Viessmann VITOCROSSAL 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 300
Type CM3, 87 to 142 kW
Gas condensing boiler
For applicability, see the last page
VITOCROSSAL 300
5692 501 GB 11/2014 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 author-
ised contractors.
■Work on gas installations must only be carried out by
a registered gas fitter.
■Work on electrical equipment must 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 the protection of the envi-
ronment
■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-TR Gas, 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.
Danger
Hot surfaces can cause burns.
■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 your
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 for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Never smoke. Prevent naked flames and
sparks. Never switch lights or electrical appli-
ances on or off.
■Close the gas shut-off valve.
■Open windows and doors.
■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).
Safety instructions
Safety instructions
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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.
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 causes. Ensure an adequate supply of
combustion air.
Instruct system users that subsequent modifications to
the structural conditions 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.
Apertures for supplying combustion air must be
non-closable.
Extractors
Operating appliances that route exhaust air outdoors
(cooker hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to reverse flow of the
flue gas.
Danger
The simultaneous operation of the boiler and
appliances that route exhaust air outdoors can
result in life threatening poisoning due to
reverse flow of the flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5692 501 GB

4
1. Information Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 6
3. Parts lists Ordering parts ........................................................................................ 13
Thermal insulation ................................................................................. 14
Boiler ...................................................................................................... 16
4. Commissioning/service
reports
.................................................................................................................. 18
5. Specification .................................................................................................................. 19
6. Certificates Declaration of conformity ....................................................................... 22
Manufacturer's certificate according to the 1st BImSchV [Germany] .... 22
7. Keyword index .................................................................................................................. 23
Index
Index
5692 501 GB

5
Symbol Meaning
Reference to other document containing
further information
Additional information, not safety relevant
1.
Step:
The numbering corresponds to the se-
quence of work.
The work sequences for commissioning, inspection
and maintenance are summarised in the chapter
"Commissioning, inspection and maintenance "and are
marked as follows:
Symbol Meaning
Work sequences required during commis-
sioning
Not required during commissioning
Work sequences required during inspec-
tion
Not required during inspection
Work sequences required during mainte-
nance
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. It is only designed for the heating of water that is
of potable water quality.
Intended use presupposes that a fixed installation in
conjunction with permissible, system-specific compo-
nents has been carried out.
Commercial or industrial usage for a purpose other
than heating the building or DHW shall be deemed
inappropriate.
Any usage beyond this must be approved by the man-
ufacturer in each individual case.
Incorrect usage or operation of the appliance (e.g. the
appliance being opened by the system user) is prohibi-
ted and will result in an exclusion of liability. Incorrect
usage also occurs if the components in the heating
system are modified from their intended use (e.g. if the
flue gas and ventilation air paths are sealed).
Information
Symbols
5692 501 GB
Information

