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VIESMANN
Service instructions
for contractors
Vitocrossal 300
Type CT3, 187 to 635 kW
Gas fired condensing boiler
VITOCROSSAL 300
Please keep safe.
5692 405 GB
2/2007
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Summary of Contents for Viessmann VITOCROSSAL 300
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Page 1: Service Instructions
VIESMANN Service instructions for contractors Vitocrossal 300 Type CT3, 187 to 635 kW Gas fired condensing boiler VITOCROSSAL 300 Please keep safe. 5692 405 GB 2/2007…
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Page 2: Safety Instructions
Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained & the Code of Practice of relevant trade associations, Danger & all current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury.
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Page 3
Instal- charge static loads. 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. -
Page 4: Table Of Contents
Index Index Commissioning, inspection, maintenance Steps – commissioning, inspection and maintenance ……..Further details regarding the individual steps ……….Parts lists ………………..20 Commissioning/service reports …………… 28 Specification ………………… 29 Certificates Declaration of conformity …………….33 Manufacturer’s certificate according to the 1st BImSchV [Germany]….. 34…
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Page 5: Commissioning, Inspection, Maintenance
Commissioning, inspection, maintenance Steps – commissioning, inspection and maintenance 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 … •…
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Page 6: Commissioning Steps
Commissioning, inspection, maintenance Steps – commissioning, inspection and . . . (cont.) 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 .
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Page 7: Further Details Regarding The Individual Steps
Commissioning, inspection, maintenance Further details regarding the individual steps Checking the high limit safety cut-out setting The high limit safety cut-out must not Control unit installation and be set higher than 110 °C; if required, service instructions set it to a maximum of 110 °C. Filling the heating system with water and venting the system Record the fill volume, water hard- Please note…
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Page 8: Minimising Pulsation Noise
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 7. Check the function of the neutralis- 8. Check all gaskets/seals and plugs ing system. and retighten, if necessary. Neutralising system operat- Note ing instructions We recommend you check all heat- ing water connections after approx.
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Page 9: Shutting Down The Heating System
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Undo M 10 nut A on lever B of 3. Lock the rotary damper with M 10 rotary damper C. nut. 2. Adjust the lever until all pulsating 4. Readjust the burner, if required. noises have ceased (the lever mir- rors the damper position).
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Page 10: Cleaning The Combustion Chamber And Heating Surfaces
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Clean the inside of the condensate 4. Connect the drain hose to the con- drain with a plastic brush. densate drain and run to a sewer. Cleaning the combustion chamber and heating surfaces Please note 2.
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Page 11: Checking Gaskets And Thermal Insulation Components
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking gaskets and thermal insulation components 1. Check gaskets and the packing 2. Check the thermal insulation com- cord in the boiler door for damage. ponents of the boiler door for possi- ble damage.
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Page 12: Checking The Diaphragm Expansion Vessel And System Pressure
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the diaphragm expansion vessel and system pres- sure Note Observe the diaphragm expansion vessel manufacturer’s instructions. Carry out this test on a cold system. Pump controlled pressure maintaining systems Note Carry out all checks in accordance In heating systems with automatic…
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Page 13
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Diaphragm expansion vessel 1. Drain the system or close the cap 2. If the inlet pressure of the dia- valve on the diaphragm expansion phragm expansion vessel is lower vessel and reduce the pressure, than the value calculated according until the pressure gauge indicates to the adjacent formula, top up with… -
Page 14: Checking The Flue Gas Header For Soundness
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the flue gas header for soundness 1. Visually inspect the gasket through 2. If required, retighten the gasket at clean-out aperture A on the flue clamping clips B. gas collector. Traces of conden- sate on the outside of the flue gas header indicate a leak.
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Page 15: Cleaning The Sight Glass In The Boiler Door
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the sight glass in the boiler door Check gaskets A and hose connec- tion B for leaks. Closing the boiler door 1. Tighten the screws on the boiler 2. Install the gas supply pipe and door evenly and diagonally.
