Viessmann VITOCROSSAL 300 Operating instructions

VIESMANN
Service instructions
for contractors
Vitocrossal 300
Type CT3, 187 to 635 kW
Gas fired condensing boiler
VITOCROSSAL 300
5692 405 GB 2/2007 Please keep safe.

Please follow these safety instructions closely to prevent accidents and
material 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
environmental pollution.
Note
Details identified by the word "Note"
contain 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 fit-
ter.
&Work on electrical equipment must
only be carried out by a qualified
electrician.
&The system must be commissioned
by the system installer or a qualified
person authorised by the installer.
Regulations
Observe the following when working
on this system
&all legal instructions regarding the
prevention of accidents,
&all legal instructions regarding
environmental protection,
&theCodeofPracticeofrelevant
trade associations,
&all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards.
If you smell gas
Danger
Escaping gas can lead to
explosions which may result in
serious injury.
&Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical
appliances 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
building.
&Shut off the electricity supply
to the building from a safe
place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life-threa-
tening poisoning.
&Shut down the heating sys-
tem.
&Ventilate the boiler room.
&Closealldoorsleadingtothe
living space.
Safety instructions
2
Safety instructions
5692 405 GB

Workingonthesystem
&When using gas as fuel, also close
the main gas shut-off valve and
safeguard against unauthorised
reopening.
&Isolate the system from the power
supply 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
unauthorised reconnection.
!Please note
Electronic modules can be
damaged 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
fulfil a safety function can com-
promise 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
compromise its function. Instal-
ling non-authorised compo-
nents and non-approved
modifications/conversion can
compromise safety and may
invalidate our warranty.
For replacements, use only ori-
ginal spare parts from
Viessmann or those which are
approved by Viessmann.
Safety instructions (cont.)
3
Safety instructions
5692 405 GB

Commissioning, inspection, maintenance
Steps –commissioning, inspection and maintenance .................................. 5
Further details regarding the individual steps .............................................. 7
Parts lists .................................................................................................. 20
Commissioning/service reports............................................................... 28
Specification............................................................................................. 29
Certificates
Declaration of conformity ............................................................................ 33
Manufacturer's certificate according to the 1st BImSchV [Germany]............. 34
Index
4
Index
5692 405 GB

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 heating system .............................................. 7
•5. Minimising pulsation noise............................................... 8
•• 6. Shutting down the heating system................................. 9
•• 7. Opening the boiler door...................................................... 9
•• 8. Separating the neutralising system from the boiler
and connecting the drain hose ........................................ 9
•• 9. Cleaning the combustion chamber and heating
surfaces.................................................................................... 10
•• 10. Checking gaskets and thermal insulation
components ............................................................................ 11
•• 11. Checking all heating water connections and the
sensor well for leaks ............................................................ 11
•• 12. Checking the function of the safety equipment......... 11
••• 13. Checking the diaphragm expansion vessel and
system pressure.................................................................... 12
•• 14. Checking the flue gas header for soundness............. 14
•15. Cleaning the sight glass in the boiler door ................. 15
•• 16. Closing the boiler door ....................................................... 15
•17. Checking the thermal insulation ..................................... 15
•• 18. Checking the mixer for obstructions and leaks ........ 15
•• 19. Check the water quality ...................................................... 16
•• 20. Cleaning and reconnecting the condensate drain
system....................................................................................... 17
Steps –commissioning, inspection and maintenance
5
Commissioning, inspection, maintenance
5692 405 GB

Commissioning steps
Inspection steps
Maintenance steps Page
!!!





















•21. Checking the boiler room ventilation
•22. Checking the function of the flue gas system
••23. Adjusting the burner............................................................ 18
•24. Instructing the system user .............................................. 18
•25. Operating and service documents ................................. 19
Steps –commissioning, inspection and . . . (cont.)
6
Commissioning, inspection, maintenance
5692 405 GB

Checking the high limit safety cut-out setting
The high limit safety cut-out must not
be set higher than 110 °C; if required,
setittoamaximumof110°C.
Control unit installation and
service instructions
Filling the heating system with water and venting the system
Record the fill volume, water hard-
ness and pH value on page 16
and 17. !Please note
Unsuitable water qualities can
result in damage to the boiler
body and the heating system.
Observe the "Water quality
requirements" on page 30.
Fully opening the flue outlet damper and locking it open
The damper must be in the horizontal
position.
Note
For handling the damper, see "Mini-
mising pulsation noises", page 8.
Starting the heating system
Operating instructions –con-
trol unit, burner and neutralis-
ing system, service
instructions –control unit and
burner manufacturer's docu-
mentation
1. Check the heating system pres-
sure.
Permissible boiler operating pres-
sure: 4 bar
2. Check that the boiler room ventila-
tion aperture is open.
3. Check the gas supply pressure.
4. Check that the cleaning aperture
ontheflueoutletisclosed.
5. Open the gas supply line shut-off
valves.
6. Switch ON the main isolator, the
switch for the heating circuit pump
and the burner control switch, in
that order.
Burner manufacturer's oper-
ating instructions
Further details regarding the individual steps
7
Commissioning, inspection, maintenance
5692 405 GB