6
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Checking the high limit safety cut-out setting................................................................ 7
•2. Filling the heating system with water and venting the system...................................... 7
•3. Filling the trap with water.................................................................................................. 7
••• 4. Commissioning the system............................................................................................... 7
• • 5. Shutting down the system................................................................................................. 8
• • 6. Opening the boiler door..................................................................................................... 8
• • 7. Separating the neutralising system (if installed) from the boiler and connecting the
drain hose........................................................................................................................... 8
• • 8. Cleaning the combustion chamber and heating surfaces............................................. 8
• • 9. Checking components exposed to flue gas for corrosion damage
• • 10. Checking the gaskets, packing cords and thermal insulation components of the
boiler door........................................................................................................................... 9
• • 11. Checking gaskets and thermal insulation components on the boiler.......................... 10
••• 12. Checking the function of safety valves
• • 13. Checking the mixer for ease of operation and tightness............................................... 10
• • 14. Checking the water quality................................................................................................ 10
• • 15. Cleaning and reconnecting the condensate drain system............................................. 11
• • 16. Checking the condensate drain and the neutralising system (if installed).................. 12
••• 17. Closing the boiler door...................................................................................................... 12
• • 18. Checking the installation room ventilation
• • 19. Checking the flue system for tightness
• • 20. Adjusting the burner.......................................................................................................... 12
•21. Instructing the system user.............................................................................................. 12
•22. Operating and service documents................................................................................... 12
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 the system
Enter the amount of water charged, water hardness
and pH value into the table on page 11.
Permissible boiler operating pressure: 4 bar (0.4 MPa)
Minimum operating pressure: 0.5 bar (50 kPa)
Note
The minimum operating pressure is essential for safe
operation. The minimum operating pressure can be
ensured with a minimum pressure switch (one per sys-
tem for multi boiler systems).
!Please note
Unsuitable water quality can result in damage to
the boiler shell and the heating system.
Observe section "Water quality requirements" on
page 20.
Filling the trap with water
Fig.1
1. Undo the trap and fill it with water.
!Please note
Risk of escaping flue gas.
Fill the trap with water.
2. Check that the condensate can drain freely.
3. Remount the trap.
Commissioning the system
Control unit operating and service instructions,
burner and neutralising system, as well as docu-
mentation from the burner manufacturer
1. Check the heating system pressure.
Permissible boiler operating pressure: 4 bar
(0.4 MPa)
Minimum operating pressure: 0.5 bar (50 kPa)
Note
The minimum operating pressure is essential for
safe operation. The minimum operating pressure
can be ensured with a minimum pressure switch
(one per system for multi boiler systems).
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
Commissioning, inspection, maintenance
Checking the high limit safety cut-out setting
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7. Check the function of the neutralising system.
Neutralising system operating instructions
8. Check all gaskets and plugs, and retighten if neces-
sary.
Note
We recommend you check all connections on the
heating water side for leaks around every 500
hours run.
9. Check the boiler door and cleaning cover a few
days after commissioning and retighten all screws.
Shutting down the system
1. Isolate the system from the power supply and safe-
guard against re-connection.
2. Pull plug 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 6 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.
Separating the neutralising system (if installed) from the boiler and
connecting the drain hose
C
B
A
Fig.2
1. Separate hose A to the neutralising system from
trap B.
2. Remove trap B from the condensate drain.
3. Clean the inside of the condensate drain with a
plastic brush.
4. Connect drain hose C to the condensate drain.
Connect drain hose C to the on-site drain connec-
tion.
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.
Commissioning, inspection, maintenance
Commissioning the system (cont.)
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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 components exposed to flue gas for corrosion damage
Checking the gaskets, packing cords and thermal insulation components of
the boiler door
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.
Commissioning, inspection, maintenance
Cleaning the combustion chamber and heating… (cont.)
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A
B
C
D E
Fig.3
1. Check flue gas collector seal A between flue gas
collector C and boiler body B for tightness.
2. Check lip seal D on the boiler flue connection for
tightness.
Note
■The gaskets can also be checked under full load
with an inspection mirror. If required, remove the
thermal insulation components.
■Traces of condensate on the outside of flue gas
collector C indicate a leak.
3. If required, retighten flue gas collector seal A at
tensioning toggles E or replace. Replace lip seal
D if it leaks.
4. Check fittings on the water side for tightness. If
required replace the gaskets.
Danger
There is a risk of injury when working on
pressurised components.
■Only open the connections on the heating
water side after the boiler has been depres-
surised.
■Only drain the boiler with a suction pump
when the boiler air vent valve is open.
5. Check the boiler thermal insulation for good fit. Cor-
rect if required or replace if it is damaged.
Checking the function of safety valves
Checking the mixer for ease of operation and tightness
1. Remove the motorised lever from the mixer handle.
2. Check the mixer for ease of operation.
3. Check the mixer for leaks. Replace the O-rings if
the mixer leaks.
4. Snap the motorised lever into place.
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.
For water quality requirements, see page 20.
Commissioning, inspection, maintenance
Checking gaskets and thermal insulation components on the boiler
5692 501 GB

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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 20).
The pH value should be between 8.2 and 9.5.
Cleaning and reconnecting the condensate drain system
The condensate drain, trap, neutralising system (if
installed) and all intermediate hoses and pipes are part
of the condensate drain system.
Note
Clean the inside of the condensate drain system at
least annually.
B
A
C
D
Fig.4
1. Undo and flush lower part A of trap B. Clean the
inlet connector of trap B with a brush.
2. Fill lower section A of the trap with water and refit.
Commissioning, inspection, maintenance
Checking the water quality (cont.)
5692 501 GB

12
3. Clean the neutralising system (if installed) in
accordance with the manufacturer's instructions.
Neutralising system operating instructions
Note
The neutralising agent can be obtained by quoting
part no. 9524 670.
4. Pull off hose C and fit trap B to the condensate
drain.
5. Refit hose D of the neutralising system to the trap.
Checking the condensate drain and the neutralising system (if installed)
Add water to the combustion chamber.
The water must flow from the condensate drain pipe
without back pressure.
If necessary, clean the condensate drain pipe again.
Closing the boiler door
1. Tighten the screws on the boiler door evenly and
diagonally.
2. Mount the gas supply pipe and check for tightness.
Checking the installation room ventilation
Checking the flue system for tightness
Adjusting the burner
Observe the burner manufacturer's instructions.
Instructing the system user
The installer should instruct the user in the operation of
the system.
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 instructions
in the folder and hand this over to the system user.
Commissioning, inspection, maintenance
Cleaning and reconnecting the condensate drain… (cont.)
5692 501 GB

13
The following details are required when ordering parts:
■Serial no. (see type plate A)
■Assembly (from this parts list)
■Position number of the individual part within the
assembly (from this parts list)
Parts not shown
Pos. Part
300 Decorative adhesive tape
301 Touch-up spray paint, Vitosilver
302 Touch-up paint stick, Vitosilver
303 Installation instructions
304 Service instructions
Parts lists
Ordering parts
5692 501 GB
Components

14
210
201
200
A
B
202
202
211
206
203
Fig.5
AType plate
BBoiler control unit, see separate parts list
Parts lists
Thermal insulation
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Components

15
Pos. Part
200 Fascia
201 Top panel
202 Side panel, l.h. and r.h. side
203 Front panel
206 Thermal insulation mat, front
210 Vitocrossal 300 logo
211 Edge protector
Parts lists
Thermal insulation (cont.)
5692 501 GB
Components

