Viessmann Vitocrossal 100 Series Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 100
Type CI1, 80 to 318 kW
Type CI1 twin boiler, 240 to 636 kW
Gas condensing boiler with MatriX cylinder burner
Open flue and room sealed operation
For applicability, see the last page
VITOCROSSAL 100
5792 925 GB 4/2017 Please keep safe.

2
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 Guidelines,
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 can cause burns.
■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
Safety instructions
5792 925 GB

3
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 causes. 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-
closable.
Extractors
Operating appliances that extract 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 reverse flow of the
flue gas.
Danger
The simultaneous operation of the boiler and
appliances that extract air to the outside can
result in life threatening poisoning due to
reverse flow of the flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5792 925 GB

4
1. Information Symbols ................................................................................................. 6
Intended use .......................................................................................... 6
Information for twin boilers ..................................................................... 7
2. Commissioning, inspec-
tion, maintenance
Steps – commissioning, inspection and maintenance ........................... 8
3. Code 1 Calling up coding level 1 ........................................................................ 33
General/Group "1" ................................................................................. 34
Boiler/Group "2" ..................................................................................... 35
DHW/Group "3" ...................................................................................... 36
Solar/Group "4" ...................................................................................... 36
Heating circuit 1, heating circuit 2, heating circuit 3/Group "5" .............. 37
4. Code 2 Calling up coding level 2 ........................................................................ 41
General/Group "1" ................................................................................. 41
Boiler/Group "2" ..................................................................................... 46
DHW/Group "3" ...................................................................................... 47
Solar/Group "4" ...................................................................................... 49
Heating circuit 1, heating circuit 2, heating circuit 3/Group "5" .............. 53
5. Diagnosis and service
scans
Service level, weather-compensated control unit .................................. 59
Diagnosis, weather-compensated control unit ....................................... 59
■Calling up operating data .................................................................... 59
■Brief scan ............................................................................................ 60
■Testing outputs (relay test) ................................................................. 61
Service level, constant temperature control unit .................................... 61
Diagnosis, constant temperature control unit ........................................ 61
■Testing outputs (relay test) ................................................................. 63
6. Troubleshooting Fault display ........................................................................................... 64
■Weather-compensated control unit ..................................................... 64
■Constant temperature control unit ...................................................... 64
Fault codes ............................................................................................ 65
7. Maintenance Checking the outside temperature sensor ............................................. 77
Checking the cylinder temperature sensor ............................................ 78
Checking the boiler water temperature sensor ...................................... 78
Checking the flue gas temperature sensor ............................................ 79
Checking the fuse .................................................................................. 80
Mixer extension kit ................................................................................. 81
Checking the Vitotronic 200-H (accessories) ......................................... 82
8. Parts lists Overview of assemblies ......................................................................... 83
Thermal insulation assembly ................................................................. 84
Twin boiler thermal insulation assembly ................................................ 86
Boiler assembly, boilers up to 160 kW ................................................... 88
Boiler assembly, boilers from 200 to 318 kW ......................................... 90
Burner assembly, burners up to 80 kW .................................................. 92
Burner assembly, burners 120/160 kW .................................................. 94
Burner assembly, burners 200 to 318 kW .............................................. 96
Programming unit assembly .................................................................. 98
Control unit assembly ............................................................................ 100
Miscellaneous ........................................................................................ 102
9. Function description Weather-compensated control unit ........................................................103
■Heating mode ..................................................................................... 103
■DHW heating ...................................................................................... 103
■Boosting DHW heating ....................................................................... 103
Internal extensions .................................................................................104
Index
Index
5792 925 GB

