Viessmann VITOCROSSAL Service Instructions Manual
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Viessmann VITOCROSSAL Service Instructions Manual

Single boiler: 80 to 318 kw. twin boiler: 240 to 636 kw. gas condensing boiler with matrix cylinder burner. open flue and room sealed operation
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Service instructions
for contractors
Vitocrossal
Type CIB
■
Single boiler: 80 to 318 kW
■
Twin boiler: 240 to 636 kW
Gas condensing boiler with MatriX cylinder burner
Open flue and room sealed operation
VITOCROSSAL
5839829 GB
7/2020
VIESMANN
Please keep safe.

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Summary of Contents for Viessmann VITOCROSSAL

  • Page 1 VIESMANN Service instructions for contractors Vitocrossal Type CIB ■ Single boiler: 80 to 318 kW ■ Twin boiler: 240 to 636 kW Gas condensing boiler with MatriX cylinder burner Open flue and room sealed operation VITOCROSSAL Please keep safe. 5839829 GB...
  • Page 2 Safety instructions Safety instructions Please follow these safety instruc- tions closely to prevent accidents and material losses. Safety instructions explained Danger Note This symbol warns against the risk Details identified by the word "Note" of injury. contain additional information. Please note This symbol warns against the risk of material losses and environmen- tal pollution.
  • Page 3 Viessmann. 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.
  • Page 4 Safety instructions Safety instructions (cont.) Safety instructions for operating the system If you smell gas Condensate Danger Danger Escaping gas can lead to explo- Contact with condensate can be sions which may result in serious harmful to health. injury. Never let condensate touch your Do not smoke.
  • Page 5 Safety instructions Safety instructions (cont.) 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 suita- ble steps to ensure an adequate supply of combustion air.

  • Page 6: Table Of Contents

    Index Index 1. Information Symbols ....................Intended use ..................Product information ................Information for twin boilers ..............■ System examples ................■ Spare parts lists .................. ■ 2. Commissioning, inspec- Steps – commissioning, inspection and maintenance ......10 tion, maintenance 3.
  • Page 7 Requirements ..................102 Commissioning/service Fill and top-up water ................104 reports Settings and test values .................104 12. Specification Vitocrossal specification ................ 106 ......................108 ■ Specification – MatriX cylinder burner ........... 108 13. Shutdown and disposal Final decommissioning and disposal ............. 109 14.

  • Page 8: Information Symbols

    Information Symbols The steps in connection with commissioning, inspec- Symbol Meaning tion and maintenance are found in the "Commission- Reference to other document containing ing, inspection and maintenance" section and identified further information as follows: Step in a diagram: Symbol Meaning The numbers correspond to the order in Steps required during commissioning...

  • Page 9: Product Information

    Information Product information Vitocrossal, type CIB, 80 to 318 kW with permissible Note operating pressure 6 bar (0.6 MPa). For twin and multi boiler systems, use a cascade con- Gas condensing boiler for natural gas E, L and LL, with trol unit as per the pricelist.

  • Page 10: Commissioning, Inspec-Steps - Commissioning, Inspection And Maintenance

    Commissioning, inspection, maintenance Steps – commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • 1. Filling the heating system and checking the supply of ventilation air......11 • • 2. Checking the power supply • 3. Changing the language (if required)................. 11 •...

  • Page 11: Filling The Heating System And Checking The Supply Of Ventilation Air

    102. may otherwise occur. Viessmann accepts no liability for any resulting dam- 6. Return the check valves to their operating position. age or consequential losses. 1. Check whether the ventilation air supply is unre- stricted.

  • Page 12: Setting The Time And Date (If Required)

    Commissioning, inspection, maintenance Changing the language (if required) (cont.) Sprache Deutsch ê ç Bulgarski ê Cesky ê Dansk ê Wählen mit Fig. 1 Setting the time and date (if required) Only for weather-compensated control units The time and date need to be reset during commis- 4.

  • Page 13: Removing The Front Panel

    Commissioning, inspection, maintenance Removing the front panel 1. Tip the front panel forward slightly at the top. 2. Undo the locking screws until the front panel can be removed. Fig. 2 Function sequence and possible faults Shown on display Measure Control unit issues a heat Increase set value.

  • Page 14: Testing The Static And Supply Pressure

    Commissioning, inspection, maintenance Function sequence and possible faults (cont.) Ionisation current builds Fault EE Check setting for ionisation Symbol electrode. Purge the gas line. Burner in operation Shuts down below the set Check the flue system for boiler water temperature and tightness (flue gas recircula- restarts immediately.

