Viessmann VITOCROSSAL 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 300
Type CT3B, 187 to 635 kW
Gas condensing boiler
For applicability, see the last page
VITOCROSSAL 300
5614 461 GB 1/2014 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively inten-
ded for qualified 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 elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system:
■ Statutory regulations regarding the
prevention of accidents
■ Statutory regulations regarding envi-
ronmental protection
■ The Code of Practice of 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
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Do not smoke. Prevent naked
flames and sparks. Do not
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
supplier and your local heating
contractor from outside the
building.
■ Shut off the electricity supply to
the building 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 threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the installation site.
■ Close all doors in the living
space.
Flue systems and combustion air
Ensure that flue systems are clear and
cannot be sealed, for instance due to
accumulation of condensate or other
causes. Ensure a sufficient supply of
combustion air.
Instruct system users that subsequent
modifications to the building characteris-
tics are not permissible (e.g. cable/pipe-
work routing, cladding or partitions).
Danger
Leaking or blocked flue systems,
or an insufficient supply of com-
bustion air can cause life threat-
ening poisoning from carbon
monoxide in the flue gas.
Ensure the flue system is in
proper working order. Apertures
for supplying combustion air
must be non-closable.
Extractors
Operating appliances that extract air to
the outside (cooker hoods, extractors, air
conditioning units, etc.) can create neg-
ative 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
extract air to the outside can
result in life threatening poison-
ing due to reverse flow of the flue
gas.
Fit an interlock circuit or take suit-
able steps to ensure a sufficient
supply of combustion air.
Working on the system
■ Where gas is used as the fuel, close
the main gas shut-off valve and safe-
guard it against unintentional reopen-
ing.
■ Isolate the system from the power sup-
ply (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 recon-
nection.
Danger
Hot surfaces can cause burns.
■ Before maintenance or service
work, switch OFF the appli-
ance 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 electrostatic dis-
charge.
Before beginning work, touch
earthed objects, such as heating
or water pipes, to discharge static
loads.
Safety instructions
Safety instructions (cont.)
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Repair work
!Please note
Repairing components that fulfil a
safety function can compromise
the safe operation of the sys-
tem.
Faulty components must be
replaced with original Viessmann
spare parts.
Auxiliary components, spare and
wearing parts
!Please note
Spare and wearing parts that
have not been tested together
with the system can compromise
its function. Installing non-author-
ised components and making
non-approved modifications or
conversions can compromise
safety and may invalidate the
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5614 461 GB

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Product information
Intended use......................................................................................................... 6
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 7
Further details regarding the individual steps....................................................... 9
Parts lists
Overview of the assemblies................................................................................. 22
Boiler assembly.................................................................................................... 23
Thermal insulation assembly................................................................................ 27
Boiler door assembly for third party burners........................................................ 31
Commissioning/service reports........................................................................ 33
Specification....................................................................................................... 34
Certificates
Declaration of Conformity..................................................................................... 38
Certificates
Manufacturer's certificate..................................................................................... 39
Keyword index.................................................................................................... 40
Index
Index
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The appliance is only intended to be
installed and operated in sealed unven-
ted heating systems that comply with
EN 12828, with due attention paid to the
associated installation, service and
operating instructions 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 pur-
pose other than the heating up of heating
water shall be deemed inappropriate.
Intended use presupposes that a fixed
installation in conjunction with permissi-
ble components designed for this pur-
pose has been carried out.
Every other use will be deemed to be
inappropriate. Any resulting losses are
excluded from the manufacturer's liabil-
ity.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Intended use also includes the adher-
ence to maintenance and inspection
intervals.
Product information
Intended use
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Checking the high limit safety cut-out setting............. 9
•2. Filling the heating system with water and venting...... 9
•3. Fully opening and securing the rotary damper in the
flue outlet......................................................................... 9
••• 4. Commissioning the system........................................... 9
•5. Minimising pulsation noise............................................ 10
• • 6. Shutting down the system............................................. 11
• • 7. Opening the boiler door................................................. 11
• • 8. Separating the neutralising system from the boiler
and connecting the drain hose...................................... 12
• • 9. Cleaning the combustion chamber and heating
surfaces........................................................................... 12
• • 10. Checking gaskets and thermal insulation
components.................................................................... 13
• • 11. Checking the sensor well and all connections on the
heating water side for leaks........................................... 13
• • 12. Checking the function of the safety equipment........... 14
••• 13. Checking the expansion vessel and system pressure 14
• • 14. Checking the flue gas collector for tightness.............. 16
•15. Cleaning the sight glass in the boiler door.................. 16
• • 16. Closing the boiler door.................................................. 18
•17. Checking the thermal insulation................................... 18
• • 18. Checking the mixer for ease of operation and leaks... 18
• • 19. Checking the water quality............................................ 19
• • 20. Cleaning and reconnecting the condensate drain
system............................................................................. 20
•21. Checking the installation room ventilation
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
•22. Checking the flue system for tightness
• • 23. Adjusting the burner...................................................... 21
•24. Instructing the system user........................................... 21
•25. Operating and service documents................................ 21
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
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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 serv-
ice instructions
Filling the heating system with water and venting
Record the charge volume, water hard-
ness and pH value on page 19. !Please note Unsuitable water quality can
result in damage to the boiler
shell and the heating system.
Observe section "Water quality
requirements" on page 35.
Fully opening and securing the rotary damper in the flue outlet
The rotary damper must be in the hori-
zontal position.
Note
For correct handling of the rotary
damper, see "Minimising pulsation
noise" on page 10.
