Viessmann CIB Service Instructions Manual Download Page 1

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Service instructions

for contractors

VIESMANN

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

Please keep safe.

Summary of Contents for CIB

Page 1: ...contractors VIESMANN 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 Please keep safe ...

Page 2: ... system installer or a qualified per son authorised by the installer Regulations to be observed National installation regulations Statutory regulations for the prevention of accidents Statutory regulations for environmental protection Codes of practice of the relevant trade associations Relevant country specific safety regu lations Safety instructions for working on the system Working on the syste...

Page 3: ...ase 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 Auxiliary components spare and wearing parts Please note Spare and wearing parts that have not been tested together with the system can compromise its func tion Installing non authorised com ponents and making non approved mod...

Page 4: ...ater escapes from the appliance there is a risk of scalding Never touch hot heating water Condensate Danger Contact with condensate can be harmful to health Never let condensate touch your skin or eyes and do not swallow it Flue systems and combustion air Ensure that flue systems are clear and cannot be sealed for instance due to accumulation of condensate or other external causes Ensure an adequa...

Page 5: ...nces 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 Safety instructions Safety instructions cont 5839829 ...

Page 6: ...esting outputs relay test 64 Service level constant temperature control unit 64 Diagnosis constant temperature control unit 64 Testing outputs relay test 66 6 Troubleshooting Fault display 67 Weather compensated control unit 67 Constant temperature control unit 67 Fault codes 68 7 Maintenance Checking the outside temperature sensor 75 Checking the cylinder temperature sensor 76 Checking the boiler...

Page 7: ...20 to 160 kW 99 Main PCB from 240 kW 100 External connection diagram 101 10 Water quality Requirements 102 11 Commissioning service reports Fill and top up water 104 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 Certificates Declaration of conformity 110 Man...

Page 8: ...ed during maintenance Not required during maintenance Intended use The appliance is intended solely for installation and operation in sealed unvented heating systems that comply with EN 12828 with due attention paid to the associated installation service and operating instruc tions It is only designed for heating up heating water that is of potable water quality Intended use presupposes that a fix...

Page 9: ...rom 240 to 636 kW Note For twin and multi boiler systems use a cascade con trol unit as per the pricelist Information for twin boilers The tasks for commissioning inspection and mainte nance are depicted on a single boiler For twin boilers the work must be carried out on both boilers For this reason the illustrations may differ partly System examples Available system examples See www viessmann sch...

Page 10: ...ate drain and neutralising system if installed for obstructions and leaks 27 19 Checking the gaskets and thermal insulation sections on the boiler side 27 20 Checking the flue gas damper and flue gas header 28 21 Checking the expansion vessel and system pressure 29 22 Checking the water quality 29 23 Checking the mixer for ease of operation and leaks 29 24 Checking all connections on the heating w...

Page 11: ... pre charge pressure of the expansion vessel is lower than the static system pressure top up with nitrogen until the pre charge pressure is 0 1 to 0 2 bar 10 to 20 kPa higher than the static system pressure The static pressure corresponds to the static head 3 Open any installed check valves 4 Fill the heating system with water and vent until the charge pressure is 0 1 to 0 2 bar 10 to 20 kPa highe...

Page 12: ... system user prefers the heating circuits can be renamed to suit the specific system To enter names for heating circuits Operating instructions Checking the gas type The boiler is equipped with an electronic combustion controller that adjusts the burner for optimum combus tion in accordance with the prevailing gas quality For operation with natural gas no adjustment is therefore required across th...

Page 13: ... connect ing cables power to the fan and fan control Burner blocked and 3 is dis played in code 38 Coding level 2 boiler Check the connecting cable combustion chamber pres sure switch and water pres sure switch Yes Ignition No Fault EE Check the ignition electrode and ignition module control voltage 230 V across plugs X2 1 and X2 2 Check the gas supply Yes The gas train opens No Fault EE Check the...

Page 14: ...ate heat trans fer Press reset button R Fault EB Check gap between ionisa tion electrode and burner gauze assembly Check allocation of gas type coding address 82 gas train setting Check flue system remove flue gas recirculation if re quired Press reset button R For further details regarding faults see page 67 Testing the static and supply pressure Danger CO formation can have serious health implic...

Page 15: ...table below 8 Shut down the boiler Close the gas shut off valve Remove the pressure gauge Close test connec tor A with the screw 9 Open the gas shut off valve Start up the appli ance Danger Gas escaping from the test connector leads to a risk of explosion Check gas tightness at test connector A Supply pres sure flow pres sure Measures Below 17 mbar 1 7 kPa Do not commission the appliance and notif...

Page 16: ...r and pre vents flue gas escaping if the flue system is damaged Check whether the combustion chamber pressure switch has responded 4 3 2 1 Fig 5 Measure the resistance across terminals 1 and 3 If the resistance is 0 Ω the pressure switch has respon ded If the combustion chamber pressure switch has responded check the following components and replace if necessary Electrodes Burner gauze assembly Ig...

