to the outside

(extractor hoods, extractors, air conditioning units, etc.) can create negative pressure. If the boiler is operated at the same time, this can lead to a reverse flow of flue gas.

Danger

The simultaneous operation of the boiler and appliances that exhausts air to the outside can result in life threatening poisoning due to a reverse flow of flue gas.

Fit an interlock circuit or take suitable steps to ensure an adequate supply of combustion air.

3

4

Index

Index

1. Information

2. Commissioning, inspection, maintenance

3. Burner control unit

4. Troubleshooting

5. Parts lists

6. Component overview

7. Function description

8. Connection diagrams

9. Reports

10. Specification

11. Final decommissioning

12. Certificates

13. Keyword index

Symbols .................................................................................................

5

Intended use ..........................................................................................

5

Product information ................................................................................

6

■ System examples ...............................................................................

6

Steps - commissioning, inspection and maintenance ............................

7

Burner control unit VUC 310 .................................................................. 31

■ Display and programming unit ............................................................ 31

■

■

Operating display ................................................................................ 31

Selecting the menu ............................................................................. 32

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■

■

■

Calling up information and resetting meters ....................................... 32

Changing the configuration ................................................................. 33

Resetting operating parameters to their delivered condition .............. 35

Setting the modulation level for manual operation ............................. 35

Flow diagram for burner start ................................................................. 36

■ Description of state ............................................................................. 37

Fault display ........................................................................................... 38

■ Calling up the fault history (fault memory) .......................................... 38

Fault codes with display on burner control unit ...................................... 39

■ General process errors: Displayed fault codes ................................... 39

■ Internal system faults: Displayed fault codes and detailed fault codes .................................................................................................. 42

Faults without fault display ..................................................................... 43

Overview of assemblies ......................................................................... 45

Boiler assembly ..................................................................................... 46

Casing assembly ................................................................................... 48

MatriX-Disk burner assembly ................................................................. 50

Burner control unit assembly ................................................................. 52

Vitotronic control unit assembly ............................................................. 54

Overview of burner components ............................................................ 56

Air pressure switch ................................................................................ 57

■ Fan pressure monitoring function (LDW1) .......................................... 57

■ Combustion chamber pressure monitoring function (LDW2) .............. 57

Boiler water temperature sensors and flue gas temperature sensors ... 57

Burner control unit connection diagram ................................................. 58

................................................................................................................ 61

................................................................................................................ 64

Final decommissioning and disposal ..................................................... 67

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

Manufacturer's certificate according to the 1st BImSchV [Germany] .... 68

................................................................................................................ 69

Information

Symbols

Symbol Meaning

1.

Reference to other document containing further information

Step in a diagram:

The numbers correspond to the order in which the steps are carried out.

Warning of material losses and environmental pollution

Live electrical area

Pay particular attention.

■

■

Component must audibly click into place.

or

Acoustic signal

■

■

Fit new component.

or

In conjunction with a tool: Clean the surface.

Dispose of component correctly.

Dispose of component at a suitable collection point. Do not dispose of component in domestic waste.

The steps in connection with commissioning, inspection and maintenance are found in the "Commissioning, inspection and maintenance" section and identified as follows:

Symbol Meaning

Steps required during commissioning

Not required during commissioning

Steps required during inspection

Not required during inspection

Steps required during maintenance

Not required during maintenance

Intended use

The appliance is only intended to be installed and operated in sealed unvented heating systems that comply with EN 12828, with due attention paid to the associated installation, service and operating instructions as well as the details in the datasheet.

It is only designed for the heating up of heating water.

Commercial or industrial usage for a purpose other than the heating up of heating water shall be deemed inappropriate.

Intended use presupposes that a fixed installation in conjunction with permissible components designed for this purpose has been carried out.

Every other use will be deemed to be inappropriate.

Any resulting losses are excluded from the manufacturer's liability.

Any usage beyond this must be approved by the manufacturer for the individual case.

Intended use also includes the adherence to maintenance and inspection intervals.

5

6

Information

Product information

Vitocrossal, type CRU

■ Gas condensing boiler, 800 kW and 1000 kW rated heating output with modulating MatriX-Disk burner for natural gas E and natural gas LL

■ Permissible operating pressure for the heating system: 6 bar/0.6 MPa.

System examples

For available system examples, see www.viessmannschemes.com

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

Commissioning steps

Inspection steps

Maintenance steps Page

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1. Filling the heating system with water and venting the system ......................................

9

2. Filling the trap with water ..................................................................................................

9

3. Checking the sensor well and all connections on the heating water side for tightness ............................................................................................................................. 10

4. Checking the electrical connections ................................................................................ 11

5. Checking the gas type ....................................................................................................... 11

6. Setting the gas type ........................................................................................................... 12

7. Commissioning the system ............................................................................................... 12

8. Checking the flue gas damper .......................................................................................... 13

9. Reducing the maximum heating output (if required) ...................................................... 14

10. Checking the static pressure and supply pressure ........................................................ 14

11. Measuring the CO

2

content ............................................................................................... 16

12. Measuring the CO content ................................................................................................. 17

13. Measuring the flue gas temperature ................................................................................. 17

14. Checking the ionisation current ....................................................................................... 17

15. Shutting down the system ................................................................................................. 18

16. Opening the boiler .............................................................................................................. 19

17. Opening the combustion chamber ................................................................................... 20

18. Cleaning the combustion chamber and heating surfaces ............................................. 20

19. Cleaning the burner ........................................................................................................... 22

20. Checking the burner door ................................................................................................. 22

21. Checking the burner gauze assembly .............................................................................. 23

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

23. Fitting the burner ................................................................................................................ 24

24. Closing the combustion chamber .................................................................................... 24

25. Checking the gas train valves for tightness .................................................................... 25

26. Checking the gas train filter element ............................................................................... 26

27. Checking the filter element in the gas line ...................................................................... 26

28. Checking the gas connections for tightness ................................................................... 26

29. Cleaning the condensate drain pipe and trap ................................................................. 27

30. Checking the condensate drain and the neutralising system (if installed) .................. 28

31. Closing the boiler casing ................................................................................................... 28

32. Checking the expansion vessel ........................................................................................ 28

33. Checking the water quality ................................................................................................ 28

34. Checking the gaskets on the flue gas side ...................................................................... 28

35. Performing final checks ..................................................................................................... 29

36. Checking the safety valve function

37. Checking the mixer for ease of operation and leaks ...................................................... 29

38. Checking the thermal insulation for firm seating

7

8


Steps - commissioning, inspection and…

(cont.)

Commissioning steps

Inspection steps

Maintenance steps Page

• • •

• • •

•

39. Checking the flue system for unrestricted flow and tightness ...................................... 30

40. Checking the installation room ventilation air apertures ............................................... 30

41. Instructing the system user .............................................................................................. 30

!


Filling the heating system with water and venting the system

Please note

Unsuitable water quality can damage the boiler body.

Only fill the boiler with water that complies with

the "Water quality requirements": See page 59

Enter the amount of fill water, water hardness and pH

value in the log on page 61.

Filling the trap with water

A B

Fig. 1

A

B

Trap lower section

Condensate drain hose

1. Undo lower section of trap. Fill the lower section with water.

Danger

If the trap is not full, flue gas can escape.

Escaping flue gas can cause life threatening carbon monoxide poisoning.

Always fill the trap with water before commissioning.

2. Check that the condensate can drain freely.

3. Refit lower trap section.

9


Checking the sensor well and all connections on the heating water side for tightness

A

B

C

D

E

F

Fig. 2

C

D

E

F

G

H

A

B

Female connection for control equipment: R ½

Boiler flow: PN 6, DN 100 with sensor well for boiler water temperature sensor

Female connection for pressure limiter: R ½

Safety connection (safety valve): R 2

Boiler return 2: PN 6, DN 100

Boiler return 1: PN 6, DN 100

Drain outlet: R 1 ¼

Condensate drain: R ½

Check the connection for the sensor well and the minimum pressure switch (low water indicator) for tightness.

10

H

G


Checking the electrical connections

Check all electrical connections for firm seating.

With control cables also check:

■ Connection and kink-free routing

■ Application and seating of retaining clips

Checking the gas type

1. Check with your gas supply utility regarding the gas type and Wobbe index W s

(0 °C;

1013.25 mbar).

The boiler can be operated in the following Wobbe index ranges:

■ With natural gas E:

Wobbe index range 12.0 to 16.1 kWh/m 3 (43.2 to

■

58.0 MJ/m 3 )

With natural gas LL:

Wobbe index range 10.0 to 13.1 kWh/m 3 (36.0 to

47.2 MJ/m 3 )

2. In the delivered condition, the burner is set up for natural gas E. If required, change the gas type setting to natural gas LL: See chapter "Setting the gas

type", page 12

3.

Record the gas type in the report on page 62.

11


Setting the gas type

In the delivered condition, the boiler is preset for natural gas E and can be changed over to natural gas LL.

The setting can later be changed back to natural gas E.

A

Fig. 3

A Adjusting screw

1. Turn the adjusting screw on the main volume butterfly of the gas train fully towards " – ".

2. Turn the adjusting screw in direction " + " as detailed in the table below:

Rated heating output

800 kW

1000 kW

Natural gas LL

5 turns

7 turns

3. Start the burner.

4. Measure the CO

2

content in the flue gas and

adjust: See page 16.

