Viessmann VITOCROSSAL 300 User manual

for use by heating contractor
Please file in Service Binder
5673 649 - 01 04/2015
Service Instructions
VITOCROSSAL 300
Vitocrossal 300
CU3A Series 26 to 57
Floor mounted, gas-fired condensing boiler with MatriX gas burner and Lambda Pro control
For operation with natural gas and liquid propane gas
Heating input 19 to 199 MBH
5.6 to 58 kW
Read and save these instructions
for future reference.
Product may not be exactly as shown
IMPORTANT
H
Please file in Service Binder
5673 650 - 01 04/2015
Operating Instructions
VITOCROSSAL 300
With Vitotronic 200 KW6B Controls
Vitocrossal 300
CU3A Series 26 to 57
Floor mounted, gas-fired condensing boiler with MatriX gas burner and Lambda Pro control
For operation with natural gas and liquid propane gas
Heating input 19 to 199 MBH
5.6 to 58 kW
Read and save these instructions
for future reference.
Product may not be exactly as shown
IMPORTANT
H
Do not store or use gasoline or other
flammable liquids in the vicinity of this
or any other appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliances.
Do not touch any electrical switches,
do not use any phone in your building.
Immediately call your gas supplier
from a neighbor’s phone. Follow
the gas supplier’s instructions.
If you cannot reach your gas supplier,
call the fire department.
Installation and service must be
performed by a qualified installer,
service agency or the gas supplier.
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
WARNING
Improper installation, adjustment, and/
or operation could cause carbon monoxide
poisoning resulting in injury or loss of life.
This product must be installed and serviced
by a professional service technician who is
experienced and qualified in hot water boiler
installation and gas combustion.
WARNING
Please file in Service Binder
for use by heating contractor
5673 648 - 01 04/2015
Installation Instructions
Vitocrossal 300
CU3A Series 26 to 57
Floor mounted, gas-fired condensing boiler with MatriX gas burner and Lambda Pro control
For operation with natural gas and liquid propane gas
Heating input 19 to 199 MBH
5.6 to 58 kW
VITOCROSSAL 300
Read and save these instructions
for future reference.
Product may not be exactly as shown
IMPORTANT
H
Please file in Service Binder
5774 472 - 03 04/2015
Mixing Valve
Extension Module
Installation Instructions
for use by heating contractor
Mixing Valve Extension Module
for one heating circuit with mixing valve
Product may not be exactly as shown
Read and save these instructions
for future reference.
IMPORTANT
Certified as a component
part for Viessmann boilers
QUICK START GUIDE
VITOCROSSAL 300,CU3A
UNCOMPROMISE.US
FOR LPG CONVERSION DETAIL, SEE PAGES 14-15
FOR CODINGS, SEE PAGES 57-70
FOR TROUBLESHOOTING AND FAULT CODES, SEE PAGES 75-86
FOR WIRING DIAGRAM, SEE PAGES 94-95
FOR HEATING/DHW PUMP AND SENSOR WIRING, SEE PAGES 24-38
FOR SYSTEM LAYOUT, SEE PAGES 40-48
FOR PROGRAMMING, SEE PAGES 11-33
FOR PUMP AND SENSOR WIRING, SEE PAGE 8
Vitocrossal 300 CU3A Quick Start Guide:
INSTRUCTIONS
UNCOMPROMISE.US
For the latest updates on the Quick Start Guide, please visit
9442120 05 / 2015

