Viessmann VITOCROSSAL 300 Betriebsanleitung

Service instructions

for contractors

VIESMANN

Vitocrossal 300

Type CT3B, 187 to 635 kW

Gas condensing boiler

For applicability, see the last page

VITOCROSSAL 300

5614 461 GB 1/2014 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 inten-

ded for qualified contractors.

■ Work on gas installations must only be

carried out by a registered 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:

■ Statutory regulations regarding the

prevention of accidents

■ Statutory regulations 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

aÖNORM, EN, ÖVGW-TR Gas,

ÖVGW-TRF and ÖVE

cSEV, SUVA, SVGW, SVTI,

SWKI, VKF and EKAS guideline

1942: LPG, part 2

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. Do not

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

supplier and your local heating

contractor from outside the

building.

■ Shut off the electricity supply to

the building from a safe place

(outside the building).

Safety instructions

5614 461 GB

If you smell flue gas

Danger

Flue gas can lead to life threat-

ening poisoning.

■ Shut down the heating system.

■ Ventilate the installation site.

■ Close all doors in the living

space.

Flue systems and combustion air

Ensure that flue systems are clear and

cannot be sealed, for instance due to

accumulation of condensate or other

causes. Ensure a sufficient supply of

combustion air.

Instruct 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 insufficient supply of com-

bustion air can cause life threat-

ening poisoning from carbon

monoxide in the flue gas.

Ensure the flue system is in

proper working order. Apertures

for supplying combustion air

must be non-closable.

Extractors

Operating appliances that extract air to

the outside (cooker hoods, extractors, air

conditioning units, etc.) can create neg-

ative pressure. If the boiler is operated at

the same time, this can lead to reverse

flow of the flue gas.

Danger

The simultaneous operation of

the boiler and appliances that

extract air to the outside can

result in life threatening poison-

ing due to reverse flow of the flue

gas.

Fit an interlock circuit or take suit-

able steps to ensure a sufficient

supply of combustion air.

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.

Danger

Hot surfaces can cause burns.

■ Before maintenance or service

work, switch OFF the appli-

ance 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 electrostatic dis-

charge.

Before beginning work, touch

earthed objects, such as heating

or water pipes, to discharge static

loads.

Safety instructions

Safety instructions (cont.)

5614 461 GB

Repair work

!Please note

Repairing components that fulfil a

safety function can compromise

the safe operation of the sys-

tem.

Faulty components must be

replaced with original 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 function. Installing non-author-

ised components and making

non-approved modifications or

conversions can compromise

safety and may invalidate the

warranty.

For replacements, use only orig-

inal spare parts supplied or

approved by Viessmann.

Safety instructions

Safety instructions (cont.)

5614 461 GB

Product information

Intended use......................................................................................................... 6

Commissioning, inspection, maintenance

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

Further details regarding the individual steps....................................................... 9

Parts lists

Overview of the assemblies................................................................................. 22

Boiler assembly.................................................................................................... 23

Thermal insulation assembly................................................................................ 27

Boiler door assembly for third party burners........................................................ 31

Commissioning/service reports........................................................................ 33

Specification....................................................................................................... 34

Certificates

Declaration of Conformity..................................................................................... 38

Certificates

Manufacturer's certificate..................................................................................... 39

Keyword index.................................................................................................... 40

Index

5614 461 GB

The appliance is only intended to be

installed and operated in sealed unven-

ted heating systems that comply with

EN 12828, with due attention paid to the

associated installation, service and

operating instructions 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 pur-

pose other than the heating up of heating

water shall be deemed inappropriate.

Intended use presupposes that a fixed

installation in conjunction with permissi-

ble components designed for this pur-

pose has been carried out.

Every other use will be deemed to be

inappropriate. Any resulting losses are

excluded from the manufacturer's liabil-

ity.

Any usage beyond this must be

approved by the manufacturer for the

individual case.

Intended use also includes the adher-

ence to maintenance and inspection

intervals.