Natural gas E

4 turns

6 turns

Commissioning the system

Danger

CO build-up as a result of incorrect burner adjustment or flue gas system leakage can have serious health implications.

Always carry out a CO test before and after work on gas appliances.

■

■

■ Vitotronic control unit operating instructions and service instructions

Neutralising system operating instructions

Flue system installation instructions

12


Commissioning the system

(cont.)

Fig. 4

1. Check the heating system pressure.

Permiss. operating pressure

Minimum operating pressure

6 bar (0.6 MPa)

0.5 bar (50 kPa)

Danger

If the operating pressure is too low, excess temperatures in the flue system can cause leaks. Escaping flue gas can cause life threatening carbon monoxide poisoning.

Ensure the minimum operating pressure with a minimum pressure switch.

2. For open flue operation: Check that the ventilation facility in the installation room is open.

3. Open the gas line shut-off valves.

4.

Check the static pressure. See page 15.

5. Check the setting at air pressure switch 1 A :

■ Rated heating output 800 kW: 2 mbar (0.2 kPa)


6. Switch ON the mains isolator (outside the installation room).

7. Switch on the ON/OFF switch at the programming unit of the control unit.

Vitotronic operating instructions

Note

During commissioning, the appliance may enter a fault state due to remaining airlocks in the gas line:

"Burner fault" and are shown on the display

■

■

Purge the gas line again.

Reset burner:

to acknowledge the fault message

to reset the burner.

8. Check all gaskets and plugs, and retighten if necessary.

Note

Recommendation: Check all connections on the heating water side for leaks after approx.

500 hours run. See page 10.

Checking the flue gas damper

Where present: Check the motorised flue gas damper

(flue gas cascade accessory).

The flue gas damper must be closed in its zero volt state (plug gD ).

13


Reducing the maximum heating output (if required)

The maximum heating output of the burner can be reduced if required.

Programming unit on the burner control unit

Status Service

R

Fig. 5

S

Press the following buttons:

1. Press and hold S for longer than 2 s, flashes.

2. repeatedly, until "6" is shown under "Service".

3. S to confirm, "6" is shown under "Status" and "1" is shown under "Service".

4. S to confirm, "1" is shown under "Status". The current value for the maximum heating output in % is shown under "Service".

5. Use or to select the required maximum heating output.

6. S to confirm. If adopted successfully, "1" is shown under "Service"; if it failed, "0" will appear.

7. S to change to the operating display.

8. R , the system will be restarted.

Checking the static pressure and supply pressure

A

Fig. 6

A Test connector

14



(cont.)

Static pressure

1. Close the gas shut-off valve.

2. Undo the screw in test connector A . Do not remove the screw.

3. Connect the pressure tester at test connector A .

4. Open the gas shut-off valve.

5. Measure the static pressure: Max. 100 mbar

(10 kPa).

Note

The max. static pressure corresponds to the max.

permissible gas pressure at the burner to allow for safe commissioning of the appliance.

6. Record the actual value in the report.

Supply pressure

1. Activate emissions test mode.

Vitotronic control unit operating instructions

2. Measure the supply pressure (flow pressure) at rated heating output.

Natural gas E/LL

■ Set value: 17 to 25 mbar (1.7 to 2.5 kPa)

■ Nominal supply pressure: 20 mbar (2 kPa)

Note

■ The nominal supply pressure can differ from these values subject to region; see type plate of the burner.

■ The gas pressure switch on the gas train is set to

15 mbar (1.5 kPa).

i.e. the burner cannot be operated at a gas supply pressure below 15 mbar (1.5 kPa).

Note

Use a suitable measuring device with a resolution of at least 0.1 mbar (0.01 kPa) to check the supply pressure.

3. Record the actual value in the report.

4. Switch off the ON/OFF switch at the programming unit of the Vitotronic control unit.


6.

7.

Remove pressure gauge. Close test connector with the screw.

Open the gas shut-off valve. Start up the appliance. Check gas tightness at test connector

Danger

A .

A

Gas escaping from the test connector leads to a risk of explosion.

Check for gas tightness.

Supply pressure

(flow pressure) natural gas E and LL

< 15 mbar

< 1.5 kPa

15 to 17 mbar

1.5 to 1.7 kPa

Measure

Do not make any adjustments.

Notify the gas supply utility.

Please note: The boiler may only be operated temporarily with this setting (emergency mode).

Notify the gas supply utility.

15



(cont.)

Supply pressure

(flow pressure) natural gas E and LL

17 to 25 mbar

1.7 to 2.5 kPa

> 25 mbar

> 2.5 kPa

Measure

Start the boiler.

Install a separate gas pressure governor with zero off upstream of the boiler system. Set it to 20 mbar (2 kPa) (nominal supply pressure).

Note

The nominal supply pressure must be set subject to regional conditions, see type plate of the burner.

Measuring the CO

2

content


Status Service

R

S

Fig. 7

Adjusting screws on the gas train

B A

Fig. 8

0 1. Check control cables:

■

■

Connection and kink-free routing

Fixing and firm seating of the connecting points

0 2. Open the gas shut-off valve.

0 3. Activate emissions test mode.


0 4. On the burner control unit, hold down S + simultaneously for longer than 2 s.

■

■

"P" is displayed under "Status" (controlled stop).

The current modulation level in % is shown under "Service".

0 5. To measure the CO2, set the upper and lower heating output in turn:

■ Upper heating output:

Press until "100" ( ≙ 100 %) is shown under

"Service".

■ Lower heating output:

Press until "0" ( ≙ 0 %) is shown under "Service".

0 6. Measure the CO

2

content at the flue pipe.

For permissible CO

2

content, see the table.

Note

At the lower heating output, the CO

2

content must always be lower than at the upper heating output.

16


Measuring the CO

2

content

(cont.)

0 7. If the CO

2

content lies outside the specified range:

■ Upper heating output:

Turn adjusting screw A in very small incre-

■ ments until the CO

2

content is within the specified range.

Lower heating output:

Turn adjusting screw B in small increments until the CO

2

content is within the specified range.

Rotational direction of adjusting screws A and

B :

■

■

Direction " – ": CO

2

content falls .

Direction " + ": CO

2

content rises .

Permissible CO

2

content

Gas type

Natural gas E

Wobbe index W s

12.0 to 16.1 kWh/m 3

(0 °C; 1013.25 mbar)

Natural gas LL

Wobbe index W s

10.0 to 13.1 kWh/m 3

(0 °C; 1013.25 mbar)

0 8. Check the CO

2

content at the upper and lower

0 9. heating output again.

If required, set the CO

2

content for the upper and lower heating output again.

Enter the actual values into the report.

10. On the burner control unit, press and hold S and simultaneously for longer than 2 s. Burner

Heating output switches to operating mode.

Upper heating output (100 %)

Lower heating output (0 %)

Upper heating output (100 %)

Lower heating output (0 %)

CO

8.9

7.9

8.8

7.8

2

±

±

±

±

content, dry

0.1 %

0.1 %

0.1 %

0.1 %

Measuring the CO content

Enter the actual value in the service report.

Measuring the flue gas temperature

Enter the actual value in the service report.

Checking the ionisation current

Note

The ionisation current can only be called up via the programming unit of the burner control unit. It is not possible to measure it with Testomatik-Gas or a multimeter.


Status Service

R

Fig. 9

S

Press the following buttons:

0 1. Press and hold S for longer than 2 s, flashes.

0 2. repeatedly, until "5" is shown under "Service".

0 3. S to confirm, "5" is shown under "Status".

0 4. repeatedly, until "3" is shown under "Service".

0 5. S to confirm, "3" is shown under "Status". During operation, the actual ionisation current is shown under "Service" (e.g. 30 ≙ 3.0 µ A).

0 6. Activate emissions test mode.


17


Checking the ionisation current

(cont.)

0 7. Read the ionisation current.

0 8. Enter the actual value in the service report.

0 9. Press and hold S for longer than 2 s, flashes.


11. S to confirm, "5" is shown under "Status".



Shutting down the system

1. Isolate the system from the power supply, e.g. by removing the separate fuse or by means of a mains isolator, and check that it is no longer live.

Safeguard the system against reconnection.

Danger

An electric shock can be life threatening.

Before opening the boiler, disconnect it from the mains voltage, e.g. at the fuse or mains isolator.


18

Fig. 10

1.

Opening the boiler

4.


2.

3.

2x

19


Opening the combustion chamber

5.

1.

4. 6x

2.

Fig. 11

Danger

Serious injuries can result from the burner door falling shut.

Secure the burner door against unintentional closure.

!

Please note

Scratches inside the combustion chamber can lead to corrosion damage.

Never place tools or other objects inside the combustion chamber.

20

Cleaning the combustion chamber and heating surfaces

!

Please note

Scratches inside the combustion chamber or on components that come into contact with flue gas can lead to corrosion damage.

■ Only clean with synthetic brushes, never use

■ wire brushes or sharp objects.

Never place tools or other objects inside the combustion chamber.

To clean, thoroughly flush the heating surfaces with a jet of water.


Cleaning the combustion chamber and heating…

(cont.)

For stubborn residues, surface stains or soot deposits, cleaning agents can be used under the following conditions:

■ Only use solvent-free cleaning agents. Ensure that

■ no cleaning agent gets between the boiler body and the thermal insulation.

Remove soot deposits with an alkaline cleaning agent with surfactant additive (e.g. Fauch 600).

