Viessmann VITOCROSSAL 300 Operating instructions

VITOCROSSAL 300
Service instructions
for heating engineers
Vitocrossal300
TypeCU3
Gas fired condensing boiler with MatriX−compact gas burner,
for open flue and balanced flue operation
See notes on applicability, page2.
5692500GB1/2004 Please keep safe

2
General information
Safety instructions
Please follow these safety instructions closely to prevent accidents and
material losses.
Work on the equipment
Installation, initial start−up, inspection,
maintenance and repairs must only
be carried out by a competent
person (heating engineer/installation
contractor).
Before working on the equipment/
heating system, isolate the mains
electrical supply (e.g. by removing a
separate mains fuse or by means of
a mains electrical isolator) and
safeguard against unauthorised
reconnection.
Close the main gas shut−off valve
and safeguard against unauthorised
reopening.
Work on gas equipment
This must only be carried out by an
approved contractor.
Please observe all commissioning
work specified for gas installations to
TRGI or TRF and all local regulations.
Repair work
It is not permitted to carry out
repairs on parts that fulfil a safety
function.
Use only original Viessmann spare
parts, or equivalent parts that have
been approved by Viessmann.
Initial start−up
The initial start−up must be carried
out by the system installer or a
designated commissioning engineer.
All actual values should be recorded
in a commissioning/service report.
Instructing the system user
The system installer must hand the
operating instructions to the system
user and instruct him/her in the
operation of the system.
¨Safety instructions
In this instruction manual, this
heading denotes information which
must be observed to prevent
accidents and material losses.
¨This symbol denotes important
information which must be
observed to prevent material
losses.
Applicability
Applicable for the respective burner
from the respective serial no.
7170777k00000kkk,
7170778k00000kkk,
7170779k00000kkk,
7170780k00000kkk
5692500GB

3
Contents
Index
Page
General information
Safety instructions 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicability 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start−up, inspection and maintenance
Stepsinitial start−up, inspection and maintenance 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further details regarding the individual steps 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting
Display and programming unit at the burner control unit 23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HDisplay and programming unit 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOperating display 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting manual mode 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HManual mode and service display 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the burner control unit parameters 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HDIP switch settings 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HConfirming a parameter set 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostics 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HFault display 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HCalling up the fault memory 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HFaults with fault display 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HFaults without fault display 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HBurner control unit flow chart 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Burner
Component summary 38
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H
Burner control unit connection diagram 40
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts list41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Commissioning/service report 46
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specification 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of conformity 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer’s certificate 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keyword index 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692500GB

4
Initial start−up, inspection and maintenance
Stepsinitial start−up, inspection and maintenance
For further instructions on individual steps, see pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
C1. Checking all safety equipment 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C2. Filling heating system and
checking ventilation air supply 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C3. Checking electrical mains connection
C4. Filling the siphon with water 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 5. Checking gas type 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C6. Changing gas type (if required)9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 7. Checking static and supply pressure 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 8. Checking CO2settings 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C9. Checking gas valve control pressure 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C M 10. Checking the draught 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C11. Leak testing balanced flue system (annular gap check) 14
C M 12. Checking ionisation current 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 13. System shutdown 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 14. Removing burner and checking burner gasket 16. . . . . . . . . . . . .
I M 15. Checking burner gauze assembly 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 16. Checking & adjusting ignition & ionisation electrodes 18
M17. Disconnecting neutralising system (if installed)
and connecting a drain hose 18
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 18. Cleaning combustion chamber and heating surfaces 19
M19. Cleaning and reconnecting the condensate drain 20. . . . . . .
I M 20. Checking condensate drain and
neutralising system for leaks 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 21. Checking gaskets, packing cords and
thermal insulation 21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692500GB

5
Initial start−up, inspection and maintenance
Stepsinitial start−up, inspection and maintenance (cont.)
Commissioning steps
Inspection steps
Maintenance steps Page
C I M 22. Checking all connections on primary and
DHW side for leaks
C M 23. Checking diaphragm expansion vessel and
system pressure
C I M 24. Checking function of all safety valves
I M 25. Burner installation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I M 26. Checking tightness of electrical connections
C I M 27. Checking all gas equipment for leaks
at operating pressure 22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 28. Checking the mixer (if installed) for
ease of operation and leaks 22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692500GB

