Viessmann VITOCROSSAL 300 Operating instructions

VITOCROSSAL 300
Service instructions
for heating engineers
VitocrossalĂ300
typeĂCR3, 186 to 311ĂkW
Gas-fired condensing boiler
5692Ă48 ĂGBăăă9/2 2 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 be carried out by a competent
person (heating engineer/installation
contractor).
Before working on the equipment/
heating system, isolate the mains
electrical supply (e.Ăg. 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
acc. to TRGI or TRF and all local
regulations.
Repair ork
This must not be carried out 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
This must be carried out by the
system installer or a commissioning
engineer designated by him; 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.
¨ĂSafety 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.
Operating and service documents
1. Complete and detach the customer
registration card:
HGive the system user this part
for safe-keeping.
HKeep the part for the heating
engineer.
2. Keep all parts lists, operating and
service instructions in the folder
and hand this over to the system
user.
5692Ă48 ĂGB

3
Contents
Index
Page
General Information
Safety instructionsĂ 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating and service documentsĂ 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start-up, inspection and maintenance
StepsĂ 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further details of the individual stepsĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts listsĂ18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Water quality requirementsĂ24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of conformityĂ 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer's certificateĂ 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service reportĂ 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692Ă48 ĂGB

4
Initial start-up, inspection and maintenance
StepsĂćĂinitial start-up, inspection and maintenance
For further instructions concerning the individual steps, see pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
C1. Checking the high limit safety cut-out adjustmentĂ 5. . . . . . . .
C2. Filling the heating system ith ater and
ventilating the systemĂ 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C3. Fully opening the flue outlet damper and
locking it openĂ 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C4. Checking the neutralising system connections
and filling ith neutralising agentĂ
C I M 5. System start-upĂ 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C6. Pulsation noisesĂ 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 7. System shutdo n
I M 8. Opening the boiler doorĂ 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M9. Separating the neutralising system from the boiler
and connecting the drain hoseĂ 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M10. Cleaning the combustion chamber & heating surfacesĂ 9
I11. Checking the boiler door thermal insulation and gaskets
C I M 12. Checking all heating ater connections and
the sensor ell for leaksĂ 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I 13. Checking the function of all safety equipmentĂ 11. . . . . . . . . . . . .
C I M 14. Checking the expansion vessel and system pressureĂ 11
M15. Cleaning the sight glass in the boiler doorĂ 13. . . . . . . . . . . . . . . . . . . .
I M 16. Closing the boiler doorĂ 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 17. Checking the ater qualityĂ 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I18. Checking the thermal insulationĂ 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I19. Checking the flue cover for leaksĂ 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I20. Checking the mixer for easy operation and leaksĂ 15. . . . . . .
M21. Cleaning and reconnecting the condensate drainĂ 16. . . . . . .
I22. Checking the boiler room ventilation
I23. Checking the function of the flue gas system
M24. Burner adjustmentĂ 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692Ă48 ĂGB

5
Initial start-up, inspection and maintenance
Further details of the individual steps
Checking the high limit safety cut-out adjustment
The high limit safety cut-out must
not be set higher than 11 ĂºC; set to a
maximum of 11 ĂºC, if necessary.
Control unit installation and
service instructions
Filling the heating system ith ater and ventilating the
system
Record the fill volume of calcium
hydrogen carbonate on pageĂ14.
Please note:
Observe the " ater quality
requirements" on pageĂ24.
Fully opening the flue outlet damper and locking it open
The damper must be in the
horizontal position.
Please note:
For handling the damper, see chapter
"Pulsation noises" (pageĂ7).
5692Ă48 ĂGB

6
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
System start-up
Operating instructions ć control unit, burner and neutralising system
Service instructions ć control unit and burner manufacturer's
documentation
1. Check the system pressure.
Permissible boiler operating
pressure: 4Ăbar
2. Check that the boiler room
ventilation duct is unobstructed.
3. Check the mains gas supply
pressure.
4. Check whether the cleaning
aperture on the flue outlet is
closed.
5. Open the gas main shut-off valves.
6. Switch on the mains isolator, the
heating circuit pump switch and
the burner control switch in this
order.
Burner manufacturer's
operating instructions
7. Check the function of the
neutralising system.
Neutralising system
operating instructions
8. Check all gaskets/seals and plugs
for leaks and re-tighten, if
necessary.
Please note:
In addition, we recommend you
check all heating water
connections after approx.
500Ăhours operation for leaks
(see pageĂ10).
9. Check the boiler door and
clean-out cover a few days after
commissioning and re-tighten all
screws.
5692Ă48 ĂGB

