Viessmann 7502860 Service Instructions Manual Download Page 16

Page: 16 / 96

Press button

The system will be restarted.

Note
The setting parameters are displayed
each time the system is restarted.
1 Max. output (70-100 %)

The output setting is not limited.
The base load can also be set (CS
configuration).

2 Gas type (NG = natural gas or LPG

= liquid gas)

3 Installation height (LA or HA)
4 Temperature of temperature lim-

iter

5 Integral for minimum pause time
6 Cycle protection method

Note
Once the gas type has been converted,
the CO

values need to be checked for

full load and partial load and corrected if
necessary (see page 27 and 28).

Height adjustment

Note
To be able to adjust the settings the
burner must be on standby (Status "0",
Service "C").

Commissioning, inspection, maintenance

Further details regarding the individual steps

(cont.)

5794 780 GB

Summary of Contents for 7502860

Page 1: ...structions for contractors VIESMANN Vitocrossal 200 Type CM2 400 to 620 kW Gas condensing boiler with MatriX cylinder burner For applicability see the last page VITOCROSSAL 200 5794 780 GB 4 2013 Please keep safe ...

Page 2: ...n The system must be commissioned by the system installer or a qualified per son authorised by the installer This appliance has not been designed to be operated by individuals includ ing children with limited physical sen sory or mental capacities or who are lacking in the appropriate experience and or knowledge unless they are supervised by a person with responsi bility for their safety or were i...

Page 3: ...e the building If you smell flue gas Danger Flue gas can lead to life threat ening poisoning Shut down the heating system Ventilate boiler room Close all doors in the living space Working on the system Where gas is used as the fuel close the main gas shut off valve and safe guard it against unintentional reopen ing Isolate the system from the power sup ply e g at the separate fuse or a main switch...

Page 4: ... the system can compromise its function Installing non author ised components and making non approved modifications or conversions can compromise safety and may invalidate our warranty For replacements use only orig inal spare parts supplied or approved by Viessmann Safety instructions Safety instructions cont 5794 780 GB ...

Page 5: ...play 64 Burner control unit flow chart 65 Connection diagrams Burner control unit connection diagram 67 Mains filter unit connection diagram 71 Component overview 73 Control unit Adjusting codes at the control unit 75 Parts lists Ordering parts 76 Overview of the assemblies 76 Parts not shown 76 Boiler assembly 77 Thermal insulation assembly 77 Burner assembly 400 kW 80 Burner assembly 500 kW 81 B...

Page 6: ... pose other than the heating up of heating water shall be deemed inappropriate Intended use presupposes that a fixed installation in conjunction with permissi ble components designed for this pur pose has been carried out Every other use will be deemed to be inappropriate Any resulting losses are excluded from the manufacturer s liabil ity Any usage beyond this must be approved by the manufacturer...

Page 7: ...mmissioning the system 18 10 Reducing operational output if necessary 20 11 Checking static pressure and supply pressure 21 12 Checking the rotary damper setting for 400 and 620 kW 23 13 Overview of differences between the three burner sizes 24 14 Checking the CO2 content 27 15 Checking the CO content 16 Checking the flue gas temperature 17 Displaying the ionisation current 29 18 Shutting down the...

Page 8: ...ecking both gas train valves automatically for tightness 42 32 Checking the filter element in the gas line if installed and replacing if required 33 Checking all gas connections for tightness 42 34 Implementing final checks 43 35 Checking the water quality 44 36 Checking the function of safety valves 37 Checking the expansion vessel and system pressure 44 38 Checking the mixer for ease of operatio...

Page 9: ...ty require ments on page 87 Filling the siphon with water 1 Undo four screws and remove the rear centre and lower back panels 2 Undo the siphon and fill with water otherwise flue gas may escape 3 Check that the condensate can drain freely 4 Remount the siphon Note The hose connection to the on site condensate system or to the neutral ising system must not be permitted to sag support with a pipe if...

Page 10: ... burner is set up for natural gas E If required convert the burner to a different gas type see from page 11 in accord ance with details provided by your gas supply utility Note The 500 kW burner requires a natural gas restrictor A natural gas restrictor is not required for the 400 and 620 kW burners Rated heating output kW 400 500 620 Restrictor for natural gas E 7 mm 21 5 Restrictor for LPG P 7 m...

