Viessmann VITOCROSSAL 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 300
Type CT3B, 187 to 635 kW
Gas condensing boiler
VITOCROSSAL 300
5800357 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
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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.)
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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 Overview of assemblies ......................................................................... 19
Boiler assembly ..................................................................................... 20
Thermal insulation assembly ................................................................. 22
Boiler door assembly ............................................................................. 24
4. Commissioning/service
reports
................................................................................................................ 26
5. Specification ................................................................................................................ 27
6. Disposal Final decommissioning and disposal ..................................................... 30
7. Certificates EU Declaration of Conformity ................................................................ 31
Manufacturer's certificate ....................................................................... 31
8. Keyword index ................................................................................................................ 32
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
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Vitocrossal 300, type CT3B
■Fuel: Natural gas E and natural gas LL
■Rated heating output 187 to 635 kW
■Permissible operating pressure for the heating sys-
tem: 6 bar (0.6 MPa)
Information
Product information
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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 and securing the rotary damper in the flue outlet.................................. 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 boiler and connecting the drain hose.. 10
• • 9. Cleaning the combustion chamber and heating surfaces............................................. 10
• • 10. Checking gaskets and thermal insulation components................................................. 11
• • 11. Checking the sensor well and all connections on the heating water side for leaks.... 11
• • 12. Checking the function of the safety equipment.............................................................. 11
••• 13. Checking the function of the pressure switch................................................................ 11
• • 14. Check the setting for the temperature controller,........................................................... 12
••• 15. Checking the expansion vessel and system pressure................................................... 12
• • 16. Checking the flue gas collector for tightness................................................................. 13
•17. Cleaning the sight glass in the boiler door...................................................................... 13
• • 18. Closing the boiler door...................................................................................................... 14
•19. Checking the thermal insulation....................................................................................... 14
• • 20. Checking the mixer for ease of operation and leaks...................................................... 14
• • 21. Checking the water quality................................................................................................ 15
• • 22. Cleaning and reconnecting the condensate drain system............................................. 15
•23. Checking the installation room ventilation
•24. Checking the flue system for tightness
• • 25. Adjusting the burner.......................................................................................................... 16
•26. Instructing the system user.............................................................................................. 17
•27. Operating and service documents................................................................................... 17
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 15. !Please note Unsuitable water quality can result in damage to
the boiler shell and the heating system.
Observe section "Water quality requirements" on
page 28.
Fully opening and securing the rotary damper in the flue outlet
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
1. Check the heating system pressure.
Danger
For safe operation, a minimum operating
pressure of 0.5 bar (50 kPa) is essential.
A minimum pressure switch can be used to
safeguard this.
Permissible boiler operating pressure:
187 to 314 kW 4 bar (0.4 MPa)
408 to 635 kW 5.5 bar (0.55 MPa)
2. Check that the ventilation of the installation room is
unobstructed.
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 operating instructions
7. Check the function of the neutralising system.
Neutralising system operating instructions
8. Check all gaskets and plugs, and retighten if nec-
essary.
Note
We recommend checking all connections on the
heating water side for tightness after approx.
500 hours run (see page 11).
9. A few days after commissioning, check the boiler
door and retighten the screws (tightening torque
10 Nm).
Danger
Leaks can result in a risk of poisoning
through escaping gas.
Prior to commissioning, check the boiler
door gasket for correct seating and realign if
necessary.
Commissioning, inspection, maintenance
Checking the high limit safety cut-out setting
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Pressure-tight flue systems can generate pulsation
noise regardless of the make of boiler, burner or flue
system. A change of resonance may be affected by
turning the rotary damper fitted into the flue outlet.
D
B
A
E
C
Fig. 1
1. Remove back panel C; for this undo quarter-turn
closures E.
2. Undo nut A on lever B of rotary damper D.
3. Adjust the lever until all pulsation noise has ceased
(the lever mirrors the position of the rotary
damper).
4. Lock the rotary damper with nut A.
5. Remount the back panel.
6. 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 connectors 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 place tools or other objects inside the
combustion chamber.
Commissioning, inspection, maintenance
Minimising pulsation noise
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A
BD
E
C
Fig. 2
1. Separate hose 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 drainage system E.
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
Commissioning, inspection, maintenance
Separating the neutralising system from the boiler and connecting the drain
hose
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1. Check the gaskets and packing cord in the boiler
door for damage.
2. Check the thermal insulation components on the
boiler door for damage.
3. Replace any damaged parts.
Checking the sensor well and all connections on the heating water side for
leaks
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.
Only drain the boiler with a suction pump when
the boiler air vent valve is open.
A B
Fig. 3
1. Undo cap A from the back of the boiler.
2. Check sensor well B for leaks.
3. Secure cap A.
Checking the function of the safety equipment
Check safety valves, water level and pressure limiter in
accordance with manufacturer's details.
Checking the function of the pressure switch
Installation instructions, pressure switch set
Commissioning, inspection, maintenance
Checking gaskets and thermal insulation components
5800357