7
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Pulsation noises
Independent of the make of boiler, burner or flue gas system, gas-tight flue
systems can create pulsation noises.
A change of resonance may be effected by rotating the damper fitted into the
flue outlet.
1. Loosen MĂ1 nutĂA in handleĂB
of damperĂC.
2. Adjust the handle until all
pulsation noises have ceased
(the handle mirrors the damper
position).
3. Lock the damper with MĂ1 nutĂA.
4. If necessary, readjust the burner.
5692Ă48 ĂGB

8
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Opening the boiler door
1. Remove the gas supply pipe.
2. Loosen the screws on the boiler
door and open it.
¨Do not insert tools or other
objects into the combustion
chamber.
Separating the neutralising system from the boiler and
connecting the drain hose
1. Pull hoseĂD to the neutralising
system off stench trap plugĂE.
2. Unscrew stench trap plugĂE from
condensate drainĂF.
3. Clean the inside of condensate
drainĂF with a plastic brush.
4. Connect drain hoseĂGĂto
condensate drainĂFĂand run to a
sewer.
5692Ă48 ĂGB

9
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Cleaning the combustion chamber and heating surfaces
Thoroughly clean the combustion
chamber and heating surfaces with a
water jet.
¨Do not use a wire brush or sharp
objects.
Scratches or other damage to
components which are in contact
with flue gases should be avoided.
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
necessary.
For normal cleaning, rinse the
heating surfaces with a water jet.
However, you may use cleaning
agents if you notice stubborn
residues, surface discolouration
or soot deposits.
When doing so, please observe the
following:
HOnly use solvent-free cleaning
agents. Ensure that no solvent
enters between the heat exchanger
and the thermal insulation.
HRemove soot deposits with alkaline
agents containing surfactants (e.Ăg.
FauchĂ6 *1).
HCombustion 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.Ăg. Antox Ă75ĂE*1).
HRemove loosened deposits from
the heat exchanger and thoroughly
rinse the heating surfaces and the
flue gas collector with a water jet.
¨ĂSafety instructions
ear goggles, protective gloves and
protective clothing, if necessary.
Cleaning agent
manufacturer's details.
*1Manufacturer:
Hebro Chemie GmbH
Rostocker StraßeĂ40
DĆ41199ĂMönchengladbach
5692Ă48 ĂGB

10
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Checking all heating ater connections and the sensor ell for
leaks
¨ĂSafety instructions
Only open the heating water connections after the boiler has been
depressurised.
Only drain the boiler with a vacuum pump when the boiler vent is open.
1. Loosen the screws of top
panelsĂHand remove the panels.
2. Check sensor wellĂK and all
heating water connections for
leaks.
3. Position the top panels and secure
with screws.
5692Ă48 ĂGB

11
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Checking the function of all safety equipment
Check the safety valves, the water
level and pressure limiters in
accordance with manufacturer's
instructions.
Checking the expansion vessel and the system pressure
Note the manufacturer's instructions. Carry out this test on a cold system.
Expansion vessels ith pump or compressor control
¨In heating systems where the pressure is maintained automatically
(especially for systems with pump control) and/or de-gassing systems
(operating acc. to the pressure reduction method for de-gassing), we
recommend the installation of a diaphragm expansion vessel (MAG) as
individual boiler protection.
A common expansion vessel can be used for any multi-boiler systems.
The diaphragm expansion vessel must be able to hold the heating water
expansion volume inside the boiler, and provide a capacity of at least
35Ălitres.
This diaphragm expansion vessel reduces the frequency and severity of
pressure fluctuations; the service life of the pressure pump is improved
and therefore the operational reliability and service life of system
components is increased.
Damage to the boiler or other system components may result if these
recommendations are not followed.
Carry out the checks in accordance
with manufacturer's instructions.
Limit pressure fluctuations to the
lowest possible differential.
Cyclical pressure fluctuations and
greater pressure differentials
indicate a system fault. Immediately
remedy such faults, otherwise other
heating system components may
become faulty.
5692Ă48 ĂGB

12
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Diaphragm expansion vessels
1. Drain the system or close the cap
valve on the diaphragm expansion
vessel and reduce the pressure,
until the pressure gauge
indicatesĂ" ".
Please note:
The inlet pressure of the
diaphragm expansion vessel (p0)
comprises the static system
pressure (pSt) (= static head)
and a supplement
(p0Ă=ĂpStĂ+Ăsupplement).
The supplement is subject to the
settings of the high limit safety
cut-out.
Depending on the temperature
settings, the following supplements
apply:
H100ĂºC 0.2Ăbar
H110ĂºC 0.7Ăbar
2. If the inlet pressure of the
diaphragm expansion vessel is
lower than the value calculated
acc. to the adjacent formula, top
up with sufficient nitrogen to
achieve this value.
3. Re-fill with water until the filling
pressure is .2Ăhigher than the
inlet pressure of the diaphragm
expansion vessel when the system
is cold.
4. Mark this value on the pressure
gauge as minimum filling
pressure.
5692Ă48 ĂGB

