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
5834360

3
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.)
5834360

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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
5834360

5
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
5834360
Information

6
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
5834360
Information

7
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
5834360

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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
5834360

9
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

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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.
Disconnecting cables
C
BA
D
aB]
B
fÖ
fÖ aBH
aB]/
A
/
2.
3.
lÖ
fA
1.
Fig. 4
ABurner cables with plugs fA and lÖ
BPower cable with plug fÖ
CControl unit connecting cable with plug fÖ/aBH
DFlue gas temperature sensors aGA/aGB
1. Disconnect burner cables A from the burner con-
trol unit. Route the cables out of the burner casing.
2. Disconnect cables B to D from the burner and
strain relief, and remove from the burner casing.
3. Remove the gas supply pipe.
4. If available, remove the hose for room sealed oper-
ation.
Commissioning, inspection, maintenance
Opening the boiler door
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Opening the boiler door
6.
5.
Fig. 5
!Please note
Scratches inside the combustion chamber can
lead to corrosion.
Never place tools or other objects inside the
combustion chamber.
Separating the neutralising system, connecting the drain hose
A
BD
E
C
Fig. 6
1. Separate hose A to the neutralising system from
siphon B.
2. Undo siphon B from condensate drain C.
3. Connect drain hose D to condensate drain C and
route it to drainage system E.
4. Clean the combustion chamber and heating surfa-
ces.
Commissioning, inspection, maintenance
Opening the boiler door (cont.)
5834360

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5. Remove drain hose D. Clean condensate
drain C on the inside using a plastic brush.
6. Connect siphon B and hose A.
7. Fill trap B with water (see page 9).
Cleaning the combustion chamber and heating surfaces
Thoroughly clean the combustion chamber and heat-
ing surfaces with a water jet. For this, separate the
neutralising system (if installed) from the boiler and
connect the drain hose. See page 12.
!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 an alkaline clean-
ing agent with surfactant additive (e.g. Fauch
condensing boiler cleaner or Sotin 300).
–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" and "Antox 75 E"
Manufacturer: Hebro Chemie GmbH, Mönchenglad-
bach
www.hebro-chemie.de
"Sotin 300"
Manufacturer: Sotin Chemische und technische Pro-
dukte GmbH & Co., Bad Kreuznach
www.sotin.de
!Please note
Scratches on parts that come into contact with
flue gas can lead to corrosion.
Only use plastic brushes, no wire brushes or
sharp objects.
For normal cleaning, flush the heating surfaces thor-
oughly with a jet of water. For stubborn residues, sur-
face discolouration or soot deposits cleaning agents
may be used.
For this, observe the following:
■Only use solvent-free cleaning agents. Ensure that
no cleaning agent gets between the boiler body and
the thermal insulation.
■Remove soot deposits with an alkaline cleaning
agent 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).
■Remove loose deposits from the boiler; thoroughly
flush the heating surfaces and the flue gas collector
with a water jet.
Cleaning agent manufacturer's instructions
Note
"Fauch 600" and "Antox 75 E"
Manufacturer:
Hebro Chemie GmbH
Rostocker Strasse 40
D-41199 Mönchengladbach
Commissioning, inspection, maintenance
Separating the neutralising system, connecting… (cont.)
5834360

14
Note
Clean the inside of the condensate drain pipe at least
once a year.
AB
C
D
E
Fig. 7
1. Disconnect drain hose C.
2. Clean the inside of the condensate drain pipe
(hose, pipes).
3. Clean the neutralising system (if installed) in
accordance with the manufacturer's instructions.
Neutralising system operating instructions
Note
The neutralising agent can be ordered with part
no. 9521702.
4. Undo and flush lower part D of siphon E.
5. Fill lower part D of siphon E with water and refit.
Check the trap for leaks.
6. Insert 4 quarter-turn rotary latches B. Refit lower
back panel A.
Checking the condensate drain and neutralising system (if installed)
Fill water into the combustion chamber.
Note
The water must flow from the condensate drain pipe
without backing up.
If necessary, clean the condensate drain pipe again.
Checking gaskets and thermal insulation sections
1. Check the gaskets and packing cords in the boiler
door for damage.
2. Check the thermal insulation components on the
boiler door for damage.
3. Replace any damaged components.
Commissioning, inspection, maintenance
Cleaning and reconnecting the condensate drain pipe
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Danger
There is a risk of injury when working on pres-
surised components.
The connections on the heating water side must
only be opened after the boiler has been dep-
ressurised.
Only drain the boiler with a suction pump when
the boiler air vent valve is open.
Note
Also check the connections for the control equipment
and the minimum pressure switch (low water indicator)
for tightness.
Closing the boiler door
1.
2.
18 Nm
Fig. 8
Danger
Leaks can result in a risk of poisoning through
escaping gas.
Before commissioning
■Clean the sealing faces.
■Check gaskets for damage and replace if
required.
■Check the boiler door gasket is seated cor-
rectly and realign the boiler door if necessary.
Checking the filter element in the gas line (if installed); replacing if
necessary
Checking gas connections for tightness
Danger
Escaping gas leads to a risk of explosion.
Always carry out the following steps.
1. Insert new gaskets in all gas fittings that have been
opened and retighten them.
Commissioning, inspection, maintenance
Checking all connections on the heating water side for leaks
5834360

