Viessmann VITOCROSSAL CRU 1000 kW Service Instructions Manual Download Page 1

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Service instructions

for contractors

VIESMANN

Vitocrossal
Type CRU, 800 and 1000 kW

Gas condensing boiler
For

open flue

and

room sealed

operation

Permissible operating pressure 6 bar

VITOCROSSAL

5816717 GB

1/2018

Please keep safe.

Summary of Contents for VITOCROSSAL CRU 1000 kW

Page 1: ...uctions for contractors VIESMANN Vitocrossal Type CRU 800 and 1000 kW Gas condensing boiler For open flue and room sealed operation Permissible operating pressure 6 bar VITOCROSSAL 5816717 GB 1 2018 Please keep safe ...

Page 2: ...ocally applicable standards a ÖNORM EN ÖVGW G K directives ÖVGW TRF and ÖVE c SEV SUVA SVGW SVTI SWKI VKF and EKAS guideline 1942 LPG part 2 Safety instructions for working on the system Working on the system Where gas is used as the fuel close the main gas shut off valve and safeguard it against unintentional reopening Isolate the system from the power supply e g by removing the separate fuse or ...

Page 3: ...c distribution board Danger If water escapes from the appliance there is a risk of scalding Never touch hot heating water Condensate Danger Contact with condensate can be harmful to health Never let condensate touch your skin or eyes and do not swallow it Flue systems and combustion air Ensure that flue systems are clear and cannot be sealed for instance due to accumulation of conden sate or other...

Page 4: ...lt display 43 5 Parts lists Overview of assemblies 45 Boiler assembly 46 Casing assembly 48 MatriX Disk burner assembly 50 Burner control unit assembly 52 Control unit assembly 54 6 Component overview Overview of burner components 56 7 Function description Air pressure switch 57 Fan pressure monitoring function LDW1 57 Combustion chamber pressure monitoring function LDW2 57 Boiler water temperatur...

Page 5: ...on Not required during inspection Steps required during maintenance Not required during maintenance Intended use The appliance is only intended to be installed and operated in sealed unvented heating systems that comply with EN 12828 with due attention paid to the associated installation service and operating instruc tions as well as the details in the datasheet It is only designed for the heating...

Page 6: ...RU Gas condensing boiler 800 and 1000 kW rated heat ing output with modulating MatriX Disk burner for natural gas E and LPG P Permissible operating pressure 6 bar 0 6 MPa Information Product information 5816717 Information ...

Page 7: ...nnections and the sensor well on the heating water side for tightness 21 20 Cleaning the condensate drain pipe and trap 21 21 Checking the condensate drain and neutralising system if installed 22 22 Opening the burner door 23 23 Checking the burner gauze assembly 24 24 Checking the ignition electrodes and ionisation electrode 24 25 Cleaning the burner 25 26 Fitting the burner 26 27 Closing the bur...

Page 8: ...hecking the thermal insulation for firm seating 40 Checking the installation room ventilation air apertures 31 41 Instructing the system user 31 42 Operating and service documents 31 Commissioning inspection maintenance Steps commissioning inspection and cont 5816717 ...

Page 9: ...onic operating instructions and service instructions Neutralising system operating instructions Flue system installation instructions Note To ensure stable operation the following minimum lengths for the flue system must be observed Natural gas E 5 m LPG P 10 m 01 Check the heating system pressure Permiss operating pressure 6 bar 0 6 MPa Minimum operating pressure 0 5 bar 50 kPa Danger If the oper...

Page 10: ...the burner door with 40 Nm Tighten the screws of the flue gas collector with 30 Nm Checking the flue gas damper Where present Check the motorised flue gas damper flue gas cascade accessory The flue gas damper must be closed in its zero volt state plug 53 Checking the gas type 1 Check with your gas supply utility regarding the gas type and Wobbe index Ws 0 C 1013 25 mbar With the natural gas E sett...

Page 11: ...rew the screws until the front panel can be removed 2 Pivot up the top panel 3 Undo the bottom screws on the rail extension on both sides 4 Lift the side panels slightly and remove to the side Commissioning inspection maintenance Opening the boiler 5816717 ...

