Viessmann Vitocrossal 100 Series Service Instructions For Contractors
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Viessmann Vitocrossal 100 Series Service Instructions For Contractors

Gas condensing boiler with matrix cylinder burner, open flue and room sealed operation 80 to 318 kw/240 to 636 kw
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VIESMANN
Service instructions
for contractors
Vitocrossal 100
Type CI1, 80 to 318 kW
Type CI1 twin boiler, 240 to 636 kW
Gas condensing boiler with MatriX cylinder burner
Open flue and room sealed operation
For applicability, see the last page
VITOCROSSAL 100
Please keep safe.
5792 925 GB
4/2017

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Summary of Contents for Viessmann Vitocrossal 100 Series

  • Page 1 VIESMANN Service instructions for contractors Vitocrossal 100 Type CI1, 80 to 318 kW Type CI1 twin boiler, 240 to 636 kW Gas condensing boiler with MatriX cylinder burner Open flue and room sealed operation For applicability, see the last page VITOCROSSAL 100 Please keep safe.
  • Page 2 Hot surfaces can cause burns. Replace faulty components only with genuine ■ Before maintenance and service work, switch Viessmann spare parts. OFF the appliance and let it cool down. Never touch hot surfaces on the boiler, burner, ■ flue system or pipework.

  • Page 3: Safety Instructions

    For replacements, use only original spare parts supplied or approved by Viessmann. Safety instructions for operating the system If you smell gas Condensate Danger...

  • Page 4: Table Of Contents

    Index Index 1. Information Symbols ....................Intended use ..................Information for twin boilers ..............2. Commissioning, inspec- Steps – commissioning, inspection and maintenance ......tion, maintenance 3. Code 1 Calling up coding level 1 ................ 33 General/Group "1" ................. 34 Boiler/Group "2"...
  • Page 5 Index Index (cont.) Internal H1 extension ................104 ■ Internal H2 extension ................105 ■ External extension (accessories) ............106 AM1 extension ..................106 ■ EA1 extension ..................107 ■ Control functions ..................108 External operating program changeover ..........108 ■ External blocking ................109 ■...

  • Page 6: 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 7: Information For Twin Boilers

    Information Information for twin boilers The tasks for commissioning, inspection and servicing are depicted on a single boiler. For twin boilers, the work must be carried out on both boilers. For this rea- son, the illustrations may differ partly.

  • Page 8: 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......• 2. Checking the power supply • 3. Changing the language (if required)................. •...

  • Page 9: Filling The Heating System And Checking The Supply Of Ventilation Air

    126. 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 10: Setting The Time And Date (If Required)

    Commissioning, inspection, maintenance Setting the time and date (if required) Only for weather-compensated control units The time and date need to be reset during commis- Note sioning or after a prolonged time out of use (approx. 18 When time and date have been set, the control unit days).

  • Page 11: 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 and en- demand...

  • Page 12: 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 13: 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 14: Checking The Combustion Chamber Pressure Limiter

    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 15: Removing The Burner And Checking The Burner Gasket

    Commissioning, inspection, maintenance Removing the burner and checking the burner gasket Burners 80 kW Fig. 7 80 kW Burner fixings, 4 screws Gas train Ignition electrode Gas supply pipe Ionisation electrode Ventilation air hose, only for room sealed opera- Ignition transformer tion.
  • Page 16 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. 8 Burner fixings, 4 screws Gas train Ignition electrode Gas supply pipe Ionisation electrode Ventilation air hose, only for room sealed opera-...
  • Page 17 Commissioning, inspection, maintenance Removing the burner and checking the burner… (cont.) Burners from 200 kW Burners for 200 to 318 kW boilers and 400 to 636 kW twin boilers Fig. 9 Burner fixings, 4 screws Gas supply pipe Ignition electrode Ventilation air hose, only for room sealed opera- tion.