Product information

Intended use

5614 461 GB

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

Commissioning steps

Inspection steps

Maintenance steps Page

•1. Checking the high limit safety cut-out setting............. 9

•2. Filling the heating system with water and venting...... 9

•3. Fully opening and securing the rotary damper in the

flue outlet......................................................................... 9

••• 4. Commissioning the system........................................... 9

•5. Minimising pulsation noise............................................ 10

• • 6. Shutting down the system............................................. 11

• • 7. Opening the boiler door................................................. 11

• • 8. Separating the neutralising system from the boiler

and connecting the drain hose...................................... 12

• • 9. Cleaning the combustion chamber and heating

surfaces........................................................................... 12

• • 10. Checking gaskets and thermal insulation

components.................................................................... 13

• • 11. Checking the sensor well and all connections on the

heating water side for leaks........................................... 13

• • 12. Checking the function of the safety equipment........... 14

••• 13. Checking the expansion vessel and system pressure 14

• • 14. Checking the flue gas collector for tightness.............. 16

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

• • 16. Closing the boiler door.................................................. 18

•17. Checking the thermal insulation................................... 18

• • 18. Checking the mixer for ease of operation and leaks... 18

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

• • 20. Cleaning and reconnecting the condensate drain

system............................................................................. 20

•21. Checking the installation room ventilation

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5614 461 GB

Commissioning steps

Inspection steps

Maintenance steps Page

•22. Checking the flue system for tightness

• • 23. Adjusting the burner...................................................... 21

•24. Instructing the system user........................................... 21

•25. Operating and service documents................................ 21

Commissioning, inspection, maintenance

Steps - commissioning, inspection and… (cont.)

5614 461 GB

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 serv-

ice instructions

Filling the heating system with water and venting

Record the charge volume, water hard-

ness and pH value on page 19. !Please note

Unsuitable water quality can

result in damage to the boiler

shell and the heating system.

Observe section "Water quality

requirements" on page 35.

Fully opening and securing the rotary damper in the flue outlet

The rotary damper must be in the hori-

zontal position.

Note

For correct handling of the rotary

damper, see "Minimising pulsation

noise" on page 10.

Commissioning the system

Operating instructions for control

unit, burner and neutralising sys-

tem, service instructions for con-

trol unit, and burner manufactur-

er's documentation

1. Check the heating system pressure.

Danger

For safe operation, a mini-

mum operating pressure of

0.5 bar (50 kPa) is essential.

A minimum pressure switch

can be used to safeguard

this.

Permissible boiler operating pres-

sure:

187 to 314 kW 4 bar (0.4 MPa)

408 to 635 kW 5.5 bar (0.55

MPa)

2. Check that the ventilation of the

installation room is unobstructed.

Commissioning, inspection, maintenance

Further details regarding the individual steps

5614 461 GB

3. Check the gas supply pressure.

4. Check that the cleaning aperture on

the flue outlet is closed.

5. Open the gas line shut-off valves.

6. Switch ON the mains isolator, the

switch for the heating circuit pump

and the burner ON/OFF switch, in

that order.

Burner manufacturer's oper-

ating instructions

7. Check the function of the neutralising

system.

Neutralising system operating

instructions

8. Check all gaskets and plugs, and

retighten if necessary.

Note

We recommend checking all connec-

tions on the heating water side for

tightness after approx. 500 hours run

(see page 13).

9. A few days after commissioning,

check the boiler door and retighten

the screws (tightening torque

10 Nm).

Danger

Leaks can result in a risk of

poisoning through escaping

gas.

Prior to commissioning, check

the boiler door gasket for cor-

rect seating and realign if nec-

essary.

Minimising pulsation noise

Pressure-tight flue systems can gener-

ate pulsation noise regardless of the

make of boiler, burner or flue system. A

change of resonance may be affected by

turning the rotary damper fitted into the

flue outlet.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5614 461 GB

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