Viessmann VITOCROSSAL 300 Betriebsanleitung

Service instructions

for contractors

VIESMANN

Vitocrossal 300

Type CU3A

Gas condensing boiler with MatriX gas burner and Lambda Pro Con-

trol,

Natural gas and LPG version

open and balanced flue operation

For applicability, see the last page

VITOCROSSAL 300

5692 860 GB 6/2010 Please keep safe.

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

5692 860 GB

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 860 GB

Commissioning, inspection, maintenance

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

Further details regarding the individual steps....................................................... 8

Code 1

Calling up coding level 1...................................................................................... 56

General................................................................................................................. 57

Boiler.................................................................................................................... 58

DHW..................................................................................................................... 59

Solar..................................................................................................................... 60

Heating circuit 1, heating circuit 2, heating circuit 3............................................. 61

Code 2

Calling up coding level 2...................................................................................... 67

General................................................................................................................. 67

Boiler.................................................................................................................... 75

DHW..................................................................................................................... 76

Solar..................................................................................................................... 77

Heating circuit 1, heating circuit 2, heating circuit 3............................................. 84

Diagnosis and service scans

Calling up the service menu................................................................................. 91

Diagnosis.............................................................................................................. 91

Checking outputs (actuator test).......................................................................... 93

Troubleshooting

Fault display......................................................................................................... 95

Fault codes........................................................................................................... 96

Repairs................................................................................................................. 105

Function description

Weather-compensated control unit...................................................................... 113

Internal extensions (accessories)......................................................................... 114

External extension (accessory)............................................................................ 116

Control functions.................................................................................................. 118

Allocating heating circuits to the remote control................................................... 125

Electronic combustion controller.......................................................................... 125

Designs

Internal connection diagram................................................................................. 127

External connection diagram................................................................................ 130

Parts lists............................................................................................................ 132

Index

5692 860 GB

Commissioning/service reports........................................................................ 138

Specification....................................................................................................... 143

Certificates

Declaration of conformity...................................................................................... 144

Manufacturer's certificate according to the 1st BImSchV [Germany]................... 144

Keyword index.................................................................................................... 145

Index

Index (cont.)

5692 860 GB

For further information regarding the individual steps, see the page indicated

Commissioning steps

Inspection steps

Maintenance steps Page

•1. Filling the heating system and checking the supply of

ventilation air.................................................................. 8

•2. Filling siphon with water................................................ 9

•3. Checking the power supply

•4. Changing the language (if required)............................. 9

• • 5. Setting the time and date (if required).......................... 10

•6. Designating the heating circuits................................... 10

• • 7. Checking the gas type.................................................... 10

••• 8. Removing the front panel.............................................. 11

•9. Gas type conversion (only for operation with LPG).... 12

••• 10. Function sequence and possible faults....................... 12

••• 11. Checking the static and supply pressure..................... 14

•12. Setting the maximum output......................................... 16

•13. Checking the balanced flue system tightness (annular

gap check)....................................................................... 17

•14. Removing the burner and checking the burner

gasket.............................................................................. 18

•15. Checking burner gauze assembly and thermal

insulation block.............................................................. 19

•16. Checking and adjusting the ignition and ionisation

electrodes........................................................................ 21

• • 17. Separating the neutralising system (if installed) from

the boiler and connecting the drain hose.................... 22

• • 18. Cleaning the combustion chamber and heating

surfaces........................................................................... 22

• • 19. Cleaning and reconnecting the condensate drain

system............................................................................. 23

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5692 860 GB

Commissioning steps

Inspection steps

Maintenance steps Page

• • 20. Checking that the condensate drain and neutralising

system (if installed) are not obstructed and that they

are free from leaks.......................................................... 24

• • 21. Checking gaskets and thermal insulation

components on the boiler.............................................. 25

• • 22. Checking the diaphragm expansion vessel and

system pressure............................................................. 26

• • 23. Checking the water quality............................................ 27

• • 24. Checking the mixer for obstructions and leaks........... 27

••• 25. Checking all connections on the heating water side

and DHW side for leaks

••• 26. Checking the function of safety valves

•27. Fitting the burner............................................................ 28

••• 28. Checking firm seating of electrical connections

••• 29. Checking all gas equipment for tightness at operating

pressure........................................................................... 29

• • 30. Checking the combustion quality................................. 29

• • 31. Checking the ventilation air apertures in the

installation room (only for open flue operation)

••• 32. Checking the external LPG safety valve (if installed)

•33. Matching the control unit to the heating system......... 30

•34. Adjusting the heating curves........................................ 49

•35. Connecting the control unit to the LON....................... 52

•36. Scanning and resetting the "Service" display............. 54

••• 37. Fitting the front panel..................................................... 55

•38. Instructing the system user........................................... 55

Commissioning, inspection, maintenance

Steps - commissioning, inspection and… (cont.)

