Viessmann Vitocrossal CRU 800 Betriebsanleitung

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

5833296 GB 6/2018 Please keep safe.

Please follow these safety instructions closely to

prevent accidents and material losses.

Safety instructions explained

Danger

This symbol warns against the risk of injury.

!Please note

This symbol warns against the risk of material

losses and environmental pollution.

Note

Details identified by the word "Note" contain additional

information.

Target group

These instructions are exclusively intended for quali-

fied contractors.

■Work on gas installations may only be carried out by

a registered gas fitter.

■Work on electrical equipment may only be carried

out by a qualified electrician.

■The system must be commissioned by the system

installer or a qualified person 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

■All current safety regulations as defined by DIN, EN,

DVGW, TRGI, TRF, VDE and all locally applicable

standards

aÖNORM, EN, ÖVGW G K directives,

ÖVGW-TRF and ÖVE

cSEV, 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 by means of a mains

isolator, and check that it is no longer live.

■Safeguard the system against reconnection.

■Wear suitable personal protective equipment when

carrying out any work.

Danger

Hot surfaces and fluids can lead to burns or

scalding.

■Before maintenance and service work, switch

OFF the appliance and let it cool down.

■Never touch hot surfaces on the boiler, burner,

flue system or pipework.

!Please note

Electronic assemblies can be damaged by elec-

trostatic discharge.

Prior to commencing work, touch earthed

objects such as heating or water pipes to dis-

charge static loads.

Repair work

!Please note

Repairing components that fulfil a safety func-

tion can compromise the safe operation of the

system.

Replace faulty components only with genuine

Viessmann spare parts.

Safety instructions

5833296

Auxiliary components, spare and wearing parts

!Please note

Spare and wearing parts that have not been tes-

ted together with the system can compromise its

function. Installing non-authorised components

and making non-approved modifications or con-

versions can compromise safety and may inva-

lidate our warranty.

For replacements, use only original spare parts

supplied or approved by Viessmann.

Safety instructions for operating the system

If you smell gas

Danger

Escaping gas can lead to explosions which may

result in serious injury.

■Do not smoke. Prevent naked flames and

sparks. Never switch lights or electrical appli-

ances on or off.

■Close the gas shut-off valve.

■Open windows and doors.

■Evacuate any people from the danger zone.

■Notify your gas or electricity supply utility from

outside the building.

■Have the power supply to the building shut off

from a safe place (outside the building).

If you smell flue gas

Danger

Flue gas can lead to life threatening poisoning.

■Shut down the heating system.

■Ventilate the installation site.

■Close doors to living spaces to prevent flue

gases from spreading.

What to do if water escapes from the appliance

Danger

If water escapes from the appliance there is a

risk of electrocution.

Switch OFF the heating system at the external

isolator (e.g. fuse box, domestic 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 external causes.

Avoid continuous condensate disposal with a wind pro-

tector.

Ensure an adequate supply of combustion air.

Inform system users that subsequent modifications to

the building characteristics are not permissible (e.g.

cable/pipework routing, cladding or partitions).

Danger

Leaking or blocked flue systems, or an inade-

quate supply of combustion air can cause life

threatening poisoning from carbon monoxide in

the flue gas.

Ensure the flue system is in good working order.

Vents for supplying combustion air must be non-

sealable.

Extractors

Operating appliances that exhaust air to the outside

(extractor hoods, extractors, air conditioning units, etc.)

can create negative pressure. If the boiler is operated

at the same time, this can lead to a reverse flow of flue

gas.

Danger

The simultaneous operation of the boiler and

appliances that exhausts air to the outside can

result in life threatening poisoning due to a

reverse flow of flue gas.

Fit an interlock circuit or take suitable steps to

ensure an adequate supply of combustion air.

Safety instructions

Safety instructions (cont.)

5833296

1. Information Symbols ................................................................................................. 5

Intended use .......................................................................................... 5

Product information ................................................................................ 6

■System examples ............................................................................... 6

2. Commissioning, inspec-

tion, maintenance

Steps - commissioning, inspection and maintenance ............................ 7

3. Burner control unit Burner control unit VUC 310 .................................................................. 31

■Display and programming unit ............................................................ 31

■Operating display ................................................................................ 31

■Selecting the menu ............................................................................. 32

■Calling up information and resetting meters ....................................... 32

■Changing the configuration ................................................................. 33

■Resetting operating parameters to their delivered condition .............. 35

■Setting the modulation level for manual operation ............................. 35

Flow diagram for burner start ................................................................. 36

■Description of state ............................................................................. 37

4. Troubleshooting Fault display ........................................................................................... 38

■Calling up the fault history (fault memory) .......................................... 38

Fault codes with display on burner control unit ...................................... 39

■General process errors: Displayed fault codes ................................... 39

■Internal system faults: Displayed fault codes and detailed fault

codes .................................................................................................. 42

Faults without fault 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

Vitotronic 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 temperature sensors and flue gas temperature sensors ... 57

8. Connection diagrams Burner control unit connection diagram ................................................. 58

9. Reports ................................................................................................................ 61

10. Specification ................................................................................................................ 64

11. Final decommissioning Final decommissioning and disposal ..................................................... 67

12. Certificates Declaration of conformity ....................................................................... 68

Manufacturer's certificate according to the 1st BImSchV [Germany] .... 68

13. Keyword index ................................................................................................................ 69

Index

5833296

Symbol Meaning

Reference to other document containing

further information

Step in a diagram:

The numbers correspond to the order in

which the steps are carried out.