Page 11: ... hose G from the gas train 06 Release the gas train from flange E 07 In the case of a 500 kW burner Insert O ring B natural gas restric tor C and rubber cork gasket D Note The bevel on the natural gas restric tor must point towards the gas train In the case of a 400 and 620 kW burner Remove natural gas restrictor C with rubber cork gasket D 08 Tighten screws M 5 x 16 cross wise torque 1 5 Nm 09 Se...

Page 12: ... 500 620 Restrictor for natural gas E 7 mm 21 5 Natural gas settings on the burner control unit C D E F 1 Press button S E for longer than 2 s flashes 2 Press button F until display C shows 6 under Service 3 Press button S E until display C shows 6 under Status 4 Press button F until display C shows 2 under Status and the cur rent gas type is shown under Service 0 natural gas or 1 LPG 5 Use button...

Page 13: ...restarted 1 Max output 70 100 The output setting is not limited The base load can also be set CS configuration 2 Gas type NG natural gas or LPG liquid gas 3 Installation height LA or HA 4 Temperature of temperature lim iter 5 Integral for minimum pause time 6 Cycle protection method Note Once the gas type has been converted the CO2 values need to be checked for full load and partial load and corre...

Page 14: ...B LPG restrictor C and rubber cork gasket D Note The bevel on the LPG restrictor must point towards the gas train 08 Tighten screws M 5 x 16 cross wise torque 1 5 Nm 09 Secure fitting A 10 Push compensation hose G on to the gas train 11 Affix the enclosed label Set to over existing label F 12 Check all fittings for tightness Danger Escaping gas leads to a risk of explosion Check all fittings for g...

Page 15: ...display C shows 6 under Status 4 Press button F until display C shows 2 under Status and the cur rent gas type is shown under Service 0 natural gas or 1 LPG 5 Use button F or D to select 1 for LPG 6 Press button S E to confirm If applied successfully 1 will be shown briefly in display C under Service or 0 will appear if it failed 7 Press button S E to switch to the operating display Commissioning ...

Page 16: ...llation height LA or HA 4 Temperature of temperature lim iter 5 Integral for minimum pause time 6 Cycle protection method Note Once the gas type has been converted the CO2 values need to be checked for full load and partial load and corrected if necessary see page 27 and 28 Height adjustment Note To be able to adjust the settings the burner must be on standby Status 0 Service C Commissioning inspe...

Page 17: ...r 1 large height 07 Press button F or D until dis play C shows 1 under Service for large height 1 is displayed briefly under Serv ice 08 Press button S E to confirm Reset to 1 if 0 appears 09 Press button S E to quit adjust ment mode and return to the oper ating display 10 Press button R G for more than 2 s the system restarts and the adjustments are adopted 11 Complete the height adjustment label...

Page 18: ...cations Carry out a CO test before and after work on gas appliances Tightness test Gaskets on the boiler door and compo nents routing flue gas can be checked during operation with an inspection mir ror If required remove the thermal insula tion components Traces of condensate on the outside of the flue gas collector or on thermal insu lation components also indicate leaks Note An examination of th...

Page 19: ...n the burner control unit Note The appliance can enter a fault state during commissioning if there is insufficient gas in the gas line the fault indicator on the control unit illu minates Purge the gas line again and reset the burner control unit If the fault persists the inlet strainer of the gas train may have become blocked by work carried out on the gas line Danger Escaping gas leads to a risk...

Page 20: ... S R D C E F G 1 Press button S E for longer than 2 s flashes 2 Press button F until display C shows 6 under Service 3 Press button S E In display C 6 appears under Status 4 Press button S E 1 will be dis played under Status in display C and the current value for the maxi mum operational output is shown in under Service 5 Press button F or D for the required maximum operational out put 6 Press but...

Page 21: ...m heat ing output For this activate the emis sions test switch at the control unit 2 Check the supply flow pressure Use a suitably calibrated measuring device with divisions of at least 0 1 mbar 0 01 kPa to check the sup ply pressure Note The supply pressure flow pressure should be between 10 and 35 mbar 1 0 and 3 5 kPa The gas pressure switch for checking the supply pressure is factory set to 10 ...

