Viessmann VITOCROSSAL 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 300
Type CR3B, 787 to 1400 kW
Gas condensing boiler
VITOCROSSAL 300
5692910 GB 9/2018 Please keep safe.

2
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 and fluids can lead to burns or
scalding.
■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
5692910

3
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.)
5692910

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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. Parts lists Ordering parts ........................................................................................ 19
Parts ...................................................................................................... 20
Casing .................................................................................................... 22
Thermal insulation ................................................................................. 24
Miscellaneous ........................................................................................ 26
4. Water quality Water quality requirements .................................................................... 28
■Prevention of damage due to scaling ................................................. 28
■Prevention of damage due to corrosion on the water side ................. 29
5. Commissioning/service
reports
Water quality .......................................................................................... 30
Maintenance/service .............................................................................. 30
6. Specification ................................................................................................................ 32
7. Final decommissioning
and disposal
................................................................................................................ 33
8. Certificates EU Declaration of Conformity ................................................................ 34
Manufacturer's certificate ....................................................................... 34
9. Keyword index ................................................................................................................ 35
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
5692910
Information

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Vitocrossal 300, type CR3B
■Fuel: Natural gas E and natural gas LL
■Rated heating output 787 kW and 1400 kW
■Permissible operating pressure 6 bar (0.6 MPa)
Information
Product information
5692910
Information

7
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Checking the high limit safety cut-out setting................................................................ 8
•2. Filling the heating system with water and venting......................................................... 8
•3. Fully opening the rotary damper in the flue outlet and securing it............................... 8
••• 4. Commissioning the system............................................................................................... 8
•5. Minimising pulsation noise............................................................................................... 9
• • 6. Shutting down the system................................................................................................. 9
• • 7. Opening the boiler door..................................................................................................... 9
• • 8. Separating the neutralising system from the heat exchanger module and
connecting the drain hose................................................................................................. 10
• • 9. Cleaning the combustion chamber and heating surfaces............................................. 10
• • 10. Checking gaskets and thermal insulation components................................................. 10
• • 11. Checking all connections and the sensor well on the heating water side for
tightness............................................................................................................................. 11
• • 12. Checking the function of the safety equipment.............................................................. 12
••• 13. Checking the pressure switch function........................................................................... 12
••• 14. Checking the temperature controller setting if a building management system is
used (DCC system)............................................................................................................ 13
••• 15. Expansion vessel and system pressure ......................................................................... 13
•16. Cleaning the sight glass in the boiler door...................................................................... 14
• • 17. Closing the boiler door...................................................................................................... 14
•18. Checking the thermal insulation....................................................................................... 14
• • 19. Checking the water quality................................................................................................ 14
• • 20. Cleaning and reconnecting the condensate drain system............................................. 14
•21. Checking the installation room ventilation
•22. Checking the flue system for tightness
• • 23. Adjusting the burner.......................................................................................................... 15
• • 24. Checking the flue gas side tightness............................................................................... 16
•25. Instructing the system user.............................................................................................. 16
•26. Operating and service documents................................................................................... 16
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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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 service instructions
Filling the heating system with water and venting
Record the volume filled, water hardness and pH value
on page 30.
Permissible boiler operating pressure: 6 bar (0.6 MPa). !Please note
Unsuitable water quality can result in damage to
the boiler body and the heating system.
Fill the heating system with water and operate it
in accordance with VDI Guideline 2035. The
total of alkaline earths must not exceed
0.02 mol/m3 (total hardness 0.11 °dH).
Observe the "Water quality requirements" on
page 28.
Fully opening the rotary damper in the flue outlet and securing it
The rotary damper must be in the horizontal position. Note
For correct handling of the rotary damper, see "Mini-
mising pulsation noise" on page 9.
Commissioning the system
Operating instructions for control unit, burner
and neutralising system, service instructions for
control unit, and burner manufacturer's docu-
mentation
01. Check the heating system pressure.
Permissible boiler operating pressure: 6 bar
(0.6 MPa)
02. Check that the installation room ventilation is
unobstructed.
03. Check the gas supply pressure.
04. Check that the cleaning aperture on the flue outlet
is closed.
05. Open the gas line shut-off valves.
06. Start the system in this order:
1. Mains isolator
2. Switch for the heating circuit pump
3. ON/OFF switch for the burner
Burner manufacturer's operating instruc-
tions
07. Check the function of the neutralising system and
the hydraulic seal in the trap.
Neutralising system operating instructions
08. Check all gaskets and plugs, and retighten if nec-
essary.
Note
We recommend checking all connections on the
heating water side for leaks approx. every 500
hours run. See page 11.
09. Check the boiler door and cleaning cover a few
days after commissioning and retighten all screws.
10. Tighten the screws at the connecting points with
the following torque:
Boiler door 20 Nm
Flange connections 110 Nm
Module connection 60 Nm
Flue gas collector 7 Nm
Danger
For safe operation, a minimum operating pres-
sure of 0.5 bar (50 kPa) is essential.
For this, a minimum pressure switch can be
used.
Commissioning, inspection, maintenance
Checking the high limit safety cut-out setting
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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.
CB
B
A
Fig. 1
1. Undo M 5 screw A on lever B of the damper
lock.
2. Adjust the lever until no further pulsation noise
occurs. The lever indicates the position of rotary
damper C.
3. Tighten M 5 screw A on lever B of the damper
lock.
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 plugs fA and lÖ from the burner.
3. Close the gas shut-off valve.
Opening the boiler door
Danger
When working with high temperature insulating
materials that contain zirconium or aluminium
silicate ceramic fibres, fibre dust may develop.
This fibre dust can be harmful to health.
Only trained personnel may adjust or replace
the insulation. Wear suitable protective clothing,
especially breathing equipment and safety gog-
gles.
1. Remove the gas supply pipe.
2. Loosen 4 screws on the boiler door and open it.
!Please note
Scratches inside the combustion chamber can
lead to corrosion.
Never place tools or other objects inside the
combustion chamber.
Commissioning, inspection, maintenance
Minimising pulsation noise
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D
C
B
A
Fig. 2
1. Separate hose or pipework A to the neutralising
system from siphon B.
2. Undo siphon B from condensate drain C.
3. Clean condensate drain C on the inside using a
plastic brush.
4. Connect drain hose D to condensate drain C and
route it to a drainage system.
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 cor-
rosion.
Only use plastic brushes, not wire brushes or
sharp objects.
1. Clean the combustion chamber and heating surfa-
ces.
■For normal cleaning, flush the heating surfaces
thoroughly with a jet of water.
■You may use cleaning agents if you notice stub-
born residues, surface discolouration or soot
deposits.
For this, observe the following:
–Only use solvent-free cleaning agents. Ensure
that no cleaning agent gets between the boiler
shell and the thermal insulation.
–Remove soot deposits with alkaline cleaning
agents with surfactant additive (e.g. Fauch
600).
–Remove coatings and surface discolouration
(yellow-brown) with slightly acidic, chloride-free
cleaning agents based on phosphoric acid (e.g.
Antox 75 E).
2. Remove loosened deposits from the boiler. Thor-
oughly flush heating surfaces and the flue gas col-
lector with a jet of water.
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 components
1. Check gaskets and packing cord in the boiler door
for damage.
2. Check thermal insulation components on the boiler
door for damage.
3. Replace any damaged parts.
Commissioning, inspection, maintenance
Separating the neutralising system from the heat exchanger module and
connecting the drain hose
5692910