■

■

Remove coatings and surface discolouration (yellowbrown) with slightly acidic, chloride-free cleaning agents based on phosphoric acid (e.g. Antox 75 E).

Remove loose deposits from the boiler; thoroughly flush the heating surfaces and the flue gas collector with a water jet.

Cleaning agent manufacturer's instructions

Recommendation:

"Fauch 600" and "Antox 75 E"

Manufacturer:

Hebro Chemie GmbH

Rostocker Strasse 40

D-41199 Mönchengladbach

21


Cleaning the burner

1.

5.

4.

3.

10x

8x

3.

A

6.

B

2.

Fig. 12

4. Press and hold the blue ring on the push-fit connector to remove the compensation lines from the gas train and fan. Carefully pull off the hose.

7. Using compressed air, carefully clean the fitting with swirl plate A .

Carefully vacuum burner gauze assembly B from inside. Remove any dirt with compressed air.

Do not damage the mesh of the burner gauze assembly.

Checking the burner door

1. Check the gaskets and packing cords in the burner door for damage.

22

2. Check the thermal insulation components on the burner door for damage.

Checking the burner door

(cont.)

3. Replace any damaged seals/gaskets, packing cords and thermal insulation components.

Checking the burner gauze assembly


A

B

Fig. 13

1. Check burner gauze assembly A and thermal insulation block B for damage.

2. If a component is visibly damaged, replace the component.

Installation instructions "Replacing burner components"

23

24


Checking the ignition electrodes and ionisation electrode

Ignition electrodes Ionisation electrode

±1

17 ± 2

4 ± 1

Fig. 14

Check the ignition electrodes and ionisation electrode for the correct gap to the burner gauze assembly and for possible damage. Replace the electrodes if required.

Installation instructions "Replacing burner components"

Fitting the burner

!

Reassemble the burner in reverse order to Fig. 12

above.

Fit the gas supply pipe with a new gasket.

Danger

Leaks can result in poisoning through escaping gas.

Ensure that all gaskets are seated correctly.

Please note

Mechanically loaded connections lead to leaks and appliance damage.

Ensure the intake extension and gas connection are kept free of load and torque stress.

Closing the combustion chamber

Close the combustion chamber in reverse order: See

Fig. 11, page 20

Fig. 15

Danger

Escaping gas leads to a risk of explosion.

Check the fittings and the gasket between the fan casing and the burner door for gas tightness.

Closing the combustion chamber

(cont.)


Tighten the burner door screws diagonally to a torque of 30 Nm.

Danger

Leaks from the burner door can result in poisoning through escaping gas.

Check the burner door for flue gas tightness, e.g. with inspection mirror, gas sensor or thermal image camera.

In the case of leaks, retighten diagonally to

40 Nm.

Check the flue gas tightness again.

Checking the gas train valves for tightness

A B

Fig. 16


2. Undo screw in test connector B . Do not remove the screw.

3. Connect the pressure gauge at test connector B .

4. Using the pressure gauge, carefully build a test pressure of approx. 50 mbar (5 kPa).

5. Wait approx. 5 min for the temperature to level out.

Then observe the display on the pressure tester:

The gas train is gas-tight if the displayed pressure does not drop by more than 1 mbar (0.1 kPa) within a further 5 min.

Otherwise, replace the gas train.

25


Checking the gas train valves for tightness

(cont.)

6. After completing the test, close the screw on test connector B . Check the test connector for leaks.

Danger


Check the test connector for gas tightness.

!

Please note

The use of leak detection spray can result in faulty operation.

Leak detection spray must not come into contact with electrical contacts.

Note

Only use suitable and approved leak detection agents (EN 14291) and devices for the tightness test. Leak detection agents with unsuitable constituents (e.g. nitrides, sulphides) can cause material damage.

Remove residues of the leak detection agent after testing.

Checking the gas train filter element

1. Close the gas shut-off valve. Unscrew intake flange from the gas train.

2. Check the filter at the gas train intake for contamination. Remove the filter and carefully clean with compressed air or replace.

3. Reassemble the gas train in reverse order using new gaskets.

4. Check for gas tightness.

Danger


Check the gas train for gas tightness.

!

Please note



Note

Only use suitable and approved leak detection agents (EN 14291) and devices for the tightness test. Leak detection agents with unsuitable constituents (e.g. nitrides, sulphides) can cause material damage.


Checking the filter element in the gas line

If a filter element is fitted in the gas line, check the filter element and clean or replace if necessary.

Manufacturer's instructions for filter element

Checking the gas connections for tightness

Danger


Check all gas equipment for tightness.

1. Insert new gaskets in all gas fittings that have been opened and retighten them.

26


Checking the gas connections for tightness

(cont.)

2. Open the gas shut-off valve.

3. Check the inlet joints of the gas train for tightness.

!

4.

Commissioning the system (see page 12).

Please note



5. Check for tightness:

■ Outlet joints of the gas train

■

■

Joint between the fan and the fitting

Joint between the fan and the supply air collector

Note

Only use suitable and approved leak detection agents

(EN 14291) and devices for the tightness test. Leak detection agents with unsuitable constituents (e.g.

nitrides, sulphides) can cause material damage.


Cleaning the condensate drain pipe and trap

Note

Clean the condensate drain pipe and trap at least once a year.

A B

Fig. 17

1. Disconnect neutralising system condensate drain hose B from trap A .

2. Connect the cleaning hose to the trap and route it to the drainage system.

3. Clean the inside of the condensate drain pipe

(hose, pipes) and trap A .

4. Fill the lower section of trap A with water and secure.

Danger

If the trap is not full, flue gas can escape.

Escaping flue gas can cause life threatening carbon monoxide poisoning.

Always fill the trap with water.

5. Reconnect the condensate drain hose for the neutralising system to the trap. Route the condensate drain hose without kinks and with a constant fall.

27


Checking the condensate drain and the neutralising system (if installed)

1. Fill the combustion chamber with water.

Note

The water must flow from the condensate drain pipe without backing up.

If necessary, clean the condensate drain pipe again.

2. Check the function of the neutralising system.


3. If necessary, clean the neutralising system in accordance with the manufacturer's instructions.


Note

Neutralising medium from Viessmann Werke

GmbH & Co. KG, part no. 9521702.

4. Check entire condensate drain pipe for leaks.

Closing the boiler casing

Close the boiler again in reverse order to Fig. 10 on page 19.

Checking the expansion vessel

Note

Observe the manufacturer's instructions for the expansion vessel.

Carry out this test on a cold system.

1. Drain the system until the pressure gauge indicates "0" or close the cap valve on the expansion vessel and reduce the pressure in the expansion vessel.

2. If the expansion vessel pre-charge pressure is lower than the static system pressure, top up with nitrogen. Top up with nitrogen until the pre-charge pressure is 0.1 to 0.2 bar (10 to 20 kPa) higher.

3. Top up with water. The charge pressure of the cooled system must be 0.1 to 0.2 bar (10 to

20 kPa) higher than the pre-charge pressure of the expansion vessel.

Permiss. operating pressure: 6 bar/0.6 MPa

Checking the water quality

Enter the amount of top-up water, the total hardness

and the pH value in the tables on page 61.

For water quality requirements: See page 59.

Checking the gaskets on the flue gas side

Danger

Leaking or blocked flue systems, or an inadequate supply of combustion air, can cause life threatening poisoning from carbon monoxide in the flue gas.



28


Checking the gaskets on the flue gas side

(cont.)

B

C

A

Fig. 18

1. Check the joints between flue gas collector A and boiler back panel for tightness.

Note

Check the gaskets at full load operation, for example using an inspection mirror, gas sensor or thermal image camera. If required, remove the thermal insulation components. Traces of condensate on the outside of flue gas collector A also indicate a leak.

2. Check the flue gas temperature sensor and plug-in connection B for correct seating.

3. Check gasket C with the boiler flue connection for tightness. If necessary, replace the gasket.

Performing final checks

Enter the actual values into the report.

Checking the safety valve function

Checking the mixer for ease of operation and leaks

1. Remove the motorised lever from the mixer handle.

2. Check the mixer for ease of operation.

3. Check the mixer for tightness. Replace the O-ring seals if the mixer leaks.

4. Click the motorised lever into place.

29


Checking the thermal insulation for firm seating

Checking the flue system for unrestricted flow and tightness

Check the tightness of the burner door and the flue gas collector a few days after commissioning.

In the case of leaks, retighten the screws in the burner door with 40 Nm. Retighten the screws of the flue gas collector with 30 Nm.

Danger

Leaking or blocked flue systems, or an inadequate supply of combustion air, can cause life threatening poisoning from carbon monoxide in the flue gas.



Checking the installation room ventilation air apertures

Check that the vent is unobstructed and free from contamination in the case of open flue operation.

Instructing the system user

The system installer should hand the operating instructions to the system user and instruct the user in operating the system.

This includes all components installed as accessories, e.g. remote control units. In addition, the system installer must make the user aware of the required maintenance work.

Operating and service documents

1. Complete and detach the customer registration card:

■

■

Hand system users their section for safekeeping.

Retain the heating contractor's section.

2. File all parts lists, operating and service instructions in the folder and hand this over to the system user.

30

Burner control unit

Burner control unit VUC 310

Display and programming unit

A display and programming unit is integrated into the burner control unit.

