Viessmann VITOCROSSAL 300 Bedienungsanleitung

Operating Instructions

VITOCROSSAL 300

5790 737 - 01 03/2017

for use by heating contractor

Vitocrossal 300 CA3 Series 2.5, 3.0, 3.5, 4.0, 5.0 and 6.0

with Vitotronic 300 GW6C control

Gas condensing boiler with weather-compensated control unit

Read and save these instructions for

future reference.

Please file in Service Binder

Heating input: 2500 to 6000 MBH

(733 to 1758 kW)

Product may not be exactly as illustrated.

Do not store or use gasoline or other

ﬂammable liquids in the vicinity of this

or any other appliance.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliances.

Do not touch any electrical switches,

do not use any phone in your building.

Immediately call your gas supplier

from a neighbor’s phone. Follow

the gas supplier’s instructions.

If you cannot reach your gas supplier,

call the ﬁre department.

Installation and service must be

performed by a qualiﬁed installer,

service agency or the gas supplier.

WARNING

If the information in this manual is not followed

exactly, a fire or explosion may result causing

property damage, personal injury or loss of life.

WARNING

Improper installation, adjustment, and/

or operation could cause carbon monoxide

poisoning resulting in injury or loss of life.

This product must be installed and serviced

by a professional service technician who is

experienced and qualified in hot water boiler

installation and gas/oil combustion.

IMPORTANT

5790 737 - 01

Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating

Safety, Installation and Warranty Requirements

Please ensure that these instructions are read and understood before commencing installation. Failure to comply with

the instructions listed below and details printed in this manual can cause product/property damage, severe personal

injury, and/or loss of life. Ensure all requirements below are understood and fulfilled (including detailed information

found in manual subsections).

General Information

WARNING

Installers must follow local regulations with respect

to installation of carbon monoxide detectors. Follow

the Viessmann maintenance schedule of the boiler

contained in “Service Instructions”.

Product documentation

Read all applicable documentation before commencing

installation. Store documentation near boiler in a

readily accessible location for reference in the future

by service personnel.

For a listing of applicable literature,

please see section entitled “Important

Regulatory and Safety Requirements”.

Warranty

Information contained in this and

related product documentation must

be read and followed. Failure to do

so renders the warranty null and void.

Licensed professional heating contractor

The installation, adjustment, service and maintenance

of this equipment must be performed by a licensed

professional heating contractor.

Please see section entitled

“Important Regulatory and Installation

Requirements”.

Contaminated air

Air contaminated by chemicals can cause by-products

in the combustion process, which are poisonous to

inhabitants and destructive to

Viessmann equipment.

For a listing of chemicals which

cannot be stored in or near the

boiler room, please see subsection

entitled “Mechanical Room”.

Advice to owner

Once the installation work is complete, the heating

contractor must familiarize the system operator/

ultimate owner with all equipment, as well as safety

precautions/requirements, shutdown procedure, and

the need for professional service annually before the

heating season begins.

Carbon monoxide

Improper installation, adjustment, service and/or

maintenance can cause flue products to flow into

living space. Flue products contain poisonous carbon

monoxide gas.

For information pertaining to the

proper installation, adjustment, service

and maintenance of this equipment to

avoid formation of carbon monoxide,

please see sections entitled

“Mechanical Room” and “Venting

Connection” in the Installation Instructions.

Fresh air

This equipment requires fresh air for

safe operation and must be installed

ensuring provisions for adequate

combustion and ventilation air exist.

For information pertaining to the

fresh air requirements of this product,

please see subsection entitled

“Mechanical Room”.

Equipment venting

Never operate boiler without an installed venting

system. An improper venting system can cause

carbon monoxide poisoning.

For information pertaining to

venting and chimney requirements,

please see section entitled “Venting

Connection”. All products of

combustion must be safely vented

to the outdoors.

5790 737 - 01

Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating

About these Instructions

Take note of all symbols and notations intended to draw attention to potential hazards or important product

information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below.



IMPORTANT

Warnings draw your attention to the presence of

potential hazards or important product information.

Cautions draw your attention to the presence of

potential hazards or important product information.

Helpful hints for installation, operation or maintenance

which pertain to the product.

This symbol indicates that additional, pertinent

information is to be found.

This symbol indicates that other instructions must

be referenced.

General Information

WARNING

Indicates an imminently hazardous situation which,

if not avoided, could result in death, serious injury

or substantial product/property damage.

CAUTION

Indicates an imminently hazardous situation which,

if not avoided, may result in minor injury or product/

property damage.

Product Information

WARNING

Exposing the boiler to pressures and temperatures in

excess of those listed will result in damages, and will

render warranty null and void.