ABOUT THIS QUICK START GUIDE: The programming and wiring recommendations in this guide are
intended to enable immediate initial service under the most common conditions; they are not intended to be a
substitute for detailed, site-specific set-up and commissioning. Only for use by trained, licensed heating contractor.
SEE THE INSTALLATION AND SERVICE INSTRUCTIONS FOR IMPORTANT SAFETY INFORMATION.
VITOCROSSAL CU3A QUICK START GUIDE
FOR HEATING ONLY:
CONNECT #1 OUTDOOR SENSOR TO SCREW
TERMINALS X3, 1 + 2 ON BOILER CONTROL
USE #20 ON THE POWER/PUMP INTERFACE
TO POWER SINGLE-ZONE HEATING PUMP
DIRECTLY. ON ZONED SYSTEMS, USE #20
TO POWER ZR (REMOVE ZC-ZR JUMPER)
ON SWITCHING RELAY PROVIDED BY
OTHERS
Vitocrossal 300 CU3A Quick Start Guide:
WIRING CONNECTIONS
TO ADD A MIXING VALVE:
CONNECT THE PURPLE #145 ON THE MIXING
VALVE EXTENSION TO THE #145 KM BUS
ON THE BOILER’S EA1 EXTENSION USING
18/2 WIRE
CONNECT THE #2 SUPPLY SENSOR TO #2 ON
THE MIXING VALVE EXTENSION. CONNECT
THE MIXING VALVE MOTOR TO #52 ON THE
MIXING VALVE EXTENSION
POWER THE MIXING PUMP WITH #20 ON
THE MIXNG VALVE EXTENSION
TO ADD DOMESTIC HOT WATER:
CONNECT THE #5 DHW SENSOR TO THE RED
#5 PLUGS ON THE BOILER CONTROL. DHW
OPERATION WILL BE AUTO-ENABLED IN THE
CONTROL PROGRAM.
USE A SEPARATE DHW PUMP; POWER IT
WITH #21 ON THE POWER/PUMP INTERFACE
BEFORE BEGINNING THE QUICK START PROCESS:
1. Verify that power (120/1/60 wth earth ground, properly polarized) is supplied to the #40
connections on the POWER/PUMP INTERFACE and MIXING CONTROL, if used.
2. Verify that the fuel gas supply is available (4”-14”WC Nat, 10”-14”WC LPG) and that air has been purged from the piping.
3. Verify boiler/system water fill and purge.
4. Verify proper venting and combustion air supply.
ACCESS TO THE CU3A WIRING:
BOILER CONTROL
BOILER CONTROL
POWER/PUMP INTERFACE
POWER/PUMP INTERFACE
REMOVE FASTENERS 1 - 6
BOILER
CONTROL
EA1 EXTENSION POWER/PUMP INTERFACE
EA1 EXTENSION MIXING VALVE EXTENSION
(OPTIONAL)
Remove fastners
in order.
1.

1. Set adusting screw to position 2
2. Turn power switch on.
3. Program for LPG operation
4. Refer to SERVICE INSTRUCTIONS, pages 14-15
for important safety information and
pressure check.
Vitocrossal 300 CU3A Quick Start Guide:
LPG CONVERSION
OK Confirms your selection or saves the setting
?Calls up help or additional information on the selected menu
Calls up the extended menu
Takes you to the previous step in the menu or cancels
a setting that has been started
Cursor keys to scroll through the menu or to set values
LEGEND
FROM THE HOME SCREEN
Press
Then Press OK and
together for 4 seconds.
Press OK and together for 4 seconds
Press OK then 4 times
Press OK
Press OK
Press OK
Press OK
Press until you see :
Press until you see :
Press until you see :
Press until you see :
1
4
7
9
11
2
5
10
12
3
6
8
DONE
START

Vitocrossal 300 CU3A Quick Start Guide:
PROGRAMMING
Setting Time, Date, and Heating Curve for heating circuit #1 (High Temp)
Press Press 3 times
Press 4 times
Press 2 times
Press 4 times
Press 3 times Press 7 times
Press 3 times
Press OK
Press OK
Press PressPress OK Press OK
Press or to set time Press or to set date
Press OK
Press OK
Press OK
Press OK
Press OK
Press OK
Press Press OK
DONE
START
1
4
7
2
5
8
3
6
9
11
14
10
13
12
15
Setting Domestic Hot Water Operation
DHW operation is auto-enabled with the connection of the #5 tank sensor and
DHW temperature is set to 122F.
Refer to OPERATING INSTRUCTIONS for more programming options.
Setting the Heating Curve for mixing circuit #2 (Low Temp)
Press Press OKPress OK Press (RIGHT)
Press 7 times
DONE
1
4
2
5
3
6
Press 5 times Press 3 timesPress OK Press OK
START