6
Initial start−up, inspection and maintenance
Further details regarding the individual steps
General information regarding initial start−up, inspection and
maintenance
Please note:
The measures described here relate exclusively to gas fired boilers and
burners.
This comprises only a part of the work prescribed by TRGI’86/96 relating to
the commissioning of a gas fired system.
¨Safety instructions
Measure the CO value before and after any work on gas appliances, to
prevent any health hazards and to ensure perfect system condition.
Please note:
Record combustion values when the boiler is up to operating temperature
(min. 2minutes operating time) and with the burner hood fitted (for open flue
mode).
Operating and service documents
1. Complete and detach the
customer registration card:
HGive the system user this part
for safekeeping.
HRetain the heating engineer part.
2. Keep all parts lists, operating and
service instructions in the folder
and hand this over to the system
user.
5692500GB

7
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking all safety equipment
Check the following settings:
High limit safety cut−out max. 110ºC
. .
Control thermostat max. 95ºC. . . . . . . . .
Check the control unit adjustments
and change them, if required.
Control unit installation and
service instructions
Filling heating system and checking ventilation air supply
1. Check that the ventilation air
supply is completely
unobstructed.
2. Check the inlet pressure of the
diaphragm expansion vessel when
the system is cold.
Please note:
If the charge pressure of the
diaphragm expansion vessel is
lower than the static system
pressure, top up with sufficient
nitrogen to raise the charge
pressure (0.1 to 0.2bar) higher
than the static system pressure.
The static pressure corresponds to
the static height.
3. Open any check valves that may
be fitted.
4. Top up your heating system with
water and vent until the filling
pressure is higher (0.1 to 0.2bar)
than the inlet pressure of the
diaphragm expansion vessel.
5. Mark this pressure on pressure
gaugeA.
Permiss. operating pressure 3bar
. . . .
6. Return the check valves to their
operating position.
5692500GB

8
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Filling the siphon with water
1. Release fittingAon siphonB,
remove siphonBand fill with
water.
¨Safety instructions
There is a risk of flue gas escaping
if the siphon is not filled with
water.
2. Refit siphonB.
Checking gas type
1. Enquire the gas type and Wobbe
index (Wo) from your gas supplier.
Please note:
The burner is set up in the factory
for natural gas E.
HWith natural gas settingE, the
boiler can be operated in the
Wobbe index range
12.0 to 16.1kWh/m3
(43.2 to 58.0MJ/m3).
HWith natural gas settingLL, the
boiler can be operated in the
Wobbe index range
10.0 to 13.1kWh/m3
(36.0 to 47.2MJ/m3).
2. If necessary, convert the burner in
accordance with details provided
by your gas supplier to a different
gas type (see page 9).
3. Record the gas type in the service
report from page46.
5692500GB
B
A

9
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Changing the gas type (if required)
1. Remove the burner hood.
2. Release two screws and remove
gas restrictor retainerAfrom gas
combination valveB.
3. Push gas restrictorCout of the
side of gas restrictor retainerA.
4. ¨Safety instructions
Insert O−ringDinto the groove of
new gas restrictorC.
5. Push new gas restrictorCfor the
prevailing gas type into gas
restrictor retainerA(click into
place).
6. ¨Safety instructions
Check whether O−ring is inserted
into gas restrictor retainerA.
Insert gas restrictor retainerA
into gas combination valveBand
secure with screws.
7. Remove the self−adhesive label for
the gas type from the type
description supplied, and affix
over existing labelEon gas
restrictor retainerA.
¨Safety instructions
Check all gas connections for
leaks.
8. Affix label ("Adjusted for ...")
showing the current gas type over
existing label ("Adjusted for ...")
on the burner control unit
mounting plate.
Gas restrictor summary
Boiler
for
Rated output range
(kW)*1
927 1235 1649 2266
Natural
gasE
IDF
Gas restrictor
E24 E32 E44 E60
Natural
gasLL
IDF
Gas restrictor
LL24 LL32 LL44 LL60
*1Relative to TV/TR50/30ºC (see specification).
5692500GB
C
D
E
C
B
A
F

10
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking static and supply pressure
¨Safety instructions
Measure the CO value before and after any work on gas appliances, to
prevent any health hazards and to ensure the perfect operational condition of
the system.
Static pressure
1. Close the gas shut−off valve.
2. Release upper screwAof the
retaining plate on burner control
unitB(do not fully unscrew) and
twist burner control unitBaside
clockwise.
3. Release the screw inside test
nipple"PE"C on the gas
combination valve, but do not
remove, and connect the pressure
gauge.
4. Open the gas shut−off valve.
5. Check the static pressure; it should
be between 20 and 50mbar.
Record the actual values in the
service report from page46.
6. Start up the boiler.
Please note:
Switch the burner to max. output
(see page26).
5692500GB
A
B
PE
D
C

