Viessmann VITOCROSSAL 200 Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 200
Type CM2B, 87 to 311 kW
Gas condensing boiler with MatriX radiant burner
Permissible operating pressure 6 bar (0.6 MPa)
For applicability, see the last page
VITOCROSSAL 200
5812086 GB/en 9/2017 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 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 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
5812086

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 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.)
5812086

4
1. Information Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 7
3. Vitotronic control unit
codes
Setting the codes at the control unit ...................................................... 33
4. Burner control unit Burner control unit VUC 310 .................................................................. 34
■Display and programming unit ............................................................ 34
■Operating display ................................................................................ 34
■Info display/configuration display ........................................................ 35
■Resetting operating parameters to their delivered condition .............. 37
■Manual operation and service display ................................................ 37
Burner control unit flow chart ................................................................. 38
■Description of state: ............................................................................ 38
5. Troubleshooting Fault display ........................................................................................... 40
■Fault memory ...................................................................................... 40
Fault codes ............................................................................................ 40
■General process errors ....................................................................... 40
■Internal system faults .......................................................................... 43
Faults without fault display ..................................................................... 44
6. Parts lists Overview of assemblies ......................................................................... 45
Boiler assembly ..................................................................................... 46
Thermal insulation assembly ................................................................. 48
Gas burner assembly, 87 kW ................................................................. 50
Gas burner assembly, 115, 142 and 186 kW ......................................... 52
Gas burner assembly, 246 and 311 kW ................................................. 54
Burner control unit assembly, 87 kW ..................................................... 56
Burner control unit assembly, 115, 142 and 186 kW ............................. 58
Burner control unit assembly, 246 and 311 kW ..................................... 60
Miscellaneous assembly ........................................................................ 62
7. Component overview Overview of burner components ............................................................ 64
■Pressure-jet gas burner 87 kW ........................................................... 64
■Pressure-jet gas burners 115 to 186 kW ............................................ 64
■Pressure-jet gas burners 246 to 311 kW ............................................ 65
8. Function description Air pressure switch ................................................................................ 66
■Fan pressure monitoring (air pressure switch 1 - 131) ....................... 66
■Combustion chamber pressure monitoring (air pressure switch 2 -
131A) .................................................................................................. 66
■Fan for burners 115 to 186 kW ........................................................... 66
9. Connection diagrams Burner control unit connection diagram ................................................. 68
10. Reports ................................................................................................................ 72
11. Specification ................................................................................................................ 74
12. Final decommissioning Final decommissioning and disposal ..................................................... 77
13. Certificates EU Declaration of Conformity ................................................................ 78
Manufacturer’s certificate according to the 1st German Immissions
Order (BImSchV) ................................................................................... 79
14. Keyword index ................................................................................................................ 80
Index
Index
5812086

5
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 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
5812086
Information

6
Vitocrossal 200, type CM2B 87 to 311 kW with permis-
sible operating pressure 6 bar (0.6 MPa).
Gas condensing boiler for natural gas E and LL, with
modulating MatriX radiant burner.
Information
Product information
5812086
Information

7
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Checking the high limit safety cut-out setting................................................................ 9
•2. Filling the heating system with water and venting......................................................... 9
•3. Filling the trap with water.................................................................................................. 9
••• 4. Commissioning the system............................................................................................... 9
••• 5. Checking the motor-controlled flue gas damper (if installed)....................................... 11
•6. Checking the gas type....................................................................................................... 11
•7. Converting to natural gas LL............................................................................................ 11
•8. Reducing the heating output (if required)........................................................................ 14
••• 9. Checking static pressure and supply pressure.............................................................. 14
••• 10. Checking the rotary damper setting................................................................................. 16
••• 11. Checking the CO2 content................................................................................................. 16
• • 12. Checking the CO content.................................................................................................. 19
• • 13. Checking the flue gas temperature.................................................................................. 20
• • 14. Displaying the ionisation current..................................................................................... 20
• • 15. Shutting down the system................................................................................................. 20
• • 16. Opening the boiler door..................................................................................................... 20
• • 17. Cleaning the combustion chamber and heating surfaces............................................. 21
• • 18. Checking the gaskets and thermal insulation sections................................................. 21
• • 19. Checking all connections and the sensor well on the heating water side for
tightness............................................................................................................................. 21
• • 20. Cleaning the condensate drain pipe system and trap.................................................... 22
• • 21. Checking the condensate drain and neutralising system (if installed)......................... 22
• • 22. Checking the burner gauze assembly.............................................................................. 23
• • 23. Checking the ignition electrodes and ionisation electrode........................................... 23
• • 24. Cleaning the burner........................................................................................................... 24
•25. Fitting the burner................................................................................................................ 24
• • 26. Closing the boiler door...................................................................................................... 28
• • 27. Checking the gas train valves for tightness.................................................................... 29
• • 28. Checking the gas train filter element............................................................................... 29
••• 29. Checking gas connections for tightness......................................................................... 30
• • 30. Checking the gaskets on the flue gas side...................................................................... 30
•31. Performing final checks..................................................................................................... 30
• • 32. Checking the water quality................................................................................................ 31
••• 33. Checking the safety valve function
••• 34. Checking the temperature controller setting if a building management system is
used (DCC system)............................................................................................................ 31
• • 35. Checking the expansion vessel ....................................................................................... 31
• • 36. Checking the mixer for ease of operation and leaks...................................................... 31
••• 37. Checking the thermal insulation for firm seating
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5812086

