Viessmann VITOCROSSAL 300 Operating instructions

Service instructions
for contractors
VIESMANN
Vitocrossal 300
Type CR3, 787 and 978 kW
Gas condensing boiler
For applicability, see the last page
VITOCROSSAL 300
5692 398 GB 2/2011 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
designed for qualified personnel.
■ Work on gas equipment must only be
carried out by a qualified 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
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions 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,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions 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.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the build-
ing.
■ 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 boiler room.
■ Close all doors leading to the
living space.
Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which ful-
fil a safety function can compro-
mise the safe operation of your
heating system.
Replace faulty components only
with original Viessmann spare
parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
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Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 7
Parts lists............................................................................................................ 18
Commissioning/service reports........................................................................ 23
Specification....................................................................................................... 24
Water quality
Water quality requirements.................................................................................. 25
Certificates
Declaration of Conformity..................................................................................... 27
Certificates
Manufacturer’s certificate according to the 1st BImSchV..................................... 28
Index
Index
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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............. 7
•2. Filling the heating system with water and venting the
system............................................................................. 7
•3. Fully opening the flue outlet damper and locking it
open................................................................................. 7
••• 4. Starting the system........................................................ 7
•5. Minimising pulsation noise............................................ 8
• • 6. Shutting down the system............................................. 9
• • 7. Opening the boiler door................................................. 9
• • 8. Separating the neutralising system from the heat
exchanger module and connecting the drain hose..... 9
• • 9. Cleaning the combustion chamber and heating
surfaces........................................................................... 9
• • 10. Checking gaskets and thermal insulation parts.......... 10
• • 11. Checking all connections on the heating water side
and the sensor well for leaks......................................... 11
• • 12. Checking the safety equipment function..................... 12
••• 13. Checking the diaphragm expansion vessel and
system pressure............................................................. 12
•14. Cleaning the sight glass in the boiler door.................. 13
• • 15. Closing the boiler door.................................................. 13
•16. Checking the thermal insulation................................... 13
• • 17. Checking the mixer for ease of operation and leaks... 13
• • 18. Checking the water quality............................................ 14
• • 19. Cleaning and reconnecting the condensate drain
system............................................................................. 14
•20. Checking the installation room ventilation
Commissioning, inspection, maintenance
Steps – commissioning, inspection and maintenance
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Commissioning steps
Inspection steps
Maintenance steps Page
•21. Checking the flue system for leaks
• • 22. Adjusting the burner...................................................... 15
• • 23. Checking the gaskets/seals on the flue side............... 16
•24. Instructing the system user........................................... 17
•25. Operating and service instructions.............................. 17
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 the system
Record the fill volume, water hardness
and pH value on page 14.
Permissible boiler operating pressure: 4
bar.
!Please note
Unsuitable water qualities can
result in damage to the boiler
body and the heating system.
According to VDI Directive 2035,
the heating system must be filled
and operated with water with a
sum of alkaline earths not
exceeding 0.02 mol/m3 (overall
hardness 0.11 °dH).
Observe the "Water quality
requirements" on page 25.
Fully opening the flue outlet damper and locking it open
The damper must be in the horizontal
position.
Note
For handling the damper, see "Minimis-
ing pulsation noise", page 8.
Starting the system
Operating instructions – control
unit, burner and neutralising sys-
tem, service instructions – control
unit and burner manufacturer's
documentation
1. Check the heating system pressure.
Permissible boiler operating pres-
sure: 4 bar
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps
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6. Switch ON the mains isolator, the
switch for the heating circuit pump
and the burner control 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/seals and plugs,
and retighten if necessary.
Note
We recommend you check all con-
nections on the heating water side for
leaks after approx. 500 hours run
(see page 11).
9. Check the boiler door and cleaning
cover a few days after commissioning
and retighten all screws.