5692 860 GB

Filling the heating system and checking the supply of ventilation

air

!Please note

Unsuitable fill water increases the level of deposits and corrosion and may

lead to boiler damage.

■ Thoroughly flush the entire heating system prior to filling it with water.

■ Only use fill water of potable quality.

■ Fill water, the hardness of which exceeds the following values, must be

softened, for example with a small softening system for heating water (see

Vitoset pricelist):

–Vitocrossal 300 up to 45 kW: 16.8 °dH (3.0 mol/m3)

–Vitocrossal 300 from 60 kW: 11.2 °dH (2.0 mol/m3)

■ An antifreeze additive suitable for heating systems can be added to the fill

water. The antifreeze manufacturer must verify its suitability, since other-

wise damage to gaskets and diaphragms can occur as well as noise during

heating operation. Viessmann accepts no liability for damage or conse-

quential damage.

1. Check whether the ventilation air

supply is unrestricted.

2. Check the pre-charge pressure of the

diaphragm expansion vessel when

the system is still cold.

Note

If the pre-charge pressure of the dia-

phragm expansion vessel is lower

than the static pressure of the sys-

tem, top up with nitrogen until the pre-

charge pressure (0.1 to 0.2 bar) is

higher than the static system pres-

sure. The static pressure corre-

sponds to the static head.

3. Open any installed check valves.

4. Fill the heating system with water and

vent it, until the fill pressure (0.1 to 0.2

bar) is higher than the pre-charge

pressure of the diaphragm expansion

vessel.

Permiss. operating pressure: 3 bar

Min. operating pressure: 1 bar

Commissioning, inspection, maintenance

Further details regarding the individual steps

5692 860 GB

5. Mark the set pressure at pressure

gauge A.

6. Record the fill volume, water hard-

ness and pH value on page 27.

Note

Observe the "Water quality require-

ments" on page 139.

7. Return the check valves to their oper-

ating position.

Filling siphon with water

1. Undo fitting A of siphon B, remove

the siphon and fill it with water.

Note

There is a risk of flue gas escaping if

the siphon is not filled with water.

2. Refit siphon B.

Changing the language (if required)

Note

At the commissioning stage, the display

is in German (default setting)

Extended menu:

1. å

2. "Settings"

3. "Language"

Sprache

Cesky CZ

Deutsch DE

Dansk

English

Wählen mit

4. Set the required language with /.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 860 GB

Setting the time and date (if required)

During commissioning, or after pro-

longed time out of use, the time and date

need to be reset.

Extended menu:

1. å

2. "Settings"

3. "Time / Date"

4. Set current time and date.

Designating the heating circuits

In the delivered condition, the heating

circuits are designated "Heating circuit

1", "Heating circuit 2" and "Heating

circuit 3" (if installed).

If the system user prefers, the heating

circuits can be designated differently to

suit the specific system.

Enter names for heating cir-

cuits:

Operating instructions

Checking the gas type

The boiler is equipped with an electronic combustion controller that adjusts the burner

for optimum combustion in accordance with the prevailing gas quality.

■ Consequently, for natural gas there is no adjustment required across the entire

Wobbe index range.

The boiler can operate in the Wobbe index range 9.5 to 15.2 kWh/m3(34.2 to

54,7 MJ/m3).

■ Convert the burner for operation with LPG (see "Gas type conversion" on

page 12).

1. Determine the gas type and Wobbe

index by asking your local gas supply

utility or LPG supplier.

2. Only possible on appliances with

26 and 35 kW.

Convert the burner for operation with

LPG (see page 12).

3. Record the gas type in the report on

page 138.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 860 GB

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