Viessmann VITOCROSSAL 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 300
Type CT3U, 400 to 630 kW
Gas condensing boiler with MatriX cylinder burner
for natural gas E and LL
VITOCROSSAL 300
5834360 GB 1/2019 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
■Relevant country-specific safety regulations
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.
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
Safety instructions
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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.
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
■System examples ............................................................................... 6
Burner .................................................................................................... 6
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 7
3. Control unit Setting the codes at the control unit ...................................................... 19
4. Functions Air pressure switch ................................................................................ 20
■Fan pressure monitoring (LDW1) ....................................................... 20
■Combustion chamber pressure monitoring (LDW2) ........................... 21
5. Parts lists Overview of assemblies ......................................................................... 23
Boiler assembly ..................................................................................... 24
■Cable set assembly ............................................................................ 26
Thermal insulation assembly ................................................................. 28
Parts not shown ..................................................................................... 30
6. Water quality requirements ................................................................................................................ 31
7. Reports Water quality .......................................................................................... 33
8. Specification ................................................................................................................ 34
9. Final decommissioning
and disposal
................................................................................................................ 35
10. Certificates EU Declaration of Conformity ................................................................ 36
Manufacturer's certificate ....................................................................... 36
11. Keyword index ................................................................................................................ 37
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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Information

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Vitocrossal 300, type CT3U
■Gas condensing boiler
–Rated heating output 400 to 630 kW
–For MatriX cylinder burner for natural gas E and LL
■Permissible operating pressure 5.5 bar
System examples
Available system examples: See www.viessmann-
schemes.com.
Burner
Information about commissioning, inspec-
tion and maintenance of the burner
Burner service instructions
Information
Product information
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Information

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Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Note on initial commissioning, inspection and maintenance........................................ 8
•2. Checking the high limit safety cut-out setting................................................................ 8
•3. Filling the heating system with water and venting......................................................... 8
•4. Filling the trap with water.................................................................................................. 9
•5. Checking the gas type....................................................................................................... 9
•6. Changing the gas type....................................................................................................... 9
••• 7. Commissioning the system............................................................................................... 10
••• 8. Checking the flue gas temperature
• • 9. Opening the boiler door..................................................................................................... 11
• • 10. Separating the neutralising system, connecting the drain hose................................... 12
• • 11. Cleaning the combustion chamber and heating surfaces............................................. 13
• • 12. Cleaning and reconnecting the condensate drain pipe.................................................. 14
• • 13. Checking the condensate drain and neutralising system (if installed)......................... 14
• • 14. Checking gaskets and thermal insulation sections........................................................ 14
• • 15. Checking all connections on the heating water side for leaks...................................... 15
• • 16. Closing the boiler door...................................................................................................... 15
• • 17. Checking the filter element in the gas line (if installed); replacing if necessary
••• 18. Checking gas connections for tightness......................................................................... 15
• • 19. Checking the water quality................................................................................................ 16
••• 20. Checking the function of the safety valves
••• 21. Checking the temperature controller setting if a building management system is
used (DCC system)............................................................................................................ 16
• • 22. Checking the expansion vessel and system pressure................................................... 16
• • 23. Checking the gaskets on the flue gas side...................................................................... 17
• • 24. Checking the mixer for ease of operation and leaks...................................................... 17
••• 25. Checking the thermal insulation for firm seating
•26. Checking the flue system for leaks
• • 27. Checking the ventilation air apertures in the installation room (open flue operation)
•28. Instructing the system user.............................................................................................. 17
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Product contains ceramic fibres
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.
Burner inspection and maintenance
Steps and settings that relate to the burner are descri-
bed in separate instructions.
"MatriX cylinder burner" installation and service
instructions
Removing the burner hood
Remove the burner hood to perform any work or make
any adjustments.
OPN CLOSE
1.
2.
Fig. 1
Checking the high limit safety cut-out setting
The high limit safety cut-out must not be set higher
than 110 °C. If required, set it to a maximum of 110 °C.
Control unit installation and service instructions
Filling the heating system with water and venting
Record the fill volume, water hardness and pH value in
the table on page 33. !Please note Unsuitable water quality can result in damage to
the boiler shell and the heating system.
Observe the "Water quality requirements" on
page 31 onwards.
Commissioning, inspection, maintenance
Note on initial commissioning, inspection and maintenance
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AB
Fig. 2
1. Remove lower back panel A. To do so, undo the 4
quarter-turn rotary latches B.
2. Undo the siphon and fill with water, otherwise flue
gas may escape.
3. Check that the condensate can drain freely.
4. Refit the siphon.
Danger
Flue gas escaping from the trap can cause
potentially fatal carbon monoxide poisoning.
Always fill the trap with water before commis-
sioning.
Checking the gas type
1. Check with your gas supply utility regarding the
gas type and Wobbe index (Wo). The boiler can be
operated in the following Wobbe index ranges:
■With natural gas E:
Wobbe index range 12.0 to 16.1 kWh/m3 (43.2 to
58.0 MJ/m3)
■With natural gas LL:
Wobbe index range 10.0 to 13.1 kWh/m3 (36.0 to
47.2 MJ/m3) (not in a and c).
2. If required, convert the burner to a different gas
type in accordance with details provided by your
gas supply utility.
"MatriX cylinder burner" service instructions
Changing the gas type
"MatriX cylinder burner" service instructions
Commissioning, inspection, maintenance
Filling the trap with water
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■Burner service instructions
■Vitotronic operating instructions and service
instructions
■Neutralising system operating instructions
01. Check the heating system pressure. Permissible
boiler operating pressure: 5.5 bar (550 kPa)
02. With open flue operation: Check whether the ven-
tilation measures for the installation room are
designed and open in accordance with regula-
tions.
03. Check the gas supply pressure.
04. Open the gas line shut-off valves.
05. Switch ON the mains isolator (outside the installa-
tion room).
06.
D
C
AB
Fig. 3
Turn on ON/OFF switch B at the programming
unit of the control unit. If fault indicator A on the
control unit illuminates and display C on the
burner control unit flashes, first reset the system.
For this, press reset button D on the burner con-
trol unit.
Note
During commissioning, the appliance can enter a
fault state if there are still airlocks in the gas line.
■Purge the gas line again.
■Reset burner.
07. Adjust the codes on the boiler control unit in
accordance with the table on page 19.
Vitotronic installation and service instruc-
tions
08. Check the function of the neutralising system and
the hydraulic seal in the trap.
Neutralising system operating instructions
09. 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 15.
10. Check the boiler door and flue gas collector a few
days after commissioning and retighten all screws.
Torque: Boiler door 18 Nm
Torque: Flue gas collector 7 Nm
Danger
For safe operation, a minimum operating pres-
sure of 0.5 bar (50 kPa) is absolutely essential.
A minimum pressure switch/limiter can be used
to safeguard this.
Checking the flue gas temperature
Commissioning, inspection, maintenance
Commissioning the system
5834360