The following scans and settings are possible:

■ Operating condition

■

■

Meter, e.g. hours run

Parameter

■

■

Service functions

Fault messages

Status Service

R

Note

Depending on the system configuration, some scans and settings can be carried out on the Vitotronic control unit of the boiler.

Installation and service instructions, Vitotronic control unit operating instructions

S

Fig. 19

A

B

C

D

Reset button

Operating and fault indications:

Heat demand

Burner operation

Maintenance

Fault

Selection key

Cursor keys

Operating display

The operating display indicates the operating status

(start and test functions during burner start), both during standard operation and after pressing reset button

R following fault rectification.

■ Only adjust settings and carry out scans on the burner control unit when in standby.

■

■

Fault indication: See fault codes from page 39

onwards.

The operating display can temporarily be adjusted:

See chapter "Changing the configuration",

page 33.

Pressing reset button R or switching the power connection off and on again will return the operating display to the default display, showing the start and test functions during burner start.

Display in standby mode

Status Service

Fig. 20

31

Burner control unit


(cont.)

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Start and test functions during burner start

"Status" display "Service" display

A

0

1

2

P

3

4

5

6

7

8

U

C

9

10

Note

For further information on the start and test functions during burner start, see "Flow diagram for burner

start", page 36

Meaning

System start-up after power supply "ON"

Standby

System tests, idle state check

Fan ramp-up

Valve and/or relay check

Pre-purge

Pre-ignition

Ignition, flame formation safety time

Flame stabilisation

Operation with flame

After flame post-purge

Dwell program, no air pressure

Dwell program, no gas pressure or mains undervoltage

Forced ventilation if no flame formation has been detected.

Safety shutdown due to flame tear-off

Selecting the menu

Press the following buttons:

1. S for longer than 2 s, until " " flashes.

2.

/ repeatedly, until the required menu is shown under "Service": See table below.

3. S to confirm; the number of the selected menu is shown under "Status".

4.

/ repeatedly, until the required sub-menu is shown under "Service": See following chapter.

5. S to confirm; the number of the selected submenu is shown under "Status" and the value relating to the scan or configuration appears under "Service".

If no other key is pressed within 20 s, the setting or scan is automatically terminated.

5

6

3

4

1

2

Menu overview:

"Service" display Description

Permanent meters for start-ups and hours run

Resettable meters for start-ups and hours run

Software version

Fault history for the last 10 fault messages (fault memory)

Temporarily display process information in the operating display

Configuration of control function operating parameters

Calling up information and resetting meters

The following information can be called up:

■ Menu "1": All meter readings

■ Menu "2": Resettable meter readings and resetting.

■

■

Menu "3": Software version

Menu "4": Fault history, see page 38

32

Burner control unit


(cont.)

3

4

1

2

Overview sub-menu to menu "1" — Calling up all meter readings:


Start counter, 1 digit

Start counter, 1000 digit

Hours run meter, 1 digit

Hours run meter, 1000 digit

4

5

6

1

2

Overview sub-menu to menu "2" — Resetting meter readings:


3

Start counter with reset, 1 digit

Start counter with reset, 1000 digit

Menu point for deleting the start-up meter reading

Hours run meter with reset, 1 digit

Hours run meter with reset, 1000 digit

Menu point for deleting the hours run meter reading

Example: Resetting the hours run meter reading


1. S longer than 2 s; " " flashes.

2.

until "2" is shown under "Service".

3. S to confirm; "2" is shown under "Status". "1" is shown under "Service".

4.

5. S

7. S until "6" is shown under "Service".

to confirm; "6" is shown under "Status".

6. S to confirm the deletion. If deletion was successful, "1" is shown under Service; if it failed, "0" is shown.

to change to the operating display.

Changing the configuration

The following configurations can be carried out:

■ Menu "5": Temporarily display an item of process information in the operating display.

Note

Pressing reset button R or switching the power connection off and on again will return the operating display to the default display, showing the start and test functions during burner start.

■ Menu "6": Set parameters for the control functions of the burner control unit.

The factory settings of the operating parameters depend on the coding card of burner control unit.

The operating parameters can also be set via the

Vitotronic control unit:

Vitotronic control unit installation and service instructions

1

2

3

Overview sub-menu to menu "5" — Temporarily display process information in the operating display:

"Status" display "Service" display: Process information Unit/scale

0 Phase 1

30

Boiler water temperature

Flue gas temperature

Ionisation current

°C

°C

I in 1/10 μ A

33

Burner control unit


(cont.)

Unit/scale

%

% n in 10/min

0 or 1

0 or 1

34

Burner control unit


(cont.)

Example: Changing the maximum operational burner output



2.



4. S to confirm; "1" is shown under "Status". The current value for the maximum operational output in % is shown under "Service".

5. / for the required maximum operational output.

6. S to confirm. If adopted successfully, "1" appears under Service; if it failed, "0" will appear.


Resetting operating parameters to their delivered condition

1. S longer than 2 s, " " flashes.

2.



4.


5. S "1" is shown under "Status" and "dEL" under

"Service".

6. S to confirm. If reset successfully, "1" is shown under Service; if it failed, "0" is shown.


Setting the modulation level for manual operation

The modulation level can be temporarily adjusted for carrying out tests and settings on the gas train, e.g.

setting the max. heating output range.

During this manual operation the demands from the

Vitotronic control unit have no effect.

To call up the service display the burner must be running.

Press the following keys:

1. + S simultaneously for longer than 2 s.

The burner switches to manual mode. "P" is shown under "Status". The current modulation level flashes under "Service".

2.

3.

until the required lower heating output is shown under "Service", e.g. "0" for minimal lower heating output.

Tests and settings for operation at the lower heating output can now be carried out.

until the required upper heating output is shown under "Service", e.g. "100" for maximum upper heating output.

Tests and settings for operation at the upper heating output can now be carried out.

4. + S simultaneously for longer than 2 s.

Manual operation is terminated.

35

Burner control unit

Flow diagram for burner start

Fig. 21

36

Aux. valve/ Servomotor

Flow diagram for burner start

(cont.)

Description of state

Phase

System start

"Service" display

"A"

Relay test

Standby

Start-up

Operation

Shutdown

Waiting

Fault status

"P"

"0"

"1"

"2"

"3"

"4"

"5"

"6"

"7"

"8"

"U"

"C"

"9"

"10"

"11"

"F"

Description

System start

Fan ramp-up, system start

Forced ventilation, system start

Fan ramp-up for test

Safety relay test

Disable BV1 relay.

BV1 relay test

Ignition relay test

Disable safety relay.

Ramp up to flue gas damper test speed.

Check flue gas damper.

Start-up meter, initialisation

Standby

Flame signal amplifier test

Gas fan and air pressure switch test

Fan ramp-up

Pre-purge

Adjust start-up load, WD 1 test.

Pre-ignition

Safety time

Flame stabilising time

Start-up, partial load

Modulating operation

Adjust shutdown load.

Reheating, WD 2 test.

Fan ramp-up, post-purge

Post-purge

Waiting for restart

Waiting for mains gas pressure

Forced ventilation fault

Flame tear-off

Safety shutdown

Fault shutdown

Burner control unit

Duration

10 s max. 20 s

20 s max. 20 s

0.9 s

0.9 s

0.9 s

0.9 s

0.9 s

5 s max. 60 s

0.1 s

0 ... s max. 50 s max. 20 s max. 15 min

30 s

25 s

1 s max. 2.6 s

15 s

12 s

0 to 24 h

10 s

1 s, max. 30 s max. 20 s

10 s min. 1 min min. 5 min

20 s

0.5 s

0 ... s

0 ... s

37

Troubleshooting

Fault display

If the burner control unit recognises a fault, the fault display is automatically activated:

■ In the case of a non-lockout fault, the fault LED illuminates.

■ In the case of a lockout fault, the fault LED illuminates. The fault code flashes.

Status Service

A Fault code of the most recent fault, see table from page.

1. Remedy the fault. For fault codes and measures, see the following chapter. Carry out measures in the indicated order.

2. Hold down reset button R for longer than 0.5 s.

The operating display is shown. The burner control unit is reset.

Fig. 22

Calling up the fault history (fault memory)

The 10 most recent faults (including those remedied) are saved and can be called up. The fault messages are ordered chronologically, the most recent fault message is shown first.

If no key is pressed within 20 s, the fault memory display terminates automatically.

Note

If the burner repeatedly starts up due to a non-lockout fault, but does not display a fault code, the fault memory may give an indication of the cause.

Calling up the fault memory



2.



4.

/ for the required fault memory: See the table below

5. S to confirm; the selected fault memory is shown under "Status".

6.

/ to scroll through the fault codes.


1

2

Fault memory under menu "4" — Fault history:

"Service" display Description

3

Fault codes display

Detailed fault codes

Clear fault memory.

Note

The 10 most recent faults (including those rectified) are saved respectively in both fault memory "1" (displayed fault codes) and "2" (detailed fault codes).

Clear fault memory



2.


3. S to confirm, "4" is shown under "Status" and "1" is shown under "Service".

4.


5. S to confirm, "1" is shown under "Status" and

"dEL" under "Service".

6. S to confirm the deletion. If deletion was successful, "1" is shown under "Service"; if it failed, "0" is shown.


38

Troubleshooting

Fault codes with display on burner control unit

General process errors: Displayed fault codes

Note

Carry out measures in the order described.

Each fault message is saved in the fault memory. The

10 most recent fault messages can be called up.