  • Page 15: Setting The Maximum Heating Output

    Commissioning, inspection, maintenance Testing the static and supply pressure (cont.) 6. Check the supply (flow) pressure. Set value: 20/25 mbar (2/2.5 kPa) Note Use a suitable measuring device with a resolution of at least 0.1 mbar (10 Pa) to check the supply pressure.

  • Page 16: Checking The Combustion Chamber Pressure Switch

    Commissioning, inspection, maintenance Setting the maximum heating output (cont.) Weather-compensated control unit Constant temperature control unit Service menu Service menu 1. Press OK and simultaneously for approx. 4 s. 1. Press OK and simultaneously for approx. 4 s. å å 2.
  • Page 17 Commissioning, inspection, maintenance Checking the combustion chamber pressure switch (cont.) 3. Additional pressure switch on twin and multi boiler systems with up to 4 boilers Remove connection hose. Check function of additional combustion chamber pressure switch at connection hose connecting point using a pressure tester.

  • Page 18: Removing The Burner And Checking The Burner Gasket

    Commissioning, inspection, maintenance Removing the burner and checking the burner gasket Burners up to 80 kW Fig. 8 80 kW Burner fixings, 4 screws Gas train Ignition electrode Gas supply pipe Ionisation electrode Ventilation air hose (accessories), only for room Ignition transformer sealed operation Fan motor...
  • Page 19 Commissioning, inspection, maintenance Removing the burner and checking the burner… (cont.) Burners 120 to 160 kW Burners for 120 to 160 kW boilers and 240 to 320 kW twin boilers Fig. 9 Burner fixings, 4 screws Gas train Ignition electrode Gas supply pipe Ionisation electrode Ventilation air hose, only for room sealed operation...
  • Page 20 Commissioning, inspection, maintenance Removing the burner and checking the burner… (cont.) Burners from 200 kW Burners for boilers from 200 kW and twin boilers from 400 kW Fig. 10 Burner fixings, 4 screws Gas supply pipe Ignition electrode Ventilation air hose, only for room sealed operation Ionisation electrode Venturi extension, required for open flue operation Ignition transformer...

  • Page 21: Checking The Burner Gauze Assembly And Thermal Insulation Block

    Commissioning, inspection, maintenance Checking the burner gauze assembly and thermal insulation block Check the burner gauze assembly for damage and contamination. In the event of damage or heavy con- tamination, replace the burner gauze assembly. Fig. 11 Up to 80 kW Ignition and ionisation electrodes Thermal insulation block Burner gauze assembly gasket...
  • Page 22 Commissioning, inspection, maintenance Checking the burner gauze assembly and thermal… (cont.) Fig. 12 120 to 160 kW Ignition and ionisation electrodes Thermal insulation block Burner gauze assembly gasket Burner gauze assembly Insulation mat Burner door gasket 1. Remove electrodes. 3. Replace any damaged components. Use new gas- kets.
  • Page 23 Commissioning, inspection, maintenance Checking the burner gauze assembly and thermal… (cont.) Check the burner gauze assembly for damage and contamination. In the event of damage or heavy con- tamination, replace the burner gauze assembly. Fig. 13 From 200 kW Ignition and ionisation electrodes Thermal insulation block Burner gauze assembly gasket Burner gauze assembly...

  • Page 24: Checking And Adjusting The Ignition And Ionisation Electrodes

    Commissioning, inspection, maintenance Checking the burner gauze assembly and thermal… (cont.) 2. Undo 4 nuts. Remove burner gauze assembly and 3. Replace any damaged components. Use new gas- insulating parts. kets. Please note Note Damage to the burner gauze assembly will Observe the positioning aid on the thermal insula- impair the burner function.

  • Page 25: Cleaning The Condensate Drain System

    Commissioning, inspection, maintenance Cleaning the combustion chamber and heating… (cont.) 4. Remove loosened deposits from the boiler. Flush the heating surfaces thoroughly with a jet of water. Cleaning agent manufacturer's instructions 5. Assemble in reverse order: Check gasket for possible damage and replace if required.

  • Page 26: Cleaning The Neutralising System (If Installed)

    Commissioning, inspection, maintenance Cleaning the condensate drain system (cont.) 1. Undo union nut of the trap. Remove the trap. 2. Clean the inside of inlet connector with a plastic brush. 3. Clean all parts of the trap. 4. Fill trap with water and assemble. Fit to inlet con- nector.

  • Page 27: Checking The Condensate Drain And Neutralising System (If Installed) For Obstructions And Leaks

    Commissioning, inspection, maintenance Checking the condensate drain and neutralising system (if installed) for obstructions and leaks 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. Checking the gaskets and thermal insulation sections on the boiler side 2.

