Viessmann Vitocrossal 300 CT3 SERIES Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 300
Type CT3, 187 to 635 kW
Gas condensing boiler
For applicability, see the last page
VITOCROSSAL 300
5692 909 GB 12/2011 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on gas equipment must only be
carried out by a qualified gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental protection,
■ the Code of Practice of relevant trade
associations,
■ all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never 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.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5692 909 GB

3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the
living space.
Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which ful-
fil a safety function can compro-
mise the safe operation of your
heating system.
Replace faulty components only
with original Viessmann spare
parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5692 909 GB

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Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 7
Parts lists............................................................................................................ 18
Commissioning/service reports........................................................................ 25
Specification....................................................................................................... 26
Certificates
Declaration of Conformity..................................................................................... 30
Certificates
Manufacturer's certificate..................................................................................... 31
Keyword index.................................................................................................... 32
Index
Index
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Checking the high limit safety cut-out setting............. 7
•2. Filling the heating system with water and venting...... 7
•3. Fully opening the rotary damper in the flue outlet and
locking it again................................................................ 7
••• 4. Commissioning the system........................................... 7
•5. Minimising pulsation noise............................................ 8
• • 6. Shutting down the system............................................. 9
• • 7. Opening the boiler door................................................. 9
• • 8. Separating the neutralising system from the boiler
and connecting the drain hose...................................... 9
• • 9. Cleaning the combustion chamber and heating
surfaces........................................................................... 10
• • 10. Checking gaskets and thermal insulation parts.......... 10
• • 11. Checking all connections and the sensor well on the
heating water side for leaks........................................... 11
• • 12. Checking the function of the safety equipment........... 11
••• 13. Checking the diaphragm expansion vessel and
system pressure............................................................. 11
• • 14. Checking the flue gas collector for leaks..................... 13
•15. Cleaning the sight glass in the boiler door.................. 14
• • 16. Closing the boiler door.................................................. 14
•17. Checking the thermal insulation................................... 14
• • 18. Checking the mixer for ease of operation and leaks... 14
• • 19. Checking the water quality............................................ 15
• • 20. Cleaning and reconnecting the condensate drain
system............................................................................. 15
•21. Checking the installation room ventilation
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
•22. Checking the flue system for leaks
• • 23. Adjusting the burner...................................................... 16
•24. Instructing the system user........................................... 16
•25. Operating and service documents................................ 17
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
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Checking the high limit safety cut-out setting
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 serv-
ice instructions
Filling the heating system with water and venting
Record the fill volume, water hardness
and pH value on page 15 . !Please note Unsuitable water quality can
result in damage to the boiler
body and the heating system.
Observe the "Water quality
requirements" on page 27 .
Fully opening the rotary damper in the flue outlet and locking it
again
The rotary damper must be in the hori-
zontal position.
Note
For handling the rotary damper, see
"Minimising pulsation noise" on
page 8.
Commissioning the system
Operating instructions for control
unit, burner and neutralising sys-
tem, service instructions for con-
trol unit, and burner manufactur-
er's documentation
1. Check the heating system pressure.
Permissible boiler operating pres-
sure: 4 bar
2. Check that the installation room vent
is open.
3. Check the gas supply pressure.
4. Check that the cleaning aperture on
the flue outlet is closed.
5. Open the gas line shut-off valves.
6. Switch ON the mains isolator, the
switch for the heating circuit pump
and the burner ON/OFF switch, in
that order.
Burner manufacturer's oper-
ating instructions
7. Check the function of the neutralising
system.
Neutralising system operating
instructions
Commissioning, inspection, maintenance
Further details regarding the individual steps
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8. Check all gaskets and plugs, and
retighten if necessary.
Note
We recommend you check all con-
nections on the heating water side for
leaks after approx. 500 hours run
(see page 11).
9. Check the boiler door and cleaning
cover a few days after commissioning
and retighten all screws.
Danger
For safe operation, a minimum
operating pressure of 0.5 bar is
essential.
For this, a minimum pressure
switch can be used.
Minimising pulsation noise
Whatever the make of boiler, burner or flue system, gas-tight flue systems can still
create pulsation noise. A change of resonance may be affected by rotating the
damper fitted into the flue outlet.
C B
B
A
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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1. Undo nut A on lever B of rotary
damper C.
2. Adjust the lever until all pulsation
noise has ceased (the lever mirrors
the damper position).
3. Lock the rotary damper with nut A.
4. Re-adjust the burner if required.
Shutting down the system
1. Switch OFF the mains isolator or the
power supply and safeguard against
unauthorised reconnection.
2. Pull plug-in connector fA and lÖ
from the burner.
3. Close the gas shut-off valve.
Opening the boiler door
1. Remove the gas supply pipe.
2. Undo the screws on the boiler door
and open the door.