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Page 16: Check The Water Quality
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Check the water quality Enter the volume of top-up water, the water hardness and the pH value in the tables. For water quality requirements, see page 30. Fill water Top-up water Count Total water Date…
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Page 17: Cleaning And Reconnecting The Condensate Drain System
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Total hardness pH value Water treatment Date Feedwater Boiler Boiler Medium Metering water water volume The pH value should be between 8.2 and 9.5. Cleaning and reconnecting the condensate drain system The condensate drain, siphon, neutralising system and all intermediate hoses and pipes are part of the condensate drain system.
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Page 18: Instructing The System User
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. For de-watering, remove drain 5. Connect the line with a U-bend to hose A from the condensate the condensate drain and fill with drain. water or fit a siphon and fill that with water.
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Page 19
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Operating and service documents 1. Complete and detach the customer 2. File all parts lists, operating and registration card: service instructions in the folder & Hand the system user this part and hand this over to the system for safekeeping. -
Page 20: Parts Lists
Parts lists Parts lists When ordering spare parts: 209 Front panel, centre Quote the type and serial no. (see 210 Front panel, bottom type plate) and the item no. of the 211 Back panel, top required part (as per this parts list). 214 Side panel, bottom Obtain standard parts from your local 215 Side panel, top…
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Page 21
Parts lists Parts lists (cont.) A Type plate, optionally on the r.h. or l.h. side B Boiler circuit control, see separate parts list C Burner cable, see separate parts list… -
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Parts lists Parts lists (cont.) -
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Parts lists Parts lists (cont.) -
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Parts lists Parts lists (cont.) -
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Parts lists Parts lists (cont.) -
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Parts lists Parts lists (cont.) -
Page 27
Parts lists Parts lists (cont.) -
Page 28: Commissioning/Service Reports
Commissioning/service reports Commissioning/service reports Commissioning Service Service date: Service Service Service date: Service Service Service date: Service Service Service date: Service Service Service date:…
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Page 29: Specification
Specification Specification Rated output = 40/30 °C = 80/60 °C Rated thermal load 234.5 297 385.5 Product ID CE-0085 AQ 0257 Flue gas parameters Temperature (at return temp. 30 °C) & at rated output °C & at partial load °C Temperature (at return °C temp.
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Page 30
Specification Water quality requirements (cont.) Prevention of damage due to scaling Excessive scale deposits (calcium carbonate) on the heating surfaces should be prevented. For heating systems with operating temperatures up to 100 °C, the VDI Directive 2035 sheet 1 «Prevention of heating system damage – scaling in DHW and hot water heating systems»… -
Page 31
Specification Water quality requirements (cont.) Operating information: & In multi-boiler systems, start all boi- & During expansion or repair work, lers simultaneously to prevent the only drain the necessary pipework entire lime deposit settling in the sections. heat transfer area of just one boiler. &… -
Page 32
Specification Water quality requirements (cont.) Prevention of damage due to corrosion on the water side The corrosion resistance of ferrous The use of permeable components, e. materials on the heating water side of g. plastic pipes that are permeable to heating systems and boilers depends gas in underfloor heating systems, on the absence of oxygen in the heat-… -
Page 33: Certificates
The product characteristics determined as system values for the product Vitocrossal 300 as part of EC type testing according to the Efficiency Directive (see specification table), can be utilised to assess the energy consumption of heating and ventilation equipment to DIN V 4701–10 which is specified by the EnEV [Germany].