  • Page 28: Checking The Flue Gas Damper And Flue Gas Header

    Commissioning, inspection, maintenance Checking the gaskets and thermal insulation… (cont.) Reassemble if the boiler flue connection was removed: 3. Push plug onto the flue gas temperature sensor Fig. 27). M8 - 18 Nm Fig. 20 Checking the flue gas damper and flue gas header Check the flue gas damper for damage and leaks.

  • Page 29: Checking The Expansion Vessel And System Pressure

    Commissioning, inspection, maintenance Checking the expansion vessel and system pressure Note 3. Top up with water until the charge pressure of the Check when system is cold. cooled system is 0.1 to 0.2 bar (10 to 20 kPa) higher than the pre-charge pressure of the expan- 1.

  • Page 30: Checking The Combustion Quality

    Commissioning, inspection, maintenance Checking all gas equipment for tightness at… (cont.) 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 test- ing.

  • Page 31: Checking The Ventilation Air Apertures In The Installation Room

    Commissioning, inspection, maintenance Checking the combustion quality (cont.) Selecting the upper/lower heating output Constant temperature control unit Weather-compensated control unit Service menu Service menu 1. Press OK and simultaneously for approx. 4 s. å 1. Press OK and simultaneously for approx. 4 s. 2.
  • Page 32 Commissioning, inspection, maintenance Adjusting heating curves (cont.) Slope -5 -10 -15 -20 Outside temperature in °C Fig. 23 Slope setting ranges: Reduced set room temperature ■ Underfloor heating systems: 0.2 to 0.8 ■ Low temperature heating systems: 0.8 to 1.6 Selecting the set room temperature Individually adjustable for each heating circuit.

  • Page 33: Connecting The Control Unit To The Lon

    Control unit receives outside temper- perature. perature. ature. Set code "97:2". Set code "97:1". Set code "97:1". Viessmann system number. Viessmann system number. Viessmann system number. Code "98:1" Code "98:1" Code "98:1" LON subscriber fault monitoring. LON subscriber fault monitoring.

  • Page 34: Calling Up And Resetting The "Service" Display

    Commissioning, inspection, maintenance Connecting the control unit to the LON (cont.) Carrying out a LON subscriber check 3. "Subscriber check" 4. Select subscriber (e.g. subscriber 10). The subscriber check is used to test communication 5. Start the subscriber check with "OK". with the system devices connected to the fault man- ager.

  • Page 35: Mounting The Front Panel

    Commissioning, inspection, maintenance Mounting the front panel Fig. 27 1. Position the front panel in the lower rim but do not 2. Secure with 2 screws. quite close it yet. Instructing the system user The system installer should hand the operating instruc- tions to the system user and instruct the user in oper- ating the system.

  • Page 36: Calling Up Coding Level 1

    Code 1 Calling up coding level 1 On weather-compensated control units, codes are 2. "Coding level 1" ■ displayed as plain text. ■ Codes that are not assigned due to the heating sys- 3. Select the group of required coding addresses. tem equipment level or the setting of other codes are not displayed.
  • Page 37 Code 1 General/Group "1" (cont.) Value, ad- Description dress 00: ... 1 heating circuit without mixer A1 (heating circuit 1), with DHW heating (code is set automatical- 1 heating circuit with mixer M2 (heating circuit 2), without DHW heating 1 heating circuit with mixer M2 (heating circuit 2), with DHW heating 1 heating circuit without mixer A1 (heating circuit 1) and 1 heating circuit with mixer M2 (heating circuit 2), without DHW heating (code is set automatically) 1 heating circuit without mixer A1 (heating circuit 1) and 1 heating circuit with mixer M2 (heating...

  • Page 38: Boiler/Group "2

    Code 1 General/Group "1" (cont.) Coding in the delivered condition Possible change Set flow temperature for external demand 9B:70 Set flow temperature for external 9B:0 Set flow temperature for external de- demand 70 °C mand adjustable from 0 to 127 °C 9B:127 (limited by boiler-specific parame- ters)

  • Page 39: Dhw/Group "3

    Code 1 DHW/Group "3" Coding Coding in the delivered condition Possible change Set DHW temperature reheating suppression 67:40 For solar DHW heating: Set DHW 67:0 Set DHW temperature adjustable temperature 40 °C. Reheating is from 0 to 95 °C (limited by boiler- suppressed above the selected set 67:95 specific parameters)