Page 17: ... switch 5 If there are two pressure switches attach the con nection hoses to connection points B Check con nection hoses are seated correctly and are undam aged replace if necessary Please note Incorrect installation or installing damaged burner components can result in deflagration Check the combustion chamber pressure switch is working properly Check the burner components are undamaged and corre...

Page 18: ...horised reconnection 2 Close the gas shut off valve and safeguard against reopening 3 Pull cables from fan motor gas train and ionisation electrode 4 Undo gas supply pipe fitting Pull off ventilation air hose 5 Undo 4 screws Remove the burner Please note Damage to the burner gauze assembly will impair the burner function Do not damage the mesh Never touch the mesh of the burner gauze assembly Plac...

Page 19: ... safeguard against unauthorised reconnection 2 Close the gas shut off valve and safeguard against reopening 3 Remove cables from fan motor gas train and ioni sation electrode 4 Undo gas supply pipe fitting Pull off ventilation air hose 5 Undo 4 screws Remove the burner Please note Damage to the burner gauze assembly will impair the burner function Do not damage the mesh Never touch the mesh of the...

Page 20: ...mains isolator or the power supply and safeguard against unauthorised reconnection 2 Close the gas shut off valve and safeguard against reopening 3 Remove cables from fan motor gas train and ioni sation electrode 4 Undo gas supply pipe fitting Pull off ventilation air hose 5 Undo 4 screws Remove the burner Please note Damage to the burner gauze assembly will impair the burner function Do not damag...

Page 21: ...e the burner gauze assembly 1 Remove electrodes 2 Undo 4 nuts Remove burner gauze assembly and insulating parts Please note Damage to the burner gauze assembly will impair the burner function Do not damage the mesh Never touch the mesh of the burner gauze assembly Place the burner horizontally onto a suitable surface 3 Replace any damaged components Use new gas kets Note Observe the positioning ai...

Page 22: ...ease note Damage to the burner gauze assembly will impair the burner function Do not damage the mesh Never touch the mesh of the burner gauze assembly Place the burner horizontally onto a suitable surface 3 Replace any damaged components Use new gas kets Note Observe the positioning aid on the thermal insula tion block 4 Reassemble in reverse order Observe torque val ues see table on page 24 Commi...

Page 23: ...F G 4x H Fig 13 From 200 kW A Ignition and ionisation electrodes B Burner gauze assembly gasket C Insulation mat D Burner door gasket E Thermal insulation block F Burner gauze assembly G Fan H Venturi extension only for open flue operation 1 Remove electrodes Commissioning inspection maintenance Checking the burner gauze assembly and thermal cont 5839829 ...

Page 24: ...B Ignition electrodes 1 Check the electrodes for wear and contamination 2 Clean the electrodes with a small brush not a wire brush or cleaning fleece Please note Damage to the burner gauze assembly will impair the burner function Do not damage the mesh 3 Check the electrode gaps If the gaps are not as specified or the electrodes are damaged replace and align the electrodes together with new gas ke...

Page 25: ...g agents based on phosphoric acid 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 Before installation wet the gasket with suitable lubricating paste e g chloride free lubri cating paste part no 7568157 Position the insp...

Page 26: ...ng system if installed Separate the neutralising system if installed from the boiler for cleaning maintenance Single boiler C B A Fig 17 A Drain hose from trap to neutralising system B Drain hose from neutralising system to drainage system C Neutralising system Twin boiler D E C B A Fig 18 A Drain hose from trap to neutralising system B Drain hose from trap of flue gas collector to neu tralising s...

Page 27: ...o a sign of leaks Note Before removing the boiler flue connection discon nect plug at flue gas temperature sensor C 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 The connections on the heating water side must only be opened after the boiler has been depressurised Only drain ...

Page 28: ...sed flue gas damper C Sliding part 1 Check gaskets on the flue gas damper and flue gas header for leaks If required replace the gas kets 2 Check for leaks in the flue gas damper with the flue gas damper closed Leak tightness requirement Vmax 200 l h at 20 100 Pa Note In full load operation the gaskets can be checked with an inspection mirror Traces of condensate on the out side of the flue system ...

Page 29: ... page 104 For water quality requirements see page 102 The total hardness of the feed and top up water must not exceed the standard values specified by VDI 2035 see page 102 The pH value should be between 8 2 and 10 0 Checking the mixer for ease of operation and leaks 1 Remove the motorised lever from the mixer han dle 2 Check the mixer for ease of operation 3 Check the mixer for leaks In the event...

Page 30: ...tive ranges proceed as follows Check the ionisation electrode and connecting cable see page 24 Note During commissioning the combustion controller car ries out an automatic calibration Allow approx 30 s after the burner has started before testing the emis sions A Fig 22 01 Connect a flue gas analyser at flue gas port A on the boiler flue connection Measure the value in the core flue gas flow 02 Op...

Page 31: ...tion Matching the control unit to the heating system The control unit must be matched to the system equip ment level Various system components are recog nised automatically by the control unit and the relevant codes are set automatically For individual coding steps see page 36 Adjusting heating curves Only for weather compensated control units The heating curves illustrate the relationship between...