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A
D
B
E
C
Ø = Ø B -10
Fig. 3
ABoiler door
BFlame tube
CThermal insulation mat
DBurner plate
EThermal insulation block
Check the thermal insulation mat at the flame tube.
The blue side of the thermal insulation mat has to face
the combustion chamber. It must be in close contact
with the flame tube.
Checking all connections and the sensor well on the heating water side for
tightness
Danger
There is a risk of injury when working on pres-
surised components.
Only open the connections on the heating water
side after the boiler has been depressurised.
If draining with a suction pump, only drain the
boiler with the air vent valve open.
Commissioning, inspection, maintenance
Checking gaskets and thermal insulation… (cont.)
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A
B
C
A
A
A
Fig. 4
1. Undo the fixing screws in top panels A. Remove
the panels.
2. Open the thermal insulation of the heat exchanger
module until connecting flange C is freely accessi-
ble.
3. Check connecting flange C, sensor well B and
all connections on the heating water side for tight-
ness.
4. Close the thermal insulation of the heat exchanger
module.
5. Position the top panels and secure with screws.
Note
The gaskets can also be checked under full load with
an inspection mirror. If required, remove the thermal
insulation components.
Checking the function of the safety equipment
Check safety valves, water level and pressure limiter in
accordance with manufacturer's details.
Checking the pressure switch function
Installation instructions, pressure switch set
Commissioning, inspection, maintenance
Checking all connections and the sensor well on… (cont.)
5692910