  • Page 18: 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. In the event of damage, replace the burner gauze assembly. Fig. 10 80 kW Ignition and ionisation electrodes Thermal insulation block Burner gauze assembly gasket Burner gauze assembly Insulation mat...
  • Page 19 Commissioning, inspection, maintenance Checking the burner gauze assembly and thermal… (cont.) Fig. 11 120 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. 2. Undo 4 nuts. Remove burner gauze assembly and insulating parts.
  • Page 20 Commissioning, inspection, maintenance Checking the burner gauze assembly and thermal… (cont.) 3. Replace any damaged components. Use new gas- 4. Reassemble in reverse order. Observe torque val- kets. ues, see table on page 21. Note Check the burner gauze assembly for damage. In the Observe the positioning aid on the thermal insula- event of damage, replace the burner gauze assembly.

  • Page 21: 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 22: Cleaning The Condensate Drain System

    Commissioning, inspection, maintenance Cleaning the combustion chamber and heating… (cont.) 1. Undo 3 screws. Remove locking bracket. 2. Unscrew the inspection cover and remove. 3. Clean the combustion chamber and heating surfa- ces. For normal cleaning, flush the heating surfaces ■...

  • Page 23: 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 brush. 3. Clean all parts of the trap. 4. Assemble trap, fill with water and refit to inlet con- nector.

  • Page 24: Checking The Condensate Drain And Neutralising System (If Installed) For Obstructions And Leaks

    Commissioning, inspection, maintenance Cleaning the neutralising system (if installed) (cont.) 2. Pull the neutralising system out from under the boiler, from the front. To remove front panel, see page 11. "Neutralising system" installation and service instructions Note With twin boilers, the neutralising system is positioned behind the boiler.

  • Page 25: Checking The Gaskets And Thermal Insulation Sections On The Boiler Side

    Commissioning, inspection, maintenance Checking the gaskets and thermal insulation sections on the boiler side 2. Check the fittings on the heating water side for leaks and replace the seals/gaskets if required. Danger There is a risk of injury when working on pressurised components.

  • Page 26: Checking The Mixer For Ease Of Operation And Leaks

    Commissioning, inspection, maintenance Checking the mixer for ease of operation and leaks 1. Remove the motorised lever from the mixer han- 3. Check the mixer for leaks. In the event of a leak, dle. replace the O-rings. 2. Check the mixer for ease of operation. 4.

  • Page 27: Checking The Ventilation Air Apertures In The Installation Room

    Commissioning, inspection, maintenance Checking the combustion quality (cont.) 03. Adjust the lower heating output. 04. Check the lower heating output. 05. Check the CO content. If the actual value devi- ates from the aforementioned ranges by more than 1 %, check the ionisation electrode and con- necting cable.

  • Page 28: Matching The Control Unit To The Heating System

    Commissioning, inspection, maintenance Matching the control unit to the heating system The control unit must be matched to the system equip- For individual coding steps, see page 33. ■ ment level. Various system components are recog- nised automatically by the control unit and the relevant codes are set automatically.

  • Page 29: Connecting The Control Unit To The Lon

    Commissioning, inspection, maintenance Adjusting heating curves (cont.) Standard set room temperature Changing the reduced set room temperature Operating instructions Changing the slope and level Individually adjustable for each heating circuit. Fig. 22 Example 1: Adjustment of the standard set room temperature from 20 to 26 °C Boiler water temperature or flow temperature in °C Outside temperature in °C Set room temperature in °C...
  • Page 30 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 31: Calling Up And Resetting The "Service" Display

    Commissioning, inspection, maintenance Calling up and resetting the "Service" display The red fault indicator flashes when the limits set in coding addresses "21" and "23" have been reached. (Coding address in group "Boiler" (weather-compen- sated control unit) or group 2 (constant temperature control unit).) Weather-compensated control unit Constant temperature control unit...

  • Page 32: Instructing The System User

    Commissioning, inspection, maintenance 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 33: Calling Up Coding Level 1

    Code 1 Calling up coding level 1 On weather-compensated control units, codes are ■ displayed as plain text. ■ Codes that are not assigned due to the heating sys- tem equipment level or the setting of other codes are not displayed. Heating systems with one heating circuit without ■...