Page 32: ...erature 90 20 26 20 A C D E B Fig 24 Example 1 Adjustment of the standard set room temperature from 20 to 26 C A Boiler water temperature or flow temperature in C B Outside temperature in C C Set room temperature in C D Heating circuit pump OFF E Heating circuit pump ON Changing the standard set room temperature Operating instructions Reduced set room temperature 20 14 5 90 20 D E A C B Fig 25 Exa...

Page 33: ... be programmed as fault manager All coding addresses in the table are listed in the General group Boiler control unit Vitotronic 200 H Vitotronic 200 H LON LON Subscriber no 1 Code 77 1 Subscriber no 10 Code 77 10 Subscriber no 11 Set code 77 11 Control unit is fault manager Code 79 1 Control unit is not fault manager Code 79 0 Control unit is not fault manager Code 79 0 Control unit transmits the...

Page 34: ...icator 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 Display Service and Acknowledging a service Press OK Perform maintenance Note An acknowledged service message that has not been reset reappears the following Monday After mai...

Page 35: ...ot quite close it yet 2 Secure with 2 screws 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 Commissioning inspection maintenance Mounting the front panel 5839829 ...

Page 36: ...ing up coding level 1 Weather compensated control unit 1 Press OK and å simultaneously for approx 4 s 2 Coding level 1 3 Select the group of required coding addresses 4 Select the coding address 5 Set the value according to the following tables and confirm with OK Constant temperature control unit 1 Press OK and å simultaneously for approx 4 s 2 Select 1 with Ú for coding level 1 and confirm with ...

Page 37: ... circuit with mixer M3 heating circuit 3 without DHW heating code is set automatically 10 1 heating circuit without mixer A1 heating circuit 1 1 heating circuit with mixer M2 heating cir cuit 2 and 1 heating circuit with mixer M3 heating circuit 3 with DHW heating code is set au tomatically System examples Coding in the delivered condition Possible change Code 1 77 1 LON subscriber number if LON c...

Page 38: ...0 K Boiler number 07 1 Boiler number in multi boiler sys tems only for constant tempera ture control units 07 2 to 07 4 Boiler number 2 to 4 in multi boiler systems Burner service in 100 hours 21 0 No service interval set in hours run 21 1 to 21 100 The number of hours run before the burner should be serviced is adjust able from 100 to 10 000 h One step 100 h Service interval in months 23 0 No tim...

Page 39: ...sible change Speed control solar circuit pump 02 Data dependent on the software version of solar control module SM1 02 0 Solar circuit pump is not speed con trolled 02 1 With wave packet control function Never adjust 02 2 Solar circuit pump is speed control led with PWM control Maximum cylinder temperature 08 60 The solar circuit pump is switched off when the actual DHW tempera ture reaches the ma...

Page 40: ...5 see page 36 Coding Coding in the delivered condition Possible change Priority DHW heating A2 2 Cylinder priority applicable to heat ing circuit pump and mixer A2 0 Without cylinder priority applicable to heating circuit pump and mixer A2 1 Cylinder priority only applicable to mixer A2 3 to A2 15 Reduced priority applicable to mixer The heating circuit receives a re duced amount of energy Economy...

Page 41: ...o control function If there is a risk of frost Pump idle time transition reduced mode A9 7 With pump idle time Heating cir cuit pump OFF if the set value is altered through a change in oper ating mode or through a change in the set room temperature only for weather compensated control units A9 0 Without pump idle time A9 1 to A9 15 With pump idle time adjustable from 1 to 15 The higher the value t...

Page 42: ... or Standby mode only for weather compensated control units D5 1 The external operating program changeover switches to Continuous operation with standard room tem perature subject to coding ad dresses 3A 3B and 3C Ext operating program changeover to heating circuit D8 0 No operating program changeover via EA1 extension D8 1 Operating program changeover via input DE1 at EA1 extension D8 2 Operating...

Page 43: ... C Observe setting for coding address A3 only for weather compensa ted control units F8 10 to F8 60 Temperature limit adjustable from 10 to 60 C F8 61 Function disabled End temperature raising F9 14 Temperature limit for raising the re duced set room temperature 14 ºC only for weather compen sated control units F9 10 to F9 60 Temperature limit for raising the set room temperature to the value se l...

Page 44: ...simultaneously for approx 4 s 3 Coding level 2 4 Select the group of required coding addresses 5 Select the coding address 6 Set the value according to the following tables and confirm with OK Constant temperature control unit 1 Press OK and å simultaneously for approx 4 s 2 Press OK and ä simultaneously for approx 4 s 3 Select 2 with Ú for coding level 2 and confirm with OK 4 I flashes on the dis...

Page 45: ...ixer M2 heating cir cuit 2 and 1 heating circuit with mixer M3 heating circuit 3 with DHW heating code is set au tomatically System examples Coding in the delivered condition Possible change 11 No access to the coding addresses for the parameters of the combus tion controller 11 9 Access to the coding addresses for the parameters of the combustion controller open 25 0 Do not adjust only for consta...