5
■Internal H1 extension ..........................................................................104
■Internal H2 extension ..........................................................................105
External extension (accessories) ...........................................................106
■AM1 extension ....................................................................................106
■EA1 extension .................................................................................... 107
Control functions ....................................................................................108
■External operating program changeover ............................................ 108
■External blocking ................................................................................ 109
■External demand ................................................................................ 110
■Screed drying ..................................................................................... 110
■Raising the reduced room temperature .............................................. 112
■Reducing the heat-up time ................................................................. 113
Assigning heating circuits to the remote control .................................... 114
Electronic combustion control unit ......................................................... 115
10. Connection and wiring dia-
gram
Connection and wiring diagram ............................................................. 116
■Up to 80 kW ........................................................................................ 119
■120 to 318 kW .................................................................................... 120
■Main PCB up to 80 kW ....................................................................... 122
■Main PCB 120 to 160 kW ................................................................... 123
■Main PCB 240 to 318 kW ................................................................... 124
External connection diagram ................................................................. 125
11. Water quality Requirements ........................................................................................ 126
12. Commissioning/service
reports
................................................................................................................128
Settings and test values .........................................................................128
13. Specification Vitocrossal 100 specification ................................................................. 130
MatriX cylinder burner specification .......................................................132
14. Shutdown and disposal Final decommissioning and disposal ..................................................... 133
15. Certificates Declaration of conformity ....................................................................... 134
Manufacturer's certificate according to the 1st BImSchV [Germany] .... 135
16. Keyword index ................................................................................................................136
Index
Index (cont.)
5792 925 GB

6
Symbol Meaning
Reference to other document containing
further information
1.
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.
or
■Acoustic signal
■Fit new component.
or
■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 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 fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than heating the building or DHW shall be deemed
inappropriate.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended use (e.g. if the
flue gas and ventilation air paths are sealed).
Information
Symbols
5792 925 GB
Information

7
The tasks for commissioning, inspection and servicing
are depicted on a single boiler. For twin boilers, the
work must be carried out on both boilers. For this rea-
son, the illustrations may differ partly.
Information
Information for twin boilers
5792 925 GB
Information

8
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system and checking the supply of ventilation air......................... 9
•2. Checking the power supply
•3. Changing the language (if required)................................................................................. 9
• • 4. Setting the time and date (if required).............................................................................. 10
•5. Naming heating circuits..................................................................................................... 10
• • 6. Checking the gas type....................................................................................................... 10
••• 7. Removing the front panel.................................................................................................. 11
••• 8. Function sequence and possible faults........................................................................... 11
••• 9. Testing the static and supply pressure............................................................................ 12
•10. Setting the maximum heating output............................................................................... 13
• • 11. Checking the combustion chamber pressure limiter..................................................... 14
• • 12. Removing the burner and checking the burner gasket.................................................. 15
• • 13. Checking the burner gauze assembly and thermal insulation block............................ 18
• • 14. Checking and adjusting the ignition and ionisation electrodes.................................... 21
• • 15. Cleaning the combustion chamber and heating surfaces............................................. 21
• • 16. Cleaning the condensate drain system............................................................................ 22
• • 17. Cleaning the neutralising system (if installed)................................................................ 23
• • 18. Checking the condensate drain and neutralising system (if installed) for
obstructions and leaks...................................................................................................... 24
• • 19. Checking the gaskets and thermal insulation sections on the boiler side................... 25
• • 20. Checking the expansion vessel and system pressure................................................... 25
• • 21. Checking the water quality................................................................................................ 25
• • 22. Checking the mixer for ease of operation and leaks...................................................... 26
••• 23. Checking all connections on the heating water and DHW sides for leaks
••• 24. Checking the safety valve function
• • 25. Installing the burner........................................................................................................... 26
••• 26. Checking the firm seating of electrical connections
••• 27. Checking all gas equipment for tightness at operating pressure................................. 26
••• 28. Checking the combustion quality..................................................................................... 26
• • 29. Checking the ventilation air apertures in the installation room (only for open flue
operation)
••• 30. Checking the external LPG safety valve (if installed)
•31. Matching the control unit to the heating system............................................................ 28
•32. Adjusting heating curves.................................................................................................. 28
•33. Connecting the control unit to the LON........................................................................... 29
•34. Calling up and resetting the "Service" display............................................................... 31
••• 35. Mounting the front panel................................................................................................... 31
•36. Instructing the system user.............................................................................................. 32
Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance
5792 925 GB