  • Page 40: Heating Circuit 1, Heating Circuit 2, Heating Circuit 3/Group "5

    Code 1 Solar/Group "4" (cont.) Coding in the delivered condition Possible change Extended solar control functions 20:0 No extended control function ena- 20:1 Auxiliary function for DHW heating bled 20:2 Differential temperature control 2. 20:3 Differential temperature control 2 and auxiliary function. 20:4 Differential temperature control 2 for central heating backup.
  • Page 41 Code 1 Heating circuit 1, heating circuit 2, heating… (cont.) Parameter address A5:... With heating circuit pump logic function: Heating circuit pump "OFF" > - 1 K > - 9 K > Coding in the delivered condition Possible change Extended economy function adjusted outside temperature A6:36 Extended economy mode disa- A6:5...
  • Page 42 Code 1 Heating circuit 1, heating circuit 2, heating… (cont.) Parameter address With heating circuit pump logic function: b5:... Heating circuit pump "OFF" Heating circuit pump "ON" + 5 K < RT + 4 K > actual actual + 4 K <...
  • Page 43 Code 1 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change Party mode time limit F2:8 Time limit for party mode or exter- F2:0 No time limit for party mode nal operating program changeover F2:1 Time limit adjustable from 1 to 12 h via pushbutton: 8 h (only for...

  • Page 44: Calling Up Coding Level 2

    Code 2 Calling up coding level 2 All codes are accessible in coding level 2. 3. "Coding level 2" ■ ■ Codes that are not assigned due to the heating sys- tem equipment level or the setting of other codes are 4.
  • Page 45 Code 2 General/Group "1" (cont.) Value, ad- Description dress 00: ... 1 heating circuit without mixer A1 (heating circuit 1), with DHW heating (code is set automatical- 1 heating circuit with mixer M2 (heating circuit 2), without DHW heating 1 heating circuit with mixer M2 (heating circuit 2), with DHW heating 1 heating circuit without mixer A1 (heating circuit 1) and 1 heating circuit with mixer M2 (heating circuit 2), without DHW heating (code is set automatically) 1 heating circuit without mixer A1 (heating circuit 1) and 1 heating circuit with mixer M2 (heating...
  • Page 46 Code 2 General/Group "1" (cont.) Coding in the delivered condition Possible change 3A:0 Function of input DE1 at EA1 ex- 3A:1 Function of input DE1: Operating tension: Not assigned program changeover 3A:2 Function of input DE1: External de- mand with set flow temperature Setting of set flow temperature for external demand: Code 9b Function, circulation pump for cylin-...
  • Page 47 Code 2 General/Group "1" (cont.) Coding in the delivered condition Possible change 3B:6 Function of input DE2: Brief opera- tion of DHW circulation pump (push- button function). Setting of DHW circulation pump runtime: Coding address 3d 3C:0 Function of input DE3 at EA1 ex- 3C:1 Function of input DE3: Operating tension: Not assigned...
  • Page 48 Code 2 General/Group "1" (cont.) Coding in the delivered condition Possible change 52:0 Without low loss header sensor 52:1 With low loss header sensor (auto- matic recognition) 53:1 Function, connection 28 at internal 53:0 Central fault message H1 extension 53:1 DHW circulation pump (delivered condition) 53:2...
  • Page 49 The control unit transmits the out- unit is used internally. side temperature to the LON sub- scribers. 98:1 Viessmann system number (in 98:1 System no. adjustable from 1 to 5 conjunction with monitoring of sev- eral systems via Vitocom 300)

  • Page 50: Boiler/Group "2

    Code 2 Boiler/Group "2" Coding Coding in the delivered condition Possible change 01:1 Single boiler system (only for con- 01:2 Multi boiler system with Vitotronic stant temperature control units) 300-K 04:1 Minimum burner pause time sub- 04:0 Minimum burner pause time set per- ject to the boiler load (specified by manently (specified by coding card) coding card)

  • Page 51: Dhw/Group "3

    Code 2 DHW/Group "3" Coding Coding in the delivered condition Possible change 56:0 Set DHW temperature adjustable 56:1 Set DHW temperature adjustable from 10 to 60 °C from 10 to above 60 °C Note Maximum value subject to coding card Observe the maximum permissible DHW temperature.

  • Page 52: Solar/Group "4

    Code 2 DHW/Group "3" (cont.) Coding in the delivered condition Possible change 71:2 "ON" during DHW heating to set val- ue 1 72:0 DHW circulation pump: "ON" ac- 72:1 "OFF" during DHW heating to set cording to time program (only for value 2 weather-compensated control unit) 72:2...
  • Page 53 Calculation of solar yield with water Viessmann heat transfer medium as heat transfer medium (do not se- lect as operation is only possible with Viessmann heat transfer medi- 0E:0 Calculation of solar yield switched 0F:70 The flow rate in the collector circuit...
  • Page 54 Code 2 Solar/Group "4" (cont.) Coding in the delivered condition Possible change 11:50 Set solar cylinder temperature 11:10 The set solar cylinder temperature is 50 °C adjustable from 10 to 90 °C. Target temperature control 11:90 ■ switched on (code 10:1): Temperature at which the solar heated water is to be stratified into the DHW cylinder.
  • Page 55 Code 2 Solar/Group "4" (cont.) Coding in the delivered condition Possible change 24:40 Start temperature for the thermo- 24:0 Start temperature for thermostat stat function 40 °C. function is adjustable from 0 to Start temperature for thermostat 24:100 100 K. function stop temperature for ≤...