Page 46: ...f input DE1 Fault mes sage input 3A 6 Function of input DE1 Brief opera tion of DHW circulation pump push button function Setting of DHW circulation pump runtime Coding address 3d 3B 0 Function of input DE2 at EA1 ex tension Not assigned 3B 1 Function of input DE2 Operating program changeover 3B 2 Function of input DE2 External de mand with set flow temperature Setting of set flow temperature for ...

Page 47: ...ion heating circuit pumps Coding address D6 3C 5 Function of input DE3 Fault mes sage input 3C 6 Function of input DE3 Brief opera tion of DHW circulation pump push button function Setting of DHW circulation pump runtime Coding address 3d 3D 5 DHW circulation pump runtime for brief operation 5 min 3D 1 to 3D 60 DHW circulation pump runtime ad justable from 1 to 60 min 4B 0 Function input 96 room t...

Page 48: ...e is installed 77 2 to 77 99 LON subscriber number adjustable from 1 to 99 1 4 Boiler 5 9 Never adjust 10 90 Vitotronic 200 H 98 Vitogate 99 Vitocom Note Allocate each number only once 79 1 With LON communication module Control unit is fault manager 79 0 Control unit is not fault manager 7B 1 With LON communication module Control unit transmits the time 7B 0 No time transmission 7F 1 Detached hous...

Page 49: ...ever adjust 97 0 With LON communication module The outside temperature of the sensor connected to the control unit is used internally 97 1 Control unit receives outside tem perature 97 2 The control unit transmits the out side temperature to the LON sub scribers 98 1 Viessmann system number in conjunction with monitoring of sev eral systems via Vitocom 300 98 1 to 98 5 System no adjustable from 1 ...

Page 50: ...20 kW 32 0D 0 Never adjust 0E 0 Never adjust 13 1 Never adjust 14 1 Never adjust 15 1 Never adjust 21 0 No service interval set in hours run 21 1 to 21 100 The number of hours run before the burner should be serviced is adjust able from 100 to 10 000 h One adjusting step 100 h 23 0 No time set for burner service in terval 23 1 to 23 24 Interval adjustable from 1 to 24 months 24 0 Service not shown...

Page 51: ...al 5F 2 Circulation pump for cylinder heating starts at External demand signal 60 20 During DHW heating the set boiler water temperature is max 20 K higher than the set DHW tempera ture 60 5 to 60 25 The differential between the set boil er water temperature and the set DHW temperature is adjustable from 5 to 25 K 62 2 Circulation pump for cylinder heat ing with 2 min run on time after cyl inder h...

Page 52: ...switched off if the differential between the collector temperature and the ac tual cylinder temperature is less than 4 K 01 1 to 01 29 The differential between the actual cylinder temperature and the stop point for the solar circuit pump is ad justable from 1 to 29 K 02 Data dependent on the software version of solar control module SM1 02 0 Solar circuit pump not speed con trolled 02 1 With wave p...

Page 53: ... temperature and the start point for reducing the stagnation time is adjustable from 0 to 40 K 0B 0 Collector frost protection function switched off 0B 1 Collector frost protection function switched on not required with Viessmann heat transfer medium 0C 1 Delta T monitoring switched on No flow rate detected in the collec tor circuit or flow rate too low 0C 0 Delta T monitoring switched off 0D 1 Ni...

Page 54: ... control 2 20 3 Differential temperature control 2 and auxiliary function 20 4 Differential temperature control 2 for central heating backup 20 5 Thermostat function 20 6 Thermostat function and auxiliary function 20 7 Solar heating via external heat ex changer without additional tempera ture sensor 20 8 Solar heating via external heat ex changer with additional temperature sensor 20 9 Solar heati...

Page 55: ...0 C Start temperature for thermostat function stop temperature for thermostat function Thermostat function e g for re heating Switching output sS is switched off if the temperature at sensor exceeds the start tem perature for the thermostat func tion Start temperature for thermostat function stop temperature for thermostat function Thermostat function e g for utilis ing excess heat Switching outpu...

Page 56: ...ion A1 0 All settings that can be made at the remote control can be execu ted only for weather compensated control units A1 1 Only party mode can be set at the remote control Only on Vitotrol 200 A A2 2 Cylinder priority control for heating circuit pump A2 0 Without cylinder priority for heating circuit pump A2 1 Cylinder priority applies only to mix ers The mixer is closed during cylin der heatin...

Page 57: ... function economy mode Heating circuit pump OFF when the out side temperature OT is 1 K high er than the set room temperature RTset only for weather compen sated control units OT RTset 1 K A5 0 Without heating circuit pump logic function A5 1 to A5 15 With heating circuit pump logic func tion Heating circuit pump OFF see the following table Parameter address A5 With heating circuit pump logic func...

