Viessmann VITOCROSSAL 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 300
Type CU3A
Gas condensing boiler with MatriX gas burner and Lambda Pro Con-
trol,
Natural gas and LPG version
open and balanced flue operation
For applicability, see the last page
VITOCROSSAL 300
5692 860 GB 6/2010 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
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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.)
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Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 6
Further details regarding the individual steps....................................................... 8
Code 1
Calling up coding level 1...................................................................................... 56
General................................................................................................................. 57
Boiler.................................................................................................................... 58
DHW..................................................................................................................... 59
Solar..................................................................................................................... 60
Heating circuit 1, heating circuit 2, heating circuit 3............................................. 61
Code 2
Calling up coding level 2...................................................................................... 67
General................................................................................................................. 67
Boiler.................................................................................................................... 75
DHW..................................................................................................................... 76
Solar..................................................................................................................... 77
Heating circuit 1, heating circuit 2, heating circuit 3............................................. 84
Diagnosis and service scans
Calling up the service menu................................................................................. 91
Diagnosis.............................................................................................................. 91
Checking outputs (actuator test).......................................................................... 93
Troubleshooting
Fault display......................................................................................................... 95
Fault codes........................................................................................................... 96
Repairs................................................................................................................. 105
Function description
Weather-compensated control unit...................................................................... 113
Internal extensions (accessories)......................................................................... 114
External extension (accessory)............................................................................ 116
Control functions.................................................................................................. 118
Allocating heating circuits to the remote control................................................... 125
Electronic combustion controller.......................................................................... 125
Designs
Internal connection diagram................................................................................. 127
External connection diagram................................................................................ 130
Parts lists............................................................................................................ 132
Index
Index
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Commissioning/service reports........................................................................ 138
Specification....................................................................................................... 143
Certificates
Declaration of conformity...................................................................................... 144
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 144
Keyword index.................................................................................................... 145
Index
Index (cont.)
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system and checking the supply of
ventilation air.................................................................. 8
•2. Filling siphon with water................................................ 9
•3. Checking the power supply
•4. Changing the language (if required)............................. 9
• • 5. Setting the time and date (if required).......................... 10
•6. Designating the heating circuits................................... 10
• • 7. Checking the gas type.................................................... 10
••• 8. Removing the front panel.............................................. 11
•9. Gas type conversion (only for operation with LPG).... 12
••• 10. Function sequence and possible faults....................... 12
••• 11. Checking the static and supply pressure..................... 14
•12. Setting the maximum output......................................... 16
•13. Checking the balanced flue system tightness (annular
gap check)....................................................................... 17
•14. Removing the burner and checking the burner
gasket.............................................................................. 18
•15. Checking burner gauze assembly and thermal
insulation block.............................................................. 19
•16. Checking and adjusting the ignition and ionisation
electrodes........................................................................ 21
• • 17. Separating the neutralising system (if installed) from
the boiler and connecting the drain hose.................... 22
• • 18. Cleaning the combustion chamber and heating
surfaces........................................................................... 22
• • 19. Cleaning and reconnecting the condensate drain
system............................................................................. 23
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
• • 20. Checking that the condensate drain and neutralising
system (if installed) are not obstructed and that they
are free from leaks.......................................................... 24
• • 21. Checking gaskets and thermal insulation
components on the boiler.............................................. 25
• • 22. Checking the diaphragm expansion vessel and
system pressure............................................................. 26
• • 23. Checking the water quality............................................ 27
• • 24. Checking the mixer for obstructions and leaks........... 27
••• 25. Checking all connections on the heating water side
and DHW side for leaks
••• 26. Checking the function of safety valves
•27. Fitting the burner............................................................ 28
••• 28. Checking firm seating of electrical connections
••• 29. Checking all gas equipment for tightness at operating
pressure........................................................................... 29
• • 30. Checking the combustion quality................................. 29
• • 31. Checking the ventilation air apertures in the
installation room (only for open flue operation)
••• 32. Checking the external LPG safety valve (if installed)
•33. Matching the control unit to the heating system......... 30
•34. Adjusting the heating curves........................................ 49
•35. Connecting the control unit to the LON....................... 52
•36. Scanning and resetting the "Service" display............. 54
••• 37. Fitting the front panel..................................................... 55
•38. Instructing the system user........................................... 55
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
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Filling the heating system and checking the supply of ventilation
air
!Please note
Unsuitable fill water increases the level of deposits and corrosion and may
lead to boiler damage.
■ Thoroughly flush the entire heating system prior to filling it with water.
■ Only use fill water of potable quality.