Page 22: ...y mode in order to maintain heating operation Not for permanent operation 15 to 35 mbar 1 5 to 3 5 kPa 20 to 35 mbar 2 0 to 3 5 kPa Start the boiler Above 35 mbar 3 5 kPa Above 35 mbar 3 5 kPa Notify your local gas supply utility in order to have the pressure reduced Pressure at the boiler valve must not exceed 50 mbar 5 0 kPa Commissioning inspection maintenance Further details regarding the indi...

Page 23: ...le mode Rotary damper window B must be fully opened and scale ring D on the air damper servomotor must be set to 0 relative to marking C 3 Check whether compensation hose A has been connected between the gas train and distributor pipe 4 Start the burner Commissioning inspection maintenance Further details regarding the individual steps cont 5794 780 GB ...

Page 24: ...le ring D must be at the following settings Rated heating output Rated heat input Rotary damper setting Pmax 50 30 C Qmax Hi net cv in kW in kW in 400 381 30 620 593 20 Overview of differences between the three burner sizes 400 kW A A Compensation hose Commissioning inspection maintenance Further details regarding the individual steps cont 5794 780 GB ...

Page 25: ...25 500 kW A A Compensation hose Commissioning inspection maintenance Further details regarding the individual steps cont 5794 780 GB ...

Page 26: ...ary damper position 30 20 Compensation hose connection Venturi mixing pipe Adaptor panel Adaptor panel Restrictor for natural gas E 7 mm 21 5 Restrictor for LPG P 7 mm 14 0 14 8 17 2 Commissioning inspection maintenance Further details regarding the individual steps cont 5794 780 GB ...

Page 27: ...ger than 2 s Display C will then show the follow ing Under Status P controlled stop Under Service Modulation level in 100 100 upper heating output 0 0 lower heating output CO2 test at the upper heating output 1 Press F until the service display has counted up to 100 100 2 Check the CO2 content at the flue pipe Commissioning inspection maintenance Further details regarding the individual steps cont...

Page 28: ...w A in small steps Allen key 3 mm until the CO2 content is within the specified range Turning clockwise CO2 content drops Turning anti clockwise CO2 con tent increases 4 Record the actual value in the report on page 86 CO2 test at the lower heating output A B C D E F 1 Press D until the service display has counted down to 0 lower heat ing output Commissioning inspection maintenance Further details...

Page 29: ...ecking the values Regulate to the upper and lower heat ing output again using the program ming unit in the burner control unit If the values do not match the permis sible CO2 content according to the tables on pages 28 and 29 repeat the steps for the upper and lower heating output 5 Hold down S E and D simulta neously for longer than 2 s The burner will change to the operating mode Displaying the ...

Page 30: ...ue in the report 09 Press S approx 2 s flashes 10 Press until 5 is shown under Service 11 Press S 5 will be displayed under Status 12 Press until 0 is shown under Service 13 Press S The operating display will be shown again Shutting down the system 1 Switch OFF the mains isolator or the power supply and safeguard against unauthorised reconnection Danger Mains voltage can be life threatening For ma...

Page 31: ...d For this undo the M 5 screw from the top section of the front panel Unhook the profiled studs from the side panels tip the front panel slightly forward and lift off the lower front panel Commissioning inspection maintenance Further details regarding the individual steps cont 5794 780 GB ...

Page 32: ...32 3 Unhook the front panel with clips at the bottom from the side panels Commissioning inspection maintenance Further details regarding the individual steps cont 5794 780 GB ...

Page 33: ...15B 41 145 40 40 156 53 5 Undo power cable with plug fÖ Then undo the burner cables with plugs A B aGA aGB fÖ aBH fA and gD in addition to plug aVG on the burner control unit and remove from the burner casing 6 Close the gas shut off valve Commissioning inspection maintenance Further details regarding the individual steps cont 5794 780 GB ...

Page 34: ...nd injuries Secure the boiler door against falling backwards after it has been opened Please note Scratches inside the combustion chamber can lead to corrosion Never put tools or other objects into the combustion chamber Cleaning the combustion chamber and heating surfaces Thoroughly clean the combustion cham ber and heating surfaces with a water jet Please note Scratches on parts that come into c...