Page 58: ...1 to A9 15 With pump idle time adjustable from 1 to 15 B0 0 With remote control Heating mode reduced mode Weather compensated only change the code for the heating circuit with mixer only for weather compen sated control units B0 1 Heating mode Weather compensa ted Reduced mode With room tempera ture hook up B0 2 Heating mode With room tempera ture hook up Reduced mode Weather compen sated B0 3 Hea...

Page 59: ... operating program to Constant operation at reduced room temperature or Standby mode only for weather compensated control units D5 1 The external operating program changeover switches to Continuous operation with standard room tem perature subject to coding ad dresses 3A 3B and 3C D6 0 Heating circuit pump remains in control mode at External blocking signal D6 1 Heating circuit pump stops at signa...

Page 60: ... boiler circuit pump run on time F5 1 to F5 20 Run on time of the boiler circuit pump adjustable from 1 to 20 min F6 25 In Only DHW mode the boiler circuit pump is constantly on only for constant temperature control units F6 0 In Only DHW mode the boiler cir cuit pump is constantly off F6 1 to F6 24 In Only DHW mode the boiler cir cuit pump is started 1 to 24 times per day for 10 min each time F7 ...

Page 61: ...th standard room temperature only for weath er compensated control units FA 0 to FA 50 Temperature increase adjustable from 0 to 50 FB 30 Duration for increasing the set boil er water or flow temperature see coding address FA 60 min only for weather compensated control units FB 0 to FB 150 Duration adjustable from 0 to 300 min 1 step 2 min Code 2 Heating circuit 1 heating circuit 2 heating cont 58...

Page 62: ...ns a weather compensated control unit into a constant temperature control unit Diagnosis weather compensated control unit Calling up operating data Operating data can be called up in 6 areas See Diagnosis in the service menu overview Operating data on heating circuits with mixer or solar thermal systems can only be called up if such compo nents are installed in the system For further information o...

Page 63: ...n burner control unit 5 Internal details for calibration 0 Software ver sion AM1 ex tension Software ver sion EA1 exten sion 0 No EA1 6 0 0 0 0 0 0 7 LON Subnet address system num ber LON Node address 0 0 8 LON SBVT config uration LON Software ver sion commu nication cop rocessor LON Neuron chip software version Number of LON subscribers 9 Heating circuit A1 HC1 Heating circuit M2 HC2 Heating circ...

Page 64: ... internal extension enabled AM1 output 1 ON Output A1 at AM1 extension active AM1 output 2 ON Output A2 at AM1 extension active EA1 output 1 ON Contact P S at plug aBJ of EA1 extension closed Solar circuit pump ON Solar circuit pump output sF on solar control module SM1 active Solar circuit pump min ON Solar circuit pump output on solar control module SM1 switched to minimum speed Solar circuit pu...

Page 65: ...ol unit Software version LON cascade communication module F 1 Code 53 setting Internal details for calibration AM1 extension F 2 Software ver sion Output A1 config uration value corre sponds to code 33 setting Output A1 switching state 0 OFF 1 ON Output A2 con figuration value corre sponds to code 34 setting Output A2 switch ing state 0 OFF 1 ON EA1 extension F 3 Output 157 con figuration value co...

Page 66: ...Shown on display Explanation 0 All actuators are off 1 Burner operated at minimum output circulation pump is started 2 Burner operated at maximum output circulation pump is started 3 Output sÖ active boiler circuit pump 10 Internal extension output active 15 Solar circuit pump output sF on solar control module SM1 active 16 Solar circuit pump output on solar control module SM1 switched to minimum ...

Page 67: ...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 are saved and can be called up Faults are sorted by date 1 Press OK and å simultaneously for approx 4 s 2 Fault history 3 Display Deleting the fault history 1 Press OK and å simultaneously for approx 4 s 2 Fault history 3 Delete Cons...

Page 68: ...bustion chamber pressure switch Inform Technical Service Fault code dis played System characteristics Cause Measures 10 Regulates as if the outside temperature were 0 C Short circuit outside tem perature sensor Check outside temperature sensor see page 75 18 Regulates as if the outside temperature were 0 C Lead break outside tem perature sensor Check outside temperature sensor see page 75 19 Regul...

Page 69: ...solar control module 99 Control mode Lead break temperature sensor aÖ Check sensor aÖ on solar control module 9A No solar DHW heating Lead break collector tem perature sensor Check temperature sensor on solar control module or sensor on the Vitosolic 9B Control mode Lead break cylinder tem perature sensor Check temperature sensor at ter minal S3 on the Vitosolic 100 9C No solar DHW heating Lead br...

Page 70: ...or Vi totrol remote control heat ing circuit 2 with mixer Check connections cable and cod ing address A0 in the Heating circuit group and the remote con trol settings For wireless remote control units Check connection place remote control close to the boiler BE Control mode without remote control Communication error Vi totrol remote control heat ing circuit 3 with mixer Check connections cable and...

Page 71: ...oom influence Lead break room temper ature sensor heating cir cuit 3 with mixer Check room temperature sensor for heating circuit 3 and the remote control settings E0 Control mode External LON subscriber error Check connections and LON sub scribers E1 Burner in a fault state Ionisation current too high during calibration Check gap between ionisation electrode and burner gauze as sembly see page 24...

