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 2/2013 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
■ 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
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
supply utility from outside the
building.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5692 501 GB

3
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
Life-threatening poisoning
caused by carbon monoxide in
the flue gas occurs as a result of
leaking or blocked flue systems
or an insufficient supply of com-
bustion air.
Ensure the flue system is in
proper working order. It must not
be possible to close apertures for
interconnected combustion air
supply.
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.
!Please note
Electronic assemblies can be
damaged by electrostatic dis-
charge.
Prior to commencing any 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 function can compromise
the safe operation of your sys-
tem.
Defective components must be
replaced with genuine
Viessmann spare parts.
Safety instructions
Safety instructions (cont.)
5692 501 GB

4
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 our
warranty.
For replacements, use only orig-
inal spare parts supplied or
approved by Viessmann.
Safety instructions
Safety instructions (cont.)
5692 501 GB

5
Product information
Intended use......................................................................................................... 6
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 7
Further details regarding the individual steps....................................................... 9
Parts lists............................................................................................................ 18
Commissioning/service reports........................................................................ 21
Specification....................................................................................................... 22
Certificates
Declaration of conformity...................................................................................... 27
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 28
Keyword index.................................................................................................... 29
Index
Index
5692 501 GB

6
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. It is only designed
for the heating of water that is of potable
water quality.
Intended usage presupposes that a fixed
installation in conjunction with permissi-
ble, system-specific components has
been carried out.
Commercial or industrial usage for a pur-
pose other than heating the building or
DHW does not comply with regulations.
Any usage beyond this must be
approved by the manufacturer for the
individual case.
Incorrect usage or operation of the appli-
ance (e.g. the appliance being opened
by the system user) is prohibited and
results in an exclusion of liability. Incor-
rect usage also occurs if the components
in the heating system are modified from
their intended function (e.g. if the flue
gas and ventilation air paths are
sealed).
Product information
Intended use
5692 501 GB

7
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 the
system............................................................................. 9
•3. Filling the siphon with water......................................... 9
••• 4. Commissioning the system........................................... 10
• • 5. Shutting down the system............................................. 10
• • 6. Opening the boiler door................................................. 10
• • 7. Separating the neutralising system (if installed) from
the boiler and connecting the drain hose.................... 11
• • 8. Cleaning the combustion chamber and heating
surfaces........................................................................... 11
• • 9. Checking components exposed to flue gas for
corrosion damage
• • 10. Checking the gaskets, packing cords and thermal
insulation components of the boiler door.................... 12
• • 11. Checking gaskets and thermal insulation
components on the boiler.............................................. 13
• • 12. Checking the function of safety valves
• • 13. Checking the mixer for ease of operation and
tightness.......................................................................... 14
• • 14. Checking the water quality............................................ 14
• • 15. Cleaning and reconnecting the condensate drain
system............................................................................. 15
• • 16. Checking the condensate drain and the neutralising
system (if installed)........................................................ 16
• • 17. Closing the boiler door.................................................. 16
•18. Checking the installation room ventilation
•19. Checking the flue system for leaks
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5692 501 GB

8
Commissioning steps
Inspection steps
Maintenance steps Page
• • 20. Adjusting the burner...................................................... 16
•21. Instructing the system user........................................... 17
•22. Operating and service documents................................ 17
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
5692 501 GB

9
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 the system
Enter the amount of fill water, water
hardness and pH value into the table on
page 15.
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 and can be
ensured with a minimum pressure switch
(one per system for multi boiler sys-
tems).
!Please note
Unsuitable water quality can
result in damage to the boiler
body and the heating system.
Observe the "Water quality
requirements" on page 23.
Filling the siphon with water
1. Undo the siphon and fill it with
water.
!Please note
Risk of escaping flue gas.
Fill the siphon with water.
2. Check that the condensate can drain
freely.
3. Remount the siphon.
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 501 GB

10
Commissioning the system
Operating and service instruc-
tions of the control unit, burner
and neutralising system, as well
as documentation from the
burner manufacturer.
1. Check the heating system pressure.
Permissible boiler operating pres-
sure: 4 bar (0.4 MPa)
Minimum operating pressure:
0.5 bar (50 kPa)
Note
The minimum operating pressure is
essential for safe operation and can
be ensured with a minimum pressure
switch (one per system for multi boiler
systems).
2. Check that the installation room vent
is open.
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 you check all con-
nections on the heating water side for
leaks approx. 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 safeguard against re-con-
nection.
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 six screws on boiler door and
open the door.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 501 GB

