Viessmann VITOCROSSAL 300 Betriebsanleitung

Service instructions

for contractors

VIESMANN

Vitocrossal 300

Type CR3B, 787 to 1400 kW

Gas condensing boiler

VITOCROSSAL 300

5692910 GB 9/2018 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 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 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

5692910

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.)

5692910

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

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

Product information ................................................................................ 6

2. Commissioning, inspec-

tion, maintenance

Steps - commissioning, inspection and maintenance ............................ 7

3. Parts lists Ordering parts ........................................................................................ 19

Parts ...................................................................................................... 20

Casing .................................................................................................... 22

Thermal insulation ................................................................................. 24

Miscellaneous ........................................................................................ 26

4. Water quality Water quality requirements .................................................................... 28

■Prevention of damage due to scaling ................................................. 28

■Prevention of damage due to corrosion on the water side ................. 29

5. Commissioning/service

reports

Water quality .......................................................................................... 30

Maintenance/service .............................................................................. 30

6. Specification ................................................................................................................ 32

7. Final decommissioning

and disposal

................................................................................................................ 33

8. Certificates EU Declaration of Conformity ................................................................ 34

Manufacturer's certificate ....................................................................... 34

9. Keyword index ................................................................................................................ 35

Index

5692910

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

5692910

Information

Vitocrossal 300, type CR3B

■Fuel: Natural gas E and natural gas LL

■Rated heating output 787 kW and 1400 kW

■Permissible operating pressure 6 bar (0.6 MPa)

Information

Product information

5692910

Information

Commissioning steps

Inspection steps

Maintenance steps Page

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

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

•3. Fully opening the rotary damper in the flue outlet and securing it............................... 8

••• 4. Commissioning the system............................................................................................... 8

•5. Minimising pulsation noise............................................................................................... 9

• • 6. Shutting down the system................................................................................................. 9

• • 7. Opening the boiler door..................................................................................................... 9

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

connecting the drain hose................................................................................................. 10

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

• • 10. Checking gaskets and thermal insulation components................................................. 10

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

tightness............................................................................................................................. 11

• • 12. Checking the function of the safety equipment.............................................................. 12

••• 13. Checking the pressure switch function........................................................................... 12

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

used (DCC system)............................................................................................................ 13

••• 15. Expansion vessel and system pressure ......................................................................... 13

•16. Cleaning the sight glass in the boiler door...................................................................... 14

• • 17. Closing the boiler door...................................................................................................... 14

•18. Checking the thermal insulation....................................................................................... 14

• • 19. Checking the water quality................................................................................................ 14

• • 20. Cleaning and reconnecting the condensate drain system............................................. 14

•21. Checking the installation room ventilation

•22. Checking the flue system for tightness

• • 23. Adjusting the burner.......................................................................................................... 15

• • 24. Checking the flue gas side tightness............................................................................... 16

•25. Instructing the system user.............................................................................................. 16

•26. Operating and service documents................................................................................... 16

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5692910

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 30.

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 28.

Fully opening the rotary damper in the flue outlet and securing it

The rotary damper must be in the horizontal position. Note

For correct handling of the rotary damper, see "Mini-

mising pulsation noise" on page 9.

Commissioning the system

Operating instructions for control unit, burner

and neutralising system, service instructions for

control unit, and burner manufacturer's docu-

mentation

01. Check the heating system pressure.

Permissible boiler operating pressure: 6 bar

(0.6 MPa)

02. Check that the installation room ventilation is

unobstructed.

03. Check the gas supply pressure.

04. Check that the cleaning aperture on the flue outlet

is closed.

05. Open the gas line shut-off valves.

06. Start the system in this order:

1. Mains isolator

2. Switch for the heating circuit pump

3. ON/OFF switch for the burner

Burner manufacturer's operating instruc-

tions

07. Check the function of the neutralising system and

the hydraulic seal in the trap.

Neutralising system operating instructions

08. 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 11.

09. Check the boiler door and cleaning cover a few

days after commissioning and retighten all screws.

10. Tighten the screws at the connecting points with

the following torque:

Boiler door 20 Nm

Flange connections 110 Nm

Module connection 60 Nm

Flue gas collector 7 Nm

Danger

For safe operation, a minimum operating pres-

sure of 0.5 bar (50 kPa) is essential.

For this, a minimum pressure switch can be

used.

Commissioning, inspection, maintenance

Checking the high limit safety cut-out setting

5692910

Whatever the make of boiler, burner or flue system,

gas-tight flue systems can still create pulsation noise.

A change of resonance may be affected by rotating the

damper fitted into the flue outlet.

Fig. 1

1. Undo M 5 screw A on lever B of the damper

lock.

2. Adjust the lever until no further pulsation noise

occurs. The lever indicates the position of rotary

damper C.

3. Tighten M 5 screw A on lever B of the damper

lock.

4. Re-adjust the burner if required.

Shutting down the system

1. Switch OFF the mains isolator or the power supply,

and safeguard against unauthorised reconnection.

2. Pull plugs fA and lÖ from the burner.

3. Close the gas shut-off valve.

Opening the boiler door

Danger

When working with high temperature insulating

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 adjust or replace

the insulation. Wear suitable protective clothing,

especially breathing equipment and safety gog-

gles.

1. Remove the gas supply pipe.

2. Loosen 4 screws on the boiler door and open it.

!Please note

Scratches inside the combustion chamber can

lead to corrosion.

Never place tools or other objects inside the

combustion chamber.

Commissioning, inspection, maintenance

Minimising pulsation noise

5692910

Fig. 2

1. Separate hose or pipework A to the neutralising

system from siphon B.

2. Undo siphon B from condensate drain C.

3. Clean condensate drain C on the inside using a

plastic brush.

4. Connect drain hose D to condensate drain C and

route it to a drainage system.

Cleaning the combustion chamber and heating surfaces

!Please note

Contact with unalloyed iron and scratches on

parts in contact with flue gases can lead to cor-

rosion.

Only use plastic brushes, not wire brushes or

sharp objects.

1. Clean the combustion chamber and heating surfa-

ces.

■For normal cleaning, flush the heating surfaces

thoroughly with a jet of water.

■You may use cleaning agents if you notice stub-

born residues, surface discolouration or soot

deposits.

For this, observe the following:

–Only use solvent-free cleaning agents. Ensure

that no cleaning agent gets between the boiler

shell and the thermal insulation.

–Remove soot deposits with alkaline cleaning

agents with surfactant additive (e.g. Fauch

600).

–Remove coatings and surface discolouration

(yellow-brown) with slightly acidic, chloride-free

cleaning agents based on phosphoric acid (e.g.

Antox 75 E).

2. Remove loosened deposits from the boiler. Thor-

oughly flush heating surfaces and the flue gas col-

lector with a jet of water.

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

Checking gaskets and thermal insulation components

1. Check gaskets and packing cord in the boiler door

for damage.

2. Check thermal insulation components on the boiler

door for damage.

3. Replace any damaged parts.

Commissioning, inspection, maintenance

Separating the neutralising system from the heat exchanger module and

connecting the drain hose

5692910

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