Viessmann VITOCROSSAL 300 Betriebsanleitung

Service instructions

for contractors

VIESMANN

Vitocrossal 300

Type CR3B, 787 to 1400 kW

Gas condensing boiler

VITOCROSSAL 300

5836858 GB 9/2020 Please keep safe.

Please follow these safety instruc-

tions 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 environmen-

tal pollution.

Note

Details identified by the word "Note"

contain additional information.

Target group

These instructions are exclusively inten-

ded for qualified 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 per-

son 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

■Relevant country-specific safety regu-

lations

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 safe-

guard it against unintentional reopen-

ing.

■Isolate the system from the power sup-

ply, 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 recon-

nection.

■Wear suitable personal protective

equipment when carrying out any work.

Safety instructions

5836858

Danger

Hot surfaces and fluids can lead to

burns or scalding.

■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 pipe-

work.

!Please note

Electronic assemblies can be dam-

aged by electrostatic discharge.

Prior to commencing work, touch

earthed objects such as heating or

water pipes to discharge static

loads.

Repair work

!Please note

Repairing components that fulfil a

safety function can compromise the

safe operation of the system.

Replace faulty components only

with genuine Viessmann spare

parts.

Auxiliary components, spare and

wearing parts

!Please note

Spare and wearing parts that have

not been tested together with the

system can compromise its func-

tion. Installing non-authorised com-

ponents and making non-approved

modifications or conversions can

compromise safety and may invalid-

ate our warranty.

For replacements, use only original

spare parts supplied or approved by

Viessmann.

Safety instructions

Safety instructions (cont.)

5836858

Safety instructions for operating the system

If you smell gas

Danger

Escaping gas can lead to explo-

sions which may result in serious

injury.

■Do not 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.

■Evacuate any people from the

danger zone.

■Notify your gas or electricity sup-

ply 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 spread-

ing.

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 condensate or other

external causes.

Ensure an adequate supply of combus-

tion air.

Inform system users that subsequent

modifications to the building characteris-

tics are not permissible (e.g. cable/pipe-

work routing, cladding or partitions).

Danger

Leaking or blocked flue systems, or

an inadequate supply of combus-

tion 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-seala-

ble.

Extractors

Operating appliances that exhaust air to

the outside (extractor hoods, extractors,

air conditioning units, etc.) can create

negative pressure. If the boiler is oper-

ated at the same time, this can lead to a

reverse flow of flue gas.

Safety instructions

Safety instructions (cont.)

5836858

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 suita-

ble steps to ensure an adequate

supply of combustion air.

Safety instructions

Safety instructions (cont.)

5836858

1. Information Key to date of manufacture .................................................................... 7

Symbols ................................................................................................. 7

Intended use .......................................................................................... 8

Product information ................................................................................ 8

■System examples ............................................................................... 8

■Spare parts lists .................................................................................. 8

2. Commissioning, inspec-

tion, maintenance

Steps - commissioning, inspection and maintenance ............................ 9

3. Water quality Water quality requirements .................................................................... 22

■Prevention of damage due to scaling ................................................. 22

■Prevention of damage due to corrosion on the water side ................. 23

4. Commissioning/service

reports

Water quality .......................................................................................... 24

Maintenance/service .............................................................................. 24

5. Specification ................................................................................................................ 26

6. Final decommissioning

and disposal

................................................................................................................ 27

7. Certificates EU Declaration of Conformity ................................................................ 28

Manufacturer's certificate ....................................................................... 28

■Vitocrossal 300, type CR3B ................................................................ 28

8. Keyword index ................................................................................................................ 29

Index

5836858

1 2 43 5 6 7

X X 0 1 2 5 5

Day

Year

Week

Fig. 1

Digits 1 and 2Internal Viessmann information

Digits 3 and 70 and 5 = calendar week 05 = 5th calendar week

Digits 4 and 61 and 5 = year 2015

Digit 52 = 2nd day of the working week

(Monday = 1, Tuesday = 2, etc.)

Example 0501255 corresponds to date of manufacture: 27 January 2015

Symbols

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

Information

Key to date of manufacture

5836858

Information

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.

Product information

Vitocrossal 300, type CR3B

■Fuel: Natural gas E, natural gas LL and LPG

■Rated heating output 787 kW and 1400 kW

■Permissible operating pressure 6 bar (0.6 MPa)

System examples

Available system examples: See

www.viessmann-schemes.com.

Spare parts lists

Information about spare parts can be found at

www.viessmann.com/etapp or in the Viessmann

spare part app.

Information

Intended use

5836858

Information

Commissioning steps

Inspection steps

Maintenance steps Page

•1. Checking the high limit safety cut-out setting................................................................ 10

•2. Filling the heating system with water and venting......................................................... 10

••• 3. Filling the trap with water.................................................................................................. 11

•4. Fully opening and locking the butterfly valve in the flue outlet (if installed)............... 11

••• 5. Commissioning the system............................................................................................... 12

•6. Minimising pulsation noise............................................................................................... 13

• • 7. Shutting down the system................................................................................................. 13

• • 8. Opening the boiler door..................................................................................................... 13

• • 9. Separating the neutralising system from the heat exchanger module and

connecting the drain hose................................................................................................. 14

• • 10. Cleaning the combustion chamber and heating surfaces............................................. 14

• • 11. Checking the boiler door/burner gaskets and thermal insulation sections................. 14

••• 12. Checking all connections and the sensor well on the heating water side for

tightness............................................................................................................................. 16

• • 13. Checking the function of the safety equipment.............................................................. 18

••• 14. Checking the pressure switch function........................................................................... 18

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

used (DCC system)............................................................................................................ 18

••• 16. Expansion vessel and system pressure.......................................................................... 18

•17. Cleaning the sight glass in the boiler door...................................................................... 19

• • 18. Closing the boiler door...................................................................................................... 19

•19. Checking the thermal insulation....................................................................................... 19

• • 20. Checking the water quality................................................................................................ 20

• • 21. Cleaning and reconnecting the condensate drain system............................................. 20

•22. Checking the installation room vent

• • 23. Adjusting the burner.......................................................................................................... 20

• • 24. Checking the flue gas side tightness............................................................................... 21

•25. Checking the flue system for leaks

•26. Instructing the system user.............................................................................................. 21

•27. Operating and service documents................................................................................... 21

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5836858

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 volume filled, water hardness and pH value

on page 24.

Permissible boiler operating pressure: 6 bar (0.6 MPa). !Please note

Unsuitable water quality can result in damage to

the boiler body and the heating system.

Fill the heating system with water and operate it

in accordance with VDI Guideline 2035. The

total of alkaline earths must not exceed

0.02 mol/m3 (total hardness 0.11 °dH).

Observe the "Water quality requirements" on

page 22.

Commissioning, inspection, maintenance

Checking the high limit safety cut-out setting

5836858

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