Viessmann VITOCROSSAL 300 Betriebsanleitung

VIESMANN

Service instructions

for contractors

Vitocrossal 300

Type CT3, 187 to 635 kW

Gas fired condensing boiler

VITOCROSSAL 300

5692 405 GB 2/2007 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

designed for qualified personnel.

&Work on gas equipment must only

be carried out by a qualified gas fit-

ter.

&Work on electrical equipment must

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

Observe the following when working

on this system

&all legal instructions regarding the

prevention of accidents,

&all legal instructions regarding

environmental protection,

&theCodeofPracticeofrelevant

trade associations,

&all current safety regulations as

defined by DIN, EN, DVGW, TRGI,

TRF, VDE and all locally applicable

standards.

If you smell gas

Danger

Escaping gas can lead to

explosions which may result in

serious injury.

&Never smoke. Prevent naked

flames and sparks. Never

switch lights or electrical

appliances 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

building.

&Shut off the electricity supply

to the building from a safe

place (outside the building).

If you smell flue gas

Danger

Flue gas can lead to life-threa-

tening poisoning.

&Shut down the heating sys-

tem.

&Ventilate the boiler room.

&Closealldoorsleadingtothe

living space.

Safety instructions

5692 405 GB

Workingonthesystem

&When using gas as fuel, also close

the main gas shut-off valve and

safeguard against unauthorised

reopening.

&Isolate the system from the power

supply 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

unauthorised reconnection.

!Please note

Electronic modules can be

damaged 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

fulfil a safety function can com-

promise 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

compromise its function. Instal-

ling non-authorised compo-

nents and non-approved

modifications/conversion can

compromise safety and may

invalidate our warranty.

For replacements, use only ori-

ginal spare parts from

Viessmann or those which are

approved by Viessmann.

Safety instructions (cont.)

Safety instructions

5692 405 GB

Commissioning, inspection, maintenance

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

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

Parts lists .................................................................................................. 20

Commissioning/service reports............................................................... 28

Specification............................................................................................. 29

Certificates

Declaration of conformity ............................................................................ 33

Manufacturer's certificate according to the 1st BImSchV [Germany]............. 34

Index

5692 405 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 heating system .............................................. 7

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

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

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

•• 8. Separating the neutralising system from the boiler

and connecting the drain hose ........................................ 9

•• 9. Cleaning the combustion chamber and heating

surfaces.................................................................................... 10

•• 10. Checking gaskets and thermal insulation

components ............................................................................ 11

•• 11. Checking all heating water connections and the

sensor well for leaks ............................................................ 11

•• 12. Checking the function of the safety equipment......... 11

••• 13. Checking the diaphragm expansion vessel and

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

•• 14. Checking the flue gas header for soundness............. 14

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

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

•17. Checking the thermal insulation ..................................... 15

•• 18. Checking the mixer for obstructions and leaks ........ 15

•• 19. Check the water quality ...................................................... 16

•• 20. Cleaning and reconnecting the condensate drain

system....................................................................................... 17

Steps –commissioning, inspection and maintenance

Commissioning, inspection, maintenance

5692 405 GB

Commissioning steps

Inspection steps

Maintenance steps Page

!!!



•21. Checking the boiler room ventilation

•22. Checking the function of the flue gas system

••23. Adjusting the burner............................................................ 18

•24. Instructing the system user .............................................. 18

•25. Operating and service documents ................................. 19

Steps –commissioning, inspection and . . . (cont.)

Commissioning, inspection, maintenance

5692 405 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,

setittoamaximumof110°C.

Control unit installation and

service instructions

Filling the heating system with water and venting the system

Record the fill volume, water hard-

ness and pH value on page 16

and 17. !Please note

Unsuitable water qualities can

result in damage to the boiler

body and the heating system.

Observe the "Water quality

requirements" on page 30.

Fully opening the flue outlet damper and locking it open

The damper must be in the horizontal

position.

Note

For handling the damper, see "Mini-

mising pulsation noises", page 8.

Starting the heating system

Operating instructions –con-

trol unit, burner and neutralis-

ing system, service

instructions –control unit and

burner manufacturer's docu-

mentation

1. Check the heating system pres-

sure.

Permissible boiler operating pres-

sure: 4 bar

2. Check that the boiler room ventila-

tion aperture is open.

3. Check the gas supply pressure.

4. Check that the cleaning aperture

ontheflueoutletisclosed.

5. Open the gas supply line shut-off

valves.

6. Switch ON the main isolator, the

switch for the heating circuit pump

and the burner control switch, in

that order.

Burner manufacturer's oper-

ating instructions

Further details regarding the individual steps

Commissioning, inspection, maintenance

5692 405 GB

7. Check the function of the neutralis-

ing system.

Neutralising system operat-

ing instructions

8. Check all gaskets/seals and plugs

and retighten, if necessary.

Note

We recommend you check all heat-

ing water connections after approx.

500 hours for leaks (see page 11).

9. Check the boiler door and clean-

out cover a few days after commis-

sioning and retighten all screws.

Minimising pulsation noise

Whatever the make of boiler, burner or flue gas 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.

Further details regarding the individual steps (cont.)

Commissioning, inspection, maintenance

5692 405 GB

1. Undo M 10 nut Aon lever Bof

rotary damper C.

2. Adjust the lever until all pulsating

noises have ceased (the lever mir-

rors the damper position).

3. Lock the rotary damper with M 10

nut.

4. Readjust the burner, if required.

Shutting down the heating system

1. Switch OFF the main isolator or the

power supply and safeguard

against unauthorised reconnection.

2. Pull plug-in connectors 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 screws on the boiler door

and open the door.

!Please note

Scratches inside the combus-

tion chamber can lead to corro-

sion.

Neverputtoolsorotherobjects

into the combustion chamber.

Separating the neutralising system from the boiler and con-

necting the drain hose

1. Separate hose or pipe Ato the

neutralising system from the flue

gas collector or siphon.

2. Remove the siphon (if installed)

from the condensate drain.

Further details regarding the individual steps (cont.)

Commissioning, inspection, maintenance

5692 405 GB

3. Clean the inside of the condensate

drain with a plastic brush.

4. Connect the drain hose to the con-

densate drain and run to a sewer.

Cleaning the combustion chamber and heating surfaces

!Please note

Contact with unalloyed iron

and scratches on parts in con-

tact with flue gases can lead to

corrosion.

Only use plastic brushes, NOT

wire brushes or sharp objects.

1. Clean the combustion chamber

and the heating surfaces.

&For normal cleaning, flush the

heating surfaces with a water jet.

&However, you may use cleaning

agents if you notice stubborn

residues, surface discolouration

or soot deposits.

For this, observe the following:

–Only use solvent-free cleaning

agents. Ensure that no cleaning

agent enters between the boiler

body and the thermal insula-

tion.

–Remove soot deposits with

alkaline cleaning agents with

additional surfactants (e.g.

Fauch 600).

–Remove coatings and surface

discolouration (yellow-brown)

with slightly acidic, chloride-

free cleaning agents based on

phosphoric acid (for example,

Antox 75 E).

2. Remove loose deposits from the

boiler; flush the heating surfaces

and the flue gas header thoroughly

withawaterjet.

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

Further details regarding the individual steps (cont.)

Commissioning, inspection, maintenance

5692 405 GB

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