The Viessmann Vitocrossal 300, CA3 boiler series is CSA

certified for Canada, is constructed in compliance with

CSA B51 Standard and carries Canadian Registration

Numbers. The boiler is suitable for a maximum operating

pressure of 160 psig and a maximum boiler water

temperature of 210°F (99°C).

The Vitocrossal 300, CA3 boiler must only be installed

in closed loop hot water heating systems using a pre-

charged membrane expansion tank.

5790 737 - 01

Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating

Table of Contents

Safety, Installation and Warranty Instructions ............... 2

About these Instructions ............................................ 3

Product Information ................................................... 3

For your Safety ......................................................... 6

Operation ................................................................. 6

Gas Smell............................................................. 6

Flue gas Smell ...................................................... 6

Dangerous conditions ............................................ 6

Working on the Equipment ..................................... 6

Combustion air and ventilation openings................... 6

Carbon monoxide .................................................. 6

Frozen water pipe hazard ....................................... 7

Boiler room conditions ........................................... 7

Maintenance and cleaning ...................................... 8

Regular maintenance and service............................. 8

Technical information ............................................ 8

Description............................................................... 9

Fuel....................................................................10

Boiler control .......................................................10

Condensate disposal .............................................10

Boiler location ......................................................10

Venting connection ..............................................10

Optimum operation...............................................10

Operation ................................................................11

Starting the heating system ...................................11

Separate heating system controls ...........................11

Domestic hot water production ..............................11

System shutdown ................................................11

Commissioning ................................................... 12

Your System is Preset at the Factory ..........................12

Energy Saving Tips...................................................13

Tips for Greater Comfort...........................................13

General Boiler Information .........................................14

System and Lead Control Boiler Section 1

Programming Unit ....................................................15

Service Display Lag Boiler Sections ............................16

Starting the Heating System....................................17

Shutting Down the Heating System ............................18

Operating Program ...................................................18

General Information

Safety

System Information

Operation

Page

5790 737 - 01

Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Table of Contents

Central Heating

DHW Heating

Further Adjustments

Scanning

Scanning Options

Emissions

Troubleshooting

Maintenance

Additional Information

Page

Time Program ..........................................................19

Room Temperature ...................................................21

Operating Program ...................................................22

Time Program ..........................................................22

Heating Curve..........................................................23

Stopping Central Heating ..........................................23

Comfort Function.....................................................24

Energy Saving Function “Economy Mode”...................25

Energy Saving Function “Holiday Program”..................26

DHW Temperature....................................................27

Operating Program ...................................................27

Time Program ..........................................................27

Setting the Display Backlighting .................................29

Naming Heating Circuits............................................29

Setting the Time and Date ........................................29

Language Selection ..................................................30

Setting the Measuring Units.......................................30

Restoring Factory Settings.........................................30

Scanning Information................................................31

Main Menu Overview................................................34

Scanning Options under “Information” ........................36

Emissions Test Mode................................................37

Rooms are Too Cold ................................................38

Rooms are Too Hot ..................................................39

There is No DHW ....................................................39

The DHW is Too Hot ................................................40

“Fault” will be Displayed ...........................................40

“Service” will be Displayed ........................................40

Inspection and Maintenance ......................................41

Service Schedule......................................................41

Additional Maintenance Information............................42

Terminology ............................................................42

5790 737 - 01

Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating

For your Safety

Working on the equipment

All personnel working on the equipment or the heating

system must have the proper qualifications and hold all

necessary licenses.

Ensure main power to equipment, heating system, and

all external controls have been deactivated. Close main

gas supply valve. Take precautions in all instances to

avoid accidental activation of power during service

work.

Combustion air and ventilation openings

Ensure that combustion air openings and ventilation

air openings in the mechanical room are open.

Carbon monoxide

The U.S. Consumer Product Safety Commission

strongly recommends the installation of carbon

monoxide detectors in buildings in which gas-burning

equipment is installed. Carbon monoxide (CO) is a

colorless, odorless gas, which may be produced during

incomplete combustion of fuel and/or when the flame

does not receive an adequate supply of combustion air.

Carbon monoxide can cause severe personal injury or

loss of life.

Therefore, carbon monoxide detectors that are in

compliance with a nationally recognized latest standard

(e.g. ANSI/UL 2034, CSA 6.19-01) should be installed

and maintained in buildings that contain gas-burning

equipment.

Note: Viessmann does not test any detectors and

makes no representation regarding any brand

or type of detector.

Incomplete combustion and poisonous gases result if the

fresh air intakes in the mechanical room are closed. Never

close these openings.

CAUTION

Operation

Before operating the boiler, make sure you fully

understand its method of operation. Your heating

contractor should always perform the initial start-up and

explain the system. Any warranty is null and void if these

instructions are not followed.

Gas smell

Follow the instructions on the front of the manual.