Page 12: ...e but terfly of the gas train fully towards Natural gas E with Wobbe index Ws 13 5 kWh m3 0 C 1013 25 mbar Burner can be commissioned in the delivered condition 2 Start the burner 3 Measure the CO2 content in the flue gas and adjust See page 16 Commissioning inspection maintenance Conversion to natural gas E 5816717 ...

Page 13: ... the following chapter Note Coding card must be ordered separately 3 Adjust gas pressure switch B to a new value To 40 mbar for a nominal supply pressure flow pressure of 50 mbar To 25 mbar for a nominal supply pressure flow pressure of 37 mbar 4 Start the burner 5 Measure the CO2 content in the flue gas and adjust See page 16 Commissioning inspection maintenance Conversion to LPG P 5816717 ...

Page 14: ... output if required The maximum heating output of the burner can be reduced if required Status Service S R Fig 6 1 Press S and hold for longer than 2 s flashes 2 Press until the display shows 6 under Service 3 Press S On the display 6 appears under Status 4 Press S On the display 1 appears under Status The current value for the maximum heating output in is shown under Service 5 Press or to set the...

Page 15: ...t do not remove 3 Connect the pressure tester at test connector A 4 Open the gas shut off valve 5 Check the static pressure Max 100 mbar 10 kPa 6 Record the actual value in the report on page 61 Supply pressure 1 Start the burner with emissions test mode enabled control unit menu Vitotronic operating instructions Commissioning inspection maintenance Reducing the heating output if required cont 581...

Page 16: ...adjustments Notify your gas supply utility or LPG supplier 15 to 18 mbar 1 5 to 1 8 kPa Please note The boiler may only be operat ed temporarily with this setting emergency mode Notify your gas supply utility or LPG suppli er 18 to 25 mbar 1 8 to 2 5 kPa 42 5 to 57 5 mbar pN 50 mbar 4 2 to 5 75 kPa pN 5 kPa 25 to 45 mbar pN 37 mbar 2 5 to 4 5 kPa pN 3 7 kPa Start the boiler 50 mbar 5 kPa 57 5 mbar...

Page 17: ...mbar Upper heating output 100 9 2 0 1 Lower heating output 0 8 2 0 1 Natural gas E Wobbe index Ws 13 5 kWh m3 0 C 1013 25 mbar Upper heating output 100 9 0 0 1 Lower heating output 0 8 0 0 1 LPG P Upper heating output 100 10 9 0 1 Lower heating output 0 10 0 0 1 CO2 test at the upper heating output A Fig 9 1 Press until the service display has counted up to 100 100 2 Check the CO2 content at the f...

Page 18: ...1 Press until the service display has counted down to 0 lower heating output 2 Check the CO2 content at the flue pipe For permissible CO2 content see above table page 17 Note At the lower heating output the CO2 content must always be lower than at the upper heating output 3 If the CO2 content needs adjusting Turn adjusting screw B in very small increments Continue turning until CO2 content falls w...

Page 19: ...rs under Status 04 Press until 3 appears under Service 05 Press S 3 appears under Status During opera tion the ionisation current is shown under Service e g 30 3 0 µA 06 Start the burner with emissions test mode enabled in control unit menu 07 Read the ionisation current 08 Record the actual value in the report 09 Hold down S for approx 2 s flashes 10 Press until 5 appears under Service 11 Press S...

Page 20: ... For cleaning flush the heating surfaces thoroughly with a jet of water For stubborn residues surface stains or soot deposits cleaning agents can be used For this observe the following Only use solvent free cleaning agents Ensure that no cleaning agent gets between the boiler body and the thermal insulation Remove soot deposits with an alkaline cleaning agent with surfactant additive e g Fauch 600...

Page 21: ...E Boiler return 2 PN 6 DN 100 F Boiler return 1 PN 6 DN 100 G Drain outlet R 1 H Condensate drain R Note Check the connection for the sensor well and the mini mum pressure switch low water indicator for tight ness Cleaning the condensate drain pipe and trap Note Clean the condensate drain pipe and trap at least once a year Commissioning inspection maintenance Checking all connections and the senso...