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2. Open the gas shut-off valve.
3. Check the joints in the gas train for leaks using a
gas leak detector.
!Please note
The use of leak detection spray can result in
faulty operation.
Leak detection spray must not come into
contact with electrical contacts.
4. Start the burner (see page 10).
Checking the water quality
Enter the amount of top-up water, the total hardness
and the pH value in the table on page 33.
For water quality requirements, see page 31.
The pH value should be between 8.2 and 9.5.
Checking the function of the safety valves
Checking the temperature controller setting if a building management system
is used (DCC system)
!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.
Checking the expansion vessel and system pressure
Note
Observe the manufacturer's instructions for the dia-
phragm expansion vessel (MAG).
Carry out this test on a cold system.
1. Drain the system until the pressure gauge indi-
cates "0" or close the cap valve on the expansion
vessel and reduce the pressure in the expansion
vessel.
2. If the pre-charge pressure of the expansion vessel
is lower than the static system pressure, top up
with nitrogen until the pre-charge pressure is 0.1 to
0.2 bar (10 to 20 kPa) higher.
3. Top up with water until the charge pressure of the
cooled system is 0.1 to 0.2 bar (10 to 20 kPa)
higher than the pre-charge pressure of the expan-
sion vessel.
Permiss. operating pressure: 5.5 bar (550 kPa)
Commissioning, inspection, maintenance
Checking gas connections for tightness (cont.)
5834360

17
A
B
C
Fig. 9
AClamping clips
BActuator damper
CFlue gas temperature sensor
1. Check the flue gas collector seals for tightness.
Danger
Escaping flue gas poses a risk to health.
Check gaskets on the flue gas collector and
adjust if required.
Note
Check the gaskets at full load operation, for exam-
ple using an inspection mirror, dew point indicator
or thermal image camera. If required, remove the
thermal insulation sections. Traces of condensate
on the outside of the flue gas collector also indicate
a leak.
2. If required, retighten the flue gas collector at the
clamping clips. Tighten screws diagonally to 7 Nm.
Replace the lip seal in the case of leaks.
3. Check the flue gas temperature sensor and plug-in
connection for correct seating.
Note
Repeat the tightness test after approx. 500 hours run;
retighten the screws if necessary. Ensure that the gas-
ket and clamping clip are seated correctly.
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 tightness. In the event of a
leak, replace the O-ring.
4. Snap the motorised lever into place.
Checking the thermal insulation for firm seating
Checking the flue system for leaks
Checking the ventilation air apertures in the installation room (open flue
operation)
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.
Commissioning, inspection, maintenance
Checking the gaskets on the flue gas side
5834360

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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 (cont.)
5834360

19
Vitotronic service instructions
In conjunction with the following control units:
■Vitotronic 100, type CC1E
■Vitotronic 200, type CO1E
■Vitotronic 300, type CM1E
Parameter
Boiler group
Rated heating output of the MatriX cylinder burner in kW Coding card
400 500 630
02 2 2 2 1042
05 0 0 0
08 70 60 75
09 3 4 5
15 11 13 13
0A 33 33 33
Control unit
Setting the codes at the control unit
5834360
Codes

20
Fan pressure monitoring (LDW1)
BA
Fig. 10
AReset button R
BAir pressure switch 1
The switching threshold of air pressure switch 1
(LDW1) is monitored in the fan ramp-up phases and
checked in modulating burner operation. This ensures
a minimum pre-purge.
The air pressure switch triggers a fault shutdown of the
burner control unit under the following circumstances:
■If the static pressure check was unsuccessful after
approx. 5 minutes
■If the air pressure is outside the permiss. range in
the pre-purge phase (tolerance time approx. 5 min.)
■If the air pressure switch fails in control mode or the
air pressure lies outside the permissible range
The fault shutdown is indicated by fault codes "F F5"
and "F F7" on the burner control unit display. Reset
the burner control unit by pressing reset button R.
"MatriX cylinder burner" service instructions
Rated heat-
ing output
Rated heat in-
put
LDW1 setting value
Pmax
(50/30 °C)
Qmax (Hi)
[net cv]
in kW in kW in mbar (kPa)
400 381
2 (0.2) ↑
500 474
630 593
Functions
Air pressure switch
5834360
Functions