Flue gas smell

- Deactivate heating equipment.

- Open windows and doors.

- Inform your heating contractor immediately.

Dangerous conditions

- Deactivate main power immediately

- Close gas supply valve

CAUTION

Follow these safety instructions closely to avoid the risk

of injury and damage to property.

In emergencies

Immediately switch off the power supply, e.g. at the

separate fuse or power supply disconnect switch

(unless there is a smell of gas).

Close the shut-off valves in the oil pipes or close the

gas shut-off valve, whichever applicable.

Use suitable extinguishers in the event of fire.

Safety

5790 737 - 01

Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Safety

For your Safety (continued)

WARNING

The boiler must not be located in areas or rooms

where chemicals are stored, or aggressive vapors

from (i.e. bleach, hair spray, methyl chloride, carbon

tetrachloride or perchloroethylene) or high dust levels

or humidity levels are present. Heat exchanger

corrosion might occur and reduce the lifetime of the

boiler significantly. If above criteria are not properly

observed and boiler damage results, any warranty on

the complete boiler and related components will be

null and void.

IMPORTANT

Keep boiler and boiler room clear and free from combustible

materials, gasoline and other flammable vapors and liquids.

Do not obstruct the flow of combustion and ventilation air.

All inspection, maintenance and service must be performed

by a qualified heating contractor.

Boiler room conditions

- Do not use a room in which the air is polluted by

halogenated hydro-carbons (e.g. as contained in aerosols,

paints, solvents and cleaning agents)

- Do not use a room subject to high levels of dust

- Do not use a room subject to permanently high humidity

- The room should be frost-protected

- Max. ambient temperature 95°F (35°C).

- Provide good ventilation and do not close or obstruct vents

(if installed).

Frozen water pipe hazard

Your heating boiler is designed to provide a warm and

comfortable living environment. It is NOT designed to

ensure against freezing of water pipes.

The boiler is equipped with several safety devices that are

designed to shut down the boiler and to prevent it from

restarting in the event of various unsafe conditions.

If your boiler remains off for an extended period of time

during cold weather, water pipes may freeze and burst,

resulting in extensive water damage and conditions in

which mold could grow. Certain molds are known to

cause respiratory problems, as well as to pose other

serious health risks. In case of water damage, immediate

measures should be taken to dry out affected areas as

quickly as possible to prevent mold from developing.

If your home will be unattended for an extended period

of time during cold weather, you should...

- Shut off the water supply to the building, drain the

water pipes and add an antifreeze for potable water

to drain traps and toilet tanks. Open faucets where

appropriate.

or...

- Have someone check the building frequently during

cold weather and call a qualified service agency if

required.

or...

- Install a reliable remote temperature sensor that will

notify somebody of freezing conditions within the

home.

WARNING

Failure to protect against frozen pipes could result in

burst water pipes, serious property damage and/or

personal injury. Boiler may shut down. Do not leave

your home unattended for long periods of time during

freezing weather conditions without turning off the

water supply and draining water pipes or otherwise

protecting against the risk of frozen pipes.

Installation of additional components

The installation of additional components which have not

been tested together with the boiler can adversely affect

the function and performance of the boiler.

Our warranty does not cover and we accept no liability

for damage attributable to the installation of such

components.

5790 737 - 01

Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating

WARNING

Improper installation, adjustment, service, or

maintenance can cause flue products to flow into

living space. Flue products contain poisonous carbon

monoxide gas which can cause nausea or asphyxiation

resulting in severe personal injury or loss of life.

WARNING

As there are no user-serviceable parts on the boiler,

burners or control, the end-user must not perform

service activities of any kind on system components.

Failure to heed this warning can cause property

damage, severe personal injury, or loss of life.

WARNING

Do not use this boiler if any part has been under or

exposed to water. Immediately call a qualified heating

contractor to inspect the boiler and to replace any part

of the control system and any gas control which has

been under, or exposed to, water.

Maintenance and cleaning

Regular inspection and service by a qualified heating

contractor is important to the performance of the

Viessmann Vitocrossal 300, CA3 boilers. Neglected

maintenance impacts on warranty; regular inspection

ensures clean, environmentally friendly and efficient

operation. We recommend a maintenance contract

with a qualified heating contractor.

Regular maintenance and service

The entire heating system must be cleaned and

serviced on a regular basis by a qualified heating

contractor or service agency to ensure reliable,

energy-efficient, and environmentally friendly

operation.

The build-up of soot on the heat exchanger raises

the flue gas temperature and reduces efficiency.

Indirect-fired domestic hot water storage tanks (if

installed) should be serviced within two years (at

most) of the installation date, and regularly thereafter.

For an overview of scheduled service procedures,

please see section entitled “Service Schedule” on

page 42 of this manual.