  • Page 56: Heating Circuit 1, Heating Circuit 2, Heating Circuit 3/Group "5

    Code 2 Solar/Group "4" (cont.) Coding in the delivered condition Possible change 27:15 Cyclical heating time 15 min. 27:5 Cyclical heating time is adjustable If the DHW cylinder with priority from 5 to 60 min. has been heated up, the DHW cyl- 27:60 inder without priority is heated for a maximum duration equal to the set...
  • Page 57 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Parameter Heating circuit pump address A3:... "ON" "OFF" -5 °C -3 °C -4 °C -2 °C -3 °C -1 °C -2 °C 0 °C -1 °C 1 °C 0 °C 2 °C 1 °C 3 °C...
  • Page 58 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change A6:36 Extended economy mode disa- A6:5 Extended economy mode active, i.e. bled (only for weather-compensa- the burner and heating circuit pump ted control units) A6:35 are switched off at a variable value, adjustable from 5 to 35 °C plus 1 °C.
  • Page 59 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Parameter address With heating circuit pump logic function: b5:... Heating circuit pump "OFF" Heating circuit pump "ON" + 3 K < RT + 2 K > actual actual + 2 K <...
  • Page 60 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change E6:... Maximum speed of the variable E6:0 Maximum speed adjustable from 0 speed heating circuit pump in % of to 100 % the max. speed in standard mode. E6:100 This value is specified by boiler- specific parameters.
  • Page 61 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change FA:20 Increasing the set boiler water FA:0 Temperature increase adjustable temperature or set flow tempera- from 0 to 50 % ture by 20 % when changing from FA:50 operation with reduced room tem- perature to operation with standard...

  • Page 62: Diagnosis And Service Service Level, Weather-Compensated Control Unit

    Diagnosis and service scans Service level, weather-compensated control unit Calling up the service level Service menu: 1. Select "Terminate service?". Service menu: 2. Select "Yes". 1. Press OK and simultaneously for approx. 4 s. 3. Confirm with OK. å 2. Select required menu. See following diagram. Note Leaving the service level The system exits the service level automatically after...

  • Page 63: Brief Scan

    Diagnosis and service scans Diagnosis, weather-compensated control unit (cont.) Brief scan In the brief scan, you can call up temperatures, soft- 4. Press OK. ware versions and connected components, The display shows 9 rows with 6 fields each. for example. Diagnosis Brief scan 1.

  • Page 64: Testing Outputs (Relay Test)

    Diagnosis and service scans Diagnosis, weather-compensated control unit (cont.) Testing outputs (relay test) 1. Press OK and simultaneously for approx. 4 s. 2. "Actuator test" å The following relay outputs can be controlled subject to the system equipment level: Shown on display Explanation All actuators All actuators are off.
  • Page 65 Diagnosis and service scans Diagnosis, constant temperature control unit (cont.) For explanations of individual scans, see the following table: Brief scan Shown on display System scheme 1 Software version Software version to 2 Control unit Programming unit Adjusted outside temperature Set boiler water temperature Common demand temperature Set cylinder temperature...

  • Page 66: Testing Outputs (Relay Test)

    Diagnosis and service scans Diagnosis, constant temperature control unit (cont.) Brief scan Shown on display Solar central Output 22 switch- heating backup ing state 0: Disabled 0: OFF 1: Enabled 1: ON OpenTherm extension (if installed) Software ver- DHW heating sta- External hook-up 0 - 10 V sion Display in %...

  • Page 67: Troubleshooting Fault Display

    Troubleshooting Fault display Weather-compensated control unit In the event of a fault, red fault indicator flashes. Calling up acknowledged faults " " flashes on the display and "Fault" is shown. In the standard menu, select "Fault". Current faults will be listed. Calling up fault codes from the fault memory (fault history) The 10 most recent faults (including those remedied)