Displayed fault code

F 80

F 81

F 82

F 83

F 88

F 89

F B7

F B7

System characteristics

Burner control unit in a fault state; system cooling down; burner control unit locked out.

Burner control unit in a fault state






Type of coding card

Cause

Short circuit, boiler water temperature sensor

Sensor drift, boiler water temperature sensor

Short circuit, flue gas temperature sensor

Sensor drift, flue gas temperature sensor

Lead break, boiler water temperature sensor

Flue gas temperature sensor disconnection

Coding card not inserted in the burner control unit; incorrect or faulty coding card

Coding card does not match burner control unit.

Measures

Check connecting cable and boiler water temperature sensor 3A/3B

(dual sensor). Replace sensor if required.



Check connecting cable and flue gas temperature sensor 15A/15B








Insert coding card. Check coding card. Replace if necessary.

Replace coding card or burner control unit.

F E3

F E4


Burner shuts down.

Safety equipment has responded.

Multiple detection of undervoltage with recurrence and renewed undervoltage

Danger

Plug-in terminals on the burner control unit are live.

Only replace the coding card when the burner control unit has been isolated from the power supply.

Check safety equipment on

STB/STB at plug aBÖ of the

Vitotronic.

Check the power supply.

39

Troubleshooting


(cont.)


F E5

F EB

F EC

F ED

F EE

F EF

F F1

F F2

F F3

F F4

F F4

F F4



Burner locked out





Burner control unit in a fault state; system cools down.

Burner control unit in a fault state; system cools down.

Ionisation flame monitor reports faulty flame signal during start-up or after the postpurge.

Ionisation electrode or burner gauze assembly damaged.

No flame formation during safety time; ionisation flame monitor reports no flame signal.



Cause Measures

Internal fault of the burner control unit and during test of ionisation input

Burner not enabled via external contact.

Internal error in feedback from safety relay.

Internal error in feedback from ignition relay.

Internal error in feedback from gas safety valves.

The output relay does not respond.

Internal error in feedback from gas safety valves.

The output relay does not respond.

Flue gas temperature limiter has responded

■ Flue gas temperature too high

■ Excessive gas throughput

Replace burner control unit.

Check component connected to

TR/TR EIN at plug

Vitotronic.

Reset or replace burner control unit.

aBÖ of the

Reset burner control unit. Replace burner control unit if required.

Reset burner control unit. Replace burner control unit if required.

Reset or replace burner control unit.

Boiler water temperature limiter has responded.

Boiler water temperature too high.

Gas train leaks (gas is escaping and burning). Incorrect coding card.

Ionisation electrode incorrectly adjusted; ionisation electrode not plugged in.

Earth leakage of electrode or cable.

Ignition electrodes incorrectly adjusted, electrode earth fault, ignition unit faulty, burner control unit faulty

Insulation body of ignition or ionisation electrode cracked

■

■

■

■

■

■

■

■

Wait until temperature falls below the permissible flue gas temperature.

Check the system pressure.

Check heat exchanger surfaces for contamination.

Reset burner control unit.

Check the CO

2

setting.

Adjust gas throughput in accordance with the rated boiler heating output. See "Specification" for connected values.

Wait until temperature falls below the permissible boiler water temperature.

Reset burner control unit.

Check ionisation path. Check ionisation electrode for earth fault.

Check burner gauze assembly for deformation.

Replace coding card. Replace gas train.

Insert plug of ionisation electrode; check cable; adjust ionisation elec-

trode (see page 24).

Adjust ignition electrodes (see

page 24); replace ignition unit. Re-

place burner control unit.

Replace ignition or ionisation electrode.

40

Troubleshooting


(cont.)


F F4


F F4

F F4

F F4

F F5

F F5

F F6

F F7

F F7

F F8

F F8

F F8

F F8

F F9

F F9

F F9

Cause Measures

Poor start-up characteristics

(start enrichment). Solenoid valve not switching.

Flame does not build during the safety time, no signal reported by the ionisation flame monitor.



Air pressure switch 1 reports no air pressure, fan not running.

Air pressure switch 1 switches off during operation.

Gas pressure switch reports no gas pressure.

Fan pressure is created during the idle state check of air pressure switch 1.

Contact of air pressure switch

1 not in idle state

Flame tears off during operation.



Flame tears off during modulation (burner output increases).

Fan not running; fan speed not reached.

Status duration too long, fan ramp-up

Fan speed deviation

Compensation lines not connected, solenoid valve faulty, output relay of burner control unit faulty

Incorrect gas type selected

Gas train does not open.

Combustion characteristics not ideal

Air pressure switch 1 faulty, incorrectly connected or incorrectly set

Flue gas back pressure, condensate banked up, air pressure switch 1 hose faulty, connecting hose leaking

Gas shut-off valve closed; gas pressure switch faulty; multiple problems with gas supply

Wind influence on fan

Air pressure switch 1 faulty

Incorrect gas type selected

Burner gauze assembly faulty

Check compensation lines and connections, replace compensation lines. Replace the solenoid valve. Replace burner control unit.

Adjust gas type (see page 11).

Check connecting cable. Check the gas train and replace if required.

Adjust burner setting. If necessary also adjust the setting screws when the burner is off to facilitate the burner start.

Replace air pressure switch 1, connect or adjust correctly.

Remove flue gas back pressure.

Check for backed up condensate.

Reset the burner control unit. Replace hose.

Open the gas shut-off valve. Check gas flow pressure. Replace gas filter if required. Reset the burner control unit. Replace gas train.

Check the flue draught (chimney).

Replace air pressure switch 1.

Adjust gas type (see page 11).

Check the burner gauze assembly.

Replace the burner gauze assembly if it is damaged.

Adjust burner (see from page 16).



Air pressure switch adjusted incorrectly.

Fan faulty; cables are faulty or broken

Internal fault; fan cannot reach its set value.

Fan faulty, cable " a-Ö A" faulty or broken

Adjust burner (see page 16).

Adjust air pressure switch (see

page 57).

Check cables. Replace fan if required.

Replace fan or burner control unit.

Check cable. Replace cable

" a-Ö A" or fan if necessary.

41

Troubleshooting


(cont.)


F F9

F FA

F FB


No feedback from fan

Fan runs without demand; burner control unit in a fault state.

Burner does not start.

Cause Measures

External fan power supply not connected, faulty or defective. If voltage is present at connected plug

" a-Ö " and the fan does not start up when plug

" a-Ö A" is disconnected, there is a fault with the fan. Cable " a-Ö A" faulty or broken.

Relay in the terminal box does not switch.

Fan blocked (possibly by foreign bodies).

Fan does not reach idle state, cable " a-Ö A" faulty, fan faulty, burner control unit faulty

■

■

■

■

■

Combustion chamber pressure too high

(LDW2)

Condensate backed up

Flue gas path blocked

Flue gas damper does not open or close.

Burner control unit configured incorrectly

Check cable" a-Ö A" and external power supply. Replace cable or fan. Remove foreign bodies.

Wind influence on fan; check flue outlet and fan. Replace cable

" a-Ö A". Replace fan. Replace burner control unit.

■

■

■

Check condensate drain and flue gas path for blockages.

Check flue gas damper.

Check motorised flue gas damper operating parameters.

Internal system faults: Displayed fault codes and detailed fault codes

Internal system faults will be shown if the correct program sequence can no longer be guaranteed.


F E5, F EC,

F ED, F FF


Fault in burner control unit area

Cause

Internal system fault and

EMC

Measures

Reset burner control unit. Replace the burner control unit if the fault persists.

See the following table F FD Fault in burner control unit area

See the following table

Detailed error codes for F FD

Detailed error code

Component/signal Cause of fault

30 Reset button

31 Fuel valve 2 feedback

Programming unit faulty

Wiring

Incorrect return voltage

(e.g. DC voltage)

Actuator faulty

32 Air pressure switch

1

High switching sequence, switch flutters

External voltage

Measure

Replace programming unit.

Check wiring.

Remove plug from fuel valve 2, reset burner control unit and check error messages. If F Fd recurs, replace burner control unit. Otherwise, replace fuel valve 2.

Check flue gas path and combustion. Check setting LDW1. Check burner gauze assembly for contamination.

42

Troubleshooting


(cont.)

Detailed error code

34

Component/signal Cause of fault

35

36

37

38

Gas pressure switch 1


External voltage

Plug 41 demand T2 High switching sequence, switch flutters

External voltage

Plug 90 T8 High switching sequence, switch flutters

External voltage

Plug 90 T7 SK

Fuel valve 1 feedback


External voltage

Incorrect return voltage

(e.g. DC voltage)

Actuator faulty

3A

3B

60

Ignition feedback Incorrect return voltage

(e.g. DC voltage)

Actuator faulty

Air pressure switch

2

Hall signal fan feedback (RM-N)

For type CM3C only:


External voltage

Fan speed too high. Incorrect fan or incorrect coding card

Measure

Check the gas supply. Check setting GDW1 and gas train intake screen.

Check whether external voltage present.

Check on-site connection.





Remove plug from fuel valve 1, reset burner control unit and check error messages. If F Fd recurs, replace burner control unit. Otherwise, replace fuel valve 1.

Disconnect cable from ignition module, reset burner control unit and check error messages. If

F Fd recurs, replace burner control unit. Otherwise, replace ignition module.

Check flue gas path and reheating surfaces.