Minimising pulsation noise
Whatever the make of boiler, burner or flue system, sound flue systems can still create
pulsation noise. A change of resonance may be affected by rotating the damper fitted
into the flue outlet.
CB
AB
1. Undo M 10 nut A on lever B of
rotary damper C.
2. Adjust the lever until all pulsating
noise has ceased (the lever mirrors
the damper position).
3. Lock the rotary damper with M 10
nut.
4. Readjust the burner if required.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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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. Undo the four screws on the boiler
door and open the door.
!Please note
Scratches inside the combustion
chamber can lead to corrosion.
Never insert 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 pipe A to the neu-
tralising system from siphon B.
2. Remove siphon B from condensate
drain C.
3. Clean the inside of condensate drain
C with a plastic brush.
4. Connect drain hose D to conden-
sate drain C and run to a sewer.
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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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■ 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:
– 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 parts
1. Check gaskets and the packing cord
in the boiler door for damage.
2. Check the thermal insulation compo-
nents of the boiler door for possible
damage.
3. Replace any damaged parts.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking all connections on the heating water side and the sen-
sor well 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 de-pressurised.
Only drain the boiler with a suc-
tion pump when the boiler air vent
valve is open.
A
A
A
DC
B
1. Undo the screws of top panels A
and remove the panels.
2. Open thermal insulation C of the
heat exchanger module until con-
necting flange D is freely accessi-
ble.
3. Check connecting flange D, sensor
well B and all connections on the
heating water side for leaks.
4. Close the thermal insulation of the
heat exchanger module.
5. Position the top panels and secure
with screws.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the safety equipment function
Check the safety valves, the water level
and pressure limiters in accordance with
manufacturer's details.
Checking the diaphragm expansion vessel and system pressure
Note
Observe the diaphragm expansion ves-
sel manufacturer's instructions.
Carry out this test on a cold system.
Pump controlled pressure maintain-
ing systems
Note
In heating systems with automatic pres-
sure maintaining systems and/or deaer-
ating systems (operating according to
the pressure reduction method for dea-
erating), we recommend the installation
of a diaphragm expansion vessel (DEV)
as individual boiler protection.
The diaphragm expansion vessel must
be able to hold the heating water expan-
sion volume inside the boiler and provide
a capacity of at least 35 l.
This diaphragm expansion vessel
reduces the frequency and severity of
pressure fluctuations; the runtime of the
pressure pump is improved and there-
fore the operational reliability and serv-
ice life of system components increased.
Damage to the boiler or to other sys-
tem components may result if these
recommendations are not followed.
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 become faulty.
Diaphragm expansion vessel
1. Drain the system or close the cap
valve on the diaphragm expansion
vessel and reduce the pressure, until
the pressure gauge indicates "0".
Note
The pre-charge pressure of the dia-
phragm expansion vessel (p0) com-
prises the static system pressure
(pSt) (= static head) and a supplement
(p0 = pSt + supplement).
The supplement is subject to the
adjustment of the high limit safety cut-
out.
For a high limit safety cut-out set to
100 ºC: 0.2 bar
110 ºC: 0.7 bar
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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2. If the pre-charge pressure of the dia-
phragm expansion vessel is lower
than the value calculated according
to the adjacent formula, top up with
sufficient nitrogen to achieve this
value.
3. Refill with water until the filling pres-
sure is 0.2 bar higher than the pre-
charge pressure of the diaphragm
expansion vessel when the system is
cold.
4. Mark this value on the pressure
gauge as the minimum filling pres-
sure.
Cleaning the sight glass in the boiler door
A B
Check gaskets A and hose connection
B for leaks.
Closing the boiler door
1. Tighten the screws on the boiler door
evenly and diagonally.
2. Install the gas supply pipe and check
for tightness.
Checking the thermal insulation
Check the thermal insulation fit and
adjust 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.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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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 following table.
For water quality requirements, see page 25.