■ Fill water, the hardness of which exceeds the following values, must be
softened, for example with a small softening system for heating water (see
Vitoset pricelist):
–Vitocrossal 300 up to 45 kW: 16.8 °dH (3.0 mol/m3)
–Vitocrossal 300 from 60 kW: 11.2 °dH (2.0 mol/m3)
■ An antifreeze additive suitable for heating systems can be added to the fill
water. The antifreeze manufacturer must verify its suitability, since other-
wise damage to gaskets and diaphragms can occur as well as noise during
heating operation. Viessmann accepts no liability for damage or conse-
quential damage.
1. Check whether the ventilation air
supply is unrestricted.
2. Check the pre-charge pressure of the
diaphragm expansion vessel when
the system is still cold.
Note
If the pre-charge pressure of the dia-
phragm expansion vessel is lower
than the static pressure of the sys-
tem, top up with nitrogen until the pre-
charge pressure (0.1 to 0.2 bar) is
higher than the static system pres-
sure. The static pressure corre-
sponds to the static head.
3. Open any installed check valves.
4. Fill the heating system with water and
vent it, until the fill pressure (0.1 to 0.2
bar) is higher than the pre-charge
pressure of the diaphragm expansion
vessel.
Permiss. operating pressure: 3 bar
Min. operating pressure: 1 bar
Commissioning, inspection, maintenance
Further details regarding the individual steps
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5. Mark the set pressure at pressure
gauge A.
6. Record the fill volume, water hard-
ness and pH value on page 27.
Note
Observe the "Water quality require-
ments" on page 139.
7. Return the check valves to their oper-
ating position.
Filling siphon with water
1. Undo fitting A of siphon B, remove
the siphon and fill it with water.
Note
There is a risk of flue gas escaping if
the siphon is not filled with water.
2. Refit siphon B.
Changing the language (if required)
Note
At the commissioning stage, the display
is in German (default setting)
Extended menu:
1. å
2. "Settings"
3. "Language"
Sprache
Cesky CZ
Deutsch DE
Dansk
English
DK
GB
Wählen mit
Ø
ç
4. Set the required language with /.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Setting the time and date (if required)
During commissioning, or after pro-
longed time out of use, the time and date
need to be reset.
Extended menu:
1. å
2. "Settings"
3. "Time / Date"
4. Set current time and date.
Designating the heating circuits
In the delivered condition, the heating
circuits are designated "Heating circuit
1", "Heating circuit 2" and "Heating
circuit 3" (if installed).
If the system user prefers, the heating
circuits can be designated differently to
suit the specific system.
Enter names for heating cir-
cuits:
Operating instructions
Checking the gas type
The boiler is equipped with an electronic combustion controller that adjusts the burner
for optimum combustion in accordance with the prevailing gas quality.
■ Consequently, for natural gas there is no adjustment required across the entire
Wobbe index range.
The boiler can operate in the Wobbe index range 9.5 to 15.2 kWh/m3(34.2 to
54,7 MJ/m3).
■ Convert the burner for operation with LPG (see "Gas type conversion" on
page 12).
1. Determine the gas type and Wobbe
index by asking your local gas supply
utility or LPG supplier.
2. Only possible on appliances with
26 and 35 kW.
Convert the burner for operation with
LPG (see page 12).
3. Record the gas type in the report on
page 138.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Removing the front panel
2.
1.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Gas type conversion (only for operation with LPG)
1
2
1. Only possible on appliances with
26 and 35 kW.
Set adjusting screw A on the gas
train to "2".
2. Turn ON/OFF switch 8 ON.
3. Select the gas type in coding address
"82".
■ Call up code 2.
■"General"
■ In coding address "11", select
value "9".
■ In coding address "82", select
value "1" (LPG operation).
■ Set code "11" value unequal "9".
■ End service functions.
4. Open the gas shut-off valve.
5. Affix label "G31" (supplied with the
technical documentation) below the
type plate on the side panel.
Function sequence and possible faults
Display Measures
Control unit
issues a heat
demand
no Increase set value
and ensure heat is
drawn off
yes
Fan starts no After approx. 51 s
fault F9
Check the fan, fan
connecting cables,
power at the fan
and fan control
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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yes
Ignition no Fault EE Check the ignition
module (control
voltage 230 V
across plugs
"X2.1" and "X2.2")
yes
Gas train opens no Fault EE Check the gas train
(control voltage
230 V); check the
gas supply pres-
sure
yes
Ionisation current
builds
Symbol A
no Fault EE Check the ionisa-
tion electrode
adjustment and the
gas line for air-
locks
yes
Burner in opera-
tion
no Stops below the
set boiler water
temperature and
restarts immedi-
ately
Check the flue gas
system for tight-
ness (flue gas
recirculation),
check the gas flow
pressure
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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yes
Automatic calibra-
tion of the com-
bustion controller
no
Fault E3 Ensure adequate
heat transfer.
Press reset button
R.