Page 72: ...pts replace the coding card and press reset button R EB Burner in a fault state Repeated flame loss dur ing calibration Check gap between ionisation electrode and burner gauze as sembly see page 24 Check flue system remove flue gas recirculation if required Press reset button R EC Burner in a fault state Parameter error during calibration Press reset button R or Replace coding card and then press ...

Page 73: ...onnecting cable Press reset button R F6 Burner in a fault state Temperature values of the boiler water temperature sensors vary too widely from one another Replace the boiler water tempera ture sensors F9 Burner in a fault state Fan speed too low during burner start Check the fan Check the fan con necting cables Check the fan pow er supply Check the fan control Press reset button R FA Burner in a ...

Page 74: ... fault per sists check the coding card and replace coding card or control unit if necessary FF Burner blocked or in a fault state Internal fault or reset but ton R blocked Restart the appliance Replace the control unit if the appliance will not restart Increase the water pressure or re set the combustion chamber pres sure limiter Troubleshooting Fault codes cont 5839829 Diagnosis ...

Page 75: ...ce 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 Repeat the test directly on the sensor 6 Depending on the result replace the lead or the outside temperature sensor Maintenance Checking the outside temperature sensor 5839829 Maintenance ...

Page 76: ...ensor type NTC 10 kΩ 3 In the event of severe deviation replace the sensor Checking the boiler water temperature sensor Note The boiler water temperature sensor is a dual sensor A B C D Fig 37 A Boiler water temperature sensor B Connection C Connection 1 D Water pressure switch 1 Boiler water temperature sensor A Pull plug and measure the resistance Maintenance Checking the cylinder temperature se...

Page 77: ...nt of severe deviation replace the sensor Checking the flue gas temperature sensor Note The flue gas temperature sensor is a dual sensor The flue gas temperature sensor locks out the boiler if the permissible flue gas temperature is exceeded After the flue system has cooled down press reset button R to cancel the lock Maintenance Checking the boiler water temperature sensor cont 5839829 Maintenanc...

Page 78: ...6 0 8 2 4 6 8 20 Resistance in kΩ Fig 40 Sensor type NTC 10 kΩ 2 Measure the resistance of both sensors and com pare each with the curve 3 In the event of severe deviation replace the sensor Checking the fuse Note Switch OFF the power supply Maintenance Checking the flue gas temperature sensor cont 5839829 Maintenance ...

Page 79: ...the rotational direction of the mixer motor After being switched on the boiler implements a self test During this the mixer is opened and closed again Note The mixer motor can also be started via the actuator test see chapter Checking outputs Observe the rotational direction of the mixer motor dur ing its self test Then manually set the mixer back to Open The flow temperature sensor must now captu...

Page 80: ...ck flow temperature sensor 10 1 10 30 50 70 90 110 Temperature in C 0 4 0 6 0 8 2 4 6 8 20 Resistance in kΩ Fig 43 Sensor type NTC 10 kΩ 1 Disconnect plug flow temperature sensor 2 Check the sensor resistance and compare it to the curve In the event of severe deviation replace the sensor Checking the Vitotronic 200 H accessories The Vitotronic 200 H is connected to the control unit via the LON cab...

Page 81: ...HW heating The burner and the circulation pump for cylinder heat ing are started if the cylinder temperature during the cylinder enable time lies 2 5 K below the set cylinder temperature In the delivered condition the set boiler water temper ature is 20 K higher than the set cylinder temperature adjustable via coding address 60 If the actual cylin der temperature exceeds the set cylinder temperatu...

Page 82: ...ed via coding address 53 in the General group Central fault message code 53 0 DHW circulation pump code 53 1 only for weather compensated operation Connect DHW circulation pumps with standalone functions directly to the 230 V supply An external safety valve can be linked to connection gD lH Power supply for accessories and Vitotrol 100 Function description Internal extensions 5839829 Functions ...

Page 83: ...address 53 in the General group Central fault message code 53 0 DHW circulation pump code 53 1 only for weather compensated operation Connect DHW circulation pumps with standalone functions directly to the 230 V supply An extractor fan can be switched off via connection aBJ when the burner starts lH Power supply for accessories and Vitotrol 100 Function description Internal extensions cont 5839829...

Page 84: ...circulation pump only for weather compensa ted control units Connect DHW circulation pumps with standalone functions directly to the 230 V supply Select the output functions via parameter changes codes at the boiler control unit Function assignment Function Parameter code General group Output A1 Output A2 DHW circulation pump sK 33 0 34 0 delivered condition Heating circuit pump sÖ 33 1 delivered ...

Page 85: ... be potential free When con necting external contacts observe the requirements of protection class II 8 0 mm air and creep path or 2 0 mm insulation thickness to live parts Input function assignment The functions of the inputs are selected via the codes on the boiler control unit DE1 Code 3A DE2 Code 3b DE3 Code 3C Assigning the operating program changeover function to the heating circuits The hea...