11
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Gas supply pressure (flow pressure)
7. Check the supply pressure (flow
pressure), see the table below.
Use test equipment with a
resolution of at least 0.1mbar.
Record the actual values in the
service report from page46.
Take the action shown in the table.
Please note:
At a flow pressure under
17.4mbar, also check the filter
downstream of flangeDon the
gas supply pipe (see page10), for
contamination.
8. Shut down the boiler, close the
gas shut−off valve, remove the
pressure gauge, and close test
nipple "PE"Cwith the previously
removed screw.
Refit the mounting plate with the
burner control unit.
Torque: 2Nm
9. ¨Safety instructions
Open the gas shut−off valve and
check test nipple "PE" and all gas
connections for soundness.
Supply pressure
(flow pressure)
Remedy
below 15mbar Do not start up boiler  notify your gas supply
company.
15 up to 17.4mbar ¨Boiler may only be operated temporarily
with these settings (emergency mode).
Notify your gas supply company.
17.4 up to 50mbar Start up boiler.
above 50mbar Install a separate gas governor upstream of
system and regulate pressure to 20mbar.
Notify your gas supply company.
5692500GB

12
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking CO2settings
The burner is factory set to natural gasE.
During commissioning or maintenance, check the CO2level on the boiler
adaptor.
Please note:
The MatriX burner is preset for the entire gas group. Therefore, the burner
requires no further setting or adjustment.
Subject to the Wobbe index, the CO2content ranges between
H6.6 and 9.5% for natural gasE and
H7.0 to 9.0% for natural gasLL.
Compare the actual CO2value with the above CO2value ranges for the
individual gas groups (check the gas group with your gas supplier).
If the actual CO2value deviates from the stated ranges by more than 1%,
proceed as follows:
HCheck that the correct gas restrictor has been installed (see page9).
HCarry out a leak test on the balanced flue system (see page14).
1. Connect a flue gas analyser at
boiler adaptorA("flue gas"
port).
2. Start up the boiler.
3. Operate the boiler at its lower
rated output (see page26) and
check the CO2content.
4. Operate the boiler at its upper
rated output (see page26) and
check the CO2content.
5. Terminate the manual mode (see
page26), and enter actual values
into the service report (from
page46).
5692500GB
A

13
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking the gas valve control pressure
1. Start up the boiler.
2. Operate the boiler at the higher
rated output (see page26).
3. Remove the caps from test
nipplesAof the gas combination
valve.
4. Connect the gauge to both test
nipplesA.
The differential pressure should
be 4.0mbar (400Pa).
If the actual value deviates by
more than "0.4mbar (40Pa)
HCheck the settings of the DIP
switches (see page27)
HCheck the flue gas and
ventilation air lines
HCheck pressure limiterBfor
soundness (sealing washers).
Please note:
Use suitable test equipment with a
range from 0 to 1000Pa.
Vacuum pressure is applied to
both test nipples. The vacuum
pressure at the test nipple with the
"+" symbol is lower, and that at
the test nipple with the ""
symbol is higher.
Connect the pressure gauge
accordingly.
5. Record the actual values in the
service report from page46.
Checking the draught
1. Check the draught in Pa
(1Pa=0.01mbar) at connection
A(flue gas, see page12) of the
boiler adaptor.
2. Record the actual values in the
service report from page46.
5692500GB
A
B

14
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Leak testing the balanced flue system (annular gap check)
For balanced flue systems tested together with a gas fired boiler, some
Federal States (e.g. North Rhine Westphalia) waive the leak test (overpressure
test) during commissioning by the flue gas inspector.
We recommend that your heating engineer carries out a simple leak test
during the initial start−up of your system. For this it would be sufficient to
check the CO2concentration in the combustion air at the annular gap in the
balanced flue pipe.
The flue pipe is deemed to be sound if the CO2concentration in the
combustion air is lower than 0.2% or if the O2concentration is at least 20.6%.
If actual CO2values are higher or O2values are lower, then pressure check the
flue pipe at a static pressure of 200Pa.
For location of combustion air test nippleB(ventilation air), see the diagram
on page12.
Checking ionisation current
5692500GB
CD
B
A

15
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
1. Switch OFF the control unit
ON/OFF switch.
2. Pull plugCof the ionisation
current lead off the ionisation
electrode.
3. Switch ON the system ON/OFF
switch.
There must be a fault shutdown
after twoburner start attempts.
DisplayAflashes fault codeF25.
4. Switch OFF the system ON/OFF
switch.
Please note:
Test cable no.1 is required when
checking with Testomatik−Gas.
You can also carry out this check with
a multimeter.
5. Push plugCof the ionisation
current lead into adaptorD.
6. Plug socketBof the test cable
onto the ionisation electrode.
7. Switch ON the system ON/OFF
switch and check the ionisation
current at the upper and lower
rated output.
For settings of the upper and
lower values, see page26.
Please note:
Ionisation current at
Hupper rated output min. 10mA,
Hlower rated output min. 3mA.
8. Record the actual values in the
service report (see from page46).
9. Switch the system ON/OFF switch
OFF, remove the test equipment
and reconnect the plug connector
of the ionisation current cable.
Please note:
The strength of the ionisation
current can also be shown in the
burner control unit display.
For this, simultaneously press
keysaand Son the burner
control unit. Under status, the
following is shown in the display:
"1, 2 or 3".
Meaning of display (strength of
the ionisation current):
1=weak
2=medium
3=good.
System shutdown
1. Switch OFF the system ON/OFF
switch and the mains electric
supply and safeguard against
unauthorised reconnection.
2. Pull plug connectorsfA and lÖ
off the burner control unitA(see
page16).
3. Close the gas shut−off valve.
5692500GB