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if using a building management system (DCC system)
!Please note
Shutting down from full load can result in high
material stress and material damage to the
boiler.
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 TR to at least 10 K below
the mechanical temperature controller TR of the
Vitotronic.
Checking the expansion vessel and system pressure
Note
Observe the information provided by the expansion
vessel manufacturer.
Carry out this test on a cold system.
Pump-controlled pressure maintaining systems
Note
In heating systems with automatic pressure maintain-
ing equipment and/or deaeration systems (operating
according to the pressure reduction method for deaer-
ation), install an expansion vessel (DEV) as individual
boiler protection.
The expansion vessel must have the following mini-
mum size, subject to the boiler output:
■up to 300 kW: 50 l
■up to 500 kW: 80 l
■up to 1000 kW: 140 l
The expansion vessel reduces the frequency and
severity of pressure fluctuations. This improves the
runtime of the pressure maintaining pump and there-
fore increases the operational reliability and service life
of the system components.
Failure to observe these recommendations may
result in damage to the boiler or to other system
components.
Carry out all checks in accordance with the manufac-
turer's instructions. Limit pressure fluctuations to the
lowest possible differential. Cyclical pressure fluctua-
tions and more significant pressure differentials point
towards a system fault. Immediately remedy such
faults, otherwise other heating system components
may be damaged.
Commissioning, inspection, maintenance
Check the setting for the temperature controller,
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Expansion vessels
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.
Supplements are as follows. For high limit safety
cut-out setting
100 °C: 0.2 bar (20 kPa)
110 ºC: 0.7 bar (70 kPa)
2. If the pre-charge pressure of the expansion vessel
is lower than the value calculated according to the
given formula, top up with nitrogen until this value
has been achieved.
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.
Checking the flue gas collector for tightness
A
B
C
Fig. 4
1. Traces of condensate on the outside of the flue
gas collector indicate a leak. The gaskets can also
be checked under full load with an inspection mir-
ror. If required, remove the thermal insulation com-
ponents.
Danger
Escaping flue gas can lead to a health haz-
ard.
Check gaskets on the flue gas collector and
adjust if required.
2. If required, retighten the gasket on tensioning tog-
gles A and on actuator damper B torque-free
(torque 7 Nm).
Note
Repeat the leak test after approx. 500 hours run
and tighten the screws if required. Also ensure that
the gasket and tensioning toggle are correctly
seated.
Cleaning the sight glass in the boiler door
Only with boiler doors for third party burners with vent
facility
Commissioning, inspection, maintenance
Checking the expansion vessel and system… (cont.)
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A
B
Fig. 5
Check gaskets A and hose connection B for leaks.
Danger
Leaks can result in a risk of poisoning through
escaping gas.
Check gaskets carefully.
Closing the boiler door
1. Tighten the screws on the boiler door evenly and
diagonally.
Torque 10 Nm
Danger
Leaks can result in a risk of poisoning
through escaping gas.
Prior to commissioning, check the boiler
door gasket for correct seating and realign if
necessary.
2. Mount the gas supply pipe and check for tightness.
Checking the thermal insulation
Check the thermal insulation for fit and realign if
required.
Checking the mixer for ease of operation and leaks
1. Remove the motorised lever from the mixer han-
dle.
2. Check the mixer for ease of operation.
3. Check the mixer for leaks. In the event of a leak,
replace the O-rings.
4. Click the motorised lever into place.
Commissioning, inspection, maintenance
Cleaning the sight glass in the boiler door (cont.)
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Enter the amount of top-up water and the total hard-
ness of the feed and boiler water into the following
table.
For water quality requirements, see page 28.
Meter reading Fill and top-up water Total water volume Total hardness pH value Date
Feedwater Boiler water
m3m3m3
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 system comprises the conden-
sate drain, siphon, neutralising system and all hoses
and pipes running between them.
Note
Clean the inside of the condensate drain system at
least annually.
Commissioning, inspection, maintenance
Checking the water quality
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A
BD
E
C
Fig. 6
1. Undo drain hose D to drainage system E from
condensate drain C.
2. Clean condensate drain C again from the inside
using a plastic brush.
3. Clean siphon B.
4. Clean the inside of the pipes of the condensate
drain system and the neutralising system.
Neutralising system operating instructions
5. Mount siphon B on condensate drain C and fill
with water.
Note
There is a risk of flue gas escaping if the siphon is
not filled with water.
6. Connect supply line A to siphon B and to the
neutralising system. Ensure the condensate is
draining correctly into the drainage system.
Danger
Escaping flue gas can lead to a health hazard.
To stop flue gas from escaping, always connect
a condensate drain with siphon.
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.)
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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 system users their section for safekeeping.
■Retain the heating contractor's section.
2. File all parts lists, operating and service instruc-
tions in the folder and hand this over to the system
user.
Commissioning, inspection, maintenance
Instructing the system user
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Commissioning, inspection, maintenance
Operating and service documents (cont.)
5800357

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The following details are required when ordering
parts:
■Serial no. (see type plate)
■Assembly (from this parts list)
■Position number of the individual part within the
assembly (from this parts list)
Standard parts are available from your local supplier.
A
B
C
Fig. 7
AType plate
BBoiler assembly
CThermal insulation assembly
Parts lists
Overview of assemblies
5800357

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0006
0014
0006
0005
0004
0003
0005
0008
0004
0002
0007
0005
0013
0011
0012
0009
0010
0001
Fig. 8
Parts lists
Boiler assembly
5800357