Check air pressure switch 2 setting.

Check the fan. Check coding card.

Faults without fault display

Fault

Combustion faults due to pulsation

Thermo-acoustics/combustion noise

CO

2

content too low

CO formation or burner is very sooty.

Cause of fault

Excessive gas throughput

Insufficient or excessive air

Condensate backed up in flue system

Flue outlet not installed correctly

Incorrect CO

2

settings; insufficient or excessive air

Incorrect setting

Insufficient or excessive air

Insufficient draught in flue system

Measure

Adjust gas throughput in accordance with the rated boiler heating output.

Check condensate drain.

Check flue outlet and flue system.

Adjust burner in accordance with the details on

page 16 onwards.

Check whether the burner has been adjusted to the correct gas type; change gas restrictor if required

(see page 11 onwards).

Adjust burner in accordance with the details on

page 16 onwards.

Correct the settings. Check ventilation in installation room.

Check flue system.

43

Troubleshooting

Faults without fault display

(cont.)

Fault

Flame tears off during operation

Flue gas temperature too high

Cause of fault

Intake strainer of gas train soiled

Excessive gas throughput

Measure

Remove flange. Clean strainer. See page 26.

Adjust gas throughput in accordance with the rated boiler heating output. Checking the condition of the heating surfaces. Clean if necessary.

44

Overview of assemblies

The following details are required when ordering parts:

■

■

Serial no. (see type plate A )

Assembly (from this parts list)

■ Position number of the individual part within the assembly (from this parts list)

0003

0004

Parts lists

A

Fig. 23

0001 Boiler assembly

0002 Casing assembly

0001 0002

0003 MatriX-Disk burner assembly

0004 Vitotronic control unit assembly

45

Parts lists

Boiler assembly

0001

0002

0005

0004

0003

0001

0001

0006 0007

0005

0008

Fig. 24

46

Boiler assembly

(cont.)

Pos.

0001

0002

0003

0004

0005

0006

0007

0008

Part

Gasket DN 100 PN 6

Sensor well with clip

Packing cord

Gasket set

Sealant

Flue gas collector with gasket

Flue system collar

Stench trap

Parts lists

47

Parts lists

Casing assembly

0009 0011 0029

0030

0008

0005

0006

0007

0006

0007

0008

0005

0013

0020

0013

0021

0013

0013

0014

0012

0010

0022

0003 0004

0019

0028

0017

0015

0024 0025

0038

0039

0023

0027

0038

0039

0001 0002

0016 0018

Fig. 25

0031 0032 0033

0026

0040

0034

0035

0036

0037

48

Casing assembly

(cont.)

0029

0030

0031

0032

0033

0034

0035

0036

0037

0038

0019

0020

0021

0022

0023

0024

0025

0026

0027

0028

0039

0040

0009

0010

0011

0012

0013

0014

0015

0016

0017

0018

Pos.

0001

0002

0003

0004

0005

0006

0007

0008

Part

Front thermal insulation mat

Thermal insulation jacket, combustion chamber module

Thermal insulation jacket, heat exchanger module

Thermal insulation mat, heat exchanger module

Fixing strut

Gas strut

Joint, long

Joint, short

Rail, short, top left

Rail, short, top right

Rail, top left

Rail, top right

Crossbar

Distribution panel

Extension, bottom left

Extension, bottom right

Rail, bottom left

Rail, bottom right

Side panel, front left

Centre side panel 1, left

Centre side panel 2, left

Side panel, back left

Side panel, front right

Centre side panel 1, right

Centre side panel 2, right

Side panel, back right

Front panel

Control unit panel

Top panel, front

Top panel, left

Top panel, right

Top panel, centre

Top panel, back

Back panel, top

Control unit cover

Back panel, centre

Back panel, bottom

Viessmann logo

Vitocrossal logo

Fixings

Parts lists

49

Parts lists

MatriX-Disk burner assembly

0020

0021

0017

0007

0016

0022

0015

0004

0006 0013

0014

0011

0008

0016

0018

0002

0012

0019

0023

0005

0010 0003 0009

Fig. 26

0023

0001

50

MatriX-Disk burner assembly

(cont.)

0009

0010

0011

0012

0013

0014

0015

0016

0017

0018

Pos.

0001

0002

0003

0004

0005

0006

0007

0008

0019

0020

0021

0022

0023

Part

Matrix-Disk burner

Burner control unit and cables

Fan

Gas train

Mixer unit

Gas pressure switch

Gas pressure switch

Supply air collector

Gasket, gas fan

O-ring gasket

Ignition cable

Additional cover

2/2-way solenoid valve

Ignition module

Gasket

Clip

Hose set

Coding card

Intake extension

Small parts, burner

Fixing parts

Connection piece, gas train

Fixing parts, intake extension

Parts lists

51

Parts lists

Burner control unit assembly

0001

0002

0003 0004 0005

0006

0009 0010 0011 0012 0013

Fig. 27

52

0014 0015 0016 0017

0019

0018

Burner control unit assembly

(cont.)

0011

0012

0013

0014

0015

0016

0017

0018

0019

Pos.

0001

0002

0003

0004

0005

0006

0009

0010

Part

Burner control unit VUC310-C01.005

Programming unit

Connecting cable, 38 bypass

Ionisation cable 11/auxiliary earth

Ignition transformer connecting cable 54

Gas train connecting cable

Air pressure switch with connecting cable 131

Air pressure switch with connecting cable 131A

Sensor lead

Cable, control unit programming unit

Cable, flue gas temperature sensor 15

Connecting cable, control unit GFA

Cable, CAN bus 72

Cable, flue gas damper 53

Dual temperature sensor

Cable harness, CAN bus programming unit

Fan motor connecting cables

Parts lists

53

Parts lists

Vitotronic control unit assembly

0008

0003 0001

0002

0003

0004

0002

0003

0006

0013

0007

0010

0011

0017

0019

Fig. 28

0018

0009 0014

0012

0016

54

Vitotronic control unit assembly

(cont.)

0010

0011

0012

0013

0014

0016

0017

0018

0019

Pos.

0001

0002

0003

0004

0006

0007

0008

0009

Part

Programming module

Toggle switch OFF 2-pole

Slider, left and right

Vitotronic programming unit

Cable with 2 angle connectors

LAN cable

Vitocrossal junction box

Coding card

Cover, cable entry (2 pce)

Control board CU404

Power board MB205

PCB CU103 - controller board extension

Strapping plug X6

Fuse, 6.3 A (slow), 250 V (10 pce)

PCB IU100-B10

LON connecting cable, length 7 m

LON terminator (2 pce)

Parts lists

55

Component overview

Overview of burner components

R S T

A

B

C

D

E

F

G

H

Fig. 29

A

B

C

D

E

F

G

H

K

Display and programming unit

Burner control unit

Burner door

Gas train



Gas supply pipe

Intake extension

Fan

K

L

M

N

O

P

U

L

R

S

T

U

M

N

O

P

Supply air collector

Thermal insulation block

Ignition electrodes

Burner gauze assembly, MatriX-Disk

Ionisation electrode

Ignition unit

Air pressure switch LDW2

Air pressure switch LDW1

2/2-way solenoid valve

56

Function description

Air pressure switch

Fan pressure monitoring function (LDW1)

The switching threshold of air pressure switch 1 (plug aCA ) is monitored in all fan ramp-up phases and checked during modulating burner operation. This ensures a minimum pre-purge.

Air pressure switch 1 triggers a fault shutdown of the burner control unit under the following circumstances:

■ The static pressure check was unsuccessful after approx. 5 minutes.

■

■

The air pressure is outside the permissible range during the pre-purge phase. Tolerance time approx.

5 min.

The air pressure switch fails in control mode or the air pressure lies outside the permissible range.

The fault shutdown is indicated by fault codes "F F5" and "F F7" on the burner control unit display (see

page 39).

Fault resetting: Hold down reset button R for longer than 0.5 s.

LDW1 setting :



Combustion chamber pressure monitoring function (LDW2)

To monitor the combustion chamber pressure, the switching threshold of air pressure switch 2 (plug aCA A) is monitored in all operating phases (except during safety and stabilising time).

If the combustion chamber pressure lies outside the permissible range, air pressure switch 2 triggers a fault shutdown on the burner control unit.

The combustion chamber pressure lies outside the permissible range in the following operating phases:

■

■

In the pre-purge phase

In control mode

■ In the post-purge phase after 2 attempts

The fault shutdown is indicated by fault code "F FB" on

the burner control unit display (see page 39).

Fault resetting: Hold down reset button R for longer than 0.5 s.

LDW2 setting : 10 mbar (1 kPa)

Boiler water temperature sensors and flue gas temperature sensors

The temperature sensors are of a dual sensor design.

Connection to burner control unit:

§ A/ § B Boiler water temperature sensors aG A/ aG B Flue gas temperature sensors

NTC 10 k Ω

20

10

8

6

4

2

1

0.8

0.6

0.4

10 30 50

Temperature in °C

Fig. 30

70 90 110

57

Connection diagrams

Burner control unit connection diagram

A

W

C

V

U

T

S

R

D

W

P

E

O

N

M

F

K

L

G

H

Fig. 31

C

D

E

F

A

B

G

H

K

Junction box

Mains connection to main MCB/fuse 400 V/50 Hz, see the following chapter

Burner control unit VUC 310

Flame monitor (ionisation current)

Vitotronic control unit

Servomotor for rotary damper or 2/2-way solenoid valve

Flue gas damper

Ignition unit

Fuel valve BV1

L

R

S

T

U

M

N

O

P

V

W

Fuel valve BV2

Display and programming unit

Gas pressure switch GDW2

Air pressure switch 1

Gas pressure switch GDW1

Air pressure switch 2

Flue gas temperature sensor 2

Flue gas temperature sensor 1

Boiler water temperature sensor 2

Boiler water temperature sensor 1

Fan motor with PWM switching and feedback

58

B

Water quality requirements


Note

Observing the following requirements is necessary to safeguard your warranty rights.