Commissioning the system
Operating instructions for control
unit, burner and neutralising sys-
tem, service instructions for con-
trol unit, and burner manufactur-
er's documentation
1. Check the heating system pressure.
Danger
For safe operation, a mini-
mum operating pressure of
0.5 bar (50 kPa) is essential.
A minimum pressure switch
can be used to safeguard
this.
Permissible boiler operating pres-
sure:
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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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 oper-
ating instructions
7. Check the function of the neutralising
system.
Neutralising system operating
instructions
8. Check all gaskets and plugs, and
retighten if necessary.
Note
We recommend checking all connec-
tions on the heating water side for
tightness after approx. 500 hours run
(see page 13).
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 cor-
rect seating and realign if nec-
essary.
Minimising pulsation noise
Pressure-tight flue systems can gener-
ate 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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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D
B
A
E
C
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
Further details regarding the individual steps (cont.)
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Separating the neutralising system from the boiler and connect-
ing the drain hose
A
BD
E
C
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 conden-
sate 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 corrosion.
Only use plastic brushes, NOT
wire brushes or sharp objects.
1. Clean the combustion chamber and
heating surfaces.
■ For normal cleaning, flush the heat-
ing surfaces thoroughly with a
water jet.
■ However, you may use cleaning
agents if you notice stubborn resi-
dues, surface discolouration or
soot deposits.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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For this, observe the following:
– Only use solvent-free cleaning
agents. Ensure that no cleaning
agents enter between the boiler
body and the thermal insulation.
– Remove soot deposits with alka-
line cleaning agents with addi-
tional surfactants (e.g. Fauch
600).
– Remove coatings and surface
discolouration (yellow-brown)
with slightly acidic, chloride-free
cleaning agents based on phos-
phoric acid (e.g. Antox 75 E).
2. Remove loose deposits from the
boiler; flush the heating surfaces and
the flue gas collector thoroughly with
a water jet.
Danger
Loose residues and residual
cleaning agents can lead to
injury.
Wear goggles, protective gloves
and protective clothing.
Cleaning agent manufacturer's
details.
Note
"Fauch 600" and "Antox 75 E"
Manufacturer:
Hebro Chemie GmbH
Rostocker Straße 40
D -41199 Mönchengladbach
Checking gaskets and thermal insulation components
1. Check the gaskets and packing cord
in the boiler door for damage.
2. Check the thermal insulation compo-
nents 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 pressurised compo-
nents.
Only open the connections on the
heating water side after the boiler
has been depressurised.
Only drain the boiler with a suc-
tion pump when the boiler air vent
valve is open.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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A B
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 man-
ufacturer's details.
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 maintain-
ing systems
Note
In heating systems with automatic pres-
sure maintaining equipment and/or dea-
eration systems (operating according to
the pressure reduction method for dea-
eration), install an expansion vessel
(DEV) as individual boiler protection.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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The expansion vessel must have the fol-
lowing minimum 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 fre-
quency and severity of pressure fluctua-
tions. This improves the runtime of the
pressure maintaining pump and there-
fore increases the operational reliability
and service life of the system compo-
nents.
Failure to observe these recommen-
dations may result in damage to the
boiler or to other system compo-
nents.
Carry out all checks in accordance with
the manufacturer's instructions. Limit
pressure fluctuations to the lowest pos-
sible differential. Cyclical pressure fluc-
tuations and more significant pressure
differentials point towards a system fault.
Immediately remedy such faults, other-
wise other heating system components
may be damaged.
Expansion vessels
1. Drain the system or close the cap
valve on the expansion vessel and
reduce the pressure until the pres-
sure 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 + supplement).
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 pres-
sure is 0.2 (20 kPa) higher than the
pre-charge pressure of the expan-
sion vessel when the system is cold.
4. Mark this value on the pressure
gauge as the minimum charge pres-
sure.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the flue gas collector for tightness
A
B
1. Traces of condensate on the outside
of the flue gas collector indicate a
leak.
Danger
Escaping flue gas can lead to
a health hazard.
Check gaskets on the flue gas
collector and adjust if
required.
2. If required, retighten the gasket on
tensioning toggles A and on actua-
tor damper B torque-free (torque
7 Nm).
Note
We recommend checking the gasket
roughly every 500 hours run and retight-
ening the screws if necessary. Also
ensure that the gasket and tensioning
toggles 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
Further details regarding the individual steps (cont.)
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A
B
Check gaskets A and hose connection
B for leaks.
Danger
Leaks can result in a risk of poi-
soning through escaping gas.
Check gaskets carefully.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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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 cor-
rect seating and realign if nec-
essary.
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 handle.
2. Check the mixer for ease of opera-
tion.
3. Check the mixer for leaks. Replace
the O-rings if the mixer leaks.
4. Snap the motorised lever into place.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the water quality
Enter the amount of top-up water and the
total hardness of the feed and boiler
water into the following table.
For water quality requirements, see
page 35.
Meter read-
ing
Fill and top-
up water
Total water
volume
Total hardness pH value Date
Feedwater Boiler wa-
ter
m3m3m3
The total hardness of the feed and top-
up water must not exceed the standard
values specified by VDI 2035 (see
page 35).
The pH value should be between 8.2 and
9.5.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning and reconnecting the condensate drain system
The condensate drain system comprises
the condensate drain, siphon, neutralis-
ing system and all hoses and pipes run-
ning between them.
Note
Clean the inside of the condensate drain
system at least annually.
A
BD
E
C
1. Undo drain hose D to drainage sys-
tem 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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5614 461 GB