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Commissioning steps
Inspection steps
Maintenance steps Page
••• 38. Checking the installation room ventilation air apertures............................................... 31
•39. Instructing the system user.............................................................................................. 32
•40. Operating and service documents................................................................................... 32
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
5812086

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The high limit safety cut-out must not be set higher
than 110 °C; if required, set it to a maximum of 110 °C.
Control unit installation and service instructions
Filling the heating system with water and venting
Record the volume filled, water hardness and pH value
on page 72.
Note
Observe the "Water quality requirements" on
page 70.
Filling the trap with water
Fig. 1
1. Undo the trap and fill it with water. There is a risk of
flue gas escaping if it is not filled with water prior to
commissioning.
2. Check that the condensate can drain freely.
3. Refit the trap.
Commissioning the system
Danger
CO build-up as a result of incorrect burner
adjustment can have serious health implications.
Always carry out a CO test before and after
work on gas appliances.
■Vitotronic operating instructions and service
instructions
■Neutralising system operating instructions
■Flue system installation instructions
Commissioning, inspection, maintenance
Checking the high limit safety cut-out setting
5812086

10
A B
D
C
Fig. 2
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 operating pressure is too low, excess
temperatures in the flue system can cause
leaks. Escaping flue gas can cause life
threatening carbon monoxide poisoning.
Ensure the minimum operating pressure
with a minimum pressure switch.
02. For open flue operation: check that the ventilation
facility in the installation room is open.
03. Check control cables:
■Connection and kink-free routing
■Application and seating of retaining clips
04. Check the gas supply pressure.
05. Open the gas line shut-off valves.
06. Switch ON the mains isolator (outside the installa-
tion room).
07. Turn on system ON/OFF switch B at the control
unit.
If "Burner fault" and A on the display appear
and display C flashes on the burner control unit,
unlock first.
1. Press to confirm the fault message on the
control unit.
2. To do this, press reset button D on the burner
control unit.
Note
The boiler can enter a fault state during commis-
sioning if the gas line carries insufficient gas.
Purge the gas line again and reset the burner.
08. Adjust the parameters on the boiler control unit in
accordance with the table on page 33.
Note
If the parameters are not set, the boiler service life
and efficiency may be adversely affected.
Control unit installation and service instruc-
tions
09. Check the function of the neutralising system.
Neutralising system operating instructions
Commissioning, inspection, maintenance
Commissioning the system (cont.)
5812086

11
10. Check all gaskets and plugs, and retighten if nec-
essary.
Note
We recommend checking all connections on the
heating water side for leaks approx. every
500 hours run. See page 21.
11. Check the boiler door and flue gas cover a few
days after commissioning. In the case of leaks,
tighten the screws in the boiler door and flue gas
collector with 30 Nm.
Checking the motor-controlled flue gas damper (if installed)
The flue gas damper must be closed in its zero volt
state (plug 53/100).
Checking the gas type
1. Check with your gas supply utility regarding the
gas type and Wobbe index Ws (0 °C).
■With the natural gas H/E setting, the boiler can
be operated in the Wobbe index range 12.0 to
16.1 kWh/m3 (43.2 to 58.0 MJ/m3).
■With the natural gas L/LL setting, the boiler can
be operated in the Wobbe index range 10.0 to
13.1 kWh/m3 (36.0 to 47.2 MJ/m3) (not in AT and
CH).
2. In the delivered condition, the burner is set up for
natural gas H/E. If required, convert the burner to a
different gas type in accordance with details provi-
ded by your gas supply utility.
3. Record the gas type in the report in the appendix
on page 73.
Converting to natural gas LL
(not in AT and CH)
Commissioning, inspection, maintenance
Commissioning the system (cont.)
5812086

