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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3
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.)
5692 398 GB

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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.)
5692 398 GB

7
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.)
5692 398 GB