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

VITOCROSSAL 300

5834360 GB 1/2019 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

■Relevant country-specific safety regulations

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.

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

5834360

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.

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.)

5834360

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

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

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

■System examples ............................................................................... 6

Burner .................................................................................................... 6

2. Commissioning, inspec-

tion, maintenance

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

3. Control unit Setting the codes at the control unit ...................................................... 19

4. Functions Air pressure switch ................................................................................ 20

■Fan pressure monitoring (LDW1) ....................................................... 20

■Combustion chamber pressure monitoring (LDW2) ........................... 21

5. Parts lists Overview of assemblies ......................................................................... 23

Boiler assembly ..................................................................................... 24

■Cable set assembly ............................................................................ 26

Thermal insulation assembly ................................................................. 28

Parts not shown ..................................................................................... 30

6. Water quality requirements ................................................................................................................ 31

7. Reports Water quality .......................................................................................... 33

8. Specification ................................................................................................................ 34

9. Final decommissioning

and disposal

................................................................................................................ 35

10. Certificates EU Declaration of Conformity ................................................................ 36

Manufacturer's certificate ....................................................................... 36

11. Keyword index ................................................................................................................ 37

Index

5834360

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

5834360

Information

Vitocrossal 300, type CT3U

■Gas condensing boiler

–Rated heating output 400 to 630 kW

–For MatriX cylinder burner for natural gas E and LL

■Permissible operating pressure 5.5 bar

System examples

Available system examples: See www.viessmann-

schemes.com.

Burner

Information about commissioning, inspec-

tion and maintenance of the burner

Burner service instructions

Information

Product information

5834360

Information

Commissioning steps

Inspection steps

Maintenance steps Page

••• 1. Note on initial commissioning, inspection and maintenance........................................ 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.................................................................................................. 9

•5. Checking the gas type....................................................................................................... 9

•6. Changing the gas type....................................................................................................... 9

••• 7. Commissioning the system............................................................................................... 10

••• 8. Checking the flue gas temperature

• • 9. Opening the boiler door..................................................................................................... 11

• • 10. Separating the neutralising system, connecting the drain hose................................... 12

• • 11. Cleaning the combustion chamber and heating surfaces............................................. 13

• • 12. Cleaning and reconnecting the condensate drain pipe.................................................. 14

• • 13. Checking the condensate drain and neutralising system (if installed)......................... 14

• • 14. Checking gaskets and thermal insulation sections........................................................ 14

• • 15. Checking all connections on the heating water side for leaks...................................... 15

• • 16. Closing the boiler door...................................................................................................... 15

• • 17. Checking the filter element in the gas line (if installed); replacing if necessary

••• 18. Checking gas connections for tightness......................................................................... 15

• • 19. Checking the water quality................................................................................................ 16

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

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

used (DCC system)............................................................................................................ 16

• • 22. Checking the expansion vessel and system pressure................................................... 16

• • 23. Checking the gaskets on the flue gas side...................................................................... 17

• • 24. Checking the mixer for ease of operation and leaks...................................................... 17

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

•26. Checking the flue system for leaks

• • 27. Checking the ventilation air apertures in the installation room (open flue operation)

•28. Instructing the system user.............................................................................................. 17

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5834360

Product contains ceramic fibres

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.

Burner inspection and maintenance

Steps and settings that relate to the burner are descri-

bed in separate instructions.

"MatriX cylinder burner" installation and service

instructions

Removing the burner hood

Remove the burner hood to perform any work or make

any adjustments.

OPN CLOSE

Fig. 1

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 33. !Please note

Unsuitable water quality can result in damage to

the boiler shell and the heating system.

Observe the "Water quality requirements" on

page 31 onwards.

Commissioning, inspection, maintenance

Note on initial commissioning, inspection and maintenance

5834360

Fig. 2

1. Remove lower back panel A. To do so, undo the 4

quarter-turn rotary latches B.

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

gas may escape.

3. Check that the condensate can drain freely.

4. Refit the siphon.

Danger

Flue gas escaping from the trap can cause

potentially fatal carbon monoxide poisoning.

Always fill the trap with water before commis-

sioning.

Checking the gas type

1. Check with your gas supply utility regarding the

gas type and Wobbe index (Wo). The boiler can be

operated in the following Wobbe index ranges:

■With natural gas E:

Wobbe index range 12.0 to 16.1 kWh/m3 (43.2 to

58.0 MJ/m3)

■With natural gas LL:

Wobbe index range 10.0 to 13.1 kWh/m3 (36.0 to

47.2 MJ/m3) (not in a and c).

2. If required, convert the burner to a different gas

type in accordance with details provided by your

gas supply utility.

"MatriX cylinder burner" service instructions

Changing the gas type

"MatriX cylinder burner" service instructions

Commissioning, inspection, maintenance

Filling the trap with water

5834360

■Burner service instructions

■Vitotronic operating instructions and service

instructions

■Neutralising system operating instructions

01. Check the heating system pressure. Permissible

boiler operating pressure: 5.5 bar (550 kPa)

02. With open flue operation: Check whether the ven-

tilation measures for the installation room are

designed and open in accordance with regula-

tions.

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.

Fig. 3

Turn on ON/OFF switch B at the programming

unit of the control unit. If fault indicator A on the

control unit illuminates and display C on the

burner control unit flashes, first reset the system.

For this, press reset button D on the burner con-

trol unit.

Note

During commissioning, the appliance can enter a

fault state if there are still airlocks in the gas line.

■Purge the gas line again.

■Reset burner.

07. Adjust the codes on the boiler control unit in

accordance with the table on page 19.

Vitotronic 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 15.

10. Check the boiler door and flue gas collector a few

days after commissioning and retighten all screws.

Torque: Boiler door 18 Nm

Torque: Flue gas collector 7 Nm

Danger

For safe operation, a minimum operating pres-

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

A minimum pressure switch/limiter can be used

to safeguard this.

Checking the flue gas temperature

Commissioning, inspection, maintenance

Commissioning the system

5834360

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