Page 22: ... constant fall Checking the condensate drain and neutralising system if installed 1 Fill the combustion chamber with water Note The water must flow from the condensate drain pipe without backing up If necessary clean the condensate drain pipe again 2 If necessary clean the neutralising system in accordance with the manufacturer s instructions Neutralising system operating instructions Note Neutral...

Page 23: ...23 6x 2 3 1 Fig 13 Commissioning inspection maintenance Opening the burner door 5816717 ...

Page 24: ...assembly A and thermal insulation block B for damage 2 If a component is visibly damaged replace the component Installation instructions Replacing burner components Checking the ignition electrodes and ionisation electrode Ignition electrodes 17 6 4 2 1 1 Fig 15 Ionisation electrode 21 1 Fig 16 Commissioning inspection maintenance Opening the burner door cont 5816717 ...

Page 25: ...er gauze assembly and for possible damage Replace the electrodes if required Installation instructions Replacing burner components Cleaning the burner 5 4 8x 10x 95 152 53 2 B A 2 3 3 1 Fig 17 Commissioning inspection maintenance Checking the ignition electrodes and ionisation cont 5816717 ...

Page 26: ...bly 5 Undo 10 nuts Remove the fitting 6 Clean the fitting and swirl plate carefully with com pressed air Carefully vacuum the burner gauze assembly from inside Remove any dirt with compressed air Fitting the burner Reassemble the burner in reverse order See Fig 17 Note Ensure that all gaskets are seated correctly Danger Escaping gas leads to a risk of explosion Check the fitting and gasket between...

Page 27: ...ng through escaping gas Check the burner door for flue gas tightness e g with inspection mirror gas sensor or thermal image camera In the case of leaks tighten diagonally to 50 Nm 3 Check flue gas tightness again 2 1 3 Fig 19 Attach the intake extension Commissioning inspection maintenance Closing the burner door cont 5816717 ...

Page 28: ... completing the test close the screw on test connector B Check the test connector for leaks Danger Escaping gas leads to a risk of explosion Check the test connectors for gas tightness Please note The use of leak detection spray can result in faulty operation Leak detection spray must not come into contact with electrical contacts Checking the gas train filter element 1 Close the gas shut off valv...

Page 29: ...tions for tightness Danger Escaping gas leads to a risk of explosion Always carry out the following steps Please note The use of leak detection spray can result in faulty operation Leak detection spray must not come into contact with electrical contacts 1 Insert new gaskets in all gas fittings that have been opened and retighten them 2 Open the gas shut off valve 3 Check the inlet joints of the ga...

Page 30: ...seating 3 Check gasket C with the boiler flue connection for tightness If necessary replace the gasket Performing final checks Record the actual values in the report on page 62 Checking the water quality Enter the amount of top up water the total hardness and the pH value in the tables on page 61 For water quality requirements see page 59 Checking the safety valve function Checking the expansion v...

Page 31: ...rmal insulation for firm seating Checking the installation room ventilation air apertures Check that the vent is unobstructed and free from soil ing in the case of open flue operation 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 This includes all components installed as accessories e g rem...

Page 32: ...r control unit Control unit installation and service instructions operating instructions Operating display In standard mode the status indicator shows the cur rent operating status The same applies in a fault state after pressing reset button R The following displays are shown automatically If a fault occurs see the fault codes on page 38 onwards You can exit at any time by pressing reset button R...

Page 33: ...play Information Menu point Description 1 Permanent meters for start ups and hours run 2 Resettable meters for start ups and hours run 3 Software version 4 Fault history for the last 10 fault codes Example To clear the hours run meter press the fol lowing keys 1 S longer than 2 s flashes 2 until 2 is shown under Service 3 S 1 is displayed under Status 4 Scroll through Status until 6 is shown Statu...

Page 34: ...hown under Service 3 S 5 is displayed under Status 4 until 3 is shown under Service 5 S 3 appears under Status During operation the ionisation current is shown under Service e g 30 3 0 µA Menu point 6 is used to change the following operating parameters Sub menu point Parameter Setting range unit Delivered condition 1 Maximum operational output of rated heating out put 100 2 Gas type 0 Natural gas...