7. Check the function of the neutralis-
ing system.
Neutralising system operat-
ing instructions
8. Check all gaskets/seals and plugs
and retighten, if necessary.
Note
We recommend you check all heat-
ing water connections after approx.
500 hours for leaks (see page 11).
9. Check the boiler door and clean-
out cover a few days after commis-
sioning and retighten all screws.
Minimising pulsation noise
Whatever the make of boiler, burner or flue gas 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.
Further details regarding the individual steps (cont.)
8
Commissioning, inspection, maintenance
5692 405 GB

1. Undo M 10 nut Aon lever Bof
rotary damper C.
2. Adjust the lever until all pulsating
noises have ceased (the lever mir-
rors the damper position).
3. Lock the rotary damper with M 10
nut.
4. Readjust the burner, if required.
Shutting down the heating system
1. Switch OFF the main isolator or the
power supply and safeguard
against unauthorised reconnection.
2. Pull plug-in connectors 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 screws on the boiler door
and open the door.
!Please note
Scratches inside the combus-
tion chamber can lead to corro-
sion.
Neverputtoolsorotherobjects
into the combustion chamber.
Separating the neutralising system from the boiler and con-
necting the drain hose
1. Separate hose or pipe Ato the
neutralising system from the flue
gas collector or siphon.
2. Remove the siphon (if installed)
from the condensate drain.
Further details regarding the individual steps (cont.)
9
Commissioning, inspection, maintenance
5692 405 GB

3. Clean the inside of the condensate
drain with a plastic brush.
4. Connect the drain hose to the con-
densate drain and run to a sewer.
Cleaning the combustion chamber and heating surfaces
!Please note
Contact with unalloyed iron
and scratches on parts in con-
tact with flue gases can lead to
corrosion.
Only use plastic brushes, NOT
wire brushes or sharp objects.
1. Clean the combustion chamber
and the heating surfaces.
&For normal cleaning, flush the
heating surfaces with a water jet.
&However, you may use cleaning
agents if you notice stubborn
residues, surface discolouration
or soot deposits.
For this, observe the following:
–Only use solvent-free cleaning
agents. Ensure that no cleaning
agent enters between the boiler
body and the thermal insula-
tion.
–Remove soot deposits with
alkaline cleaning agents with
additional surfactants (e.g.
Fauch 600).
–Remove coatings and surface
discolouration (yellow-brown)
with slightly acidic, chloride-
free cleaning agents based on
phosphoric acid (for example,
Antox 75 E).
2. Remove loose deposits from the
boiler; flush the heating surfaces
and the flue gas header thoroughly
withawaterjet.
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
Further details regarding the individual steps (cont.)
10
Commissioning, inspection, maintenance
5692 405 GB

Checking gaskets and thermal insulation components
1. Check gaskets and the packing
cord in the boiler door for damage.
2. Check the thermal insulation com-
ponents of the boiler door for possi-
ble damage.
3. Replace all faulty parts.
Checking all heating water connections and the sensor well
for leaks
Danger
There is a risk of injury when
workingonpressurisedcompo-
nents.
Only open the connections on
the heating water side after the
boiler has been de-pres-
surised.
Only drain the boiler with a
vacuum pump when the boiler
air vent valve is open.
1. Remove cap Afrom the back of
the boiler.
2. Check sensor well Bfor leaks.
3. Fit cap A.
Checking the function of the safety equipment
Check the safety valves, the water
level and pressure limiters in accor-
dance with manufacturer's details.
Further details regarding the individual steps (cont.)
11
Commissioning, inspection, maintenance
5692 405 GB

Checking the diaphragm expansion vessel and system pres-
sure
Note
Observe the diaphragm expansion
vessel manufacturer's instructions.
Carry out this test on a cold system.
Pump controlled pressure maintaining systems
Note
In heating systems with automatic
pressure maintaining equipment and/
or de-gassing systems (operating
according to the pressure reduction
method for de-gassing), install a dia-
phragm expansion vessel (DEV) as
individual boiler protection.
The diaphragm expansion vessel
must have the following minimum size
(volume in litres), subject to the boiler
output:
up to 300 kW: 50 litres
up to 500 kW: 80 litres
up to 1000 kW: 140 litres
This diaphragm expansion vessel
reduces the frequency and severity of
pressure fluctuations; the service life
ofthepressurepumpisimprovedand
therefore the operational reliability
and service life of system components
increased.
Damage to the boiler or to other
system components may result if
these recommendations are not fol-
lowed.
Carry out all checks in accordance
with manufacturer's instructions. Limit
pressure fluctuations to the lowest
possible differential. Cyclical pressure
fluctuations and more significant pres-
sure differentials point towards a sys-
tem fault. Immediately remedy such
faults, otherwise other heating system
components may become faulty.
Further details regarding the individual steps (cont.)
12
Commissioning, inspection, maintenance
5692 405 GB