16
211
001
204207
209
004
005
003003
003
208
209
002
209
205209
Fig.6
Parts lists
Boiler
5692 501 GB
Components

17
Pos. Part
001 Flue gas collector
002 Flue gas collector gasket
003 Adjustable foot
004 Trap
005 Flue gasket
204 Back panel
205 Thermal insulation jacket
207 Thermal insulation mat, back
208 Cover plate, bottom
209 Thermal insulation fixings
Parts lists
Boiler (cont.)
5692 501 GB
Components

18
Commissioning Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Service Service Service
date:
by:
Commissioning/service reports
Commissioning/service reports
5692 501 GB
Appendix

19
Rated heating output range
TF/TR = 50/30 °C kW 29 to 87 38 to 115 47 to 142
TF/TR = 80/60 °C kW 27 to 80 35 to 105 43 to 130
Rated heating input range kW 27 to 82 36 to 108 45 to 134
Product ID CE-0085 BN 0569
Connection/supply values*1
Relative to max. load
■Natural gas E m3/h 8.7 11.4 14.2
■Natural gas LL m3/h 10.1 13.3 16.5
Product parameters (according to EnEV)
Efficiency η
■At 100 % rated heating output % 97.2 97.5 97.6
■At 30 % rated heating output % 108.0 108.1 107.6
Standby loss qB,70 % 0.6 0.5 0.4
Power consumption
■At 100 % rated heating output W 369 420 465
■At 30 % rated heating output W 123 140 155
*1 The connection/supply values are only for reference (e.g. in the gas contract application) or for a supplementary, rough esti-
mate to check the volumetric settings. Due to factory settings, the gas pressure must not be altered from these values. Ref-
erence: 15 °C, 1013 mbar (101.3 kPa)
Specification
Specification
5692 501 GB
Appendix

20
Note
Observing the following requirements is necessary to
safeguard your warranty rights.
The warranty excludes damage due to corrosion and
scaling.
Prevention of damage due to scaling
Prevent excessive scale build-up (calcium carbonate)
on the heating surfaces. For heating systems with
operating temperatures up to 100 °C, VDI Guideline
2035 Part 1 "Prevention of damage in water heating
installations - Scale formation in domestic hot water
supply installations and water heating installations"
applies together with the following standard values.
See the explanations in the original text of the Guide-
line.
Total heating output
kW
Total alkaline earths
mol/m3
Total hardness
°dH
≤ 50 ≤ 3.0 ≤ 16.8
> 50 to ≤ 200 ≤ 2.0 ≤ 11.2
> 200 to ≤ 600 ≤ 1.5 ≤ 8.4
> 600 < 0.02 < 0.11
The standard values assume the following:
■The total volume of fill and top-up water will not
exceed three times the water content of the heating
system during its service life.
■The specific system volume is less than 20 l/kW
heating output. In multi boiler systems, apply the out-
put of the smallest boiler.
■All measures to prevent corrosion on the water side
in accordance with VDI 2035 Part 2 have been
implemented.
Soften the fill and top-up water in heating systems
operating under the following conditions:
■The total of alkaline earths in the fill and top-up water
exceeds the standard value.
■Higher fill and top-up water volumes are expected.
■The specific system volume is greater than 20 l/kW
heating output. In multi boiler systems, apply the out-
put of the smallest boiler.
■In systems > 50 kW, install a water meter to capture
the amount of fill and top-up water. Enter the volume
of fill water and the water hardness into the boiler
maintenance checklists.
■For systems with a specific system volume greater
than 20 l/kW heating output, apply the requirements
of the next higher category of total heating output (in
accordance with the table). In multi boiler systems,
apply the output of the smallest boiler. In the case of
severe overshoot (> 50 l/kW), soften the water down
to a total of alkaline earths of ≤ 0.02 mol/m3.
Operating information:
■During expansion or repair work, only drain the pipe-
work sections necessary.
■Check, clean and activate filters, dirt traps and other
blow-down or separating facilities in the heating
water circuit frequently after commissioning and in
new installations. Thereafter check and maintain
these facilities as required, depending on the type of
water treatment applied (e.g. water softening).
■No further steps are required during commissioning
if you fill the heating system with fully softened
water.
If the heating system is charged, not with fully soft-
ened water, but with water that meets the require-
ments in the above table, also observe the follow-
ing during commissioning:
■Commission the system step by step with a high
heating water flow rate, starting with the lowest boiler
output. This prevents localised concentration of lime-
scale deposits on the boiler heating surfaces.
■In multi boiler systems, start all boilers simultane-
ously to prevent the entire limescale deposit settling
in the heat exchanger of just one boiler.
■Where water treatment is required, treat even the
first fill of the heating system prior to commissioning.
This also applies to any subsequent filling, e.g. when
adding top-up water or after a repair, or for any sys-
tem expansion.
The build-up of limescale deposits on the heating sur-
faces will be minimised if these instructions are fol-
lowed.
Water quality requirements
5692 501 GB
Appendix