Page 35: ... operating parameters to their delivered condition 1 S longer than 2 s flashes 2 until 6 is shown under Service 3 S 6 is displayed under Status 4 until 0 is shown under Service 5 S 1 is shown under Status and dEL under Serv ice 6 S to confirm If reset successfully 1 is shown under Service if it failed 0 is shown 7 S to change to the operating display Manual operation and service display To call up...

Page 36: ...3 1 2 4 5 6 8 U System start Relay test Start up Operation Shutdown Fault states 9 7 C Waiting Standby F6 10 11 Code Enable plug 152 T2 P Operation with flue gas damper Demand CAN bus Enable plug 152 T2 Operation without flue gas damper Plug 100 Blocking fan output plug 152 S3 Gas pressure switch1 Outputs L Signal change Assessed subject to output Output active L Subject to heat demand Fuel valve ...

Page 37: ... Flame signal amplifier test max 50 s Gas fan and air pressure switch test max 20 s 2 Fan ramp up max 15 min 3 Pre purge 30 s Adjust start up load WD 1 test 25 s 4 Pre ignition 1 s 5 Safety time max 2 6 s Operation 6 Flame stabilising time 15 s 7 Start up partial load 12 s Modulating operation 0 to 24 h Adjust shutdown load 10 s Shutdown 8 Reheating WD 2 test 1 s max 30 s Fan ramp up post purge ma...

Page 38: ...out fault without displaying a fault code the fault memory may give an indication of the cause Call up the fault codes 1 S longer than 2 s flashes 2 until 4 is shown under Service 3 S 4 is displayed under Status 4 to scroll through the fault memory display Service Description 1 Fault codes display 2 Detailed fault codes 3 Clear fault memory 5 S the selected fault memory display is shown under Stat...

Page 39: ...art up or after the post purge Ionisation electrode or burner gauze assembly damaged Gas train leaks gas is es caping and burning In correct coding card Check ionisation path Check ioni sation electrode for earth fault Check burner gauze assembly for deformation Replace coding card Replace gas train F F4 No flame formation during safety time ionisation flame monitor reports no flame sig nal Ionisa...

Page 40: ...ressure switch faulty multiple problems with gas supply Open the gas shut off valve Check gas flow pressure Replace gas fil ter if required Reset the burner control unit Replace gas train F F7 Fan pressure is created dur ing the idle state check of air pressure switch 1 Wind influence on fan Check the flue draught chimney F F7 Contact of air pressure switch 1 not in idle state Air pressure switch ...

Page 41: ...tate system cooling down burner control unit locked out Short circ flue gas temp sensor Check connecting cable and flue gas temperature sensor 15A 15B dual sensor Replace sensor if re quired F 83 Burner control unit in a fault state Sensor drift flue gas tem perature sensor Check connecting cable and flue gas temperature sensor 15A 15B dual sensor Replace sensor if re quired F 88 Burner control un...

Page 42: ...lue gas damp er operating parameters Internal system faults Internal system faults will be shown if the correct pro gram sequence can no longer be guaranteed Displayed fault code System characteristics Cause Measures F E5 F EC F ED F FF Fault in burner control unit area Internal system fault and EMC Reset the burner control unit Re place the burner control unit if the fault persists F FD Fault in ...

Page 43: ...n feed back RM N Fan speed too high In correct fan or incorrect coding card Check the fan Check coding card Faults without fault display Fault Cause of fault Measure Combustion faults due to pulsation Excessive gas throughput Adjust gas throughput in accordance with the rated boiler heating output Insufficient or excessive air Condensate backed up in flue system Check condensate drain Flue outlet ...

Page 44: ...44 Troubleshooting Faults without fault display cont 5816717 Diagnosis ...

Page 45: ... type plate A Assembly from this parts list Position number of the individual part within the assembly from this parts list 0001 0003 0004 0002 A Fig 26 0001 Boiler 0002 Casing 0003 MatriX Disk burner 0004 Control unit Parts lists Overview of assemblies 5816717 Components ...

Page 46: ...46 0001 0002 0003 0005 0007 0006 0005 0008 0001 0001 0004 Fig 27 Parts lists Boiler assembly 5816717 Components ...