  • Page 68: Fault Codes

    Troubleshooting Fault display (cont.) Any fault message facility connected will be switched Faults are sorted by date. off. If an acknowledged fault is not remedied, the fault 1. Press OK and simultaneously for approx. 4 s. å message will be redisplayed the following day and the fault message facility restarted.
  • Page 69 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Mixer is being closed. Lead break, flow tempera- Check flow temperature sensor. ture sensor, heating circuit 2 (with mixer) Mixer is being closed. Lead break, flow tempera- Check flow temperature sensor. ture sensor, heating circuit 3 (with mixer) No DHW heating...
  • Page 70 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Control mode as per deliv- Communication error, pro- Check connections; replace pro- ered condition gramming unit gramming unit if necessary. Control mode as per deliv- Internal fault Replace control unit. ered condition Burner blocked Fault, coding card...
  • Page 71 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Control mode without room Short circuit, room tem- Check room temperature sensor, influence perature sensor, heating heating circuit 1. circuit 1 (without mixer) Control mode without room Short circuit, room tem- Check room temperature sensor, influence perature sensor, heating...
  • Page 72 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Burner in a fault state Ionisation current lies out- Check gas supply (gas pressure side the permissible range and gas flow switch), gas train and connecting cable. Check ionisation electrode for the following: Distance to burner gauze assem- ■...
  • Page 73 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Burner in a fault state Flame is lost immediately Check gas supply (gas pressure after it has built (during and gas flow switch). safety time). Check balanced flue system for flue gas recirculation.
  • Page 74 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Burner blocked or in a fault Coding card or main PCB Press reset button R. If fault per- state faulty, or incorrect coding sists, check the coding card and card replace coding card or control unit if necessary.

  • Page 75: Maintenance Checking The Outside Temperature Sensor

    Maintenance Checking the outside temperature sensor Fig. 33 3. Disconnect plug "X3" from the control unit. 4. Measure the resistance of the outside temperature sensor across terminals "X3.1" and "X3.2" on the disconnected plug. Compare with the curve. 5. If the results are very different from the curve, dis- connect the wires from the sensor.

  • Page 76: Checking The Cylinder Temperature Sensor

    Maintenance Checking the cylinder temperature sensor 1. Cylinder temperature sensor Pull out plug . Measure the resistance. 2. Check sensor resistance and compare it to the curve. Fig. 35 3. In the event of severe deviation replace the sensor. Temperature in °C Fig.

  • Page 77: Checking The Flue Gas Temperature Sensor

    Maintenance Checking the boiler water temperature sensor (cont.) 2. Measure the resistance of both sensors and com- pare each with the curve. 3. In the event of severe deviation replace the sensor. Temperature in °C Fig. 38 Sensor type: NTC 10 k Ω...

  • Page 78: Checking The Fuse

    Maintenance Checking the flue gas temperature sensor (cont.) 1. Disconnect the leads from the flue gas temperature sensor. Fig. 39 2. Measure the resistance of both sensors and com- pare each with the curve. 3. In the event of severe deviation replace the sensor. Temperature in °C Fig.

  • Page 79: Mixer Extension Kit

    Maintenance Checking the fuse (cont.) Fig. 41 5. Check fuse F1 (see connection diagram, page 93) Mixer extension kit Checking the setting of rotary selector S1 Note The mixer motor can also be started via the actuator The rotary selector on the PCB of the extension kit test (see chapter "Checking outputs").

  • Page 80: Checking The Vitotronic 200-H (Accessories)

    Maintenance Mixer extension kit (cont.) Changing the rotational direction of the mixer motor (if required) 1. Remove the upper casing cover of the extension kit. 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.

  • Page 81: Function Description Weather-Compensated Control Unit

    Function description Weather-compensated control unit 21°C 14°C Boiler temperature 48 °C Fig. 44 Heating mode The control unit determines a set boiler water tempera- The electronic temperature limiter inside the burner ture subject to outside temperature or room tempera- control unit limits the boiler water temperature. ture (if a room temperature-dependent remote control is connected) and to the slope level of the heating...

  • Page 82: Internal Extensions

    Function description Internal extensions Internal H1 extension Fig. 45 The internal extension is integrated into the control unit An external safety valve can be linked to connection enclosure. The following alternative functions can be connected to relay output . The function is assigned Power supply for accessories and Vitotrol 100 via coding address "53"...

  • Page 83: Internal H2 Extension

    Function description Internal extensions (cont.) Internal H2 extension Fig. 46 The internal extension is integrated into the control unit An extractor fan can be switched off via connection enclosure. The following alternative functions can be when the burner starts. connected to relay output .

  • Page 84: External Extension (Accessories)

    Function description External extension (accessories) AM1 extension Fig. 47 Circulation pump A Power supply for additional accessories fÖ Circulation pump KM-BUS Power supply fÖ Functions Select the output functions via parameter changes/ codes at the boiler control unit. One of the following circulation pumps can be connec- ted to each of connections A1 and A2: Heating circuit pump for heating circuit without mixer ■...