!Please note
Scratches inside the combustion
chamber can lead to corrosion.
Never put tools or other objects
into the combustion chamber.
Separating the neutralising system from the boiler and connect-
ing the drain hose
A
1. Separate hose or pipe A to the neu-
tralising system from the flue gas col-
lector or siphon.
2. Remove the siphon (if installed) from
the condensate drain.
3. Clean the inside of the condensate
drain with a plastic brush.
4. Connect the drain hose to the con-
densate drain and run to a sewer.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the combustion chamber and heating surfaces
!Please note
Contact with unalloyed iron and
scratches on parts in contact with
flue gases can lead to corrosion.
Only use plastic brushes, NOT
wire brushes or sharp objects.
1. Clean the combustion chamber and
heating surfaces.
■ For normal cleaning, flush the heat-
ing surfaces thoroughly with a
water jet.
■ However, you may use cleaning
agents if you notice stubborn resi-
dues, surface discolouration or
soot deposits.
For this, observe the following:
– Only use solvent-free cleaning
agents. Ensure that no cleaning
agents enter between the boiler
body and the thermal insulation.
– Remove soot deposits with alka-
line cleaning agents with addi-
tional surfactants (e.g. Fauch
600).
– Remove coatings and surface
discolouration (yellow-brown)
with slightly acidic, chloride-free
cleaning agents based on phos-
phoric acid (e.g. Antox 75 E).
2. Remove loose deposits from the
boiler; flush the heating surfaces and
the flue gas collector thoroughly with
a water jet.
Danger
Loose residues and residual
cleaning agents can lead to
injury.
Wear goggles, protective gloves
and protective clothing.
Cleaning agent manufacturer's
details.
Note
"Fauch 600" and "Antox 75 E"
Manufacturer:
Hebro Chemie GmbH
Rostocker Straße 40
D -41199 Mönchengladbach
Checking gaskets and thermal insulation parts
1. Check gaskets and the packing cord
in the boiler door for damage.
2. Check the thermal insulation compo-
nents of the boiler door for damage.
3. Replace any damaged parts.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking all connections and the sensor well on the heating
water side for leaks
Danger
There is a risk of injury when
working on pressurised compo-
nents.
Only open the connections on the
heating water side after the boiler
has been depressurised.
Only drain the boiler with a suc-
tion pump when the boiler air vent
valve is open.
B
A
1. Remove cap A from the back of the
boiler.
2. Check sensor well B for leaks.
3. Fit cap A.
Checking the function of the safety equipment
Check the safety valves, water level lim-
iter and pressure limiter in accordance
with manufacturer's details.
Checking the diaphragm expansion vessel and system pressure
Note
Observe the diaphragm expansion ves-
sel manufacturer's instructions.
Carry out this test on a cold system.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Pump-controlled pressure maintain-
ing systems
Note
Install a diaphragm expansion vessel
(DEV) as individual boiler protection in
heating systems with automatic pres-
sure maintaining equipment and/or dea-
eration systems (operating according to
the pressure reduction method for dea-
eration).
The diaphragm expansion vessel must
have the following minimum size (vol-
ume in litres), subject to the boiler output:
Up to 300 kW: 50 litres
Up to 500 kW: 80 litres
Up to 1000 kW: 140 litres
This diaphragm expansion vessel
reduces the frequency and severity of
pressure fluctuations; the runtime of the
pressure maintaining pump is improved
and therefore the operational reliability
and service life of system components is
increased.
Failure to observe these recommen-
dations may result in damage to the
boiler or to other system compo-
nents.
Carry out all checks in accordance with
the manufacturer's instructions. Limit
pressure fluctuations to the lowest pos-
sible differential. Cyclical pressure fluc-
tuations and more significant pressure
differentials point towards a system fault.
Immediately remedy such faults, other-
wise other heating system components
may become damaged.
Diaphragm expansion vessel
1. Drain the system or close the cap
valve on the diaphragm expansion
vessel and reduce the pressure until
the pressure gauge indicates "0".
Note
The pre-charge pressure of the dia-
phragm expansion vessel (p0) is
made up of the static system pres-
sure (pSt) (= static head) and a sup-
plement (p0 = pSt + supplement).
The supplement is subject to the set-
tings of the high limit safety cut-out.
For a high limit safety cut-out setting
of
100 ºC: 0.2 bar
110 ºC: 0.7 bar
2. If the pre-charge pressure of the dia-
phragm expansion vessel is lower
than the value calculated according
to the given formula, top up with nitro-
gen until this value has been ach-
ieved.
3. Top up with water until the charge
pressure of the cooled system is 0.2
bar higher than the pre-charge pres-
sure of the diaphragm expansion
vessel.
4. Mark this value on the pressure
gauge as the minimum charge pres-
sure.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the flue gas collector for leaks
A
B
1. Traces of condensate on the outside
of the flue gas collector indicate a
leak.
