Viessmann VITOCROSSAL 300 Betriebsanleitung

Service instructions

for contractors

VIESMANN

Vitocrossal 300

Type CT3U, 400 to 630 kW

Gas condensing boiler with MatriX cylinder burner

for natural gas E and LL

For applicability, see the last page

VITOCROSSAL 300

5783 337 GB 8/2017 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 intended for quali-

fied contractors.

■Work on gas installations may only be carried out by

a registered gas fitter.

■Work on electrical equipment may 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 to be observed

■National installation regulations

■Statutory regulations for the prevention of accidents

■Statutory regulations for environmental protection

■Codes of practice of the relevant trade associations

■All current safety regulations as defined by DIN, EN,

DVGW, TRGI, TRF, VDE and all locally applicable

standards

aÖNORM, EN, ÖVGW G K directives,

ÖVGW-TRF and ÖVE

cSEV, SUVA, SVGW, SVTI, SWKI, VKF and

EKAS guideline 1942: LPG, part 2

Safety instructions for working on the system

Working on the system

■Where gas is used as the fuel, close the main gas

shut-off valve and safeguard it against unintentional

reopening.

■Isolate the system from the power supply, 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 reconnection.

■Wear suitable personal protective equipment when

carrying out any work.

Danger

Hot surfaces can cause burns.

■Before maintenance and service work, switch

OFF the appliance 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 elec-

trostatic discharge.

Prior to commencing work, touch earthed

objects such as heating or water pipes to dis-

charge static loads.

Repair work

!Please note

Repairing components that fulfil a safety func-

tion can compromise the safe operation of the

system.

Replace faulty components only with genuine

Viessmann spare parts.

Safety instructions

5783 337 GB

Auxiliary components, spare and wearing parts

!Please note

Spare and wearing parts that have not been tes-

ted together with the system can compromise its

function. Installing non-authorised components

and making non-approved modifications or con-

versions can compromise safety and may inva-

lidate our warranty.

For replacements, use only original spare parts

supplied or approved by Viessmann.

Safety instructions for operating the system

If you smell gas

Danger

Escaping gas can lead to explosions which may

result in serious injury.

■Do not 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.

■Evacuate any people from the danger zone.

■Notify your gas or electricity supply utility from

outside the building.

■Have the power supply to the building shut off

from a safe place (outside the building).

If you smell flue gas

Danger

Flue gas can lead to life threatening poisoning.

■Shut down the heating system.

■Ventilate the installation site.

■Close doors to living spaces to prevent flue

gases from spreading.

What to do if water escapes from the appliance

Danger

If water escapes from the appliance there is a

risk of electrocution.

Switch OFF the heating system at the external

isolator (e.g. fuse box, domestic distribution

board).

Danger

If water escapes from the appliance there is a

risk of scalding.

Never touch hot heating water.

Condensate

Danger

Contact with condensate can be harmful to

health.

Never let condensate touch your skin or eyes

and do not swallow it.

Flue systems and combustion air

Ensure that flue systems are clear and cannot be

sealed, for instance due to accumulation of conden-

sate or other external causes.

Avoid continuous condensate disposal with a wind pro-

tector.

Ensure an adequate supply of combustion air.

Inform system users that subsequent modifications to

the building characteristics are not permissible (e.g.

cable/pipework routing, cladding or partitions).

Danger

Leaking or blocked flue systems, or an inade-

quate supply of combustion air can cause life

threatening poisoning from carbon monoxide in

the flue gas.

Ensure the flue system is in good working order.

Vents for supplying combustion air must be non-

sealable.

Extractors

Operating appliances that exhaust air to the outside

(extractor hoods, extractors, air conditioning units, etc.)

can create negative pressure. If the boiler is operated

at the same time, this can lead to a reverse flow of flue

gas.

Danger

The simultaneous operation of the boiler and

appliances that exhausts air to the outside can

result in life threatening poisoning due to a

reverse flow of flue gas.

Fit an interlock circuit or take suitable steps to

ensure an adequate supply of combustion air.

Safety instructions

Safety instructions (cont.)