  • Page 34: General/Group "1

    Code 1 General/Group "1" Coding Coding in the delivered condition Possible change System design 00:1 System version 1: 00:2 For system schemes, see the follow- One heating circuit without mixer ing table: A1 (heating circuit 1), without DHW 00:10 heating Value, ad- Description dress 00: ...

  • Page 35: Boiler/Group "2

    Code 1 General/Group "1" (cont.) Coding in the delivered condition Possible change Lock out controls 8F:0 Operation enabled in standard 8F:1 Operation is blocked in standard menu and extended menu. menu and extended menu. Emis- sions test mode can be activated. Note 8F:2 Operation is enabled in standard...

  • Page 36: 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 37: 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 38 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 39 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 40 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 41: Calling Up Coding Level 2

    Code 2 Calling up coding level 2 All codes are accessible in coding level 2. ■ ■ Codes that are not assigned due to the heating sys- tem equipment level or the setting of other codes are not displayed. ■ The heating circuit without mixer is designated "Heating circuit 1"...
  • Page 42 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 43 Code 2 General/Group "1" (cont.) Coding in the delivered condition Possible change 39:1 Function of output : Heating cir- cuit pump 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...
  • Page 44 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 45 Code 2 General/Group "1" (cont.) Coding in the delivered condition Possible change 54:0 Without solar thermal system 54:1 With Vitosolic 100 (automatic recog- nition) 54:2 With Vitosolic 200 (automatic recog- nition) 54:4 With solar control module SM1 with auxiliary function, e.g. central heat- ing backup (automatic recognition) 6E:50 No correction of measured outside...

  • Page 46: Boiler/Group "2

    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 47: Dhw/Group "3

    Code 2 Boiler/Group "2" (cont.) Coding in the delivered condition Possible change 07:1 Boiler number in multi boiler sys- 07:2 Boiler number 2 to 4 in multi boiler tems (only for constant tempera- systems ture control units) 07:4 08:... Maximum burner heating output in 08:0 Maximum burner heating output ad- kW, in multi boiler systems...
  • Page 48 Code 2 DHW/Group "3" (cont.) Coding in the delivered condition Possible change Note Maximum value subject to coding card Observe the maximum permissible DHW temperature. 58:0 Without auxiliary function for DHW 58:10 Input of a second set DHW tempera- heating ture, adjustable from 10 to 60 °C 58:60 (observe coding addresses "56"...

  • Page 49: Solar/Group "4

    Code 2 DHW/Group "3" (cont.) Coding in the delivered condition Possible change 73:0 DHW circulation pump: "ON" ac- 73:1 "ON" from once per hour for 5 min cording to time program (only for up to 6 times per hour for 5 min dur- weather-compensated control 73:6 ing the time program...
  • Page 50 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 51 Code 2 Solar/Group "4" (cont.) Coding in the delivered condition Possible change 12:20 Minimum collector temperature 12:0 Minimum collector temperature func- 20 °C tion switched off The solar circuit pump is only star- 12:1 The minimum collector temperature ted when the set minimum collec- is adjustable from 1 to 90 °C.
  • Page 52 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 53: 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 54 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Parameter Heating circuit pump address A3:... "ON" "OFF" -6 °C -4 °C -5 °C -3 °C -4 °C -2 °C -3 °C -1 °C -2 °C 0 °C -1 °C 1 °C 0 °C 2 °C...
  • Page 55 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: bled (only for weather-compensa- Meaning the burner and heating cir- ted control units) A6:35 cuit pump are switched off at a vari- able value, adjustable from 5 to...
  • Page 56 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" + 5 K < RT + 4 K > actual actual + 4 K <...
  • Page 57 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change E2:51 Display correction +0.1 K E2:99 Display correction +4.9 K E5:... Never adjust. E6:... Maximum speed of the variable E6:0 Maximum speed adjustable from 0 speed heating circuit pump in % of to 100 % the max.
  • Page 58 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 59: Diagnosis And Service Service Level, Weather-Compensated Control Unit