  • Page 85: Ea1 Extension

    Function description External extension (accessories) (cont.) EA1 extension Fig. 48 Digital input 1 Power supply fÖ Digital input 2 Power supply for additional accessories fÖ Digital input 3 Central fault message/feed pump/DHW circu- Fuse lation pump (potential-free) 0 - 10 V 0 to 10 V input KM-BUS Digital data inputs DE1 to DE3 Input function assignment...

  • Page 86: Control Functions

    Function description External extension (accessories) (cont.) ≙ Effect of the "External blocking" function on the 0 - 1 V "No specification for set boiler water temper- circulation pumps ature" ≙ Set value 10 °C ≙ The effect on the relevant heating circuit pump is 10 V Set value 100 °C selected with code d6.

  • Page 87: External Blocking

    Function description Control functions (cont.) The duration of the operating program changeover can be adjusted in coding address "F2": Operating program changeover Code No operating program changeover F2:0 Duration of the operating program changeover 1 to 12 h F2:1 to F2:12 The operating program changeover stays enabled for as long as the contact remains closed, but at least as...

  • Page 88: Screed Drying

    Function description Control functions (cont.) EA1 extension Plug ■ The function is selected via code 4b:1 in the "Gen- The "External demand" function is implemented via the eral"/1 group. EA1 extension. There are 3 inputs available at the EA1 The effect on the circulation pump for cylinder heat- extension (DE1 to DE3).

  • Page 89: Raising The Reduced Room Temperature

    Function description Control functions (cont.) Temperature profile 3 (to ÖNORM): Code "F1:3" ϑ/°C Fig. 51 Temperature profile 4: Code "F1:4" ϑ/°C Fig. 52 Temperature profile 5: Code "F1:5" ϑ/°C Fig. 53 Temperature profile 6: Code "F1:6" ϑ/°C Fig. 54 Temperature profile 7: Code "F1:15" Days Fig.

  • Page 90: Reducing The Heat-Up Time

    Function description Control functions (cont.) Example using the settings in the delivered condition Outside temperature in °C Fig. 56 Heating curve for operation at standard room tem- perature Heating curve for operation at reduced room tem- perature Reducing the heat-up time During the transition from operation with reduced room The value and duration of the additional increase of temperature to operation with standard room tempera-...

  • Page 91: Allocating Heating Circuits To The Remote Control

    Function description Control functions (cont.) Example using the settings in the delivered condition Time Fig. 57 Start of operation at standard room temperature Set boiler water or flow temperature in accordance Set boiler water or flow temperature in accordance with coding address "FA": with the selected heating curve 50 °C + 20 % = 60 °C Duration of operation with raised set boiler water...
  • Page 92 Function description Electronic combustion control unit (cont.) To check the combustion quality, the CO content or the O content of the flue gas is measured. The pre- vailing air ratio is determined using the actual values. The correlation between CO or O content and air ratio...

  • Page 93: Connection And Wiring Dia-Connection And Wiring Diagram

    Connection and wiring diagram Connection and wiring diagram Fig. 58 Outside temperature sensor Circulation pump, either: Flow temperature sensor for low loss header ■ Circulation pump for cylinder heating (accessories) ■ External heating circuit pump Cylinder temperature sensor ■ DHW circulation pump Boiler circuit pump or butterfly valve with return sÖ...
  • Page 94 Connection and wiring diagram Connection and wiring diagram (cont.) Internal H1 extension Main PCB ■ Central fault message Coding card ■ DHW circulation pump ON/OFF switch ■ External heating circuit pump Programming unit ■ Circulation pump for cylinder heating Connection adaptor with Optolink Gas train Connection adaptor Flue gas damper (accessories)
  • Page 95 Connection and wiring diagram Connection and wiring diagram (cont.) Fig. 59 A1 Main PCB A11 Output extension SA 169 A4 ON/OFF switch Boiler circuit pump or butterfly valve with return sÖ spring Power supply fÖ Fan motor a¢Ö...

  • Page 96: Gram ■ Up To 80 Kw

    Connection and wiring diagram Connection and wiring diagram (cont.) Up to 80 kW Fig. 60...

  • Page 97: From 120 Kw

    Connection and wiring diagram Connection and wiring diagram (cont.) From 120 kW Fig. 61 Outside temperature sensor, only with weather- Internal H1 extension compensated system ■ Central fault message Flow temperature sensor ■ DHW circulation pump Cylinder temperature sensor External heating circuit pump ■...

  • Page 98: Main Pcb Up To 80 Kw

    Connection and wiring diagram Connection and wiring diagram (cont.) Flue gas damper Coding card Power supply for accessories and Vitotrol 100 ON/OFF switch Gas pressure switch Programming unit KM-BUS subscriber (accessories) Connection adaptor with Optolink Vitotrol 200-A or 300-A remote control Connection adaptor ■...

