Viessmann VITOCROSSAL 300 Mode d'emploi
VITOCROSSAL 300
Service instructions
for heating engineers
VitocrossalĂ300
typeĂCR3, 186 to 311ĂkW
Gas-fired condensing boiler
5692Ă48 ĂGBăăă9/2 2 Please keep safe
2
General Information
Safety instructions
Please follow these safety instructions closely to prevent accidents and
material losses.
Work on the equipment
Installation, initial start-up,
inspection, maintenance and repairs
must be carried out by a competent
person (heating engineer/installation
contractor).
Before working on the equipment/
heating system, isolate the mains
electrical supply (e.Ăg. by removing a
separate mains fuse or by means of
a mains electrical isolator) and
safeguard against unauthorised
reconnection.
Close the main gas shut-off valve
and safeguard against unauthorised
reopening.
Work on gas equipment
This must only be carried out by an
approved contractor.
Please observe all commissioning
work specified for gas installations
acc. to TRGI or TRF and all local
regulations.
Repair ork
This must not be carried out on parts
that fulfil a safety function.
Use only original Viessmann spare
parts, or equivalent parts that have
been approved by Viessmann.
Initial start-up
This must be carried out by the
system installer or a commissioning
engineer designated by him; all
actual values should be recorded in a
commissioning/service report.
Instructing the system user
The system installer must hand the
operating instructions to the system
user and instruct him/her in the
operation of the system.
¨ĂSafety instructions
In this instruction manual, this
heading denotes information which
must be observed to prevent
accidents and material losses.
¨This symbol denotes important
information which must be
observed to prevent material
losses.
Operating and service documents
1. Complete and detach the customer
registration card:
HGive the system user this part
for safe-keeping.
HKeep the part for the heating
engineer.
2. Keep all parts lists, operating and
service instructions in the folder
and hand this over to the system
user.
5692Ă48 ĂGB
3
Contents
Index
Page
General Information
Safety instructionsĂ 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating and service documentsĂ 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial start-up, inspection and maintenance
StepsĂ 4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further details of the individual stepsĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts listsĂ18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix
Water quality requirementsĂ24
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of conformityĂ 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manufacturer's certificateĂ 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Commissioning/service reportĂ 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692Ă48 ĂGB
4
Initial start-up, inspection and maintenance
StepsĂćĂinitial start-up, inspection and maintenance
For further instructions concerning the individual steps, see pages indicated.
Commissioning steps
Inspection steps
Maintenance steps Page
C1. Checking the high limit safety cut-out adjustmentĂ 5. . . . . . . .
C2. Filling the heating system ith ater and
ventilating the systemĂ 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C3. Fully opening the flue outlet damper and
locking it openĂ 5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C4. Checking the neutralising system connections
and filling ith neutralising agentĂ
C I M 5. System start-upĂ 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C6. Pulsation noisesĂ 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 7. System shutdo n
I M 8. Opening the boiler doorĂ 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M9. Separating the neutralising system from the boiler
and connecting the drain hoseĂ 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M10. Cleaning the combustion chamber & heating surfacesĂ 9
I11. Checking the boiler door thermal insulation and gaskets
C I M 12. Checking all heating ater connections and
the sensor ell for leaksĂ 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C I 13. Checking the function of all safety equipmentĂ 11. . . . . . . . . . . . .
C I M 14. Checking the expansion vessel and system pressureĂ 11
M15. Cleaning the sight glass in the boiler doorĂ 13. . . . . . . . . . . . . . . . . . . .
I M 16. Closing the boiler doorĂ 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I M 17. Checking the ater qualityĂ 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I18. Checking the thermal insulationĂ 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I19. Checking the flue cover for leaksĂ 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I20. Checking the mixer for easy operation and leaksĂ 15. . . . . . .
M21. Cleaning and reconnecting the condensate drainĂ 16. . . . . . .
I22. Checking the boiler room ventilation
I23. Checking the function of the flue gas system
M24. Burner adjustmentĂ 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5692Ă48 ĂGB
5
Initial start-up, inspection and maintenance
Further details of the individual steps
Checking the high limit safety cut-out adjustment
The high limit safety cut-out must
not be set higher than 11 ĂºC; set to a
maximum of 11 ĂºC, if necessary.
Control unit installation and
service instructions
Filling the heating system ith ater and ventilating the
system
Record the fill volume of calcium
hydrogen carbonate on pageĂ14.