Meter read-
ing
Fill and top-
up water
Total water
volume
Total hardness pH value Date
Feedwater Boiler
water
m3m3m3°dH/mmol/l °dH/mmol/l
The total hardness of the feed and top-up water must not exceed the guidelines
specified by the VDI 2035 (see page 25).
The pH value should be between 8.2 and 9.5.
Cleaning and reconnecting the condensate drain system
The condensate drain, siphon, neutralising system and all intermediate hoses and
pipes are part of the condensate drain system.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Note
Clean the inside of the condensate drain
system at least annually.
A
B
C
E
D
1. Pull drain or cleaning hose C off.
2. Clean the inside of condensate drain
A once more with the plastic
brush.
3. Release 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 part E of the siphon with
water and reassemble.
Note
There is a risk of flue gas escaping if
the siphon is not filled with water.
6. Clean the inside of the pipes of the
condensate drain system and the
neutralising system.
Neutralising system operating
instructions
7. Connect the supply of the neutralis-
ing system with line D and siphon
B (if required seal in) and ensure
that the condensate is draining cor-
rectly to the sewer system.
Adjusting the burner
Observe the burner manufacturer's
instructions.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the gaskets/seals on the flue side
18x
6x
DCBA
1. Check the gasket/seal on the flue gas
collector C between the flue gas col-
lector B and the boiler body D for
tightness.
2. Check gaskets A of the cleaning
cover for tightness.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Note
The seals/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 B or on parts of
the thermal insulation also point
towards leaks.
3. If required, retighten flue gas collec-
tor seal C and seal A or replace.
Instructing the system user
The installer must instruct the user in the
operation of the system.
Operating and service instructions
1. Complete and detach the customer
registration card:
■ Hand the system user this part for
safekeeping.
■ Retain the heating contractor's
part.
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.)
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When ordering spare parts:
Quote the type and serial no. (see type
plate) and the position number of the
required part (as per this parts list).
Obtain standard parts from your local
supplier.
003 Gasket set (gaskets and sealant)
004 Flue gas collector cover (incl. pos.
006, 007 and 008)
006 Inspection cover
007 Gasket, inspection cover
008 Gasket, flue gas collector cover
009 Gasket
010 Gasket
011 Gasket
012 Boiler door
013 Sight and test pipe cover
014 Sight glass (incl. gasket)
015 Hose ferrule
016 Hose
017 Thermal insulation mat
018 Thermal insulation block
019 Packing 25 x 15
020 Packing 7 25
021 Packing 9 x 7
022 Burner plate
023 Siphon
025 Burner cable, see separate parts
list
026 Sensor well
200 Bezel
201 Front left panel, top
202 Front right panel, top
203 Centre panel, top
204 Front panel, top
205 Front panel, bottom
206 Back panel, top
207 Back panel, bottom
208 Back panel, left and right
209 Side panel, top
210 Side panel, bottom
211 Front l.h. rail
212 Front r.h. rail
213 Back l.h. rail
214 Back r.h. rail
215 Centre rail
216 Back retaining bracket
217 Thermal insulation jacket, front
218 Thermal insulation jacket, centre
219 Thermal insulation jacket, back
220 Front thermal insulation mat
221 2-fold strain relief
222 Vitocrossal 300 logo
223 Edge protector
224 Thermal insulation mat, back
Parts not shown
024 Coding card
027 Flame tube gasket
300 Thermal insulation pack
301 Decorative adhesive tape
302 Touch-up spray, Vitosilver
303 Touch-up paint stick, Vitosilver
304 Installation instructions
305 Service instructions
AType plate, optionally left or right
BBoiler control unit, see separate
parts list
Parts lists
Parts lists
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201
220
217
202
204
221
205
215
211
216
213
B
209
209
210
210
222
200
Parts lists
Parts lists (cont.)
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223206
218
219
203
224
216
215
209
212
210
210
209
214
207
208
A
Parts lists
Parts lists (cont.)
5692 398 GB