Warning of material losses and environ-

mental pollution

Live electrical area

Pay particular attention.

■Component must audibly click into place.

■Acoustic signal

■Fit new component.

■In conjunction with a tool: Clean the sur-

face.

Dispose of component correctly.

Dispose of component at a suitable collec-

tion point. Do not dispose of component in

domestic waste.

The steps in connection with commissioning, inspec-

tion and maintenance are found in the "Commission-

ing, inspection and maintenance" section and identified

as follows:

Symbol Meaning

Steps required during commissioning

Not required during commissioning

Steps required during inspection

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 up of heating water.

Commercial or industrial usage for a purpose other

than the heating up of heating water shall be deemed

inappropriate.

Intended use presupposes that a fixed installation in

conjunction with permissible components designed for

this purpose has been carried out.

Every other use will be deemed to be inappropriate.

Any resulting losses are excluded from the manufac-

turer's liability.

Any usage beyond this must be approved by the man-

ufacturer for the individual case.

Intended use also includes the adherence to mainte-

nance and inspection intervals.

Information

Symbols

5833296

Information

Vitocrossal, type CRU

■Gas condensing boiler, 800 kW and 1000 kW rated

heating output with modulating MatriX-Disk burner

for natural gas E and natural gas LL

■Permissible operating pressure for the heating sys-

tem: 6 bar/0.6 MPa.

System examples

For available system examples, see www.viessmann-

schemes.com

Information

Product information

5833296

Information

Commissioning steps

Inspection steps

Maintenance steps Page

•1. Filling the heating system with water and venting the system...................................... 9

•2. Filling the trap with water.................................................................................................. 9

• • 3. Checking the sensor well and all connections on the heating water side for

tightness............................................................................................................................. 10

•4. Checking the electrical connections................................................................................ 11

•5. Checking the gas type....................................................................................................... 11

•6. Setting the gas type........................................................................................................... 12

••• 7. Commissioning the system............................................................................................... 12

••• 8. Checking the flue gas damper.......................................................................................... 13

•9. Reducing the maximum heating output (if required)...................................................... 14

••• 10. Checking the static pressure and supply pressure........................................................ 14

••• 11. Measuring the CO2 content............................................................................................... 16

• • 12. Measuring the CO content................................................................................................. 17

• • 13. Measuring the flue gas temperature................................................................................. 17

• • 14. Checking the ionisation current....................................................................................... 17

• • 15. Shutting down the system................................................................................................. 18

••• 16. Opening the boiler.............................................................................................................. 19

• • 17. Opening the combustion chamber................................................................................... 20

• • 18. Cleaning the combustion chamber and heating surfaces............................................. 20

• • 19. Cleaning the burner........................................................................................................... 22

• • 20. Checking the burner door................................................................................................. 22

• • 21. Checking the burner gauze assembly.............................................................................. 23

• • 22. Checking the ignition electrodes and ionisation electrode........................................... 24

•23. Fitting the burner................................................................................................................ 24

• • 24. Closing the combustion chamber.................................................................................... 24

• • 25. Checking the gas train valves for tightness.................................................................... 25

• • 26. Checking the gas train filter element............................................................................... 26

• • 27. Checking the filter element in the gas line...................................................................... 26

••• 28. Checking the gas connections for tightness................................................................... 26

• • 29. Cleaning the condensate drain pipe and trap................................................................. 27

• • 30. Checking the condensate drain and the neutralising system (if installed).................. 28

• • 31. Closing the boiler casing................................................................................................... 28

• • 32. Checking the expansion vessel........................................................................................ 28

• • 33. Checking the water quality................................................................................................ 28

• • 34. Checking the gaskets on the flue gas side...................................................................... 28

•35. Performing final checks..................................................................................................... 29

••• 36. Checking the safety valve function

• • 37. Checking the mixer for ease of operation and leaks...................................................... 29

••• 38. Checking the thermal insulation for firm seating

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5833296

Commissioning steps

Inspection steps

Maintenance steps Page

••• 39. Checking the flue system for unrestricted flow and tightness...................................... 30

••• 40. Checking the installation room ventilation air apertures............................................... 30

•41. Instructing the system user.............................................................................................. 30

Commissioning, inspection, maintenance

Steps - commissioning, inspection and… (cont.)

5833296

!Please note

Unsuitable water quality can damage the boiler

body.

Only fill the boiler with water that complies with

the "Water quality requirements": See page 59

Enter the amount of fill water, water hardness and pH

value in the log on page 61.

Filling the trap with water

A B

Fig. 1

ATrap lower section

BCondensate drain hose

1. Undo lower section of trap. Fill the lower section

with water.

Danger

If the trap is not full, flue gas can escape.

Escaping flue gas can cause life threatening

carbon monoxide poisoning.

Always fill the trap with water before com-

missioning.

2. Check that the condensate can drain freely.

3. Refit lower trap section.

Commissioning, inspection, maintenance

Filling the heating system with water and venting the system

5833296

Fig. 2

AFemale connection for control equipment: R ½

BBoiler flow: PN 6, DN 100 with sensor well for

boiler water temperature sensor

CFemale connection for pressure limiter: R ½

DSafety connection (safety valve): R 2

EBoiler return 2: PN 6, DN 100

FBoiler return 1: PN 6, DN 100

GDrain outlet: R 1¼

HCondensate drain: R ½

Check the connection for the sensor well and the mini-

mum pressure switch (low water indicator) for tight-

ness.

Commissioning, inspection, maintenance

Checking the sensor well and all connections on the heating water side for

tightness

5833296

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