5783 337 GB

1. Information Symbols ................................................................................................. 5

Intended use .......................................................................................... 5

2. Commissioning, inspec-

tion, maintenance

Steps - commissioning, inspection and maintenance ............................ 6

3. Control unit Setting the codes at the control unit ...................................................... 25

4. Troubleshooting Diagnosis ............................................................................................... 32

■Faults displayed on the display and programming unit (fault codes) .. 32

■Faults without fault display ................................................................. 37

5. Burner control unit flow

chart

................................................................................................................ 38

6. Parts lists Overview of assemblies ......................................................................... 41

Boiler assembly ..................................................................................... 42

Thermal insulation assembly ................................................................. 44

Burner assembly .................................................................................... 46

Parts not shown ..................................................................................... 48

7. Component overview ................................................................................................................ 49

8. Connection and wiring dia-

gram

Burner control unit connection diagram ................................................. 50

■MatriX cylinder burner ........................................................................ 50

Mains filter unit connection diagram ...................................................... 51

9. Water quality requirements ................................................................................................................ 52

10. Reports Water quality .......................................................................................... 54

Settings and test values ......................................................................... 54

11. Specification ................................................................................................................ 56

12. Final decommissioning

and disposal

................................................................................................................ 57

13. Certificates EU Declaration of Conformity ................................................................ 58

Manufacturer's certificate ....................................................................... 59

14. Keyword index ................................................................................................................ 60

Index

5783 337 GB

Symbol Meaning

Reference to other document containing

further information

Step in a diagram:

The numbers correspond to the order in

which the steps are carried out.

Warning of material losses and environ-

mental pollution

Live electrical area

Pay particular attention.

■Component must audibly click into place.

■Acoustic signal

■Fit new component.

■In conjunction with a tool: Clean the sur-

face.

Dispose of component correctly.

Dispose of component at a suitable collec-

tion point. Do not dispose of component in

domestic waste.

The steps in connection with commissioning, inspec-

tion and maintenance are found in the "Commission-

ing, inspection and maintenance" section and identified

as follows:

Symbol Meaning

Steps required during commissioning

Not required during commissioning

Steps required during inspection

Not required during inspection

Steps required during maintenance

Not required during maintenance

Intended use

The appliance is only intended to be installed and

operated in sealed unvented heating systems that

comply with EN 12828, with due attention paid to the

associated installation, service and operating instruc-

tions 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 purpose other

than the heating up of heating water shall be deemed

inappropriate.

Intended use presupposes that a fixed installation in

conjunction with permissible components designed for

this purpose has been carried out.

Every other use will be deemed to be inappropriate.

Any resulting losses are excluded from the manufac-

turer's liability.

Any usage beyond this must be approved by the man-

ufacturer for the individual case.

Intended use also includes the adherence to mainte-

nance and inspection intervals.

Information

Symbols

5783 337 GB

Information

Commissioning steps

Inspection steps

Maintenance steps Page

• • 1. Information on maintenance work.................................................................................... 8

•2. Checking the high limit safety cut-out setting................................................................ 8

•3. Filling the heating system with water and venting......................................................... 8

•4. Filling the trap with water.................................................................................................. 8

••• 5. Commissioning the system............................................................................................... 9

•6. Checking the gas type....................................................................................................... 10

•7. Converting to natural gas LL............................................................................................ 10

••• 8. Checking static pressure and supply pressure.............................................................. 11

••• 9. Checking the CO2 content................................................................................................. 12

••• 10. Checking the CO content

••• 11. Checking the flue gas temperature

• • 12. Checking the ionisation current....................................................................................... 14

• • 13. Shutting down the system................................................................................................. 14

• • 14. Opening the boiler door..................................................................................................... 15

• • 15. Separating the neutralising system from the boiler, connecting the drain hose......... 16

• • 16. Cleaning the combustion chamber and heating surfaces............................................. 17

• • 17. Checking the gaskets and thermal insulation sections................................................. 17

• • 18. Checking all connections on the heating water side for tightness............................... 17

• • 19. Cleaning and reconnecting the condensate drain system............................................. 17

• • 20. Checking the condensate drain and neutralising system (if installed)......................... 18

• • 21. Checking the burner gauze assembly.............................................................................. 18

• • 22. Checking the ignition and ionisation electrodes............................................................ 19

• • 23. Cleaning the burner........................................................................................................... 19

•24. Installing the burner........................................................................................................... 20

• • 25. Closing the boiler door...................................................................................................... 20

• • 26. Automatic tightness test on the two gas train valves.................................................... 20

• • 27. Checking the filter element in the gas line (if installed) and replacing if required

••• 28. Checking all gas connections for tightness.................................................................... 21

••• 29. Checking the rotary damper setting................................................................................. 21

•30. Performing final checks..................................................................................................... 22

• • 31. Checking the water quality................................................................................................ 22

••• 32. Checking the function of the safety valves

••• 33. Checking the temperature controller setting if a building management system is

used (DCC system)............................................................................................................ 22

• • 34. Checking the expansion vessel and system pressure................................................... 22

• • 35. Checking the flue gas collector for tightness................................................................. 23

• • 36. Checking the mixer for ease of operation and leaks...................................................... 23

••• 37. Checking the thermal insulation for firm seating

•38. Checking the flue system for leaks

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5783 337 GB

Commissioning steps

Inspection steps

Maintenance steps Page

• • 39. Checking the ventilation air apertures in the installation room (only for open flue

operation)

•40. Instructing the system user.............................................................................................. 23

•41. Operating and service documents................................................................................... 24

Commissioning, inspection, maintenance

Steps - commissioning, inspection and… (cont.)