The owner or dedicated personnel should perform

the checks outlined in the Service Schedule to ensure

proper operation of the heating system.

IMPORTANT

Technical information

Literature applicable to the Vitocrossal 300, CA3 boiler:

- Installation and Service Instructions

- Operating Instructions

Keep all literature in a safe place at the installation site.

Contact Viessmann for additional copies.

For your Safety (continued)

Safety

5790 737 - 01

Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating

Description

System Information

Legend

SA Safety header

KV Boiler supply

LG Natural gas connection

KR Boiler return

AGA Flue gas outlet (vent pipe connection)

CA3 2.5, 3.0, 3.5 and 4.0

CA3 5.0 and 6.0

Dimensions

Boiler Model 2.5 and 3.0 3.5 and 4.0 5.0 and 6.0

L in. (mm) 6 (152) 6 (152) 6 (152)

M*1 in. (mm) 11c(299) 11c(299) 11c(299)

N in. (mm) 35 (889) 40 (1015) 44 (1118)

O in. (mm) 28e(720) 32a(820) 32a(820)

P*1 in. (mm) 14 (357) 14 (357) 14 (357)

Dimensions

Boiler Model 2.5 and 3.0 3.5 and 4.0 5.0 and 6.0

A in. (mm) 90c(2305) 101f(2581) 138 (3503)

B in. (mm) 33b(851) 39e(1000) 39e(1000)

C*1 in. (mm) 78 (1981) 84 (2131) 84 (2131)

D in. (mm) 85e(2168) 96f(2453) 133 (3376)

E in. (mm) 31b(800) 36 (936) 36 (936)

F*1 in. (mm) 73 (1875) 78 (2002) 78 (2002)

G*1 in. (mm) 69e(1760) 74e(1887) 74e(1887)

H*1 in. (mm) 62 (1574) 64d(1628) 64d(1628)

I*1 in. (mm) 26a(667) 26a(665) 26a(665)

J in. (mm) 12 (325) 9c(248) 9c(248)

K in. (mm) 71e(1813) 79a(2013) 111d(2823)

*1 Heights do not include the concrete pad or seismic brackets.

Seismic brackets will add 2einches (60 mm).

Seismic brackets are only for boiler models 3.5 to 6.0.

5790 737 - 01

Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating

System Information

Description (continued)

Fuel

Natural gas (NG) or liquid propane gas (LPG).

Boiler control

The Vitocrossal 300, CA3 boiler series is operated with

a Vitotronic control and microcomputer indoor/outdoor

control system for boiler operation without low temperature

limit. The control system must be programmed for this type

of operation by the installing heating contractor.

Refer to the boiler Installation and Service

Instructions.

CAUTION

The boiler room must be safe from frost and be

properly ventilated.

Condensate disposal

During the operation of the Vitocrossal 300 CA3 boiler,

the amount of condensate as per the diagram can be

expected.

The values given are approximate amounts occurring under

practical conditions. Not included in the chart is the amount

of condensate occurring in the vent pipe and chimney

system. The condensate from the chimney system can be

collected together with the condensate from the heating

boiler and be disposed of into a floor drain.

The condensate occurring will have a pH value between

3 and 4. If local building requirements demand neutralizing

the condensate before disposal, contact Viessmann

Manufacturing Company Inc. for a correctly sized

neutralization tank. The treated condensate will show pH

values of between 6.5 and 9 and can then be disposed of

into the waste water system.

Boiler location

The boiler must not be installed in rooms or areas where

halogenated hydrocarbons are present in the combustion

air, such as barber shops and beauty salons, printing

shops, chemical cleaners, laboratories etc.

Vitocrossal 300, CA3 boiler efficiency is dependent

on system heating water return temperatures and load

conditions.

Venting connection

A large amount of water vapor is contained in the flue

gases of a condensing boiler. The condensate pH value is

between 3 and 5.5. The flue gas temperatures depending

on the boiler water temperature may be between 77°F

(25°C) and 257°F (125°C).

The manufacturer of the chimney system or venting

system has to properly design the venting system as well

as select proper materials.

If there are any questions in regards to the neutralization

of the condensate and/or to the venting of this boiler

series, contact your local Viessmann Sales Representative.

Optimum operation

To ensure optimum operation of your heating system do

the following:

Keep the boiler and the boiler room clean and free

of dust and dirt.

Ensure proper and adequate system pressure by

occasionally checking the pressure gage.

Have a qualified heating contractor service and

maintain your heating system on a regular basis.

See Service Schedule starting on page 42 for details.

Amount of condensate

Boiler water return temperature

Flue gas temperature gross

Flue gas temp.

at full input

at partial load

Flue gas temp.

Amount of

condensate

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