Page 35: ...gs and surface disco louration yellow brown with slightly acidic chloride free cleaning agents based on phosphoric acid e g Antox 75 E Remove loose deposits from the boiler flush the heating surfaces and the flue gas collector thoroughly with a water jet Cleaning agent manufacturer s details Note Fauch 600 and Antox 75 E Manufacturer Hebro Chemie GmbH Rostocker Strasse 40 D 41199 Mönchengladbach C...

Page 36: ...n pump when the boiler air vent valve is open Note Also check the connections to control equipment and to the minimum pressure switch low water indicator for tight ness Cleaning and reconnecting the condensate drain system Note Clean the inside of the condensate drain system at least annually C D A B 1 Undo four screws and remove the rear centre and lower back panels Commissioning inspection maint...

Page 37: ...tem if installed in accordance with the manufacturer s instructions Neutralising system operating instructions Note The neutralising agent can be obtained from Viessmann by quoting part no 9521 702 7 Undo and flush lower part A of siphon B 8 Fill lower part A of siphon B with water and reassemble 9 Refit the condensate drain system and the back cover panel Note The hose connection to the on site c...

Page 38: ... A or on thermal insulation components also indicate a leak 2 If required flue gas collector A can be tightened to a torque of 10 Nm Note We recommend you check the gas ket roughly every 500 hours run and if necessary retighten the nuts and ensure that the gasket is correctly seated Checking the condensate drain and the neutralising system if installed Add water to the combustion chamber Note The ...

Page 39: ...n Never put tools or other objects into the combustion chamber Please note Contamination of the burner gauze assembly can lead to mal function When replacing the burner gauze assembly ensure that no fibres from the thermal insulation block adhere to the burner gauze assembly In addition when installing the burner gauze assembly fit a protective sleeve Burner component installation instructions Ple...

Page 40: ...1 Undo fitting C on gas supply pipe B 2 Undo Venturi mixing pipe D from fan E 3 Remove Venturi mixing pipe D with gas train A and gas supply pipe B and if necessary pull out con necting cables lines 4 Pull out connecting cables a Ö and a ÖA from fan E and remove the fan 5 Clean the fan housing and impeller with compressed air 6 If required vacuum the inside and outside of burner gauze assembly F C...

Page 41: ...nd tighten the screws on the boiler door evenly and diagonally Torque 40 Nm 5 Secure fitting B to the gas supply pipe Torque 40 Nm Danger Escaping gas leads to a risk of explosion Check the fitting and gasket between the fan housing and the boiler door for gas tightness Making the burner electrical connections Please note Never allow cables leads to come into contact with hot com ponents Secure al...

Page 42: ...lves are gas tight the burner enters standard mode and the burner starts If the first valve is not tight fault code F E1 is shown on the burner control unit display if the second valve is not tight fault code F E2 is displayed In either case the gas train must be replaced Danger Escaping gas leads to a risk of explosion Check test connector for gas tightness Checking all gas connections for tightn...

Page 43: ... page 18 5 Check the outlet joints of the gas train and fittings between the fan and the boiler door and between the fan and the Venturi pipe for tightness Implementing final checks 1 Carry out final checks in accordance with the points on pages 27 to 29 2 Record the actual values in the report on page 86 Commissioning inspection maintenance Further details regarding the individual steps cont 5794...

Page 44: ... m3 m3 mol m3 mol m3 The pH value should be between 8 2 and 9 5 Checking the expansion vessel and system pressure Note Please observe expansion vessel man ufacturer s instructions 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 Commissioning inspection mainten...

Page 45: ...3 Check the mixer for tightness Replace the O ring gaskets if the mixer is leaking 4 Snap the motorised lever into place Instructing the system user The installer should instruct the user in the operation of the system 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 a...

Page 46: ... 5 minutes If the air pressure is outside the per missible range during the pre purge phase tolerance time approx 5 minutes If the air pressure switch fails in regular operation or the air pressure lies out side the permissible range The fault shutdown is shown with fault indicators F F5 and F F7 on the burner control unit display see page 48 and can be reset by pressing reset button B Rated heati...