9
!Please note
Unsuitable fill water increases the level of
deposits and corrosion. It can lead to boiler
damage.
Only use suitable fill water.
■Flush the heating system thoroughly before filling.
■For water quality requirements, see page 126.
■Only use fill water of potable water quality.
■Fill water must be softened in accordance with the
requirements of VDI 2035, e.g. with a small softening
system for heating water. See water quality require-
ments on page 128.
Vitoset pricelist
■Special antifreeze suitable for heating systems can
be added to the fill water. The antifreeze manufac-
turer must verify its suitability, as damage to gaskets
or diaphragms and noise during heating operation
may otherwise occur.
Viessmann accepts no liability for any resulting dam-
age or consequential losses.
1. Check whether the ventilation air supply is unre-
stricted.
2. Check the pre-charge pressure of the expansion
vessel when the system is still cold.
Note
If the 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)
higher than the pre-charge pressure of the expan-
sion vessel.
Permiss. operating pressure: 6 bar (0.6 MPa)
Minimum operating pressure: 0.5 bar (50 kPa)
Note
The minimum operating pressure is essential for
safe operation.
5. Record the fill volume, water hardness and pH
value in the table on page 128.
Note
Observe section "Water quality requirements" on
page 126.
6. Return the check valves to their operating position.
Checking the power supply
Changing the language (if required)
Only for weather-compensated control units
At the commissioning stage, the display is in German
(factory setting).
Extended menu:
1. å
2. "Einstellungen"
3. "Sprache"
4. Select the required language with
/ .
Sprache
Dansk
Cesky
Bulgarski
Deutsch
Wählen mit
ê
ê
ç
DE
BG
CZ
DK
ê
ê
(
Fig. 1
Commissioning, inspection, maintenance
Filling the heating system and checking the supply of ventilation air
5792 925 GB

10
Only for weather-compensated control units
The time and date need to be reset during commis-
sioning or after a prolonged time out of use (approx. 18
days).
Extended menu:
1. å
2. "Settings"
3. "Time / Date"
4. Set current time and date.
Note
When time and date have been set, the control unit
automatically checks the function of the flue gas tem-
perature sensor. The display shows: "Test, flue gas
temp. sensor" and "Active".
Naming heating circuits
Only for weather-compensated control units
In the delivered condition, the heating circuits are des-
ignated "Heating circuit 1", "Heating circuit 2" and
"Heating circuit 3" (if installed).
If the system user prefers, the heating circuits can be
designated differently to suit the specific system.
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 the entire Wobbe index
range.
The boiler can be operated within the Wobbe index
range 9.5 to 15.2 kWh/m3 (34.2 to 54.7 MJ/m3).
1. Check with your gas supply utility regarding the
gas type and Wobbe index.
2. Record the gas type in the report on page 128.
Commissioning, inspection, maintenance
Setting the time and date (if required)
5792 925 GB

11
1.
3.
2.
Fig. 2
1. Tip the front panel forward slightly at the top.
2. Undo the locking screws until the front panel can
be removed.
Function sequence and possible faults
Shown on display Measure
Control unit issues a heat
demand
No Increase set value and en-
sure heat is drawn off
Yes
Fan starts No After approx. 51 s fault F9 Check the fan, fan 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
and combustion chamber
pressure limiter.
Yes
Ignition No Fault EE Check ignition module (con-
trol voltage 230 V across
plugs "X2.1" and "X2.2").
Check the gas supply.
Yes
Gas train opens No Fault EE Check the gas train (control
voltage 230 V∼); check the
gas supply pressure.
Commissioning, inspection, maintenance
Removing the front panel
5792 925 GB

