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Viessmann Vitocrossal User Manual

Viessmann Vitocrossal
112 pages
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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.

Table of Contents

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Viessmann Vitocrossal Specifications

General IconGeneral
Heat Exchanger MaterialStainless Steel
CategoryBoiler
EfficiencyUp to 98%
Installation TypeFloor Standing
Boiler TypeCondensing
ModelVitocrossal
NOx EmissionsLow (class 5)

Summary

Safety Instructions

System Working Safety Precautions

Provides essential safety guidelines for working on the heating system.

Safety Instructions (cont.)

Hazards from Hot Surfaces and Fluids

Warns about burns from hot surfaces and fluids, advising to switch off and cool down before work.

Operating System Safety Procedures

Outlines safety procedures for operating the system under various conditions like gas or flue gas detection.

Hazards of Simultaneous Boiler and Exhaust Appliance Operation

Warns about life-threatening poisoning from reverse flue gas flow due to simultaneous operation of boiler and exhaust appliances.

Gas Leak Safety Response

Details immediate actions to take if gas is detected, emphasizing explosion risk and evacuation.

Repair Work and Component Safety

Advises caution when repairing safety-critical components and using genuine Viessmann parts.

Flue Gas Leak Safety Response

Provides instructions for responding to flue gas detection, highlighting poisoning risk and ventilation.

Water Leak Safety Response

Advises on immediate actions for water leaks due to electrocution or scalding risks.

Flue System and Combustion Air Safety

Emphasizes ensuring clear flue systems and adequate combustion air supply for safe operation.

Commissioning, Inspection, and Maintenance

Steps for Commissioning, Inspection, and Maintenance

Outlines the procedural steps for commissioning, inspecting, and maintaining the system.

Commissioning, Inspection, and Maintenance (cont.)

Filling Heating System and Checking Ventilation

Details the process of filling the heating system and verifying ventilation air supply.

Function Sequence and Fault Troubleshooting

Continues the troubleshooting flowchart for burner operation and fault identification.

Static and Supply Pressure Testing Procedure

Details the steps for checking gas pressures and implementing corrective measures.

Pressure Switch Checking Procedures

Continues the procedure for checking additional pressure switches and provides safety notes.

Burner Removal and Gasket Inspection

Details how to remove the burner and inspect the burner door gasket for damage.

Burner Removal for 120-160 kW Boilers

Continues the procedure for removing burners for 120-160 kW and 240-320 kW twin boilers.

Burner Removal for 200 kW Boilers

Covers the removal and inspection of burners for boilers from 200 kW and twin boilers from 400 kW.

Burner Gauze Assembly and Insulation Check

Explains how to check the burner gauze assembly for damage and contamination and reassemble.

Gauze Assembly and Insulation Check (cont.)

Continues the procedure for checking burner gauze and thermal insulation for different kW ranges.

Gauze Assembly and Insulation Check (200 kW)

Details checking the burner gauze assembly for 200 kW units.

Reassembly, Electrode Checks, and Cleaning

Covers torque values for reassembly and checking electrode gaps.

Gasket and Insulation Checks (cont.)

Covers reassembling flue connections and checking the flue gas damper and header.

Expansion Vessel and System Pressure Check

Guides on checking and topping up the expansion vessel and system pressure.

Gas Equipment Tightness Check (cont.)

Provides notes on using approved leak detection agents and removing residues.

Combustion Quality and Heating Output Selection

Covers selecting upper/lower heating outputs for different control units.

Heating Curve Adjustment Details

Illustrates standard and reduced set room temperature adjustments and slope/level adjustments.

Heating Curve Adjustment via Extended Menu

Details how to access the extended menu to adjust heating curves.

Function Sequence and Fault Identification

Illustrates the operational sequence and identifies potential faults with troubleshooting measures.

Testing Static and Supply Gas Pressure

Explains how to test static and supply gas pressures, including safety precautions.

Checking Combustion Chamber Pressure Switch

Explains the function of the pressure switch and how to check its response and related components.

Ignition and Ionisation Electrode Adjustment

Explains how to check, clean, and adjust ignition and ionisation electrodes.

Gaskets and Thermal Insulation Checks

Details checking gaskets on flue connections and heating water fittings for leaks.

Flue Gas Damper and Header Check

Explains how to check flue gas dampers and headers for damage and leaks.

Water Quality Checking Procedure

Details how to record water quality parameters and specifies requirements for hardness and pH.

Checking Combustion Quality

Explains how to check CO2 or O2 content for optimal combustion quality.

Setting Upper and Lower Heating Output

Details how to select lower and upper heating outputs via the service menu.

Checking Gas Type and Wobbe Index

Details how to check and record the gas type and Wobbe index for proper burner adjustment.

Service Display Call-up and Reset

Explains how to call up and reset the service display for maintenance reminders.

Checking Heating and DHW Connections for Leaks

Instructs to check all heating water and DHW connections for leaks.

Matching Control Unit to Heating System

Explains that the control unit must match system equipment level and components are recognized automatically.

Installing the Burner

Refers to previous pages for burner installation steps.

Adjusting Heating Curves

Describes adjusting heating curves based on outside and boiler water temperatures.

Gas Equipment Tightness Check

Emphasizes checking gas equipment for tightness due to explosion risk.

Code 2 (cont.)

Heating Circuit 1, 2, 3/Group "5" Coding (cont.)

Details coding for temperature increases and durations for boiler water or flow temperature.

Heating Circuit 1, 2, 3/Group "5" Coding

Explains coding for DHW priority, economy function, and heating circuit pump logic.

Diagnosis and Service Scans

Diagnosis and Service Scans (cont.)

Testing Outputs (Relay Test)

Explains how to perform an actuator test to control relay outputs and lists controllable actuators.

Relay Test for Constant Temperature Control

Lists controllable actuators (relay outputs) for system design.

Troubleshooting

Fault Display Indicators

Explains how faults are indicated on weather-compensated and constant temperature control units.

Fault History Call-up

Explains how to access the 10 most recent saved faults.

Troubleshooting (cont.)

Fault Display and Acknowledged Fault Redisplay

Continues fault display info and explains how acknowledged faults are redisplayed if not remedied.

Fault Code Explanations (cont.)

Lists fault codes related to coding cards, main PCB faults, and internal faults.

Selecting Fault Messages from History

Explains how to access and select fault messages from the history.

Fault Codes Without Specific Display

Lists faults without specific display codes, their causes, and measures.

Maintenance

Maintenance (cont.)

Function Description

Function Description (cont.)

Electronic Combustion Control Unit (cont.)

Details checking combustion quality via CO2/O2 content and the self-calibration process.

Electronic Combustion Control Unit

Explains how the electronic combustion controller uses ionisation current and air ratio for optimal combustion.

Connection and Wiring Diagram

Connection and Wiring Diagram (cont.)

Water Quality

Preventing Scale Damage

Details VDI Guideline 2035 and standard values for preventing scale build-up.

Water Quality (cont.)

Specification

Specification (cont.)

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