Page 47: ... the following circumstances If the combustion chamber pressure is outside the permissible range in the pre purge phase in control mode or in the post purge phase after 2 attempts The fault shutdown is shown with fault indicator F FB on the burner control unit display see page 48 and can be reset by pressing reset button B Rated heating output Rated heat in put LDW2 set val ue Pmax 50 30 C Qmax Hi...

Page 48: ...ay comprises four elements of 7 segments each Four keys enable adjustments to be made at the different operating levels Operating display In standard mode the status display shows the current operating conditions The same applies in a fault state after pressing reset button R The following displays are scrolled through automatically In case of faults see the fault codes from page 57 You can exit a...

Page 49: ...te check System tests Status Service Fan ramp up Status Service Valve and or relay test Status Service Pre purge Status Service Pre ignition Status Service Ignition Safety time Flame established Burner control unit Burner control unit cont 5794 780 GB ...

Page 50: ...purge Status Service Maintenance program No air pressure Status Service Maintenance program No gas pressure or mains undervoltage Status Service Forced ventilation when no flame was recognised Status Service Safety shutdown due to flame tear off Burner control unit Burner control unit cont 5794 780 GB ...

Page 51: ...rs for start ups and hours run 2 Meters for start ups and hours run with reset 3 Software version 4 Fault history for the last 10 fault codes Example to delete the hours run meter press the following keys 1 S longer than 2 s flashes 2 until 2 is shown under Service 3 S 1 will be displayed under Sta tus 4 Scroll through Status until 6 is shown under Status Status Description 1 Display of start up m...

Page 52: ... scale 0 Phase 1 1 Boiler water temperature C 2 Flue gas temperature C 3 Ionisation current I in 1 10 μA 4 Set speed 5 PWM manipulated variable 6 Actual speed n in 10 min 7 Gas pressure switch 1 0 or 1 8 Gas pressure switch 2 0 or 1 9 Air pressure switch 0 or 1 A Gas valve 1 0 or 1 B Gas valve 2 0 or 1 Example to display the ionisation cur rent press the following keys 1 S longer than 2 s flashes ...

Page 53: ... flue gas damper 0 no flue gas damper 1 with flue gas damp er 0 0 Reset all operating parame ters to their delivered condi tion Example to reduce the maximum opera tional output press the following keys 1 S longer than 2 s flashes 2 until 6 is shown under Serv ice 3 S 6 will be displayed under Sta tus 4 S 1 will be shown under Status and the current value for the maximum operational output in is s...

Page 54: ...to their delivered condition press the following keys 1 S longer than 2 s flashes 2 until 6 is shown under Service 3 S 6 will be displayed under Sta tus 4 until 0 is shown under Service 5 S 1 is shown under Status and dEL under Service 6 S to confirm If reset successfully 1 will be shown under Service if it failed 0 will appear 7 S to change to the operating dis play Manual mode and service displa...

Page 55: ...t until 0 is shown under Serv ice 3 for upper heating output until 100 is shown under Serv ice 4 S simultaneously for longer than 2 s The burner returns to modulat ing mode Burner control unit Burner control unit cont 5794 780 GB ...

Page 56: ... is shown again and the burner control unit is reset Fault memory The ten most recent faults are saved and may be called up The order of scans ranges from the most recent to the ear lier fault codes The fault memory display is terminated automatically if no key is pressed within 20 s Note If the burner does not start up due to a non lockout fault without displaying a fault code the fault memory ma...

Page 57: ...own under Service 3 S 4 will be displayed under Sta tus 4 until 3 is shown under Service 5 S 1 is shown under Status and dEL under Service 6 S to confirm the deletion If deleted successfully 1 will be shown under Service if it failed 0 will appear 7 S to change to the operating dis play Fault codes General process errors Fault display on the display and pro gramming unit on the burner Note Carry o...

Page 58: ...ensors A and B replace sensor if required F 83 Burner control unit in a fault state Sensor drift flue gas temperature sensor A or B burner control unit Check lead and sensors A and B replace sensor if required F 88 Burner control unit in a fault state Lead break boiler water temperature sensor burner control unit Check lead and dual sen sor replace sensor if re quired F 89 Burner control unit in a...

Page 59: ...ht gas pressure switch 2 does not close Check setting of gas pres sure switch 2 check con necting cable replace gas train F E2 Shortage of gas to gas pressure switch 2 valve leak test Gas valve does not open gas valve leaking gas pres sure switch 2 faul ty Replace the gas train F E4 Burner shuts down Multiple detection of undervoltage with return and re newed undervolt age Check the power supply F...

