Viessmann VITOCROSSAL 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 300
Type CR3B, 787 to 1400 kW
Gas condensing boiler
For applicability, see the last page
VITOCROSSAL 300
5692 910 GB 11/2013 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
■ 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.)
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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............................................................................................................ 23
Commissioning/service reports
Reports..................................................................................................................... 30
Specification....................................................................................................... 31
Water quality
Water quality requirements.................................................................................. 32
Certificates
Declaration of Conformity..................................................................................... 36
Certificates
Manufacturer's certificate according to the 1st BImSchV..................................... 37
Keyword index.................................................................................................... 38
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 the rotary damper in the flue outlet and
securing it........................................................................ 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 heat
exchanger module 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 all connections and the sensor well on the
heating water side for tightness.................................... 15
• • 12. Checking the function of the safety equipment........... 16
••• 13. Expansion vessel and system pressure ...................... 16
•14. Cleaning the sight glass in the boiler door.................. 18
• • 15. Closing the boiler door.................................................. 18
•16. Checking the thermal insulation................................... 18
• • 17. Checking the water quality............................................ 18
• • 18. Cleaning and reconnecting the condensate drain
system............................................................................. 19
•19. Checking the installation room ventilation
•20. Checking the flue system for tightness
• • 21. Adjusting the burner...................................................... 20
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
• • 22. Checking the flue gas side for tightness...................... 21
•23. Instructing the system user........................................... 22
•24. Operating and service documents................................ 22
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.
Permissible boiler operating pressure:
6 bar (0.6 MPa).
!Please note
Unsuitable water quality can
result in damage to the boiler
shell and the heating system.
Fill the heating system with water
and operate it in accordance with
VDI Guideline 2035. The total of
alkaline earths must not exceed
0.02 mol/m3 (total hardness
0.11 °dH).
Observe the "Water quality
requirements" on page 32.
Fully opening the rotary damper in the flue outlet and securing
it
The rotary damper must be in the hori-
zontal position.
Note
For handling 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.
Permissible boiler operating pres-
sure: 6 bar (0.6 MPa)
2. Check that the installation room ven-
tilation 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.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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6. Start the system in this order:
1. Mains isolator
2. Switch for the heating circuit pump
3. ON/OFF switch for the burner
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
tightness after approx. 500 hours run
(see page 15).
9. Check the boiler door and cleaning
cover a few days after commissioning
and retighten all screws.
10. Tighten the screws at the connec-
tions with the following torque:
Boiler door 20 Nm
Flange connections 110 Nm
Module connection 60 Nm
Flue gas collector 7 Nm
Danger
For safe operation, a minimum
operating pressure of 0.5 bar
(50 kPa) is essential.
For this, a minimum pressure
switch can be used.
Minimising pulsation noise
Whatever the make of boiler, burner or
flue system, gas-tight flue systems can
still create pulsation noise. A change of
resonance may be affected by rotating
the damper fitted into the flue outlet.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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CB
B
A
1. Undo M 5 screw A on lever B of
the damper lock.
2. Adjust the lever until no further pul-
sation noise occurs. The lever indi-
cates the position of rotary damper
C.
3. Tighten M 5 screw A on lever B of
the damper lock.
4. 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 plugs fA and lÖ from the
burner.
3. Close the gas shut-off valve.
Opening the boiler door
1. Remove the gas supply pipe. 2. Loosen 4 screws on the boiler door
and open it.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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!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 from the heat exchanger
module and connecting the drain hose
D
C
B
A
1. Separate hose or pipework 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 a drain-
age system.
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.)
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– 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 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.)
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A
D
B
E
C
Ø = Ø B -10
ABoiler door
BFlame tube
CThermal insulation mat
DBurner plate
EThermal insulation block
Check the thermal insulation mat at the
flame tube. The blue side of the thermal
insulation mat has to face the combus-
tion chamber. It must be in close contact
with the flame tube.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking all connections and the sensor well on the heating
water side for tightness
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.
If draining with a suction pump,
only drain the boiler with the air
vent valve open.
A
B
C
A
A
A
1. Undo the fixing screws of top panels
A and remove the panels.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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2. Open the thermal insulation of the
heat exchanger module until con-
necting flange C is freely accessi-
ble.
3. Check connecting flange C, sensor
well B and all connections on the
heating water side for tightness.
4. Close the thermal insulation of the
heat exchanger module.
5. Position the top panels and secure
with screws.
Note
The gaskets can also be checked under
full load with an inspection mirror. If
required, remove the thermal insulation
components.
Checking the function of the safety equipment
Check safety valves, water level and
pressure limiter in accordance with man-
ufacturer's details.
Expansion vessel and system pressure
Note
Please observe expansion vessel man-
ufacturer's instructions.
Check when system is cold.
Expansion vessel
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.
For a high limit safety cut-out setting
of
100 °C: 0.2 bar (20 kPa)
110 °C: 0.7 bar (70 kPa)
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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2. If the pre-charge pressure of the
expansion vessel is lower than the
value calculated using the formula,
top up with sufficient nitrogen to ach-
ieve this value.
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.
Pump controlled pressure maintaining systems
Note
In heating systems with automatic pres-
sure maintaining equipment or deaera-
tion systems (operating according to the
pressure reduction method for deaera-
tion), we recommend installing an
expansion vessel (DEV) for individual
boiler protection.
The expansion vessel must be able to
absorb the expansion volume of the
heating water in the boiler. Minimum size
35 l
This expansion vessel reduces the fre-
quency and severity of pressure fluctua-
tions; the runtime of the pressure main-
taining pump is improved and therefore
the operational reliability and service life
of system components is increased.
Failure to observe these recommen-
dations may result in damage to the
boiler or to other system compo-
nents.
Check the pressure maintaining system
in line with the manufacturer's instruc-
tions. Limit pressure fluctuations to the
lowest possible differential. Cyclical
pressure fluctuations and more signifi-
cant pressure differentials point towards
a system fault. Remedy any faults imme-
diately as they can cause damage to
other components in the heating sys-
tem.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Cleaning the sight glass in the boiler door
BA
Check gaskets A and hose connection
B for leaks.
Danger
Leaks can result in a risk of poi-
soning through escaping flue
gas.
Check gaskets carefully.
Closing the boiler door
1. Tighten the screws on the boiler door
evenly and diagonally. Torque of
20 Nm
2. Mount the gas supply pipe and check
for tightness.
Checking the thermal insulation
Check the thermal insulation fit and
realign if required.
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 32.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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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 32).
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 and all hoses and pipes
between them are part of the condensate
drain system.
Note
Clean the inside of the condensate drain
system at least annually.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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A
B
C
E
D
1. Disconnect drain or cleaning hose
C.
2. Clean condensate drain A again
from the inside using a plastic
brush.
3. Undo and flush lower part E of
siphon B. Clean the inlet connector
of siphon B with a brush.
4. Secure siphon B on condensate
drain A and seal in if required.
5. Fill lower section E of the siphon
with water and refit.
Note
If the siphon is not filled with water,
flue gas can escape.
6. Clean the inside of the pipes of the
condensate drain system and the
neutralising system.
Neutralising system operating
instructions
7. Connect the inlet of the neutralising
system to siphon B using line D
(and seal in if necessary). Ensure the
condensate is draining correctly into
the drainage system.
Adjusting the burner
Observe the burner manufacturer's
instructions.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 910 GB