5783 337 GB

The product contains ceramic fibres. Danger

When working with high temperature insulation

materials that contain zirconium or aluminium

silicate ceramic fibres, fibre dust may

develop. This fibre dust can be harmful to

health.

Only trained personnel may adapt or replace the

insulation. Wear suitable protective clothing,

especially breathing equipment and safety gog-

gles.

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 service instructions

Filling the heating system with water and venting

Record the fill volume, water hardness and pH value in

the table on page 54. !Please note

Unsuitable water quality can result in damage to

the boiler shell and the heating system.

Observe the "Water quality requirements" on

page 52 onwards.

Filling the trap with water

Fig. 1

1. Remove lower back panel A by undoing the 4

quarter-turn rotary latches B.

2. Undo the siphon and fill with water, otherwise flue

gas may escape.

Commissioning, inspection, maintenance

Information on maintenance work

5783 337 GB

3. Check that the condensate can drain freely. 4. Refit the siphon.

Commissioning the system

Control unit operating and service instructions,

and neutralising system operating instructions

01. Check the heating system pressure.

Permissible boiler operating pressure: 5.5 bar

(550 kPa)

02. For open flue operation: Check that the ventilation

facility in the installation room is open.

03. Check the gas supply pressure.

04. Open the gas line shut-off valves.

05. Switch ON the mains isolator (outside the installa-

tion room).

06.

A B

Fig. 2

Switch ON system ON/OFF switch B at the con-

trol unit. If fault indicator A on the control unit illu-

minates and display C on the burner control unit

flashes, first reset the system. For this, press reset

button D on the burner control unit.

Note

The system can enter a fault state during commis-

sioning due to a lack of gas in the gas line. The

fault indicator on the control unit then illuminates.

Purge the gas line again and reset the burner con-

trol unit.

07. Adjust the codes on the boiler control unit in

accordance with the table on page 25.

Control unit installation and service instruc-

tions

08. Check the function of the neutralising system and

the hydraulic seal in the trap.

Neutralising system operating instructions

09. Check all gaskets and plugs, and retighten if nec-

essary.

Note

We recommend checking all connections on the

heating water side for leaks approx. every 500

hours run. See page 17.

10. Check the boiler door and flue gas collector cover

a few days after commissioning and retighten all

screws.

Danger

For safe operation, a minimum operating pres-

sure of 0.5 bar (50 kPa) is absolutely essential.

A minimum pressure switch can be used to

safeguard this.

Commissioning, inspection, maintenance

Filling the trap with water (cont.)

5783 337 GB

1. Check with your gas supply utility regarding the

gas type and Wobbe index (Wo).

■With the natural gas E setting, the boiler can be

operated in the Wobbe index range 12.0 to

16.1 kWh/m3 (43.2 to 58.0 MJ/m3).

■With the natural gas LL setting, boilers can be

operated in the Wobbe index range 10.0 to

13.1 kWh/m3 (36.0 to 47.2 MJ/m3) (not in a or

c).

2. In the delivered condition, the burner is preset for

natural gas E. If necessary, convert the burner to

the other gas type (see page 10) in accordance

with the details provided by the gas supply utility.

3. Record the gas type in the report (on page 54).

Converting to natural gas LL

(Not in a and c)

01. Close the gas shut-off valve.

02. Switch OFF the system ON/OFF switch on the

control unit.

03. Switch OFF the mains isolator (outside the instal-

lation room) or isolate the mains power and

secure against unintentional reconnection.

04. Pull connecting cables from the gas train.

05. Undo fitting A.

Fig. 3

06. Pull compensation hose G from the gas train.

07. Release the gas train from flange E.

08. Remove restrictor C with rubber cork gasket D.

09. Secure the gas train (without restrictor C and

without rubber cork gasket D, but with O-ring B)

at flange E. Replace the factory-fitted screws

M 5 × 16 with the supplied screws M 5 × 12.

10. Secure fitting A.

11. Fit compensation hose G onto the gas train.

12. Affix supplied label "Set to..." F over the existing

label.

13. Start the burner (see page 9).

Danger

Escaping gas leads to a risk of explosion.

Check the fitting for gas tightness.

!Please note

The use of leak detection spray can result in

faulty operation.

Leak detection spray must not come into contact

with electrical contacts.

Commissioning, inspection, maintenance

Checking the gas type

5783 337 GB

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