12
Conversion for 87 kW
F
C
D
E
A
B
Fig. 3
01. Close the gas shut-off valve.
02. Turn off the system ON/OFF switch at the user
interface of the control unit.
03. Switch OFF the mains isolator (outside the instal-
lation room) or isolate the mains power and
secure against unintentional reconnection.
04. Undo fitting A.
05. Release gas train B from flange C.
06. Remove restrictor D with O-ring E from flange
C.
07. Secure gas train with O-ring E to flange C.
Restrictor D is no longer required.
08. Secure fitting A.
09. Where present for set gas type: Affix label "Set
to ..." F supplied over the existing label.
10. Check control cables:
■Correct connection and kink-free routing
■Application and seating of retaining clips
11. Start the burner.
12. Check for gas tightness.
Danger
Escaping gas leads to a risk of explosion.
Check gas routing components for leaks.
!Please note
The use of leak detection spray can result in
faulty operation.
Leak detection spray must not come into
contact with electrical contacts.
Commissioning, inspection, maintenance
Converting to natural gas LL (cont.)
5812086

13
Conversion for 115 to 311 kW
GF
A BCD E
Fig. 4
01. Close the gas shut-off valve.
02. Switch OFF the system ON/OFF switch on the
control unit.
03. Switch OFF the mains isolator (outside the instal-
lation room) or isolate the mains power and
secure against unintentional reconnection.
04. Undo fitting A.
05. Disconnect control cable G from the gas train.
06. Release the gas train from flange E.
07. Remove restrictor C with rubber cork gasket D.
08. Secure the gas train to flange E:
■With O-ring B
■Without restrictor C
■Without rubber cork gasket D
Torque for M 5 nuts: 1.5 Nm
09. Secure fitting A with a new gasket.
10. Plug control cable G into the gas train.
11. Check control cables:
■Correct connection and kink-free routing
■Application and seating of retaining clips
12. Affix supplied label "Set to ..." F over the existing
label.
13. Start the burner.
14. Check for gas tightness.
Danger
Escaping gas leads to a risk of explosion.
Check gas routing components for leaks.
!Please note
The use of leak detection spray can result in
faulty operation.
Leak detection spray must not come into
contact with electrical contacts.
Commissioning, inspection, maintenance
Converting to natural gas LL (cont.)
5812086

14
The maximum heating output of the burner can be
reduced if required.
Status Service
S
R
Fig. 5
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,
and the actual value for the maximum heating out-
put is shown in % under Service.
5. Press or to set the required maximum heating
output.
6. Press S to confirm. If applied successfully, "1" will
be shown on the display under Service, or "0" will
appear if it failed.
7. Press S to switch to the operating display.
8. Press R.
The system will be restarted.
Checking static pressure and supply pressure
Static pressure
Rated heating output 87 kW
A
Fig. 6
Rated heating output 115 to 311 kW
A
Fig. 7
1. Close the gas shut-off valve.
2. Undo the screw in test connector A, but 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. 60 mbar (6 kPa).
6. Record the actual value in the report (on
page 72).
Commissioning, inspection, maintenance
Reducing the heating output (if required)
5812086

15
Supply pressure
Note
See type plate for supply pressures for operation with
other country-specific gas types.
1. Start the burner with emissions test mode enabled
(in control unit menu).
2. Check the supply pressure (flow pressure); see the
following table.
Note
Set supply pressure (flow pressure):
■Natural gas 18 to 50 mbar (1.8 to 5 kPa)
Nominal supply pressure:
■Natural gas 20 mbar (2 kPa)
The nominal supply pressure can differ from these
values subject to country; see type plate.
The gas pressure switch on the gas train is set to
10 mbar (1 kPa).
3. Record the actual value in the report (on
page 73).
4. Close the gas shut-off valve.
5. Remove pressure gauge. Close test connector A.
Supply pressure
(flow pressure)
Action
Below 15 mbar (1.5 kPa) Do not adjust any settings. Notify your gas supply utility.
15 to 18 mbar (1.5 to
1.8 kPa)
Please note: the boiler may only be operated temporarily with this setting (emergency
mode).
Notify your gas supply utility.
18 to 50 mbar (1.8 to
5 kPa)
Start the boiler.
Above 50 mbar (5 kPa) Install a separate gas pressure governor with zero off upstream of the boiler system.
Regulate the pressure to 20 mbar (2 kPa).
Notify your gas supply utility.
Commissioning, inspection, maintenance
Checking static pressure and supply pressure (cont.)
5812086