Page 47: ...asket DN 100 PN 6 0002 Sensor well with clip 0003 Packing cord 0004 Gasket set 0005 Sealant 0006 Flue gas collector with gasket 0007 Flue system collar 0008 Stench trap Parts lists Boiler assembly cont 5816717 Components ...

Page 48: ...10 0028 0027 0013 0013 0013 0009 0004 0001 0012 0030 0029 0017 0038 0039 0022 0018 0019 0011 0008 0008 0007 0007 0006 0006 0005 0005 0002 0037 0036 0035 0023 0026 0032 0033 0034 0039 0038 0016 0040 Fig 28 Parts lists Casing assembly 5816717 Components ...

Page 49: ...ottom right 0017 Rail bottom left 0018 Rail bottom right 0019 Side panel front left 0020 Centre side panel 1 left 0021 Centre side panel 2 left 0022 Side panel back left 0023 Side panel front right 0024 Centre side panel 1 right 0025 Centre side panel 2 right 0026 Side panel back right 0027 Front panel 0028 Control unit panel 0029 Top panel front 0030 Top panel left 0031 Top panel right 0032 Top p...

Page 50: ...50 0016 0012 0008 0010 0004 0008 0010 0015 0005 0015 0018 0002 0011 0014 0013 0006 0016 0007 0017 0021 0020 0019 0003 0009 0001 Fig 29 Parts lists MatriX Disk burner assembly 5816717 Components ...

Page 51: ...essure switch 0008 Supply air collector 0009 Gasket gas fan 0010 O ring gasket 0011 Ignition cable 0012 Additional cover 0013 2 2 way solenoid valve 0014 Ignition module 0015 Gasket 0016 Clip 0017 Hose set 0018 Coding card 0019 Intake extension 0020 Small parts burner 0021 Fixing parts Parts lists MatriX Disk burner assembly cont 5816717 Components ...

Page 52: ...52 0019 0017 0018 0016 0015 0014 0013 0012 0011 0010 0009 0006 0005 0004 0003 0002 0001 Fig 30 Parts lists Burner control unit assembly 5816717 Components ...

Page 53: ...witch with connecting cable 131 0010 Air pressure switch with connecting cable 131A 0011 Sensor lead 0012 Cable control unit programming unit 0013 Cable flue gas temperature sensor 15 0014 Connecting cable control unit GFA 0015 Cable CAN bus 72 0016 Cable flue gas damper 53 0017 Dual temperature sensor 0018 Cable harness CAN bus programming unit 0019 Fan motor connecting cables Parts lists Burner ...

Page 54: ...54 0017 0019 0009 0014 0016 0012 0010 0002 0001 0003 0003 0004 0011 0013 0007 0018 0006 0008 0003 0002 Fig 31 Parts lists Control unit assembly 5816717 Components ...

Page 55: ...N cable 0008 Vitocrossal terminal box 0009 Coding card 0010 Cover cable entry 2 pce 0011 Control board CU404 0012 Power board MB205 0013 PCB CU103 controller board extension 0014 Strapping plug X6 0016 Fuse 6 3 A slow 250 V 10 pce 0017 PCB IU100 B10 0018 LON connecting cable length 7 m 0019 LON terminator 2 pce Parts lists Control unit assembly cont 5816717 Components ...

Page 56: ... pressure switch 2 G Gas supply pipe H Intake extension K Fan L Supply air collector M Thermal insulation block N Ignition electrodes O Burner gauze assembly MatriX Disk P Ionisation electrode R Ignition unit S Air pressure switch LDW2 T Air pressure switch LDW1 U 2 2 way solenoid valve Component overview Overview of burner components 5816717 Functions ...

Page 57: ...chamber pressure the switching threshold of air pressure switch 2 plug aCAA is monitored in all operating phases except dur ing safety and stabilising time The air pressure switch triggers a fault shutdown of the burner control unit under the following circumstances If the combustion chamber pressure falls outside the permissible range in the pre purge phase in control mode or in the post purge ph...

Page 58: ...an motor with PWM switching and feedback K Display and programming unit L Air pressure switch 1 M Gas pressure switch GDW1 N Air pressure switch 2 O Flue gas temperature sensor 1 P Flue gas temperature sensor 2 R Boiler water temperature sensor 1 S Boiler water temperature sensor 2 T Terminal box U Gas pressure switch 2 V Fuel valve BV2 Connection diagrams Burner control unit connection diagram 58...