The warranty excludes damage due to corrosion and scaling.

Total heating output kW

≤ 50

> 50 to ≤ 200

> 200 to ≤ 600

> 600

Total alkaline earths mol/m 3

≤ 3.0

≤ 2.0

≤ 1.5

< 0.02

Prevention of damage due to scaling

Prevent excessive scale build-up (calcium carbonate) on the heating surfaces. For heating systems with operating temperatures up to 100 °C, VDI Guideline

2035 Part 1 "Prevention of damage in water heating installations - Scale formation in domestic hot water supply installations and water heating installations" applies together with the following standard values.

See the explanations in the original text of the Guideline.

Total hardness

° dH

≤ 16.8

≤ 11.2

≤ 8.4

< 0.11

The standard values assume the following:

■ The total volume of fill and top-up water will not exceed three times the water content of the heating system during its service life.

■

■

The specific system volume is less than 20 l/kW heating output. In multi boiler systems, apply the output of the smallest boiler.

All measures to prevent corrosion on the water side in accordance with VDI 2035 Part 2 have been implemented.

Soften the fill and top-up water in heating systems operating under the following conditions:

■ The total of alkaline earths in the fill and top-up water exceeds the standard value.

■

■

Higher fill and top-up water volumes are expected.

The specific system volume is greater than 20 l/kW heating output. In multi boiler systems, apply the output of the smallest boiler.

■

■

In systems > 50 kW, install a water meter to capture the amount of fill and top-up water. Enter the volume of fill water and the water hardness into the boiler maintenance checklists.

For systems with a specific system volume greater than 20 l/kW heating output, apply the requirements of the next higher category of total heating output (in accordance with the table). In multi boiler systems, apply the output of the smallest boiler. In the case of severe overshoot (> 50 l/kW), soften the water down to a total of alkaline earths of ≤ 0.02 mol/m 3 .

Operating information:

■ During expansion or repair work, only drain the pipe-

■ work sections necessary.

Check, clean and activate filters, dirt traps and other blow-down or separating facilities in the heating water circuit frequently after commissioning and in new installations. Thereafter check and maintain these facilities as required, depending on the type of

■ water treatment applied (e.g. water softening).

No further steps are required during commissioning if you fill the heating system with fully softened water .

If the heating system is charged, not with fully softened water , but with water that meets the requirements in the above table, also observe the following during commissioning :

■

■

■

Commission the system step by step with a high heating water flow rate, starting with the lowest boiler output. This prevents localised concentration of limescale deposits on the boiler heating surfaces.

In multi boiler systems, start all boilers simultaneously to prevent the entire limescale deposit settling in the heat exchanger of just one boiler.

Where water treatment is required, treat even the first fill of the heating system prior to commissioning.

This also applies to any subsequent filling, e.g. when adding top-up water or after a repair, or for any system expansion.

The build-up of limescale deposits on the heating surfaces will be minimised if these instructions are followed.

59


(cont.)

Failure to observe the requirements of VDI Guideline

2035 can result in damaging limescale deposits. In such cases, the service life of the installed boilers will, most often, already have been reduced. Removing the limescale deposits is one option for restoring operational viability.

This measure must be carried out by a qualified contractor. Inspect the heating system for possible damage prior to returning it into use. It is essential that incorrect operating parameters are corrected to prevent renewed excessive scaling.

Prevention of damage due to corrosion on the water side

The corrosion resistance of ferrous materials on the heating water side of heating systems and heat generators depends on the absence of oxygen in the heating water. The oxygen introduced into the heating system with the first fill and subsequent top-ups reacts with the system materials without causing damage.

The characteristic blackening of the water after a certain time in operation indicates that there is no more free oxygen present. In accordance with the technical rules and in particular VDI Guideline 2035-2, we recommend that the heating system is designed and operated so that a constant ingress of oxygen into the heating water is prevented.

During operation, oxygen can enter due to:

■ Open vented expansion vessels with flow through

■

■

Negative pressure in the system

Permeable components

Correctly sized sealed unvented systems operating at the correct pressure, e.g. systems with expansion vessel, offer good protection against the ingress of airborne oxygen. Under all operating conditions and at all points in the heating system, including the intake side of the pump, the pressure must be higher than atmospheric pressure. Check the pre-charge pressure of the expansion vessel at least during the annual service.

Avoid the use of permeable components, e.g. permeable plastic pipes in underfloor heating systems. Provide system separation if such components are nevertheless used. This system separation must separate the water flowing through the plastic pipes from other heating circuits, e.g. from the boiler, by the provision of a corrosion resistant heat exchanger.

No further anti-corrosion measures are required for sealed unvented hot water heating systems, subject to the above points being observed. However, take additional precautions where there is a risk of oxygen ingress, for example by adding oxygen binder sodium sulphite (5 to 10 mg/l into the excess). The pH value of the heating water should be between 8.2 and 9.5.

Different conditions apply to systems that contain aluminium components.

Where chemicals are used as part of the corrosion protection, we recommend that the manufacturer of the chemicals issues a certificate of suitability of the additives with regard to the boiler materials and the materials of other components. Please refer questions regarding water treatment to an appropriate contractor.

Further details can be found in VDI Guideline 2035-2 and EN 14868.

60

Reports

Fill water report

Fill water m 3

Top-up water m 3

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

Max. fill volume: ...........................m

3

Meter reading m 3

Total water volume Date m 3

Reports

61

Reports

Reports

(cont.)

Water quality report

Feedwater

Total hardness

Boiler water

The pH value should be between 8.2 and 9.5.

pH value

Boiler water

Settings and measurement values

Static pressure

Supply pressure (flow pressure)

= Natural gas E

= Natural gas LL

Tick gas type.

Carbon dioxide content CO

2

■ At the upper rated heating output

■ At the lower rated heating output

Actual

Set

Actual

Set

Oxygen content O

2



Carbon monoxide content CO

Actual

Set

Actual

Set

Actual

Set mbar kPa mbar kPa mbar kPa

% by vol.

% by vol.

% by vol.

% by vol.

% by vol.

% by vol.

% by vol.

% by vol.

ppm ppm

Water treatment

Medium Dosing volume

Date

Commissioning Maintenance/Service

62

Reports

(cont.)

Flue gas temperature

(gross)

Ionisation current



Draught

Actual

Set

Actual

Set

°C

°C

μ A

μ A hPa hPa

Reports

Commissioning Maintenance/Service

63

Specification

Specification

Boiler

Vitocrossal, type

Rated heating output range

P n

: T

F

/T

R

80/60 °C

P cond

: T

F

/T

R

50/30 °C

Rated heating input range Qn (Sized for up to mean sea level (MSL) 1500 m)

Boiler product ID

Permiss. operating temperature

Permiss. flow temperature

Heating surface

(safety temperature) kW kW kW

Max. permiss. operating pressure

Min. permiss. operating pressure

Test pressure

Boiler body dimensions

Total length

Length of the combustion chamber module

Length of the heat exchanger module

Width

Height

Total dimensions incl. casing

Length

Width

Height

Foundation dimensions

Length

Height

Weight

Combustion chamber module

Heat exchanger module

Burner

Total weight, dry

Water capacity

Connections

Boiler flow

Boiler return 1

Boiler return 2

*1

*1

Safety connection (male thread)

Drain (male thread)

Condensate drain (male thread)

PN 6 DN

PN 6 DN

PN 6 DN

R

R

R

Gas flow rate, natural gas E (G20) at 15 °C, 1.013 bar

■ At rated heating output m 3 /h

■ At partial load m 3 /h l kg kg kg kg mm mm mm mm mm mm mm mm mm mm

°C

°C m 2 bar

MPa bar

MPa bar

MPa

CRU 800

125 to 750

137 to 800

127 to 762

CRU 1000

156 to 938

171 to 1000

159 to 952

2500

1200

535

615

120

1435

1150

2241

1019

1272

960

1676

3187

1060

1676

100

100

100

2

1 ¼

CE-0085CS0411

95

110

24.2

6

0.6

0.5

0.05

7.8

0.78

½

80.6

13.4

*1 When connecting 2 heating circuits, connect the heating circuit with the higher temperature level to boiler return 2.

64

2700

1200

585

615

120

1492

1180

2441

1219

1272

960

1676

3389

1060

1676

100

100

100

2

1 ¼

95

110

31.5

6

0.6

0.5

0.05

7.8

0.78

½

100.8

16.8

Specification

(cont.)