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 inlet pressure of the diaphragm
expansion vessel (p0) comprises
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
110ºC:0.7bar
2. If the inlet pressure of the dia-
phragm expansion vessel is lower
than the value calculated according
to the adjacent formula, top up with
nitrogen until this value has been
achieved.
3. Refill with water until the filling
pressure is 0.2 bar higher than the
inlet pressure of the diaphragm
expansion vessel when the system
is cold.
4. Markthisvalueonthepressure
gauge as the minimum filling pres-
sure.
Further details regarding the individual steps (cont.)
13
Commissioning, inspection, maintenance
5692 405 GB

Checking the flue gas header for soundness
1. Visually inspect the gasket through
clean-out aperture Aon the flue
gas collector. Traces of conden-
sate on the outside of the flue gas
header indicate a leak.
2. If required, retighten the gasket at
clamping clips B.
Further details regarding the individual steps (cont.)
14
Commissioning, inspection, maintenance
5692 405 GB

Cleaning the sight glass in the boiler door
Check gaskets Aand hose connec-
tion Bfor 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 soundness.
Checking the thermal insulation
Check the thermal insulation fit and
adjust, if required.
Checking the mixer for obstructions and leaks
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.
Further details regarding the individual steps (cont.)
15
Commissioning, inspection, maintenance
5692 405 GB

Check the water quality
Enter the volume of top-up water, the water hardness and the pH value in the
tables.
For water quality requirements, see page 30.
Fill water Top-up water Count Total water
volume
Date
m
3
m
3
m
3
m
3
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Max. fill volume: ...........................m
3
Further details regarding the individual steps (cont.)
16
Commissioning, inspection, maintenance
5692 405 GB

Total hardness pH value Water treatment Date
Feedwater Boiler
water
Boiler
water
Medium Metering
volume
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.
Note
Clean the inside of the condensate
drain system at least annually.
Further details regarding the individual steps (cont.)
17
Commissioning, inspection, maintenance
5692 405 GB

1. For de-watering, remove drain
hose Afrom the condensate
drain.
2. Clean the inside of the condensate
drain once more with the plastic
brush.
3. Clean the siphon (if installed).
4. Clean the inside of the pipes of the
condensate drain system and the
neutralising system.
Neutralising system operat-
ing instructions
5. Connect the line with a U-bend to
the condensate drain and fill with
water or fit a siphon and fill that
with water.
Note
There is a risk of flue gas escaping
if the U-bend or siphon is not filled
with water.
6. Connect the supply line to the neu-
tralising system and make a proper
connection between the conden-
sate drain and the sewer entry.
Adjusting the burner
Observe the burner manufacturer's
instructions.
Instructing the system user
The installer must instruct the user in
the operation of the system.
Further details regarding the individual steps (cont.)
18
Commissioning, inspection, maintenance
5692 405 GB

Operating and service documents
1. Complete and detach the customer
registration card:
&Hand the system user this part
for safekeeping.
&Retain the heating engineer's
part.
2. File all parts lists, operating and
service instructions in the folder
andhandthisovertothesystem
user.
Further details regarding the individual steps (cont.)
19
Commissioning, inspection, maintenance
5692 405 GB

When ordering spare parts:
Quote the type and serial no. (see
type plate) and the item no. of the
required part (as per this parts list).
Obtain standard parts from your local
supplier.
069 Burner plate pack
070 Boiler door
071 Packing
072 Mounting bracket
073 Packing 20 x 15
074 Thermal insulation block
075 Thermal insulation mat
076 Stud
077 Packing
080 Mating flange
081 Gasket PN 6
082 Gasket PN 6
083 Mating flange
084 Gasket PN 6
086 Mating flange
087 Gasket PN 6
090 Flue gas box, complete (with
items 091, 092 and 094)
091 Cover
092 Silicone clamping profile N 851
093 Clamping bracket
094 Silicone foam cord
095 Sight glass
096 Hose ferrule
097 Sight and test pipe cover
098 Sight glass incl. gaskets
099 Hose
200 Upper insulation mat, front panel
201 Lower thermal insulation mat,
front panel
202 Upper insulation mat, back panel
203 Lower thermal insulation mat,
back panel
206 Spacer stud
207 Threaded stud
208 Front panel, top
209 Front panel, centre
210 Front panel, bottom
211 Back panel, top
214 Side panel, bottom
215 Side panel, top
216 Side panel, l.h. and r.h.
217 Finned panel, r.h. front, bottom
220 Finned panel, l.h. front, bottom
221 Cap
222 6-fold strain relief
223 Mounting panel, back
224 Mounting panel
225 Edge protector
226 Cable trunking
227 Channel cover
228 Insulation mat, external casing,
front top
229 Insulation mat, external casing,
back top
230 Rear fixing bracket
231 Front fixing bracket
232 Back panel, r.h. bottom
233 Back panel, l.h. bottom
234 Finned panel, l.h. centre
235 Finned panel, r.h. centre
236 Cover
237 Finned panel, l.h. top
238 Finned panel, r.h. top
239 Trunking retainer (from 314 kW
only)
Parts not shown
300 Connecting parts pack
301 Installation instructions
302 Service instructions
303 Adjustable feet pack
304 Dirko-HT sealant
305 Boiler door pack
306 Thermal insulation material pack
307 Sealant pack
Parts lists
20
Parts lists
5692 405 GB