Page 60: ...as throughput according to rated boiler heating output see connection values page 91 F F2 Burner control unit in a fault state system cools down Excessive boiler water temperature Wait until temperature falls below the permiss boiler water temperature Reset burner control unit F F3 Ionisation flame mon itor reports faulty flame signal during start up or after the post purge Gas train not gas tight...

Page 61: ...cting ca ble replace servomotor replace burner control unit F F4 Flame does not build during the safety time no signal cap tured by the ionisa tion flame monitor Incorrect gas type selected Select the gas type see from page 11 F F4 Flame does not build during the safety time no signal cap tured by the ionisa tion flame monitor Gas train does not open Check connecting cable check gas train and re p...

Page 62: ...he air pressure switch idle state check Wind influence on fan Check flue outlet chim ney F F7 Air pressure switch contact is not in the idle state Air pressure switch faulty Replace air pressure switch F F8 Flame extinguishes during operation Incorrect gas type selected Select the gas type see from page 11 F F8 Flame extinguishes during operation Burner gauze as sembly faulty Check burner gauze as...

Page 63: ...ner control unit in a fault state Fan does not reach idle state cable a ÖA faulty fan faulty faulty burner control unit Fan subject to wind influ ence check flue outlet and fan replace ca ble a ÖA replace fan replace burner control unit F Fb Burner does not start Excessive com bustion chamber pressure LDW2 condensate back up or condensate path blocked off Check condensate drain and condensate path...

Page 64: ... system Check condensate drain Incorrect flue outlet Check flue outlet and flue sys tem Thermo acoustics combustion noise Incorrect CO2 settings insufficient or exces sive air Adjust burner in accordance with the details from page 27 CO2 content too low Incorrect setting Check whether the burner has been adjusted to the correct gas type change gas restrictor if re quired see from page 11 Adjust bu...

Page 65: ...ure switch 1 Gas pressure switch 1 Air pressure switch 2 Fan speed Flame Demand Fuel valve BV2 Auxiliary valve Servomotor Flue gas damper Ignition Fan Fuel valve BV1 Fault message output 3 Input assessment Output control Subsequent state depends on valve test parameters 1 2 4 5 6 8 U System start Relay test Start up Op mode Shutdown Fault states F 7 C Waiting Burner control unit flow chart Burner ...

Page 66: ...perature sensor test max 20 s 2 Fan ramp up max 20 s 3 Pre purge 10 s Adjusting start up load test WD 1 1 9 s 4 Pre ignition 2 s 5 Ignition safety time 2 3 s Flame detection safety time max 0 51 s Operation 6 Flame stabilising time 15 s 7 Start up partial load 20 s Modulating operation 0 to 24 h Adjusting shutdown load 0 1 s Switch off 8 Reheat test WD 2 min 10 s max 60 s Fan ramp up post purge ma...

Page 67: ... Q R S A Burner control unit VUC 310 H Fan motor with PWM control and feedback K Gas pressure switch 2 L Air pressure switch 1 M Gas pressure switch 1 Connection diagrams Burner control unit connection diagram 5794 780 GB ...

Page 68: ...gas temperature sensor 2 Q Flue gas temperature sensor 1 R Boiler water temperature sensor 2 S Boiler water temperature sensor 1 T Display and programming unit Connection diagrams Burner control unit connection diagram cont 5794 780 GB ...

Page 69: ...nit VUC 310 B Flame monitoring via an ionisation current C Vitotronic control unit D Servomotor for rotary damper E Ignition unit F Fuel valve BV1 G Fuel valve BV2 Connection diagrams Burner control unit connection diagram cont 5794 780 GB ...

Page 70: ...70 X Plug 150 HLSC HLSC F1 Backup fuse F2 Backup fuse H1 Hours run meter modulation H2 Fault message S1 ON OFF switch Connection diagrams Burner control unit connection diagram cont 5794 780 GB ...

Page 71: ...emperature sensor D Boiler water temperature sen sor E Air pressure switch 2 a Ö To the fan fÖ Power supply 120 V 60 Hz fÖ aBH Control unit gD Flue gas damper to a Ö burner control unit Connection diagrams Mains filter unit connection diagram 5794 780 GB ...