Please note:
Observe the " ater quality
requirements" on pageĂ24.
Fully opening the flue outlet damper and locking it open
The damper must be in the
horizontal position.
Please note:
For handling the damper, see chapter
"Pulsation noises" (pageĂ7).
5692Ă48 ĂGB
6
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
System start-up
Operating instructions ć control unit, burner and neutralising system
Service instructions ć control unit and burner manufacturer's
documentation
1. Check the system pressure.
Permissible boiler operating
pressure: 4Ăbar
2. Check that the boiler room
ventilation duct is unobstructed.
3. Check the mains gas supply
pressure.
4. Check whether the cleaning
aperture on the flue outlet is
closed.
5. Open the gas main shut-off valves.
6. Switch on the mains isolator, the
heating circuit pump switch and
the burner control switch in this
order.
Burner manufacturer's
operating instructions
7. Check the function of the
neutralising system.
Neutralising system
operating instructions
8. Check all gaskets/seals and plugs
for leaks and re-tighten, if
necessary.
Please note:
In addition, we recommend you
check all heating water
connections after approx.
500Ăhours operation for leaks
(see pageĂ10).
9. Check the boiler door and
clean-out cover a few days after
commissioning and re-tighten all
screws.
5692Ă48 ĂGB
7
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Pulsation noises
Independent of the make of boiler, burner or flue gas system, gas-tight flue
systems can create pulsation noises.
A change of resonance may be effected by rotating the damper fitted into the
flue outlet.
1. Loosen MĂ1 nutĂA in handleĂB
of damperĂC.
2. Adjust the handle until all
pulsation noises have ceased
(the handle mirrors the damper
position).
3. Lock the damper with MĂ1 nutĂA.
4. If necessary, readjust the burner.
5692Ă48 ĂGB
8
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Opening the boiler door
1. Remove the gas supply pipe.
2. Loosen the screws on the boiler
door and open it.
¨Do not insert tools or other
objects into the combustion
chamber.
Separating the neutralising system from the boiler and
connecting the drain hose
1. Pull hoseĂD to the neutralising
system off stench trap plugĂE.
2. Unscrew stench trap plugĂE from
condensate drainĂF.
3. Clean the inside of condensate
drainĂF with a plastic brush.
4. Connect drain hoseĂGĂto
condensate drainĂFĂand run to a
sewer.
5692Ă48 ĂGB
9
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Cleaning the combustion chamber and heating surfaces
Thoroughly clean the combustion
chamber and heating surfaces with a
water jet.
¨Do not use a wire brush or sharp
objects.
Scratches or other damage to
components which are in contact
with flue gases should be avoided.
Components which are in contact
with flue gases should not come
into contact with pure iron,
otherwise corrosion damage will
result. Use plastic brushes, if
necessary.
For normal cleaning, rinse the
heating surfaces with a water jet.
However, you may use cleaning
agents if you notice stubborn
residues, surface discolouration
or soot deposits.
When doing so, please observe the
following:
HOnly use solvent-free cleaning
agents. Ensure that no solvent
enters between the heat exchanger
and the thermal insulation.
HRemove soot deposits with alkaline
agents containing surfactants (e.Ăg.
FauchĂ6 *1).
HCombustion residues may create
thin, yellow-brown surface
discolouration as well as hard
deposits, which may only become
visible after removing the soot
deposits. Use slightly acidic,
chlorine-free cleaning agents
based on phosphoric acid to
remove surface discolouration and
hard deposits (e.Ăg. Antox Ă75ĂE*1).
HRemove loosened deposits from
the heat exchanger and thoroughly
rinse the heating surfaces and the
flue gas collector with a water jet.
¨ĂSafety instructions
ear goggles, protective gloves and
protective clothing, if necessary.
Cleaning agent
manufacturer's details.
*1Manufacturer:
Hebro Chemie GmbH
Rostocker StraßeĂ40
DĆ41199ĂMönchengladbach
5692Ă48 ĂGB
10
Initial start-up, inspection and maintenance
Further details of the individual steps (cont.)
Checking all heating ater connections and the sensor ell for
leaks
¨ĂSafety instructions
Only open the heating water connections after the boiler has been
depressurised.
Only drain the boiler with a vacuum pump when the boiler vent is open.
1. Loosen the screws of top
panelsĂHand remove the panels.
2. Check sensor wellĂK and all
heating water connections for
leaks.
3. Position the top panels and secure
with screws.
5692Ă48 ĂGB
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