11
!Please note
Scratches inside the combustion
chamber can lead to corrosion.
Never put tools or other objects
into the combustion chamber.
Separating the neutralising system (if installed) from the boiler
and connecting the drain hose
C
B
A
1. Separate hose A to the neutralising
system from siphon B.
2. Remove siphon B from the conden-
sate drain.
3. Clean the inside of the condensate
drain with a plastic brush.
4. Connect drain hose C to the con-
densate drain.
Connect drain hose C to the on-site
drain connection.
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.
For this, observe the following:
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 501 GB

12
– 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 the gaskets, packing cords and thermal insulation
components of the boiler door
1. Check gaskets and packing cord in
the boiler door for damage.
2. Check thermal insulation compo-
nents on the boiler door for damage.
3. Replace any damaged parts.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 501 GB

13
Checking gaskets and thermal insulation components on the
boiler
A
B
C
D E
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 seals/gaskets can also be
checked under full load with an
inspection mirror. If required,
remove the thermal insulation com-
ponents.
■ Traces of condensate on the out-
side of flue gas collector C indi-
cate a leak.
3. If required, retighten flue gas collec-
tor seal A at tensioning toggles E
or replace. Replace lip seal D if it
leaks.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 501 GB

14
4. Check the fittings on the water side
for leaks and replace the seals/gas-
kets if required.
Danger
There is a risk of injury when
working on pressurised com-
ponents.
Only open the connections on
the heating water side after
the boiler has been depres-
surised.
Only drain the boiler with a
suction pump with the boiler
air vent valve open.
5. Check the boiler thermal insulation
for good fit and correct if required or
replace if it is damaged.
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 opera-
tion.
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 hardness of the feed and boiler
water into the table.
For water quality requirements, see
page 23.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 501 GB

15
Meter
reading
Fill and
top-up
water
Total wa-
ter vol-
ume
Total hardness pH val-
ue
Date
Feed-
water
Boiler
water
m3m3m3°dH °dH
The total hardness of the feed and top-
up water must not exceed the standard
values specified by the VDI 2035 (see
page 23).
The pH value should be between 8.2 and
9.5.
Cleaning and reconnecting the condensate drain system
The condensate drain, siphon, neutralis-
ing system (if installed) and all intermedi-
ate hoses and pipes are part of the con-
densate drain system.
Note
Clean the inside of the condensate drain
system at least annually.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 501 GB

16
C
B
D
A
1. Undo and flush lower section A of
siphon B; clean the inlet connector
of siphon B with a brush.
2. Fill lower section A of the siphon
with water and refit.
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 from Viessmann by quoting
part no. 9524 670.
4. Pull off hose C and fit siphon B to
the condensate drain.
5. Refit hose D of the neutralising sys-
tem to the siphon.
Checking the condensate drain and the neutralising system (if
installed)
Add water to the combustion chamber.
The water must flow from the conden-
sate 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.
Adjusting the burner
Observe the burner manufacturer's
instructions.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 501 GB

17
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 serv-
ice instructions in the folder and hand
this over to the system user.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 501 GB

18
When ordering spare parts:
Quote the part no. and serial no. (see
type plate) and the position number of
the required part (as per this parts list).
Standard parts are available from your
local supplier.
001 Flue gas collector
002 Flue gas collector gasket
003 Adjustable foot
004 Siphon
005 Flue gasket
200 Fascia
201 Top panel
202 Side panel, l.h. and r.h. side
203 Front panel
204 Back panel
205 Thermal insulation jacket
206 Thermal insulation mat, front
207 Thermal insulation mat, back
208 Bottom cover plate
209 Thermal insulation pack
210 Vitocrossal 300 logo
211 Edge protector
Parts not shown
300 Decorative adhesive tape
301 Spray paint, Vitosilver
302 Touch-up paint stick, Vitosilver
303 Installation instructions
304 Service instructions
AType plate
BBoiler control unit, see separate
parts list
Parts lists
Parts lists
5692 501 GB

19
210
201
200
A
B
202
202
211
206
203
Parts lists
Parts lists (cont.)
5692 501 GB

20
211
001
204207
209
004
005
003003
003
208
209
002
209
205209
Parts lists
Parts lists (cont.)
5692 501 GB