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For 246 and 311 kW rated heating output only
A
C D
B
Fig. 8
1. Open the gas shut-off valve.
2. Check the position of the rotary damper with the
burner in idle mode. Rotary damper windows B
must be fully opened. Scale ring D on the air
damper servomotor must be set to "0", relative to
marking C.
3. Check control cable A between gas train and
Venturi mixing pipe:
■Connection and kink-free routing
■Fixing
4. Start the burner.
5. Check the position of the rotary damper during the
start-up phase. Rotary damper windows B must
be almost closed for approx. 5 s. During this time,
scale ring D must be at the following settings:
Rated heating output in
kW
Rotary damper set-
ting
246 35°
311 35°
Checking the CO2 content
Preparing the test
Status Service
S
R
Fig. 9
1. Open the gas shut-off valve.
2. Start the burner with emissions test mode enabled
("Test mode" in control unit menu).
Vitotronic operating instructions
3. Hold down S and longer than 2 s.
The display will then show the following:
■Status: "P" (= controlled stop)
■Service: Modulation level in % ("100" = 100 % =
upper heating output, "0" = 0 % = lower heating
output)
Commissioning, inspection, maintenance
Checking the rotary damper setting
5812086

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Permissible CO2 content
Gas type CO2 con-
tent
Rated heating output in kW
at 87 115 142 186 246 311
Natural gas
E
Upper heat-
ing output
(100 %)
7.1 - 10.2 % 7.0 - 10.1 % 7.0 - 10.1 % 7.1 - 10.2 % 7.1 - 10.2 % 7.1 - 10.2 %
Actual value at upper heating output minus
Lower heat-
ing output
(0 %)
0.3 - 0.7 % 0.3 - 0.7 % 0.3 - 0.7 % 0.4 - 0.8 % 0.4 - 0.8 % 0.4 - 0.8 %
Natural gas
H
Upper heat-
ing output
(100 %)
8.0 - 10.2 % 7.9 - 10.1 % 7.9 - 10.1 % 8.0 - 10.2 % 8.0 - 10.2 % 8.0 - 10.2 %
Actual value at upper heating output minus
Lower heat-
ing output
(0 %)
0.3 - 0.7 % 0.3 - 0.7 % 0.3 - 0.7 % 0.4 - 0.8 % 0.4 - 0.8 % 0.4 - 0.8 %
Natural gas
LL
Upper heat-
ing output
(100 %)
7.2 - 10.0 % 7.1 - 9.9 % 7.1 - 9.9 % 7.2 - 10.0 % 7.2 - 10.0 % 7.2 - 10.0 %
Actual value at upper heating output minus
Lower heat-
ing output
(0 %)
0.3 - 0.7 % 0.3 - 0.7 % 0.3 - 0.7 % 0.4 - 0.8 % 0.4 - 0.8 % 0.4 - 0.8 %
Natural gas
L
Upper heat-
ing output
(100 %)
8.3 - 10.0 % 8.2 - 9.9 % 8.2 - 9.9 % 8.3 - 10.0 % 8.3 - 10.0 % 8.3 - 10.0 %
Actual value at upper heating output minus
Lower heat-
ing output
(0 %)
0.3 - 0.7 % 0.3 - 0.7 % 0.3 - 0.7 % 0.4 - 0.8 % 0.4 - 0.8 % 0.4 - 0.8 %
CO2 test at the upper heating output (87 kW)
Fig. 10
1. Press until the service display has counted up to
"100" (= 100 %).
2. Check the CO2 content at the flue pipe.
For permissible CO2 content, see above table.
3. Check control cables:
■Connection and kink-free routing
■Application and seating of retaining clips
Note
The unconnected end of the hose is open in open
flue operation. For room sealed operation, the end
of the hose is pushed onto the intake adaptor.
Commissioning, inspection, maintenance
Checking the CO2 content (cont.)
5812086

