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.)
5614 461 GB