P n

: T

F

/T

R

80/60 °C

P cond

: T

F

/T

R

50/30 °C

Gas flow rate, natural gas LL (G25) at 15 °C,

1.013 bar

■ At rated heating output

■ At partial load

Flue gas parameters *2

Flue gas temperature ( T

V

/T

R

50/30 °C)

■

■

At rated heating output

At partial load

Flue gas temperature ( T

V

/T

R

80/60 °C)


■ At partial load

Flue gas mass flow rate, natural gas E (G20)


■ At partial load

Flue gas mass flow rate, natural gas LL (G25)

■

■


At partial load

Flue gas connection

Draught at the flue outlet

Flue gas volume

Efficiency

■ H s

at T

F

/T

R

80/60 °C, full load (100 %)

■

■

H s

at T

F

/T

R

50/30 °C, full load (100 %)

H s

at T

F

/T

R

50/30 °C, partial load (30 %)

Standard seasonal efficiency [to DIN]

■ H s

at 40/30 °C

■ H s

at 75/60 °C

Idle losses (via ambient temperature)

■ 50 K

■ 30 K

Standby loss q

B,70

Specification kW kW

%

% kW kW

%

°C

°C kg/h kg/h kg/h kg/h

7 mm

Pa mbar m 3

%

°C

°C m 3 /h m 3 /h

%

%

CRU 800

125 to 750

137 to 800

CRU 1000

156 to 938

171 to 1000

117.3

19.6

45

35

67

63

1249

233

1273

237

300

70

0.7

0.45

88

96

98

2.7

1.0

0.4

99

96

93.8

15.6

43

34

69

63

1562

291

1592

297

300

70

0.7

0.50

88

95

97

2.8

1.1

0.7

98

96

*2 Values for calculating the size of the flue system to EN 13384, based on 10 % CO

2

for natural gas.

Flue gas temperatures as actual gross values at 20 °C combustion air temperature.

The details for partial load refer to the lower rated heating output (30 %). If the partial load differs (subject to burner operating mode), calculate the flue gas mass flow rate accordingly.

65

Specification

Specification

(cont.)

MatriX-Disk burner



P n

: T

F

/T

R

80/60 °C

P cond

: T

F

/T

R

50/30 °C

Rated heating input range Qn (Sized for up to mean sea level (MSL) 1500 m)

Burner type

Burner product ID

Voltage , 3/N/PE

Frequency

Current , max

Power consumption

■

■


At partial load

Gas supply pressure

■ Natural gas E and natural gas LL

Sound power level to EN 15036 kW kW kW

V

Hz

A

W

W mbar kPa dB(A)

CRU 800

125 to 750

137 to 800

127 to 762

CRU 1000

156 to 938

171 to 1000

159 to 952

83

MDI

CE-0085CS0412

400

50

16

1500

100

18 to 25

1.8 to 2.5

85

400

50

16

2000

100

66

Final decommissioning

Final decommissioning and disposal

Viessmann products can be recycled. Components and substances from the system are not part of ordinary household waste.

For decommissioning the system, isolate the system from the power supply and allow components to cool down where appropriate.

All components must be disposed of correctly.

67

Certificates

Declaration of conformity

We, Viessmann Werke GmbH & Co. KG, D-35107

Allendorf, declare as sole responsible body that the named product complies with the European directives and supplementary national requirements in terms of its design and operational characteristics.

Conformity has been verified with the CE designation.

Using the serial number, the full Declaration of Conformity can be found on the following website: www.viessmann.co.uk/eu-conformity

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

We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, confirm that the product Vitocrossal, type CRU complies with the following conditions stipulated by the 1st German Immissions Order (BImSchV):

■ NO x

limits in accordance with paragraph 6 (1).

■ Flue gas loss up to 9 % in accordance with paragraph 10 (1).

Allendorf, 20 June 2018 Viessmann Werke GmbH & Co. KG

Authorised signatory Reiner Jansen

Head of Strategic Quality Management

68

Keyword index

Keyword index

A

Air pressure switch.....................................................57

Assembly

– Boiler....................................................................... 46

– Burner control unit...................................................52

– Casing..................................................................... 48

– MatriX-Disk burner.................................................. 50

– Overview................................................................. 45

– Vitotronic control unit...............................................54

B

Boiler, opening........................................................... 19

Boiler casing, closing................................................. 28

Boiler water requirements.......................................... 59

Boiler water temperature sensors.............................. 57

Burner

– Cleaning.................................................................. 22

– Fitting...................................................................... 24

Burner control unit......................................................31

– Configuration display...............................................33

– Display and programming unit................................ 31

– Operating display.................................................... 31

Burner door

– Checking................................................................. 22

– Closing.................................................................... 24

Burner gauze assembly, checking............................. 23

Burner start................................................................ 36

C

Calling up information................................................ 32

Checking

– Burner door............................................................. 22

– Burner gauze assembly.......................................... 23

– Condensate drain....................................................28

– Electrical connections..............................................11

– Expansion vessel.................................................... 28

– Filter element in gas line......................................... 26

– Flue gas damper..................................................... 13

– Gas connections..................................................... 26

– Gaskets................................................................... 28

– Gas train filter element............................................ 26

– Heating water side tightness................................... 10

– Ignition electrodes................................................... 24

– Ionisation current.....................................................17

– Ionisation electrode................................................. 24

– Mixer....................................................................... 29

– Neutralising system.................................................28

– Safety valves...........................................................29

– Sensor well..............................................................10

– Static pressure........................................................ 14

– Supply pressure...................................................... 14

– Thermal insulation...................................................30

– Tightness of gas train valves...................................25

– Ventilation air apertures.......................................... 30

– Water quality........................................................... 28

CO2 content, measuring............................................ 16

CO content, measuring.............................................. 17

Combustion chamber, cleaning..................................20

Combustion chamber opening................................... 20

Combustion chamber pressure monitoring................ 57

Combustion operation, service display...................... 35

Component overview, burner..................................... 56

Condensate drain, checking.......................................28

Condensate drain pipe, cleaning................................27

Configuration, changing............................................. 33

Connection diagram................................................... 58

D

Decommissioning.......................................................67

Delivered condition, resetting.....................................35

Description of state.................................................... 36

Diagnostics table........................................................39

Displayed fault codes........................................... 39, 42

Disposal..................................................................... 67

E

Electrical connections, checking................................ 11

Expansion vessel, checking....................................... 28

F

Fan pressure monitoring............................................ 57

Fault codes.................................................................39

Fault codes, detailed.................................................. 42

Fault display............................................................... 38

Fault history................................................................38

Fault memory............................................................. 38

Faults without fault display......................................... 43

Filling............................................................................9

Filter element checking, gas line................................26

Filter element checking, gas train.............................. 26

Final checks, performing............................................ 29

Flow diagram for burner start..................................... 36

Flow pressure.............................................................15

Flue gas damper, checking........................................ 13

Flue gas temperature, measuring.............................. 17

Flue gas temperature sensors................................... 57

G

Gas connections, checking tightness.........................26

Gas type

– Checking................................................................. 11

– Setting..................................................................... 12

H

Heating output reduction............................................ 14

Heating surfaces, cleaning.........................................20

Heating system, filling.................................................. 9

I

Ignition electrodes, checking......................................24

Information, calling up................................................ 32

Instructing the system user........................................ 30

Intended use................................................................ 5

Internal system faults................................................. 42

Ionisation current, checking....................................... 17

Ionisation electrode, checking....................................24

69

Keyword index

Keyword index

(cont.)

M

Manual operation....................................................... 35

Measuring

– CO2 content............................................................ 16

– CO content.............................................................. 17

– Flue gas temperature.............................................. 17

Menu overview........................................................... 32

Meters, resetting........................................................ 32

Mixer, checking.......................................................... 29

Modulation level for manual operation, setting...........35

N

Neutralising system, checking....................................28

O

Opening the boiler......................................................19

Operating and service documents............................. 30

Operating display....................................................... 31

Operating parameters

– Changing.................................................................33

– Resetting................................................................. 35

Operational output reduction......................................14

Overview of assemblies............................................. 45

P

Parts

– Boiler....................................................................... 46

– Burner control unit...................................................52

– Casing..................................................................... 48

– MatriX-Disk burner.................................................. 50

– Vitotronic control unit...............................................54

Process errors............................................................39

Product information...................................................... 6

R

Report

– Fill water..................................................................61

– Settings and measurement values..........................62

– Water quality........................................................... 62

S

Safety valves, checking..............................................29

Spare parts.................................................................45

Specification...............................................................64

Start and test functions during burner start.......... 31, 36

Static pressure, checking........................................... 14

Supply pressure, checking......................................... 14

Symbols....................................................................... 5

System

– Commissioning........................................................12

– Filling and venting..................................................... 9

– Shutting down......................................................... 18

System examples.........................................................6

System pressure, checking........................................ 28

System user instruction..............................................30

T

Thermal insulation, checking......................................30

Tightness

– Flue gas side...........................................................28

– Gas connections..................................................... 26

– Gas train valves...................................................... 25

– Heating water side connections.............................. 10

– Sensor well..............................................................10

Trap, cleaning.............................................................27

Trap, filling with water...................................................9

V

Ventilation air apertures, checking............................. 30

Venting......................................................................... 9

W

Water quality.............................................................. 62

Water quality, checking.............................................. 28

Water quality, requirements........................................59

70

71

Viessmann Werke GmbH & Co. KG

D-35107 Allendorf

Telephone: +49 6452 70-0

Fax: +49 6452 70-2780 www.viessmann.com

72

Viessmann Limited

Hortonwood 30, Telford

Shropshire, TF1 7YP, GB

Telephone: +44 1952 675000

Fax: +44 1952 675040

E-mail: [email protected]

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