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!Please note
Shutting down from full load can result in high
material stress and material damage.
If a system with a higher ranking building man-
agement system takes over the temperature
control of the boiler, adjust the settings at the
temperature controller TR. Set the electronic
temperature controller to at least 10 K below the
mechanical temperature controller.
Expansion vessel and system pressure
Note
Observe the information provided by the manufacturer
of the expansion vessel (DEV).
Check when system is cold.
1. Drain the system or close the cap valve on the
expansion vessel and reduce the pressure until the
pressure gauge indicates "0".
Note
The pre-charge pressure of the expansion vessel
(p0) is made up of the static system pressure (pSt)
(= static head) and a supplement (p0 = pSt + sup-
plement).
The supplement depends on the high limit safety
cut-out setting.
Supplement
100 °C: 0.2 bar (20 kPa)
110 °C: 0.7 bar (70 kPa)
2. If the pre-charge pressure of the expansion vessel
is lower than the value calculated using the for-
mula, top up with sufficient nitrogen to achieve this
value.
3. Refill with water until the charge pressure is 0.2
(20 kPa) higher than the pre-charge pressure of
the expansion vessel when the system is cold.
4. Mark this value on the pressure gauge as the mini-
mum charge pressure.
Pump controlled pressure maintaining systems
Note
In heating systems with automatic pressure maintain-
ing equipment or deaeration systems (operating
according to the pressure reduction method for deaer-
ation), we recommend installing an expansion vessel
(DEV) for individual boiler protection.
The expansion vessel must be able to absorb the
expansion volume of the heating water in the boiler.
Minimum size 35 l
This 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
recommendations may result in damage to the
boiler or to other system components.
Check the pressure maintaining system in line with the
manufacturer's instructions. Limit pressure fluctuations
to the lowest possible differential. Cyclical pressure
fluctuations and more significant pressure differentials
point towards a system fault. Remedy such faults
immediately to prevent damage to other components
in the heating system.
Commissioning, inspection, maintenance
Checking the temperature controller setting if a building management system
is used (DCC system)
5692910

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BA
Fig. 5
Check gaskets A and hose connection B for leaks.
Danger
Leaks can result in a risk of poisoning through
escaping flue gas.
Check gaskets carefully.
Closing the boiler door
1. Tighten the screws on the boiler door evenly and
diagonally. Torque: 20 Nm
2. Mount the gas supply pipe and check for tightness.
Checking the thermal insulation
Check the thermal insulation fit and realign if required.
Checking the water quality
Enter the amount of top-up water and the total hard-
ness of the feed and boiler water into the table in the
appendix on page 30.
For water quality requirements, see page 28.
The total hardness of the feed and top-up water must
not exceed the standard values specified by VDI 2035
(see page 28).
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 hoses and pipes between them are part of the con-
densate drain system.
Note
Clean the inside of the condensate drain system at
least annually.
Commissioning, inspection, maintenance
Cleaning the sight glass in the boiler door
5692910

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A
B
C
E
D
Fig. 6
1. Disconnect drain or cleaning hose C.
2. Clean condensate drain A again from the inside
using a plastic brush.
3. Undo and flush lower part E of siphon B. Clean
the inlet connector of siphon B with a brush.
4. Secure siphon B on condensate drain A and
seal in if required.
5. Fill lower section E of the siphon with water and
refit.
Note
If the siphon is not filled with water, flue gas can
escape.
6. Clean the inside of the pipes of the condensate
drain system and the neutralising system.
Neutralising system operating instructions
7. Connect the inlet of the neutralising system to
siphon B using line D (and seal in if necessary).
Ensure proper condensate drain to the drainage
system.
Checking the installation room ventilation
Checking the flue system for tightness
Adjusting the burner
Observe the burner manufacturer's instructions.
Commissioning, inspection, maintenance
Cleaning and reconnecting the condensate drain… (cont.)
5692910

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A
Fig. 7
1. Check flue gas collector A and the boiler body for
tightness.
Note
In full load operation, the gaskets can be checked
with an inspection mirror. If required, remove the
thermal insulation components. Traces of conden-
sate on the outside of flue gas collector A or on
sections of thermal insulation also indicate a leak.
2. If required, tighten flue gas collector A with a tor-
que of 7 Nm or replace the gasket.
Instructing the system user
The system installer should hand the operating instruc-
tions to the system user and instruct the user in oper-
ating the system.
This includes all components installed as accessories,
e.g. remote control units. In addition, the system instal-
ler must make the user aware of the required mainte-
nance work.
Operating and service documents
1. Complete and detach the customer registration
card:
■Hand the system user this part for safekeeping.
■Retain the heating contractor's part.
Commissioning, inspection, maintenance
Checking the flue gas side tightness
5692910

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2. File all parts lists, operating and service instruc-
tions in the folder and hand this over to the system
user.
The installation instructions are no longer required
after the installation and, therefore, do not need to
be retained.
Commissioning, inspection, maintenance
Operating and service documents (cont.)
5692910

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Commissioning, inspection, maintenance
Operating and service documents (cont.)
5692910

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The following information is required:
■Serial no. (see type plate A)
■Position number of the part (from this parts list)
Parts not shown
0300 Fixings
0301 Trim strip (1 roll = 10 m)
0302 Touch-up spray paint, Vitosilver, 150 ml can
0303 Touch-up paint stick, Vitosilver
0304 Vitocrossal 300 installation instructions
0305 Vitocrossal 300 service instructions
0308 Spring clip, short (10 pce)
0310 Flue system collar
0311 Butterfly valve conversion kit
Parts lists
Ordering parts
5692910

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012
011
008
005
010
014
013
012
016
015
004
003
018
006
007
008
009
021
Fig. 8
Parts lists
Parts
5692910