13
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Cleaning the sight glass in the boiler door
Check gasketsĂL and hose
connectionĂMĂfor 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 leaks.
5692Ă48 ĂGB

14
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Checking the ater quality
For water quality requirements, see pageĂ24.
Enter the quantity of top-up water and the respective calcium hydrogen
carbonate concentration [Ca(HCO3)2] into the table.
Fill
water
Top-up
water
Meter
reading
Total
water
Concen-
tration
Water treatment Date
wa
t
er
m3
wa
t
er
m3
rea
di
ng
m3
wa
t
er
volume
m3
t
ra
ti
on
[Ca(HCO3)2]
mol/m3
Medium Metering
volume
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
ććććć
Max. fill volume:Ă Ăm3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692Ă48 ĂGB

15
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Checking the thermal insulation
Check the thermal insulation fit and
adjust if necessary.
Checking the flue cover for leaks
Check flue cover gasketsĂN and
those of clean-out coverĂOĂfor leaks.
Please note:
Condensate and flue gas traces
indicate leaks.
Checking the mixer for easy operation and leaks
1. Remove the motorised lever from
the mixer handle.
2. Check the mixer for easy
operation.
3. Check the mixer for leaks.
Replace the OĆring if the mixer
leaks.
4. Snap the motorised lever into
place.
5692Ă48 ĂGB

16
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Cleaning and reconnecting the condensate drain
¨ĂSafety instructions
Clean the inside of the drain pipe at least annually.
The condensate drain, stench trap, neutralising system and all intermediate
hoses and pipes are part of the condensate drain system.
1. Remove drain hoseĂG to the drain
from condensate drain
connectionĂF.
2. Clean the inside of condensate
drainĂF again with a plastic
brush.
3. Unscrew and flush bottom partĂP
of stench trapĂE, and clean the
inlet connection of stench trapĂE
with a brush.
4. Mount stench trap plugĂEĂon
condensate drainĂFĂand seal in if
necessary.
5. Fill bottom partĂP of the stench
trap with water and fit to the
stench trap.
¨ĂSafety instructions
There is a risk of flue gas escaping
if the stench trap is not filled with
water.
6. Clean the inside of the condensate
drain and the neutralising system.
Neutralising system
operating instructions
7. Replace the spent neutralising
agent.
Neutralising system
operating instructions
5692Ă48 ĂGB

17
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
8. Connect the supply to the
neutralising system with hoseĂD
to stench trapĂEĂ(if necessary seal
in) and ensure the proper draining
of the condensate to the sewer.
Burner adjustment
Observe the burner manufacturer's
instructions.
Service instructions
"MatriX radiant burner"
5692Ă48 ĂGB

18
Parts lists
Parts list
When ordering spare parts:
Quote the manufacturing details (see
type plate) and the item no. of the
required part (as per this parts list).
Obtain common parts from your
local supplier.
Parts
22 Burner cable ć see separate
parts list
2 Fascia
2 1 Front top plate (l.h.)
2 2 Front top plate (r.h.)
2 3 Centre top plate
2 4 Top front plate
2 5 Bottom front panel
2 6 Rear top panel
2 7 Rear bottom panel
2 8 Rear panel (l.h. and r.h. side)
2 9 Side panel ć top
21 Side panel ć bottom
211 Front l.h. rail
212 Front r.h. rail
213 Rear l.h. rail
214 Rear r.h. rail
216 Rear mounting bracket
217 Front insulating casing
218 Centre insulating casing
22 Front insulating mat
221 Double strain relief
222 VitocrossalĂ3 inscription
223 Edge protector
224 Rear insulating mat
Parts not shown
21 Coding card
23 Flame tube seal
3 Insulating pack
3 1 Decorative adhesive tape
3 2 Touch-up spray, Vito silver
3 3 Touch-up paint stick, Vito silver
3 4 Installation instructions
3 5 Service instructions
AType plate ć optionally l.h. or r.h.
side.
BBoiler control unit, see separate
parts list.
5692Ă48 ĂGB

Parts lists
Parts list (cont.)
19/20
5692Ă48 ĂGB
B
2 1
217
2 2
22
218
2 5
221
222
2
2 4
21
2 9
22
21
2 9
224
211
2 8
212
216
214
221
2 3
213
216
2 6
223
223
2 7
A

Parts lists
Parts list (cont.)
21/22
5692Ă48 ĂGB
2
18
15
15
16
721
13
9
17
13
14
1
1211
5
5 6
4
1
23
8