12
Yes
Ionisation current builds
Symbol A
No Fault EE Check setting for ionisation
electrode.
Purge the gas line.
Yes
Burner in operation No Shuts down below the set
boiler water temperature and
restarts immediately.
Check the flue system for
tightness (flue gas recircula-
tion); check the gas flow
pressure.
Yes
Automatic calibration of
the combustion controller No
Fault E3 Ensure adequate 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 64.
Testing the static and supply pressure
Danger
CO formation can have serious health implica-
tions.
Always carry out a CO test before and after
work on gas appliances.
A
Fig. 3 Up to 80 kW
Commissioning, inspection, maintenance
Function sequence and possible faults (cont.)
5792 925 GB

13
A
Fig. 4 From 120 kW
1. Close the gas shut-off valve.
2. Release screw A inside test connector "PE" on
the gas train, but do not remove it. Connect the
pressure gauge.
3. Open the gas shut-off valve.
4. Check the static pressure. Record the actual value
in the report on page 128.
Set value: Max. 30 mbar (3 kPa)
5. Start the boiler.
Note
During commissioning, the appliance can enter a
fault state because of airlocks in the gas line. After
approx. 5 s, press reset button R to reset the
burner.
6. Check the supply (flow) pressure.
Set value: 20/25 mbar (2/2.5 kPa)
Note
Use a suitable measuring device with a resolution
of at least 0.1 mbar (10 Pa) to check the supply
pressure.
7. Record the actual value in the report on page 128.
Implement measures as indicated in the table
below.
8. Shut down the boiler, close the gas shut-off valve,
remove the pressure gauge and close test connec-
tor A with the screw.
9. Open the gas shut-off valve and start 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 boiler. Noti-
fy your gas supply utility or LPG
supplier.
17 to 25 mbar
(1.7 to 2.5 kPa)
Start the boiler.
Above 25 mbar
(2.5 kPa)
Connect the separate gas pressure
governor upstream of the system
and set the pre-charge pressure to
20 mbar (2 kPa). Notify your gas
supply utility.
Setting the maximum heating output
A limit can be set on the maximum heating output for
heating mode. The limit is set via the modulation
range. The upper limit of the max. adjustable heating
output is set by the coding card.
Commissioning, inspection, maintenance
Testing the static and supply pressure (cont.)
5792 925 GB

14
Weather-compensated control unit Constant temperature control unit
Service menu
1. Press OK and å simultaneously for approx. 4 s.
2. "Service functions"
3. "Max. output"
4. "Change?" Select "Yes".
A value is shown on the display (e.g. "85"). In the
delivered condition, this value is 100 % of the rated
heating output.
5. Set the required value.
Service menu
1. Press OK and å simultaneously for approx. 4 s.
2. Select "3" using Ú. Confirm with OK.
The display shows "FL" and "ON" flashes.
3. Confirm with OK.
4. The display shows the set heating output (e.g. "85")
and "A". In the delivered condition, this value is
100 % of the rated heating output.
5. Set the required value. Confirm with OK.
Checking the combustion chamber pressure limiter
The combustion chamber pressure limiter responds in
the event of deflagration, blocks the burner and pre-
vents flue gas escaping if the flue system is damaged.
A
B
C
Fig. 5
AReset button
BConnection hose
CPlug-in connection
4
3
2 1
Fig. 6
■Check connection hose B is seated correctly and is
undamaged; replace if necessary.
■Check whether the combustion chamber pressure
limiter has responded:
Measure the resistance across terminals 1 and 3. If
the resistance is > 0 Ω, the pressure limiter has
responded.
If the combustion chamber pressure limiter has
responded, check the following components and
replace if necessary:
■Electrodes
■Burner gauze assembly
■Ignition transformer and ignition cables
■Check the flue system for damage and leaks.
Check the combustion chamber pressure limiter is
working properly using a pressure tester. Switching
point 100 ±10 mbar. If the value measured differs
from this, replace the combustion chamber pressure
limiter.
!Please note
Incorrect installation or installing damaged
burner components can result in deflagration.
■Check the combustion chamber pressure lim-
iter is working properly.
■Check the burner components are undamaged
and correctly installed.
Danger
Faulty components and deflagration can cause
potentially fatal poisoning due to the escape of
carbon monoxide in the flue gas.
Observe the maintenance instructions.
Commissioning, inspection, maintenance
Setting the maximum heating output (cont.)
5792 925 GB

