Viessmann VITOCROSSAL CRU 800 kW Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal
Type CRU, 800 and 1000 kW
Gas condensing boiler
For open flue and room sealed operation
Permissible operating pressure 6 bar
VITOCROSSAL
5816717 GB 1/2018 Please keep safe.

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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
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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.)
5816717

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1. Information Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
Product information ................................................................................ 6
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 7
3. Burner control unit Burner control unit VUC 310 .................................................................. 32
■Display and programming unit ............................................................ 32
■Operating display ................................................................................ 32
■Info display/configuration display ........................................................ 33
■Resetting operating parameters to their delivered condition .............. 35
■Manual operation and service display ................................................ 35
Flow diagram ......................................................................................... 36
■Description of state: ............................................................................ 37
4. Troubleshooting Fault display ........................................................................................... 38
■Fault memory ...................................................................................... 38
Fault codes ............................................................................................ 38
■General process errors ....................................................................... 38
■Internal system faults .......................................................................... 42
Faults without fault display ..................................................................... 43
5. Parts lists Overview of assemblies ......................................................................... 45
Boiler assembly ..................................................................................... 46
Casing assembly ................................................................................... 48
MatriX-Disk burner assembly ................................................................. 50
Burner control unit assembly ................................................................. 52
Control unit assembly ............................................................................ 54
6. Component overview Overview of burner components ............................................................ 56
7. Function description Air pressure switch ................................................................................ 57
■Fan pressure monitoring function (LDW1) .......................................... 57
■Combustion chamber pressure monitoring function (LDW2) .............. 57
Boiler water temperature sensors and flue gas temperature sensors ... 57
8. Connection diagrams Burner control unit connection diagram ................................................. 58
9. Reports ................................................................................................................ 61
10. Specification ................................................................................................................ 63
11. Final decommissioning Final decommissioning and disposal ..................................................... 65
12. Certificates EU Declaration of Conformity ................................................................ 66
Manufacturer’s certificate according to the 1st German Immissions
Order (BImSchV) ................................................................................... 67
13. Keyword index ................................................................................................................ 68
Index
Index
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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
5816717
Information

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Vitocrossal, type CRU
■Gas condensing boiler, 800 and 1000 kW rated heat-
ing output with modulating MatriX-Disk burner for
natural gas E and LPG P
■Permissible operating pressure 6 bar/0.6 MPa.
Information
Product information
5816717
Information

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Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system with water and venting......................................................... 9
•2. Filling the trap with water.................................................................................................. 9
••• 3. Commissioning the system............................................................................................... 9
••• 4. Checking the flue gas damper.......................................................................................... 10
•5. Checking the gas type....................................................................................................... 10
••• 6. Opening the boiler.............................................................................................................. 11
•7. Conversion to natural gas E.............................................................................................. 12
•8. Conversion to LPG P......................................................................................................... 13
•9. Reducing the heating output (if required)........................................................................ 14
••• 10. Checking the static pressure and supply pressure........................................................ 15
••• 11. Checking the CO2 content................................................................................................. 16
• • 12. Checking the CO content.................................................................................................. 19
• • 13. Checking the flue gas temperature.................................................................................. 19
• • 14. Displaying the ionisation current..................................................................................... 19
• • 15. Shutting down the system................................................................................................. 19
• • 16. Opening the combustion chamber................................................................................... 19
• • 17. Cleaning the combustion chamber and heating surfaces............................................. 20
• • 18. Checking the gaskets and thermal insulation sections................................................. 20
• • 19. Checking all connections and the sensor well on the heating water side for
tightness............................................................................................................................. 21
• • 20. Cleaning the condensate drain pipe and trap................................................................. 21
• • 21. Checking the condensate drain and neutralising system (if installed)......................... 22
• • 22. Opening the burner door................................................................................................... 23
• • 23. Checking the burner gauze assembly.............................................................................. 24
• • 24. Checking the ignition electrodes and ionisation electrode........................................... 24
• • 25. Cleaning the burner........................................................................................................... 25
•26. Fitting the burner................................................................................................................ 26
• • 27. Closing the burner door.................................................................................................... 26
• • 28. Checking the gas train valves for tightness.................................................................... 28
• • 29. Checking the gas train filter element............................................................................... 28
• • 30. Checking the filter element in the gas line...................................................................... 29
••• 31. Checking gas connections for tightness......................................................................... 29
• • 32. Closing the boiler casing................................................................................................... 30
• • 33. Checking the gaskets on the flue gas side...................................................................... 30
•34. Performing final checks..................................................................................................... 30
• • 35. Checking the water quality................................................................................................ 30
••• 36. Checking the safety valve function
• • 37. Checking the expansion vessel ....................................................................................... 30
• • 38. Checking the mixer for ease of operation and leaks...................................................... 31
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
••• 39. Checking the thermal insulation for firm seating
••• 40. Checking the installation room ventilation air apertures............................................... 31
•41. Instructing the system user.............................................................................................. 31
•42. Operating and service documents................................................................................... 31
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
5816717

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Record the volume filled, water hardness and pH value
on page 61.
Note
Observe the "Water quality requirements" on
page 59.
Filling the trap with water
A B
Fig. 1
ATrap lower section
BDrain hose
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 or flue gas system leakage 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
Note
To ensure stable operation, the following minimum
lengths for the flue system must be observed:
■Natural gas E: 5 m
■LPG P: 10 m
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.
Commissioning, inspection, maintenance
Filling the heating system with water and venting
5816717

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03. Check control cables:
■Connection and kink-free routing
■Application and seating of retaining clips
04. Check the gas supply pressure. See page 15.
05. Open the gas line shut-off valves.
06. Switch ON the mains isolator (outside the installa-
tion room).
07. Switch on the system ON/OFF switch at the user
interface of the control unit.
Vitotronic operating instructions
If "Burner fault" and appear on the display:
1. to acknowledge the fault message
2. to reset the burner.
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. Check the function of the neutralising system.
Neutralising system operating instructions
09. Check all gaskets and plugs, and retighten if nec-
essary.
Note
Recommendation: Check all connections on the
heating water side for leaks after approx. 500
hours run. See page 21.
10. Check the burner door and flue gas cover a few
days after commissioning. In the case of leaks,
tighten the screws in the burner door with 40 Nm.
Tighten the screws of the flue gas collector with
30 Nm.
Checking the flue gas damper
Where present: Check the motorised flue gas damper
(flue gas cascade accessory).
The flue gas damper must be closed in its zero volt
state (plug 53).
Checking the gas type
1. Check with your gas supply utility regarding the
gas type and Wobbe index Ws (0 °C;
1013.25 mbar).
■With the natural gas 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 LPG P setting, the boiler can be oper-
ated in the Wobbe index range 21.3 to
22.5 kWh/m3 (76.9 to 81.2 MJ/m3).
■Relative output losses of up to 10 % may occur,
depending on gas quality.
2. In the delivered condition, the burner is set up for
natural gas E. If required, convert the burner to a
different gas type during commissioning; when
doing so, observe the information provided by your
gas supply utility.
Operation with LPG
Operation with LPG requires the coding card for P
gas. This coding card must be ordered separately.
See chapter on "Conversion to LPG P" on
page 13.
3. Record the gas type in the report in the appendix
on page 62.
Commissioning, inspection, maintenance
Commissioning the system (cont.)
5816717