Page 86: ...ion pumps with standalone func tions directly to the 230 V supply Function assignment The function of output aBJ is selected at the boiler control unit via code 36 Control functions External operating program changeover The External operating program changeover function is implemented via the EA1 extension There are 3 inputs available at the EA1 extension DE1 to DE3 The function is selected via th...

Page 87: ...at ing is selected with code 5E DHW 3 The effect on the relevant heating circuit pump is selected with code d6 Heating circuit EA1 extension The functions External blocking and External block ing with fault message input are implemented via the EA1 extension There are 3 inputs available at the EA1 extension DE1 to DE3 The function is selected via the following codes External blocking Code Input DE...

Page 88: ...ve the screed manufacturer s instructions When screed drying is enabled the heating circuit pump for the heating circuit with mixer starts and the flow temperature is maintained in accordance with the selected profile On completion 30 days the heating circuit with mixer is regulated automatically according to the set parameters Observe EN 1264 The report to be provided by the heating contractor mu...

Page 89: ...F1 15 Flow temperature C 1 5 10 15 20 25 30 Days 50 40 30 20 10 Fig 55 Raising the reduced room temperature During operation at reduced room temperature the reduced set room temperature can be automatically raised subject to the outside temperature The temper ature is raised in accordance with the selected heating curve and no higher than the standard set room tem perature The outside temperature ...

Page 90: ...ced room tem perature Reducing the heat up time During the transition from operation with reduced room temperature to operation with standard room tempera ture the boiler water or flow temperature is raised in accordance with the selected heating curve The boiler water or flow temperature increase can be automati cally raised The value and duration of the additional increase of the set boiler wate...

Page 91: ...xer M2 H 2 HC 2 The remote control affects the heating circuit with mixer M3 H 3 HC 3 The Vitotrol 200 A 200 RF can have 1 heating circuit assigned The Vitotrol 300 A can have up to 3 heating circuits assigned Up to 2 remote control units can be connected to the control unit If the heating circuit allocation is later cancelled reset parameter coding address A0 for this heating circuit to 0 fault m...

Page 92: ... 1 1 27 4 9 9 0 8 9 1 30 5 3 8 7 8 6 1 34 5 7 8 5 8 4 1 37 6 1 8 3 8 2 1 40 6 5 8 1 8 0 1 44 6 9 7 8 7 7 1 48 7 3 7 6 7 5 To achieve optimum combustion control the system regularly carries out an automatic self calibration also after power failures shutdown For this the combus tion is briefly regulated to maximum ionisation current corresponding to air ratio λ 1 Self calibration takes place shortl...

Page 93: ...sories Cylinder temperature sensor sÖ Boiler circuit pump or butterfly valve with return spring sA Circulation pump either Circulation pump for cylinder heating External heating circuit pump DHW circulation pump Connection and wiring diagram Connection and wiring diagram 5839829 Appendix ...

Page 94: ...r 300 A remote control Mixer extension kit Solar control module type SM1 EA1 extension Wireless base station AM1 extension a Ö Fan motor A1 Main PCB A3 Coding card A4 ON OFF switch A5 Programming unit A6 Connection adaptor with Optolink A7 Connection adaptor A8 LON communication module accessories A9 Reset A10 Connection extension A11 Output extension Connection and wiring diagram Connection and w...

Page 95: ...CB A11 Output extension SA 169 A4 ON OFF switch sÖ Boiler circuit pump or butterfly valve with return spring fÖ Power supply a Ö Fan motor Connection and wiring diagram Connection and wiring diagram cont 5839829 Appendix ...

Page 96: ...96 Up to 80 kW Fig 60 Connection and wiring diagram Connection and wiring diagram cont 5839829 Appendix ...

Page 97: ...pump either Circulation pump for cylinder heating External heating circuit pump DHW circulation pump sK Internal H1 extension Central fault message DHW circulation pump External heating circuit pump Circulation pump for cylinder heating Code 53 dG Gas train fÖ Power supply Connection and wiring diagram Connection and wiring diagram cont 5839829 Appendix ...

Page 98: ...upply in main PCB A3 Coding card A4 ON OFF switch A5 Programming unit A6 Connection adaptor with Optolink A7 Connection adaptor A8 LON communication module accessories A9 Reset A10 Connection extension SA 100 A11 Output extension A12 Burner control unit Main PCB up to 80 kW Fig 62 A Boiler water temperature sensor aA Ionisation electrode aG Flue gas temperature sensor gF Ignition unit a Ö Fan moto...

Page 99: ... Fig 63 A Boiler water temperature sensor aA Ionisation electrode aG Flue gas temperature sensor gF Ignition unit a Ö Fan motor a ÖA Fan motor control a Ö Modulation coil X9 8 9 Combustion chamber pressure switch and water pressure switch Connection and wiring diagram Connection and wiring diagram cont 5839829 Appendix ...