18
4. If the CO2 content needs adjusting:
Turn adjusting screw A in small increments. Con-
tinue turning until CO2 content falls within the
specified range.
■Turning clockwise
→ CO2 content falls
■Turning anti-clockwise
→ CO2 content rises
Note
The adjusting screw has no end-stop. The starting
position will be reached again after 4 turns.
5. Enter actual value into the report in the appendix.
CO2 test at the lower heating output (87 kW)
Fig. 11
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.
Note
At the lower heating output, the CO2 content must
always be lower than at the upper heating output
by a given amount. See the table above.
3. If the CO2 content needs adjusting:
■Undo cover B.
■Turn adjusting screw A in small increments
(Torx 40). Continue turning until CO2 content rea-
ches the specified range:
–Turning clockwise
→ CO2 content rises
–Turning anti-clockwise
→ CO2 content falls
4. Enter actual value into the report in the appendix.
5. Check the CO2 content at the upper and lower
heating output again.
If the CO2 content is not within the specified range:
Repeat steps for upper and lower heating output.
6. Hold down S and simultaneously for longer than
2 s. Burner switches to operating mode.
Commissioning, inspection, maintenance
Checking the CO2 content (cont.)
5812086

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CO2 test at the upper heating output (115 to 311 kW)
Fig. 12
1. Press until the service display has counted up to
"100" (= 100 %).
2. Check the CO2 content at the flue pipe.
For permissible CO2 content, see above table.
3. If the CO2 content needs adjusting:
■Remove cap B.
■Turn adjusting screw A in small increments
(3 mm Allen key). Continue turning until the CO2
content reaches the specified range:
–Turning clockwise
→ CO2 content falls
–Turning anti-clockwise
→ CO2 content rises
4. Enter actual value into the report in the appendix.
CO2 test at the lower heating output (115 to 311 kW)
Fig. 13
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.
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:
■Undo cover B.
■Turn adjusting screw A in small increments
(Torx 40). Continue turning until the CO2 content
reaches the specified range:
–Turning clockwise
→ CO2 content rises
–Turning anti-clockwise
→ CO2 content falls
4. Enter actual value into the report in the appendix.
5. Check the CO2 content at the upper and lower
heating output again.
If the CO2 content is not within the specified range:
Repeat steps for upper and lower heating output.
6. Hold down S and simultaneously for longer than
2 s. Burner switches to operating mode.
Checking the CO content
Enter actual value into the report in the appendix.
Commissioning, inspection, maintenance
Checking the CO2 content (cont.)
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20
Enter actual value into the report in the appendix.
Displaying the ionisation current
Note
The ionisation current must be called up via the burner
control unit. It is not possible to measure the ionisation
current using the Testomatik-Gas or a multimeter.
01. Press S approx. 2 s , " " flashes.
02. Press until "5" is shown under Service.
03. Press S. "5" will be displayed under Status.
04. Press until "3" is shown under Service.
05. Press S. "3" is shown under Status, and during
operation the ionisation current is shown under
Service (e.g. 30 = 3.0 µA).
06. Start the burner with the emissions test switch.
07. Read the ionisation current.
Note
The ionisation current should be at least 3 µA for
approx. 2 to 3 s after the gas train has been
opened and during operation.
08. Record the actual value in the report.
09. Press S approx. 2 s , " " flashes.
10. Press until "5" is shown under Service.
11. Press S. "5" will be displayed under Status.
12. Press until "0" is shown under Service.
13. Press S. The operating display will be shown
again.
Shutting down the system
1. Switch OFF the mains isolator or the power supply,
and safeguard against unauthorised reconnection.
Danger
Mains voltage can be life threatening.
For maintenance work, isolate the system
from the power supply.
2. Remove the burner hood.
3. Disconnect burner cables with plugs fA and lÖ
from the burner control unit. Route the burner
cable out of the burner casing.
4. Unplug the cables from the burner control unit as
necessary.
5. Close the gas shut-off valve.
Opening the boiler door
1. Remove the gas supply pipe.
2. If required, remove the ventilation air pipe.
3. Undo 7 screws on the boiler door and open.
Note
Prevent the boiler door from slamming shut.
!Please note
Scratches inside the combustion chamber can
lead to corrosion.
Never place tools or other objects inside the
combustion chamber.
Commissioning, inspection, maintenance
Checking the flue gas temperature
5812086