    Diagnosis and service scans Service level, weather-compensated control unit Calling up the service menu 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 60: 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 61: 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 62 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 63: 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 64: 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 65: Fault Codes

    Troubleshooting Fault display (cont.) Calling up acknowledged faults 1. Press OK and simultaneously for approx. 4 s. å Hold down OK for approx. 4 s. 2. Select " ". Enable fault history with OK. ã The 10 most recent faults (including those remedied) are saved and can be called up.
  • Page 66 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Mixer is being closed. Short circuit, flow temper- Check flow temperature sensor. ature sensor, heating cir- cuit 3 (with mixer) Mixer is being closed. Lead break, flow tempera- Check flow temperature sensor.
  • Page 67 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Burner blocked Short circuit, flue gas tem- Check flue gas temperature sen- perature sensor sor. Control mode as per deliv- Communication error, pro- Check connections; replace pro- ered condition gramming unit gramming unit if necessary.
  • Page 68 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Control mode Input DE3 at EA1 exten- Remedy fault at appliance con- sion reports a fault. cerned. Control mode without room Short circuit, room tem- Check room temperature sensor, influence perature sensor, heating heating circuit 1.
  • Page 69 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 70 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 71 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 72 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played No solar DHW heating Short circuit, collector Check temperature sensor & temperature sensor solar control module or sensor on the Vitosolic. Control mode Short circuit, cylinder tem- Check temperature sensor at ter- perature sensor minal S3 on the Vitosolic 100.
  • Page 73 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Control mode without remote Communication error, Check connections, cable and cod- control Vitotrol remote control, ing address "A0" in the "Heating heating circuit 1 (without circuit" group and the remote con- mixer) trol settings.
  • Page 74 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Control mode without room Lead break, room temper- Check room temperature sensor influence ature sensor, heating cir- for heating circuit 2 and the remote cuit 2 (with mixer) control settings.
  • Page 75 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Burner in a fault state Repeated flame loss dur- Check gap between ionisation ing calibration electrode and burner gauze as- sembly (see page 21). Check flue system; remove flue gas recirculation if required.
  • Page 76 Troubleshooting Fault codes (cont.) Fault code dis- System characteristics Cause Measures played Burner in a fault state Fan speed too low during Check the fan. Check the fan con- burner start necting cables. Check the fan pow- er supply. Check the fan control. Press reset button R.

  • Page 77: Maintenance Checking The Outside Temperature Sensor

    Maintenance Checking the outside temperature sensor Fig. 31 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 78: 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. 33 3. In the event of severe deviation replace the sensor. Temperature in °C Fig.

  • Page 79: Checking The Flue Gas Temperature Sensor

    Maintenance Checking the boiler water temperature sensor (cont.) 2. Check the sensor resistance and compare it with the curve. 3. In the event of severe deviation replace the sensor. Temperature in °C Fig. 36 Sensor type: NTC 10 k Ω Checking the flue gas temperature sensor Note The boiler water temperature sensor is a dual sensor.

  • Page 80: Checking The Fuse

    Maintenance Checking the flue gas temperature sensor (cont.) 1. Disconnect the leads from the flue gas temperature sensor. Fig. 37 2. Check the sensor resistance and compare it with the curve. 3. In the event of severe deviation replace the sensor. Temperature in °C Fig.

  • Page 81: Mixer Extension Kit

    Maintenance Checking the fuse (cont.) Fig. 39 5. Check fuse F1 (see connection diagram, page 116) 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 82: 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 83: Parts Lists Overview Of Assemblies

    Parts lists Overview of assemblies The following details are required when ordering: ■ Serial no. (see type plate ■ Assembly (from this parts list) ■ Position number of the individual part within the assembly (from this parts list) Type plate Thermal insulation assembly Control unit assembly Programming unit assembly...

  • Page 84: Thermal Insulation Assembly

    Parts lists Thermal insulation assembly 0019 0018 0013 0005 0012 0009 0006 0002 0003 0011 0008 0014 0016 0010 0004 0001 0007 0017 0015 0008 0016 0017 0021 0020 Fig. 42...
  • Page 85 Side panel, right 0011 Back panel, bottom 0012 Back panel, top 0013 Shield panel 0014 Control panel 0015 Front panel 0016 Viessmann logo 0017 Vitocrossal 100 logo 0018 Top panel, front 0019 Top panel, back 0020 Front cover 0021 Fixings...