Page 59: ...fill water and the water hardness into the boiler maintenance checklists For systems with a specific system volume greater than 20 l kW heating output apply the requirements of the next higher category of total heating output in accordance with the table In multi boiler systems apply the output of the smallest boiler In the case of severe overshoot 50 l kW soften the water down to a total of alkal...

Page 60: ...d systems operating at the correct pressure e g systems with expansion ves sel offer good protection against the ingress of air borne oxygen Under all operating conditions and at all points in the heating system including the intake side of the pump the pressure must be higher than atmos pheric pressure Check the pre charge pressure of the expansion vessel at least during the annual service Avoid ...

Page 61: ...ing Total water volume Date m3 m3 m3 m3 Max fill volume m3 Water quality report Total hardness pH value Water treatment Date Feedwater Boiler water Boiler water Medium Dosing volume The pH value should be between 8 2 and 9 5 Reports Reports 5816717 Appendix ...

Page 62: ... vol set by vol At the lower rated heat ing output actual by vol set by vol Oxygen content O2 At upper rated heating output actual by vol set by vol At the lower rated heat ing output actual by vol set by vol Carbon monoxide con tent CO actual ppm set ppm Flue gas temperature gross actual C set C Ionisation current At upper rated heating output μA At the lower rated heat ing output μA Draught actu...

Page 63: ...ling weight boiler body kg 1150 1200 Transport weight burner kg 120 120 Total weight dry kg 1435 1492 Total weight filled kg 2585 2672 Water capacity l 1150 1180 Connections Boiler flow PN 6 DN 100 100 Boiler return PN 6 DN 100 100 2nd boiler return PN 6 DN 100 100 Flue gas parameters 3 Flue gas temperature 50 30 C At rated heating output C 43 45 At partial load C 34 35 Flue gas temperature 80 60 ...

Page 64: ...30 C 110 110 For heating system temperature 75 60 C 107 107 Idle losses 30 K to EN 15502 kW 1 0 1 1 Idle losses 50 K to EN 15502 kW 2 7 2 8 Standby loss qB 70 0 4 0 3 MatriX Disk burner Rated heating output Pn TF TR 80 60 kW 121 to 727 152 to 909 Pcond TF TR 50 30 kW 133 to 800 167 to 1000 Rated heat input 2 kW 127 to 762 159 to 953 Burner type MDI Burner product ID CE 0085CS0412 Voltage 3 N PE V ...

Page 65: ...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 Final decommissioning Final decommissioning and disposal 5816717 Appendix ...

Page 66: ...2233 2008 AC 2008 EN 55014 2 2015 EN 301489 1 V2 1 1 EN 60335 1 2012 AC 2014 A11 2014 EN 301489 17 V2 2 1 EN 60335 2 102 2016 EN 300328 V2 1 1 In accordance with the listed directives this product is designated with Allendorf 2 January 2018 Viessmann Werke GmbH Co KG Authorised signatory Reiner Jansen Head of Strategic Quality Management Vitocrossal boiler type CRU 800 and 1000 kW We Viessmann Wer...

Page 67: ...ndorf 2 January 2018 Viessmann Werke GmbH Co KG Authorised signatory Reiner Jansen Head of Strategic Quality Management Manufacturer s certificate according to the 1st German Immissions Order BImSchV We Viessmann Werke GmbH Co KG D 35107 Allendorf confirm that the product Vitocrossal type CRU complies with the following conditions stipulated by the 1st German Immissions Order BImSchV NOx limits in...

Page 68: ...ow diagram 36 Flow pressure 15 G Gas type check 10 Gas type conversion LPG P 13 Natural gas E 12 H Heating surfaces cleaning 20 Heating system Filling with water 9 I Ignition electrodes checking 24 Instructing the system user 31 Intended use 5 Internal system faults 42 Ionisation current display 19 Ionisation electrode checking 24 O Opening the boiler door 11 Operating and service documents 31 Ope...

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Page 72: ... 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 5816717 Subject to technical modifications ...

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