Page 100: ...nisation electrode aG Flue gas temperature sensor gF Ignition unit a Ö Fan motor a ÖA Fan motor control a Ö Modulation coil X9 8 9 Combustion chamber pressure switch and water pressure switch Connection and wiring diagram Connection and wiring diagram cont 5839829 Appendix ...

Page 101: ...only with multi boiler system Rated voltage 230 V Rated current Max 2 1 A sA Circulation pump for cylinder heating B Rated voltage 230 V Rated current Max 2 1 A sK DHW circulation pump accessories Rated voltage 230 V Rated current Max 2 1 A fÖ Power supply on output extension SA 169 Connection and wiring diagram External connection diagram 5839829 Appendix ...

Page 102: ...ing output apply the requirements of the next higher category of total heating output in accordance with the table In multi boiler systems apply the output of the smallest boiler In the case of severe overshoot 50 l kW soften the water down to a total of alkaline earths of 0 02 mol m3 Operating information During expansion or repair work only drain the pipe work sections necessary Check clean and ...

Page 103: ... Under all operating conditions and at all points in the heating system including the intake side of the pump the pressure must be higher than atmos pheric pressure Check the pre charge pressure of the expansion vessel at least during the annual service Avoid the use of permeable components e g permea ble plastic pipes in underfloor heating systems Pro vide system separation if such components are...

Page 104: ...re mbar kPa 30 3 0 Supply pressure flow pres sure For natural gas E mbar kPa 17 25 1 7 2 5 For natural gas L mbar kPa 20 30 2 3 Tick gas type Carbon dioxide content CO2 For natural gas E and L At lower heating output by vol 7 2 9 2 At upper heating output by vol 7 7 9 2 Oxygen content O2 At lower heating output by vol 4 4 7 9 At upper heating output by vol 4 4 6 9 Commissioning service reports Fil...

Page 105: ...st values Set value Commissioning Maintenance service Carbon monoxide content CO At lower heating output ppm 60 At upper heating output ppm 100 Commissioning service reports Settings and test values cont 5839829 Appendix ...

Page 106: ...s Length mm 665 770 770 890 890 1004 1004 Width mm 680 Height mm 1650 Total dimensions incl casing boiler flow and return excl boil er flue connection Length mm 739 862 862 967 967 1085 1085 Width mm 750 Height mm 1650 Foundation dimensions Length mm 750 850 850 1000 1000 1100 1100 Width mm 800 800 800 800 800 800 800 Height mm 100 100 100 100 100 100 100 Weight Overall unit weight kg 238 295 295 ...

Page 107: ... 0 8 1 2 1 2 1 1 1 1 1 4 1 4 Max permissible overpressure in the header of the flue gas cascade 4 Pa mbar 70 0 7 Product parameters accord ing to EnEV Standard seasonal efficiency to DIN For heating system temperature 40 30 C Up to 98 Hs gross cv 109 Hi net cv For heating system temperature 75 60 C Up to 96 Hs gross cv 106 Hi net cv Standby loss qB 70 0 6 0 5 0 3 0 6 0 6 0 6 0 6 NOx NOx class 6 56...

Page 108: ...00 240 kW CI 280 318 kW CI 280 318 kW Product ID See boiler Voltage V 230 Frequency Hz 50 Power consumption At upper heating output W 140 5 130 268 171 279 260 393 At lower heating output W 19 5 28 28 29 29 26 5 26 5 Version Modulating Dimensions Width a mm 463 426 426 463 463 463 463 Length b mm 442 481 481 655 655 731 731 Height c mm 400 273 273 356 356 356 356 Weight Burner with combination val...

Page 109: ...re 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 All components must be disposed of correctly Shutdown and disposal Final decommissioning and disposal 5839829 Appendix ...

Page 110: ...Con formity can be found on the following website www viessmann co uk eu conformity Manufacturer s certificate according to the 1st BImSchV Germany We Viessmann Werke GmbH Co KG D 35107 Allendorf confirm that the product Vitocrossal complies with the NOx limits specified by the 1st BImSchV paragraph 6 Germany Allendorf 2 January 2018 Viessmann Werke GmbH Co KG Authorised signatory Reiner Jansen He...

Page 111: ...unction description 81 Relay test 66 Service menu 64 Control unit Connection to LON 33 Matching 31 Control unit for weather compensated operation Calling up operating data 62 Cylinder temperature sensor 76 D Date setting 12 Disposal 109 E Electronic combustion controller 91 Expansion vessel 29 Extension AM1 84 EA1 85 Internal H1 82 Internal H2 83 Extension kit for heating circuit with mixer 79 Ext...

Page 112: ...rying 88 Service menu Constant temperature control unit 64 Weather compensated control unit 62 Service scans 34 Set room temperature selection 32 Shutdown 109 Small softening system 11 Specification MatriX cylinder burner 108 Single boiler 106 Twin boiler 108 Standard set room temperature 32 Static pressure 14 15 Supply pressure 14 Symbols 8 System filling 11 System pressure 29 T Testing outputs 6...

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Viessmann CIB, Service Instructions Manual

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