Viessmann VITOCROSSAL 300 Betriebsanleitung

Service instructions

for contractors

VIESMANN

Vitocrossal 300

Type CR3, 787 and 978 kW

Gas condensing boiler

For applicability, see the last page

VITOCROSSAL 300

5692 398 GB 2/2011 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 398 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 398 GB

Commissioning, inspection, maintenance

Steps – commissioning, inspection and maintenance.......................................... 5

Further details regarding the individual steps....................................................... 7

Parts lists............................................................................................................ 18

Commissioning/service reports........................................................................ 23

Specification....................................................................................................... 24

Water quality

Water quality requirements.................................................................................. 25

Certificates

Declaration of Conformity..................................................................................... 27

Certificates

Manufacturer’s certificate according to the 1st BImSchV..................................... 28

Index

5692 398 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............. 7

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

system............................................................................. 7

•3. Fully opening the flue outlet damper and locking it

open................................................................................. 7

••• 4. Starting the system........................................................ 7

•5. Minimising pulsation noise............................................ 8

• • 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..... 9

• • 9. Cleaning the combustion chamber and heating

surfaces........................................................................... 9

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

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

and the sensor well for leaks......................................... 11

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

••• 13. Checking the diaphragm expansion vessel and

system pressure............................................................. 12

•14. Cleaning the sight glass in the boiler door.................. 13

• • 15. Closing the boiler door.................................................. 13

•16. Checking the thermal insulation................................... 13

• • 17. Checking the mixer for ease of operation and leaks... 13

• • 18. Checking the water quality............................................ 14

• • 19. Cleaning and reconnecting the condensate drain

system............................................................................. 14

•20. Checking the installation room ventilation

Commissioning, inspection, maintenance

Steps – commissioning, inspection and maintenance

5692 398 GB

Commissioning steps

Inspection steps

Maintenance steps Page

•21. Checking the flue system for leaks

• • 22. Adjusting the burner...................................................... 15

• • 23. Checking the gaskets/seals on the flue side............... 16

•24. Instructing the system user........................................... 17

•25. Operating and service instructions.............................. 17

Commissioning, inspection, maintenance

Steps – commissioning, inspection and… (cont.)

5692 398 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 the system

Record the fill volume, water hardness

and pH value on page 14.

Permissible boiler operating pressure: 4

bar.

!Please note

Unsuitable water qualities can

result in damage to the boiler

body and the heating system.

According to VDI Directive 2035,

the heating system must be filled

and operated with water with a

sum of alkaline earths not

exceeding 0.02 mol/m3 (overall

hardness 0.11 °dH).

Observe the "Water quality

requirements" on page 25.

Fully opening the flue outlet damper and locking it open

The damper must be in the horizontal

position.

Note

For handling the damper, see "Minimis-

ing pulsation noise", page 8.

Starting the system

Operating instructions – control

unit, burner and neutralising sys-

tem, service instructions – control

unit and burner manufacturer's

documentation

1. Check the heating system pressure.

Permissible boiler operating pres-

sure: 4 bar

2. Check that the installation room vent

is open.

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.

Commissioning, inspection, maintenance

Further details regarding the individual steps

5692 398 GB

6. Switch ON the mains isolator, the

switch for the heating circuit pump

and the burner control 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/seals and plugs,

and retighten if necessary.

Note

We recommend you check all con-

nections on the heating water side for

leaks after approx. 500 hours run

(see page 11).

9. Check the boiler door and cleaning

cover a few days after commissioning

and retighten all screws.

Minimising pulsation noise

Whatever the make of boiler, burner or flue system, sound flue systems can still create

pulsation noise. A change of resonance may be affected by rotating the damper fitted

into the flue outlet.

1. Undo M 10 nut A on lever B of

rotary damper C.

2. Adjust the lever until all pulsating

noise has ceased (the lever mirrors

the damper position).

3. Lock the rotary damper with M 10

nut.

4. Readjust the burner if required.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 398 GB

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

1. Remove the gas supply pipe.

2. Undo the four screws on the boiler

door and open the door.

!Please note

Scratches inside the combustion

chamber can lead to corrosion.

Never insert tools or other objects

into the combustion chamber.

Separating the neutralising system from the heat exchanger

module and connecting the drain hose

1. Separate hose or pipe A to the neu-

tralising system from siphon B.

2. Remove siphon B from condensate

drain C.

3. Clean the inside of condensate drain

C with a plastic brush.

4. Connect drain hose D to conden-

sate drain C and run to a sewer.

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 corrosion.

Only use plastic brushes, NOT

wire brushes or sharp objects.

1. Clean the combustion chamber and

heating surfaces.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 398 GB

■ For normal cleaning, flush the heat-

ing surfaces thoroughly with a

water jet.

■ However, you may use cleaning

agents if you notice stubborn resi-

dues, surface discolouration or

soot deposits.

For this, observe the following:

– Only use solvent-free cleaning

agents. Ensure that no cleaning

agents enter between the boiler

body and the thermal insulation.

– Remove soot deposits with alka-

line cleaning agents with addi-

tional surfactants (e.g. Fauch

600).

– Remove coatings and surface

discolouration (yellow-brown)

with slightly acidic, chloride-free

cleaning agents based on phos-

phoric acid (e.g. Antox 75 E).

2. Remove loose deposits from the

boiler; flush the heating surfaces and

the flue gas collector thoroughly with

a water jet.

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 parts

1. Check gaskets and the packing cord

in the boiler door for damage.

2. Check the thermal insulation compo-

nents of the boiler door for possible

damage.

3. Replace any damaged parts.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 398 GB

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