  • Page 99: Main Pcb 120 To 160 Kw

    Connection and wiring diagram Connection and wiring diagram (cont.) A Modulation coil a:Ö a:Ö X9.8/9 Combustion chamber pressure switch and water pressure switch Main PCB 120 to 160 kW Fig. 63 A Boiler water temperature sensor Fan motor control § §...

  • Page 100: Main Pcb From 240 Kw

    Connection and wiring diagram Connection and wiring diagram (cont.) Main PCB from 240 kW Fig. 64 A Boiler water temperature sensor Fan motor control § § a¢Ö Ionisation electrode Modulation coil a:Ö Flue gas temperature sensor X9.8/9 Combustion chamber pressure switch and Ignition unit water pressure switch Fan motor...

  • Page 101: External Connection Diagram

    Connection and wiring diagram External connection diagram 230V~ Fig. 65 Plug 230 V~ Rated voltage: 230 V~ Boiler circuit pump or butterfly valve with return Rated current: Max. 2 (1) A~ sÖ spring (only with multi boiler system) DHW circulation pump (accessories) Rated voltage: 230 V~ Rated voltage: 230 V~ Rated current: Max.

  • Page 102: Water Quality Requirements

    Water quality Requirements Water quality requirements Prevention of damage due to scaling Note Prevent excessive scale build-up (calcium carbonate) Observing the following requirements is necessary to on the heating surfaces. For heating systems with safeguard your warranty rights. operating temperatures up to 100 °C, VDI Guideline The warranty excludes damage due to corrosion and 2035 Part 1 "Prevention of damage in water heating scaling.
  • Page 103 Water quality Requirements (cont.) This measure must be carried out by a qualified con- No further anti-corrosion measures are required for tractor. Inspect the heating system for possible dam- sealed unvented hot water heating systems, subject to age prior to returning it into use. It is essential that the above points being observed.

  • Page 104: Commissioning/Service Fill And Top-Up Water

    Commissioning/service reports Fill and top-up water Meter reading Fill and top- Total water Total hardness pH value Date up water volume Feedwater Boiler water Settings and test values Settings and test values Set value Commissioning Maintenance/ service Static pressure mbar ≤...
  • Page 105 Commissioning/service reports Settings and test values (cont.) Settings and test values Set value Commissioning Maintenance/ service Carbon monoxide content CO At lower heating output < 60 ■ At upper heating output < 100 ■...

  • Page 106: Specification Vitocrossal Specification

    Specification Vitocrossal specification Rated voltage 230 V Rated frequency 50 Hz Protection class Permissible ambient temper- ature Operation 0 to +40 °C ■ Storage and transport -20 to +65 °C ■ Backup fuse (power supply) max. 16 A Rated heating output range...
  • Page 107 Specification Vitocrossal specification (cont.) Rated heating output range = 50/30 16 - 80 32 - 120 32 - 160 48 - 200 48 - 240 64 - 280 64 - 318 cond = 80/60 15 - 74 29 - 110 29 - 146 44 - 184 44 - 220 58 - 258...

  • Page 108: Specification - Matrix Cylinder Burner

    Specification Vitocrossal specification (cont.) Twin boiler specification Rated heating output Twin boiler comprises 2 boilers, each with Total dimensions incl. casing, boiler flow and return; excl. boiler flue connec- tion Length 1085 1085 Width 1500 Height 1650 Total weight Water capacity Specification –...

  • Page 109: Shutdown And Disposal Final Decommissioning And Disposal

    Shutdown and disposal Final decommissioning and disposal Viessmann products can be recycled. Components For decommissioning the system, isolate the system and substances from the system are not part of ordi- from the power supply and allow components to cool nary household waste.

  • Page 110: Certificates Declaration Of Conformity

    Manufacturer's certificate according to the 1st BImSchV [Germany] We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, confirm that the product Vitocrossal complies with the NO limits specified by the 1st BImSchV paragraph 6 [Germany].

  • Page 111: Keyword Index

    Keyword index Keyword index Control unit for weather-compensated operation Acknowledging a fault display........67 – Calling up operating data........62 Cylinder temperature sensor........76 Boiler flue connection..........27 Boiler water requirements........102 Date, setting............... 12 Boiler water temperature sensor........ 76 Disposal..............109 Boosting DHW heating..........81 Brief scans..............
  • Page 112 Wiring diagram............93 – Fill and top-up water..........104 – Settings/test values..........104 Rotational direction, mixer motor – Changing..............80 – Checking..............79 Viessmann Werke GmbH & Co. KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB...

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