15
Burners 80 kW
H
E
G
A
C
F
B
DK
Fig. 7 80 kW
ABurner fixings, 4 screws
BIgnition electrode
CIonisation electrode
DIgnition transformer
EFan motor
FGas train
GGas supply pipe
HVentilation air hose, only for room sealed opera-
tion.
KCombustion chamber pressure limiter
Note
Burner weight 10 kg
1. Switch OFF the mains isolator or the power supply,
and safeguard against unauthorised 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. Place the burner on a suitable
surface.
6. Check the burner door gasket for damage and
replace if required.
Commissioning, inspection, maintenance
Removing the burner and checking the burner gasket
5792 925 GB

16
Burners 120 to 160 kW
Burners for 120 to 160 kW boilers and 240 to 320 kW
twin boilers
H
A
B
G
K
C
E
F
D
Fig. 8
ABurner fixings, 4 screws
BIgnition electrode
CIonisation electrode
DIgnition transformer
EFan motor
FGas train
GGas supply pipe
HVentilation air hose, only for room sealed opera-
tion.
KCombustion chamber pressure limiter
Note
Burner weight 11 kg
1. Switch OFF the 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 damage the mesh.
Never touch the mesh of the burner gauze
assembly. Place the burner on a suitable
surface.
6. Check the burner door gasket for damage and
replace if required.
Commissioning, inspection, maintenance
Removing the burner and checking the burner… (cont.)
5792 925 GB

17
Burners from 200 kW
Burners for 200 to 318 kW boilers and 400 to 636 kW
twin boilers
DC
B
A
F
E
G
HK
L
Fig. 9
ABurner fixings, 4 screws
BIgnition electrode
CIonisation electrode
DIgnition transformer
EFan motor
FGas train
GGas supply pipe
HVentilation air hose, only for room sealed opera-
tion.
KVenturi extension, only for open flue operation with
burners from 200 kW
LCombustion chamber pressure limiter
Note
Burner weight 15 kg
1. Switch OFF the 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 damage the mesh.
Never touch the mesh of the burner gauze
assembly. Place the burner on a suitable
surface.
6. Check the burner door gasket for damage and
replace if required.
Commissioning, inspection, maintenance
Removing the burner and checking the burner… (cont.)
5792 925 GB

18
Check the burner gauze assembly for damage. In the
event of damage, replace the burner gauze assembly.
A
BC
D
E
F
G
4x
Fig. 10 80 kW
AIgnition and ionisation electrodes
BBurner gauze assembly gasket
CInsulation mat
DBurner door gasket
EThermal insulation block
FBurner gauze assembly
GFan
Check the burner gauze assembly for damage. In the
event of damage, replace 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 aid on the thermal insula-
tion block.
4. Reassemble in reverse order. Observe torque val-
ues, see table on page 21.
Commissioning, inspection, maintenance
Checking the burner gauze assembly and thermal insulation block
5792 925 GB

19
A
BC
D
E
F
G
4x
Fig. 11 120 to 160 kW
AIgnition and ionisation electrodes
BBurner gauze assembly gasket
CInsulation mat
DBurner door gasket
EThermal insulation block
FBurner gauze assembly
GFan
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.
Commissioning, inspection, maintenance
Checking the burner gauze assembly and thermal… (cont.)
5792 925 GB

20
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 21.
Check the burner gauze assembly for damage. In the
event of damage, replace the burner gauze assembly.
A
BC
D
E
F
G
4x
H
Fig. 12 200 to 318 kW
AIgnition and ionisation electrodes
BBurner gauze assembly gasket
CInsulation mat
DBurner door gasket
EThermal insulation block
FBurner gauze assembly
GFan
HVenturi extension, only for open flue operation
1. Remove electrodes.
Commissioning, inspection, maintenance
Checking the burner gauze assembly and thermal… (cont.)
5792 925 GB