  • Page 86: Twin Boiler Thermal Insulation Assembly

    Parts lists Twin boiler thermal insulation assembly 0019 0018 0012 0022 0013 0011 0005 0013 0001 0006 0009 0005 0007 0006 0002 0014 0002 0008 0007 0003 0016 0017 0016 0003 0010 0004 0001 0017 0004 0023 0008 0015 0021 0020 0016 0016...
  • Page 87 Twin boiler back panel, top 0013 Shield panel 0014 Control panel 0015 Twin boiler front panel, left 0016 Viessmann logo 0017 Vitocrossal 100 logo 0018 Twin boiler top panel, front 0019 Twin boiler top panel, back 0020 Twin boiler front panel, right...

  • Page 88: Boiler Assembly, Boilers Up To 160 Kw

    Parts lists Boiler assembly, boilers up to 160 kW 0007 0010 0008 0008 0001 0011 0002 0009 0003 0012 0004 0005 0006 0007 0006 0008 0009 0002 0005 0010 0011 0012 0005 0004 0003 0002 0005 0005 0006 Fig. 44...
  • Page 89 Parts lists Boiler assembly, boilers up to 160 kW (cont.) Pos. Part 0001 Boiler 0002 Base rail 0003 Mounting bracket 0004 Swivel castor 0005 Adjustable foot 0006 Wheel 0007 Boiler flue connection 0008 NTC temperature sensor 0009 Trap 0010 Retaining bracket 0011 Cover with pressure seal 0012...

  • Page 90: Boiler Assembly, Boilers From 200 To 318 Kw

    Parts lists Boiler assembly, boilers from 200 to 318 kW 0007 0010 0008 0008 0009 0001 0004 0011 0005 0006 0012 0007 0008 0009 0010 0011 0012 0006 0006 0005 0004 0005 0005 0005 Fig. 45...
  • Page 91 Parts lists Boiler assembly, boilers from 200 to 318 kW (cont.) Pos. Part 0001 Boiler 0004 Swivel castor 0005 Adjustable foot 0006 Wheel 0007 Boiler flue connection 0008 NTC temperature sensor 0009 Trap 0010 Retaining bracket 0011 Cover with pressure seal 0012 Locking bracket...

  • Page 92: Burner Assembly, Burners Up To 80 Kw

    Parts lists Burner assembly, burners up to 80 kW 0002 0001 0002 0009 0007 0004 0002 0003 0007 0007 0006 0009 0004 0007 0009 0004 0008 0003 0002 0005 0009 0020 0019 0018 0015 0019 0010 0014 0016 0011 0012 0016 0017 0016...
  • Page 93 Parts lists Burner assembly, burners up to 80 kW (cont.) Pos. Part 0001 Burner gauze assembly VC100 0002 Gasket, burner gauze assembly 0003 Thermal insulation components 0004 Boiler door gasket 0005 Boiler door 0006 Ignition electrode block including ignition cable 0007 Electrode block gasket 0008...

  • Page 94: Burner Assembly, Burners 120/160 Kw

    Parts lists Burner assembly, burners 120/160 kW 0002 0001 0009 0007 0004 0002 0003 0002 0007 0007 0006 0009 0004 0009 0007 0008 0004 0003 0009 0002 0005 0010 0018 0019 0020 0019 0013 0011 0012 0016 0017 0017 0015 0014 Fig.
  • Page 95 Parts lists Burner assembly, burners 120/160 kW (cont.) Pos. Part 0001 Burner gauze assembly VC100 0002 Gasket, burner gauze assembly 0003 Thermal insulation components 0004 Boiler door gasket 0005 Boiler door 0006 Ignition electrode block with ignition cable 0007 Electrode block gasket 0008 Ionisation electrode 0009...