Page 72: ...Note The power cable must be protected The maximum fuse rating is 20 A Make the power supply 120 V 60 Hz via a permanent connection Connection diagrams Mains filter unit connection diagram cont 5794 780 GB ...

Page 73: ...witch 1 C Air pressure switch 2 D Display and programming unit E Gas train F Gas supply pipe G Gas pressure switch H Rotary damper with servomotor K Venturi mixing pipe L Gas fan M Burner gauze assembly N Ignition electrodes Component overview Component overview 5794 780 GB ...

Page 74: ...74 O Ionisation electrode P Ignition unit R Burner control unit S Mains filter unit with contactor Component overview Component overview cont 5794 780 GB ...

Page 75: ...75 Service instructions Vitotronic 300 type GW5B Control unit Adjusting codes at the control unit 5794 780 GB ...

Page 76: ...lable from your local supplier Overview of the assemblies B C A A Type plate B Thermal insulation assembly C Boiler assembly D Burner assembly not shown Parts not shown 0003 Fixings 0004 Decorative strip 0005 Touch up spray paint Vitosilver 0006 Touch up paint stick Vitosilver 0007 Installation instructions 0008 Service instructions 0009 Spring clip short 10 pce Parts lists Ordering parts 5794 780...

Page 77: ...GF 20 x 15 x 2040 0012 0007 0009 0001 0010 0005 0010 0004 0011 0009 0011 0012 0006 0003 0002 0008 Thermal insulation assembly 0001 Side panel l h front 0002 Side panel r h front 0003 Side panel centre 0004 Support bottom 0005 Side panel 0006 Side panel l h rear 0007 Side panel r h rear 0008 Rail bottom 0009 Rail top right 0010 Rail top left 0011 Back panel bottom 0012 Back panel centre 0013 Back p...

Page 78: ...omplete 0020 Top panel left back 0021 Top panel right back 0022 Thermal insulation mat front 0023 Thermal insulation jacket 0024 Edge protector 0025 Vitocrossal 200 logo 0026 Viessmann logo 0027 Shock absorbing panel 0028 Bottom panel Parts lists Thermal insulation assembly cont 5794 780 GB ...

Page 79: ...024 0024 0012 0013 0025 0026 0026 0025 0015 0011 0014 0022 0008 0028 0004 0002 0005 0003 0007 0009 0010 0001 0005 0003 0006 0016 0027 0019 0017 0020 0018 0021 Parts lists Thermal insulation assembly cont 5794 780 GB ...

Page 80: ... 0016 Rotary damper 0017 Toggle link M 5 0018 Venturi mixing pipe 0020 LPG restrictor with gasket 0021 Gas train 0022 Gas pressure switch cable 0023 Mains filter unit 0024 Power contactor 0025 Flange gasket wearing part 0026 Ignition transformer connecting cable 54 0027 Servomotor connecting cable 0028 Gas pressure switch cable 111 0029 Gas valve connecting cable 35 0030 Fan connecting cable 100 0...

Page 81: ...037 0020 0038 0024 0033 0032 0002 0004 0018 0012 0004 0017 0016 0013 0021 0014 0015 0008 0006 0005 0001 0011 0010 0007 0024 0032 0033 0009 Burner assembly 500 kW 0001 Cylinder burner 0001 Burner frame 0002 Small and fixing parts Parts lists Burner assembly 400 kW cont 5794 780 GB ...

Page 82: ...ixing pipe 0019 Natural gas restrictor with gasket 0020 LPG restrictor with gasket 0021 Gas train 0022 Gas pressure switch cable 0023 Mains filter unit 0024 Power contactor 0025 Flange gasket wearing part 0026 Ignition transformer connecting cable 54 0028 Gas pressure switch cable 111 0029 Gas valve connecting cable 35 0030 Fan connecting cable 100 0031 Sensor lead 0032 Air pressure switch 0033 Ai...

Page 83: ...025 0031 0030 0029 0028 0026 0022 0014 0016 0038 0024 0024 0032 0033 0023 0032 0033 0021 0019 0018 0007 0010 0011 0012 0015 0008 0006 0005 0001 0004 0003 0004 0002 0020 0009 0036 Parts lists Burner assembly 500 kW cont 5794 780 GB ...