16
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Removing the burner and checking the burner gasket
1. Release gas connection pipeB.
2. Release six nutsC, remove the
burner and hook into the service
position in service holderDon
the boiler.
¨Never rest the burner on its
gauze assembly (wire
mesh)E.
3. Check burner gasketFfor
damage and replace, if required.
5692500GB
6x EC
A
B
DF
E

17
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking burner gauze assembly
Replace the burner gauze assembly if
the wire mesh is damaged.
1. Remove ignition and ionisation
electrodesA.
2. Turn thermal insulation ringB
clockwise and remove carefully.
3. Slacken eight Torx screwsC, and
remove burner gauze assemblyD
and assembly gasketE.
4. Insert a new burner gauze
assemblyDwith new assembly
gasketE, and secure with eight
Torx screws.
Torque: 4.5Nm
5. Refit thermal insulation ringB
and ignition and ionisation
electrodesA.
5692500GB
B A C AD E

18
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Checking and adjusting the ignition and ionisation electrodes
AIgnition electrodes
BIonisation electrode
1. Check the electrodes for wear and
contamination.
2. Clean the electrodes with a small
brush or emery paper.
¨Ensure that the wire mesh is
not damaged.
3. Check all clearances. If the gaps
are not as specified or the
electrodes are damaged, replace
and align the electrodes together
with new gaskets.
Tighten the fixing screws with
2Nm.
Disconnecting the neutralising system (if installed),
and connecting a drain hose
1. Separate the hose to the
neutralising system from
siphonA.
2. Connect drain hose to siphonA
and to a sewer.
5692500GB
7
3
AB
A
.
A

19
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Cleaning the combustion chamber and heating surfaces
¨Do not use a wire brush or sharp objects.
Avoid scratches or other damage to components which are in contact with
flue gases.
Components which are in contact with flue gases should not come into
contact with pure iron, otherwise corrosion damage will result. Use plastic
brushes, if required.
1. Clean the combustion chamber
and heating surfaces.
HFor normal cleaning, thoroughly
flush with a water jet.
HHowever, you may use cleaning
agents if you notice stubborn
residues, surface discolouration
or soot deposits.
When doing so, please observe
the following:
 Only use solvent−free cleaning
agents. Ensure that no solvent
enters between the boiler body
and the thermal insulation.
 Remove soot deposits with
alkaline agents containing
surfactants (e.g. Fauch600*1).
¨Safety instructions
Observe the cleaning agent
manufacturer’s details. Wear
goggles, protective gloves and
protective clothing if
necessary.
 Combustion residues may
create thin, yellow brown
surface discolouration as well
as hard deposits, which may
only become visible after
removing the soot deposits.
Use slightly acidic, chlorine−
free cleaning agents based on
phosphoric acid to remove
surface discolouration and
hard deposits (e.g.
Antox75E*1).
2. Remove loosened deposits from
the boiler, the heating surfaces
and the flue gas collector and
thoroughly rinse with water.
*1Manufacturer: Hebro Chemie GmbH
Rostocker Straße40
D41199 Mönchengladbach
5692500GB

20
Initial start−up, inspection and maintenance
Further details regarding the individual steps (cont.)
Cleaning and reconnecting the condensate drain
¨Safety instructions
Clean the inside of the condensate drain at least annually.
The flue gas collector, condensate drain, stench trap, neutralising system and
all intermediate hoses and pipes are part of the condensate drain system.
1. Release fittingAon siphonB,
remove siphonBfrom the boiler.
2. Clean the inside of the inlet
connectorCwith a brush.
3. Remove, clean and refit baseDof
siphonB.
4. Fill siphonBwith water and
secure on inlet connectorC.
¨Safety instructions
There is a risk of flue gas escaping
if the siphon is not filled with
water.
5. If installed:
Maintain the neutralising system.
Neutralising system
manufacturer’s
instructions
6. Release the drain hose to drain
siphonB.
7. Reconnect the neutralising system
to siphonB.
5692500GB
C A
B
D