  • Page 96: Burner Assembly, Burners 200 To 318 Kw

    Parts lists Burner assembly, burners 200 to 318 kW 0002 0001 0009 0007 0004 0002 0003 0002 0007 0006 0009 0007 0007 0004 0004 0003 0009 0002 0008 0005 0009 0016 0020 0021 0022 0021 0010 0015 0012 0018 0011 0014 0017 0019...
  • Page 97 Parts lists Burner assembly, burners 200 to 318 kW (cont.) Pos. Part 0001 Burner gauze assembly VC100 0002 Gasket, burner gauze assembly 0003 Thermal insulation components 0004 Boiler door gasket 0005 Boiler door 0006 Ignition electrode block including ignition cable 0007 Electrode block gasket 0008...

  • Page 98: Programming Unit Assembly

    Parts lists Programming unit assembly 0002 0003 0002 0003 0006 0008 0010 0001 0006 0012 0010 0013 0008 0004 0012 0005 0011 0009 0007 Fig. 49...
  • Page 99 Parts lists Programming unit assembly (cont.) Pos. Part 0001 Programming module 0002 Programming unit cover 0003 Cover panel, programming unit cover 0004 Vitotronic 100 HO1B 0005 Vitotronic 100 0006 PCB SA168 A10 0007 Ribbon cable with cable grommets 0008 Toggle switch OFF 2-pole 0009 Power cable, internal 0010...

  • Page 100: Control Unit Assembly

    Parts lists Control unit assembly 0004 0003 0005 0010 0013 0009 0014 0015 0015 0008 0010 0009 0026 0007 0006 0004 0001 0006 0008 0007 0011 0012 0016 0017 0018 0019 0020 0021 0022 0025 0023 0024 0027 Fig. 50...
  • Page 101 Parts lists Control unit assembly (cont.) 0001 Control unit VBC144-A10 0003 Coding card 0004 Fuse holder 0005 Fuse, 6.3 A (slow)/250 V (10 pce) 0006 Control unit side sections (set) 0007 Small parts (feet, screws, grommets) 0008 Side section with cable entry 0009 PCB SA169-A10 0010...

  • Page 102: Miscellaneous

    Parts lists Miscellaneous Parts not shown Pos. Part 0002 Touch-up spray paint, Vitosilver, 150 ml can 0003 Touch-up paint stick, Vitosilver 0004 Installation instructions 0005 Service instructions...

  • Page 103: Function Description Weather-Compensated Control Unit

    Function description Weather-compensated control unit 21°C 14°C Boiler temperature 48 °C Fig. 51 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 104: Internal Extensions

    Function description Internal extensions Internal H1 extension Fig. 52 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 105: Internal H2 Extension

    Function description Internal extensions (cont.) Internal H2 extension Fig. 53 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 106: External Extension (Accessories)

    Function description External extension (accessories) AM1 extension Fig. 54 Circulation pump A Power supply for additional accessories fÖ Circulation pump KM-BUS Power supply fÖ Functions Select the output functions via the codes on the boiler control unit. One of the following circulation pumps can be connec- ted to each of the connections A1 and A2: Heating circuit pump for heating circuit without mixer ■...

  • Page 107: Ea1 Extension

    Function description External extension (accessories) (cont.) EA1 extension Fig. 55 Digital input 1 Power supply for additional accessories fÖ Digital input 2 Central fault message/feed pump/DHW circu- Digital input 3 lation pump (potential-free) 0 - 10 V 0 - 10 V input KM-BUS Power supply fÖ...

  • Page 108: Control Functions

    Function description External extension (accessories) (cont.) Input function assignment The effect on a circulation pump for cylinder heating is selected with code 5F. The functions of the inputs are selected via the codes on the boiler control unit: DHW circulation pump runtime for brief operation ■...

  • Page 109: External Blocking

    Function description Control functions (cont.) Operating program changeover Code Changeover via input DE1 d8:1 Changeover via input DE2 d8:2 Changeover via input DE3 d8:3 You can select which direction the operating program changeover takes in coding address "d5": Operating program changeover Code Changeover towards "Permanently reduced"...