Page 84: ... 0016 Rotary damper 0017 Toggle link M 5 0018 Venturi mixing pipe 0020 LPG restrictor with gasket 0021 Gas train 0022 Gas pressure switch cable 0023 Mains filter unit 0024 Power contactor 0025 Flange gasket wearing part 0026 Ignition transformer connecting cable 54 0027 Servomotor connecting cable 0028 Gas pressure switch cable 111 0029 Gas valve connecting cable 35 0030 Fan connecting cable 100 0...

Page 85: ...6 0027 0028 0029 0030 0031 0016 0039 0037 0038 0035 0024 0024 0032 0033 0023 0032 0033 0002 0004 0003 0004 0021 0017 0013 0018 0020 0014 0015 0008 0006 0005 0001 0011 0010 0007 0009 Parts lists Burner assembly 620 kW cont 5794 780 GB ...

Page 86: ... set by vol At the lower rated heating output actual by vol set by vol Oxygen content O2 At the upper rated heating output actual by vol set by vol At the lower rated heating output actual by vol set by vol Carbon monoxide content CO actual ppm set ppm Flue gas tempera ture gross actual C set C Ionisation current At the upper rated heating output μA At the lower rated heating output μA Pressure in...

Page 87: ...dness dH 50 to 200 2 0 11 2 200 to 600 1 5 8 4 600 0 02 0 11 The standard values assume the follow ing 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...

Page 88: ...e also observe the follow ing during commissioning Commission the system step by step starting with the lowest boiler output and a high heating water flow rate This prevents a localised concentra tion 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 transfer area of just one bo...

Page 89: ... airborne oxygen into the system if correctly sized and operating at the cor rect pressure In all operating states and at all points in the heating system includ ing the intake side of the pump the pres sure must be higher than the surround ing atmospheric pressure The pre charge pressure of the expansion vessel should be checked at least during the annual service The use of permeable components e...

Page 90: ...rtificate of suitability of the additives with regard to the boiler mate rials and the materials of the other heat ing system components We recom mend you refer questions regarding water treatment to an appropriate spe cialist For further details see guideline VDI 2035 2 and EN 14868 Water quality requirements cont 5794 780 GB ...

Page 91: ... Natural gas E m3 h 8 1 40 4 10 0 50 2 12 5 62 7 LPG P kg h 7 4 29 6 9 2 36 8 11 5 46 1 Burner type CM2 Voltage V 120 Frequency Hz 60 Power consumption W 54 540 60 700 60 900 for natural gas E and height up to 1500 m Modulation range 20 100 25 100 2 2 Only for LPG P 3 The connection values are only for reference e g in the gas contract application or to estimate the volumetric supplementary check ...

Page 92: ...al gas E and LPG P a a Rated heating output Rated heat input Dim a Pmax 50 30 C Qmax Hi net cv Natural gas E G20 LPG P G31 in kW in kW in mm in mm 400 381 14 0 500 474 21 5 14 8 620 593 17 2 Specification Specification cont 5794 780 GB ...

Page 93: ...ay and programming unit Configuration display 51 Information display 51 Operating display 48 56 Service display 54 E Expansion vessel 44 F Fan Fitting 41 Fault code 57 Fault memory 56 Faults without fault display 64 Final checks implementing 43 Flow pressure check 21 G Gas connections checking for tight ness 42 Gaskets and thermal insulation compo nents of the boiler door checking 35 Gas restricto...

Page 94: ...lation for LPG P 11 14 Rotary damper 69 S Servomotor 69 Setting check High limit safety cut out 9 Rotary damper 23 Siphon filling with water 9 Specification 91 Static pressure check 21 Supply pressure check 21 System Commissioning 18 Filling with water and venting 9 Shutting down 30 System pressure checking 44 V Valves on the gas train checking 42 W Water quality Checking 44 Requirements 87 Keywor...

Page 95: ...95 5794 780 GB ...

Page 96: ...mann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com 5794 780 GB Subject to technical modifications ...

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Summary of Contents for 7502860

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Viessmann 7502860, Service Instructions Manual

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