Fault Eb Check gap
between ionisation
electrode and
burner gauze
assembly.
Check allocation of
gas type (coding
address 82, gas
train setting).
Check flue system;
remedy flue gas
recirculation if
required.
Press reset button
R.
For further details on faults, see
page 95.
Checking the static and supply pressure
Danger
CO build-up as a result of an incorrect burner adjustment can have serious
health implications.
Carry out a CO test before and after work on gas equipment.
Operation with LPG
Flush the LPG tank twice during commissioning/replacement. Vent the tank and gas
supply line thoroughly after flushing.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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1. Close the gas shut-off valve.
2. Release screw A inside test nipple
"PE" on the gas train, but do not
remove it; then connect the pressure
gauge.
3. Open the gas shut-off valve.
4. Measure the static pressure and
record it in the service report on
page 138.
Set value: max. 57.5 mbar.
5. Start the boiler.
Note
During commissioning, the boiler can
enter a fault state because of airlocks
in the gas line. After approx. 5 s press
reset button R to reset the burner.
6. Check the supply (flow) pressure.
Set value:
■ Natural gas: 20 mbar
■ LPG: 50 mbar
Note
Use suitable test equipment with a
resolution of at least 0.1 mbar for test-
ing the supply pressure.
7. Record the actual value in the report
on page 138.
Take the action shown in the follow-
ing table.
8. Shut down the boiler, close the gas
shut-off valve, remove the pressure
gauge and close test nipple A with
the screw.
9. Open the gas shut-off valve and start
the appliance.
Danger
Gas escaping from the test
nipple leads to a risk of explo-
sion.
Check gas tightness at test
nipple A.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Supply pressure (flow pressure) Measures
for natural gas for LPG
below 17.4 mbar below 42.5 mbar Do not start the boiler. Notify your gas
supply utility or LPG supplier.
17.4 to 25 mbar 42.5 to 57.5 mbar Start the boiler.
above 25 mbar above 57.5 mbar Install a separate gas pressure governor
upstream of the system and regulate the
pre-charge pressure to 20 mbar for natu-
ral gas or 50 mbar for LPG. Notify your
gas supply utility or LPG supplier.
Setting the maximum output
You can limit the maximum output for heating operation. The limit is set via the
modulation range. The max. adjustable output is limited upwards by the boiler coding
card.
1. Press OK and å simultaneously
for approx. 4 s.
2. "Service functions"
3. "Max. output"
4. "Change?" Select "Yes".
A value flashes on the display (e.g.
"85"). In the delivered condition, this
value represents 100 % of rated out-
put.
5. Set the required value.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the balanced flue system tightness (annular gap
check)
ACombustion air aperture
For balanced flue systems tested
together with the wall mounted gas fired
boiler, the requirement for a tightness
test during commissioning by the flue
gas inspector is not applicable.
We recommend that your heating engi-
neer carries out a simple leak/tightness
test during the commissioning of your
system. For this, it would be sufficient to
check the CO2 or O2 concentration in the
combustion air at the annular gap of the
balanced flue pipe.
The flue pipe is deemed to be gas-tight
if the CO2 concentration in the combus-
tion air is no higher than 0.2 % or the
O2 concentration is at least 20.6 %.
If actual CO2 values are higher or O2 val-
ues are lower, then pressure test the flue
pipe with a static pressure of 200 Pa.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 860 GB

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Removing the burner and checking the burner gasket
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 860 GB

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1. Switch OFF the main power supply
and the ON/OFF switch at the control
unit.
2. Close the gas shut-off valve and safe-
guard against reopening.
3. Pull power cables from fan motor
H, gas valve C and ionisation elec-
trode D. Pull plug G.
4. Undo fitting on gas supply pipe E
and pull ventilation air adaptor A.
5.
Undo four nuts B and remove burner
F, then hook it into its service
retainer L.
!Please note
Prevent damage to the
burner.
Always hook the burner into its
service retainer.
6. Check burner gasket K for possible
damage; replace if necessary.
Checking burner gauze assembly and thermal insulation block
Replace the burner gauze assembly if the wire mesh is damaged.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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1. Remove electrodes A.
2. Undo four nuts D and remove fan
with gas valve C.
3. Release three nuts B and remove
burner gauze assembly H.
4. Remove thermal insulation block F
with thermal insulating mat E.
5. Remove old burner gauze assembly
gasket G.
6. Check thermal insulation block F for
damage and replace, if required.
7. Insert thermal insulating mat E and
thermal insulation block F accord-
ing to the electrode position.
Note
Observe the positioning aid on the
thermal insulation block.
8. Insert new burner gauze assembly
H with new gasket G and secure
with three nuts.
Torque: 5 Nm
9. Fit the fan with the gas valve.
Torque: 5 Nm
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 860 GB