2. If required, retighten the gaskets at
clamping clips A and at actuator
damper B.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the sight glass in the boiler door
A
B
Check gaskets A and hose connection
B for leaks.
Closing the boiler door
1. Tighten the screws on the boiler door
evenly and diagonally.
2. Install the gas supply pipe and check
for tightness.
Checking the thermal insulation
Check the thermal insulation fit and re-
align if required.
Checking the mixer for ease of operation and leaks
1. Remove the motorised lever from the
mixer handle.
2. Check the mixer for ease of opera-
tion.
3. Check the mixer for leaks. Replace
the O-rings if the mixer leaks.
4. Snap the motorised lever into place.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the water quality
Enter the amount of top-up water and the total hardness of the feed and boiler water
into the following table.
For water quality requirements, see page 27.
Meter read-
ing
Fill and top-
up water
Total water
volume
Total hardness pH value Date
Feedwater Boiler
water
m3m3m3°dH °dH
The total hardness of the feed and top-up water must not exceed the standard values
specified by the VDI 2035 (see page 27).
The pH value should be between 8.2 and 9.5.
Cleaning and reconnecting the condensate drain system
The condensate drain, siphon, neutralising system and all intermediate hoses and
pipes are part of the condensate drain system.
Note
Clean the inside of the condensate drain
system at least annually.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 909 GB

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A
1. To dewater the condensate drain,
disconnect drain hose A.
2. Clean the inside of the condensate
drain once more with the plastic
brush.
3. Clean the siphon (if installed).
4. Clean the inside of the pipes of the
condensate drain system and the
neutralising system.
Neutralising system operating
instructions
5. Connect the line with a U-bend to the
condensate drain and fill with water or
fit a siphon and fill that with water.
Note
There is a risk of flue gas escaping if
the U-bend or siphon is not filled with
water.
6. Connect the supply line to the neu-
tralising system and make a correct
connection between the condensate
drain and the sewer entry.
Adjusting the burner
Observe the burner manufacturer's
instructions.
Instructing the system user
The installer should instruct the user in
the operation of the system.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Operating and service documents
1. Complete and detach the customer
registration card:
■ Hand system users their section for
safekeeping.
■ Retain the heating contractor's
section.
2. File all parts lists, operating and serv-
ice instructions in the folder and hand
this over to the system user.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 909 GB

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When ordering spare parts:
Quote the part no. and serial no. (see
type plate) and the position number of
the required part (as per this parts list).
Standard parts are available from your
local supplier.
069 Burner plate pack
070 Boiler door
071 Packaging
072 Mounting bracket
073 Pack 20 x 15
074 Thermal insulation block
075 Thermal insulation mat
076 Stud
077 Packaging
080 Mating flange
081 Gasket PN 6
082 Gasket PN 6
083 Mating flange
084 Gasket PN 6
086 Mating flange
087 Gasket PN 6
090 Flue gas collector, complete
093 Clamping clip
095 Sight glass
096 Hose nozzle
097 Sight and test pipe cover
098 Sight glass with gaskets
099 Hose
200 Upper insulation mat, front panel
201 Lower thermal insulation mat, front
panel
202 Upper insulation mat, back panel
203 Lower thermal insulation mat, back
panel
206 Spacer stud
207 Threaded pin
208 Front panel, top
209 Front panel, centre
210 Front panel, bottom
211 Back panel, top
214 Side panel, bottom
215 Side panel, top
216 Side panel, l.h. and r.h.
217 Finned bottom panel, r.h. front
220 Finned bottom panel, l.h. front
221 Cap
222 6-fold strain relief
223 Mounting bracket, back
224 Mounting bracket
225 Edge protector
226 Cable trunking
227 Trunking cover
228 Insulation mat, outer jacket, front
top
229 Insulation mat, outer jacket, back
top
230 Rear fixing bracket
231 Front fixing bracket
232 Back panel, r.h. bottom
233 Back panel, l.h. bottom
234 Finned panel, l.h. centre
235 Finned panel, r.h. centre
236 Cover panel
237 Finned panel, l.h. top
238 Finned panel, r.h. top
239 Trunking retainer (from 314 kW
only)
240 Mounting bracket fascia
Parts not shown
300 Connecting parts pack
301 Installation instructions
302 Service instructions
303 Adjustable feet pack
304 Dirko-HT sealant
305 Boiler door pack
306 Thermal insulation material pack
307 Sealant pack
AType plate, optionally left or right
BBoiler control unit, see separate
parts list
CBurner cable, see separate parts list
Parts lists
Parts lists
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206
229
207
207
231
231
231
228
200
201
206
082
082
Parts lists
Parts lists (cont.)
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202
203
087
090
206
207
207
207
230
230
093
Parts lists
Parts lists (cont.)
5692 909 GB