  • Page 110: External Demand

    Function description Control functions (cont.) External blocking and fault message input Code Input DE1 3A:4 Input DE2 3b:4 Input DE3 3C:4 External demand When the contact is closed, burner operation is load- Plug dependent. The boiler water is heated to the set value selected in coding address "9b"...
  • Page 111 Function description Control functions (cont.) Temperature profile 1: (EN 1264-4) code "F1:1" Days Fig. 56 Temperature profile 2: (ZV parquet and flooring technology) code "F1:2" Days Fig. 57 Temperature profile 3: Code "F1:3" Days Fig. 58 Temperature profile 4: Code "F1:4" Days Fig.

  • Page 112: Raising The Reduced Room Temperature

    Function description Control functions (cont.) Temperature profile 6: Code "F1:6" Days Fig. 61 Temperature profile 7: Code "F1:15" Days Fig. 62 Raising the reduced room temperature During operation at reduced room temperature, the The outside temperature limits for the start and end of reduced set room temperature can be automatically the temperature raising can be adjusted via coding raised subject to the outside temperature.

  • Page 113: Reducing The Heat-Up Time

    Function description Control functions (cont.) Example using the settings in the delivered condition Outside temperature in °C Fig. 63 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 114: Assigning Heating Circuits To The Remote Control

    Function description Control functions (cont.) Example using the settings in the delivered condition Time Fig. 64 Start of operation at standard room temperature Set boiler water or flow temperature in accordance with the selected heating curve Set boiler water or flow temperature in accordance with coding address "FA": 50 °C + 20 % = 60 °C Duration of operation with raised set boiler water...

  • Page 115: Electronic Combustion Control Unit

    Function description Electronic combustion control unit The electronic combustion controller utilises the physi- To check the combustion quality, the CO content or cal correlation between the level of the ionisation cur- the O content of the flue gas is measured. The pre- rent and the air ratio .

  • Page 116: Connection And Wiring Dia-Connection And Wiring Diagram

    Connection and wiring diagram Connection and wiring diagram Fig. 65 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 Code 39 sÖ...
  • Page 117 Connection and wiring diagram Connection and wiring diagram (cont.) Relay output, either: Fan motor a¢Ö ■ Central fault message 0-10 V ■ Circulation pump for cylinder heating Main PCB ■ External heating circuit pump Coding card ■ DHW circulation pump ON/OFF switch Code 53 Programming unit...
  • Page 118 Connection and wiring diagram Connection and wiring diagram (cont.) Fig. 66 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 119: Gram ■ Up To 80 Kw

    Connection and wiring diagram Connection and wiring diagram (cont.) Up to 80 kW Fig. 67...

  • Page 120: 120 To 318 Kw

    Connection and wiring diagram Connection and wiring diagram (cont.) 120 to 318 kW Fig. 68 Outside temperature sensor, only with weather- Circulation pump, either: compensated system ■ Circulation pump for cylinder heating Flow temperature sensor ■ External heating circuit pump Cylinder temperature sensor ■...
  • Page 121 Connection and wiring diagram Connection and wiring diagram (cont.) Relay output, either: Main PCB ■ Central fault message Switching mode power supply in main PCB ■ Circulation pump for cylinder heating Coding card ■ External heating circuit pump ON/OFF switch ■...

  • Page 122: Main Pcb Up To 80 Kw

    Connection and wiring diagram Connection and wiring diagram (cont.) Main PCB up to 80 kW Fig. 69 Boiler water temperature sensor Fan motor § § a¢Ö Ionisation electrode Fan motor control a¢Ö Flue gas temperature sensor A Modulation coil a:Ö a:Ö...

  • Page 123: Main Pcb 120 To 160 Kw

    Connection and wiring diagram Connection and wiring diagram (cont.) Main PCB 120 to 160 kW Fig. 70 A Boiler water temperature sensor Fan motor § § a¢Ö Ionisation electrode Fan motor control a¢Ö Flue gas temperature sensor Modulation coil a:Ö Ignition unit X9.8/9 Combustion chamber pressure limiter...