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Page 34: Manufacturer’s Certificate According To The 1St Bimschv [Germany]
Certificates Manufacturer’s certificate according to the 1st BImSchV [Germany] We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf confirm, that the fol- lowing product exceeds the efficiency of 91 % required by the 1st BImSchV paragraph 7 (3) [Germany] Boiler and burner unit…
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Page 36
Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040 E-mail: info-uk@viessmann.com…
(Ocr-Read Summary of Contents of some pages of the Viessmann VITOCROSSAL 300 Document (Main Content), UPD: 18 May 2023)
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24, Viessmann VITOCROSSAL 300 24 5790 737 — 01 Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Ending “Comfort mode” From the home screen tap the following buttons: 1. “Menu” 2. “Heating” 3. “Heating circuit 1”, “Heating circuit 2” or “Heating circuit 3” as the required heating circuit 4. “Comfort mode” 5. “Comfort mode” The white frame is reset 6. Press OK to confirm or… H Automatically when …
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3, 3 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 potentia…
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12, 12 5790 737 — 01 Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Commissioning System Information As the user of new combustion equipment, you may be obliged to notify your local service technician of the installation [check local regulations]. Your local service technician will also inform you [where appropriate] about work he may be required to perform on your combustion equipment (e.g. regular checks, cleaning). The commissioning and matching of the control unit to lo…
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6, 6 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 activatio…
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19, 19 5790 737 — 01 Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Time programs are set at the system and lead boiler section control. The following explains how to input the settings for a time program. The special features of individual time programs are allotted to the relevant chapters. You can set up a time program for the following functions: H Central heating H DHW heating H DHW recirculation pump The time program allows you to divide the day in…
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23, 23 5790 737 — 01 Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Heating Curve Central Heating Note: Further information can be found in chapter “Terminology” in this manual. You can make the following settings only at the system and lead control boiler section 1. Setting the heating curve Factory setting: H “Slope”: 1.4 H “Shift” of the heating curve: 0 From the home screen tap the following buttons: 1. “Menu” 2. “Heating” 3. “Heating circuit…
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30, 30 5790 737 — 01 Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Further Adjustments Language Selection From the home screen tap the following buttons: 1. “Menu” 2. “Settings” 3. “Language” 4. Required language 5. Tap OK to confirm Setting the Measuring Units From the home screen tap the following buttons: 1. “Menu” 2. “Settings” 3. “Measuring units” 4. “Metric” or “Imperial” 5. Tap OK to confirm …
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2, Viessmann VITOCROSSAL 300 2 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 subsec…
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18, 18 5790 737 — 01 Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Shutting Down the Heating System IMPORTANT With frost protection monitoring For every heating circuit select the “Standby mode” operating program H No central heating H No DHW heating H Frost protection for the boiler and the DHW tank is active. Pump exercise function Circulation pumps are started for 10 sec. once every 24 hours to prevent the pumps from seizing up. This function is activ…
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22, 22 5790 737 — 01 Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Operating Program Central Heating Note: Further information can be found in chapter “Terminology” in this manual. Setting the operating program You can make the following settings only at the system and lead control boiler section 1. From the home screen tap the following buttons: 1. “Menu” 2. “Heating” 3. “Heating …
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20, 20 5790 737 — 01 Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Time Program (continued) Transferring the time program to other days of the week You can copy this time program for any other days of the week. You want to copy this time program for Monday to the period Tuesday to Friday. Tap the following on-screen buttons: 1. “Menu” 2. “Heating” 3. Heating circuit 1 4. “Time program heating” 5. “Mo” 6. “Copy” 7. “Tu” , …
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7, Viessmann VITOCROSSAL 300 7 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 an…
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28, 28 5790 737 — 01 Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Time Program (continued) DHW Heating Note: DHW is not heated between the time phases. Frost protection for the DHW tank is enabled. When setting time programs, bear in mind that your heating system requires some time to heat the DHW tank to the required temperature. Any DHW heating process that has started will continue until the set DHW temperatur…
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43, 43 5790 737 — 01 Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Additional Information Heating curve Heating curves illustrate the relationship between the outdoor temperature, the set room temperature and the boiler water temperature or supply temperature. The lower the outdoor temperature, the higher the boiler water temperature or supply temperature. In order to guarantee sufficient heat and minimum fue…
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34, 34 5790 737 — 01 Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Scanning Options Lead control unit Main Menu Overview
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13, 13 5790 737 — 01 Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating System Information H Holiday: If you are going away, select the “Holiday program”: The room temperature will be reduced, and DHW heating will be turned off. H Ventilation: Close the thermostatic valves when ventilating. Open the windows fully for a brief time. H Roller shutters: Close roller shutters (if installed) at dusk. H Thermostatic valves: Ensure that thermostatic valves are properly adjust…
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