  • Page 124: Main Pcb 240 To 318 Kw

    Connection and wiring diagram Connection and wiring diagram (cont.) Main PCB 240 to 318 kW Fig. 71 A Boiler water temperature sensor Fan motor § § a¢Ö Ionisation electrode Fan motor control a¢Ö Flue gas temperature sensor Modulation coil a:Ö Ignition unit X9.8/9 Combustion chamber pressure limiter...

  • Page 125: External Connection Diagram

    Connection and wiring diagram External connection diagram 230V~ 0-10 V Fig. 72 Plug 230 V~ Boiler circuit pump or butterfly valve with return sÖ spring (only with multi boiler system) Rated voltage: 230 V~ Rated current: Max. 2 (1) A~ Circulation pump for cylinder heating Rated voltage: 230 V~ Rated current: Max.

  • Page 126: 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 127 Water quality Requirements (cont.) This measure must be carried out by a qualified con- Further details can be found in VDI Guideline 2035-2 tractor. Inspect the heating system for possible dam- and EN 14868. age prior to returning it into use. It is essential that incorrect operating parameters are corrected to pre- vent renewed excessive scaling.

  • Page 128: Commissioning/Service

    Commissioning/service reports 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 ≤ ≤ Supply pressure (flow pres- sure) For natural gas E mbar...
  • Page 129 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 130: Specification Vitocrossal 100 Specification

    Specification Vitocrossal 100 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 TF/TR = 50/30 16 - 80 32 - 120 32 - 160 48 - 200 48 - 240 64 - 280 64 - 318...
  • Page 131 Specification Vitocrossal 100 specification (cont.) Rated heating output range TF/TR = 50/30 16 - 80 32 - 120 32 - 160 48 - 200 48 - 240 64 - 280 64 - 318 TF/TR = 80/60 15 - 74 29 - 110 29 - 146 44 - 184 44 - 220 58 - 258 58 - 291 Connections Boiler flow...

  • Page 132: Matrix Cylinder Burner Specification

    Specification MatriX cylinder burner specification Rated boiler heating output 50/30 °C Twin boiler Burner heating output, lower/ 15.1/ 30.2/ 30.2/ 45.3/ 45.3/ 60/300 upper output 75.5 113.2 150.9 188.7 226.4 264.2 Burner type 120/ 120/ 200/ 200/ 280/ 280/ 80 kW 160 kW 160 kW 240 kW...

  • Page 133: Shutdown And Disposal Final Decommissioning And Disposal

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

  • Page 134: Certificates Declaration Of Conformity

    Certificates Declaration of conformity Vitocrossal 100, type CI1 We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, declare as sole responsible body that the named product complies with the provisions of the following directives and regulations: 92/42/EEC Efficiency Directive 2014/30/EU...

  • Page 135: Manufacturer's Certificate According To The 1St Bimschv [Germany]

    Certificates Manufacturer's certificate according to the 1st BImSchV [Germany] We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, confirm that the product Vitocrossal 100 complies with the NO limits specified by the 1st BImSchV paragraph 6 [Germany]. Allendorf, 2 January 2017 Viessmann Werke GmbH &...

  • Page 136: Keyword Index

    Keyword index Keyword index Control unit for constant temperature Acknowledging a fault display........64 – Relay test..............63 Control unit for weather-compensated operation – Calling up operating data........59 Boiler – Relay test..............61 – Parts..............88, 90 – Service menu............59 Boiler flue connection..........25 Cylinder temperature sensor........78 Boiler water requirements........
  • Page 137 Keyword index Keyword index (cont.) Reducing heat-up output.......... 112 Ignition electrodes............21 Reducing heat-up time..........113 Inspection cover............22 Relay test............. 61, 63 Inspection cover locking bracket........ 22 Remote control............114 Intended use..............6 Removing a fault display..........64 Ionisation electrode............ 21 Report..............
  • Page 140 7571799 7571800 7571801 7648963 7649298 7649303 7649304 7649305 7649306 Viessmann Werke GmbH & Co. KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040...

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