Viessmann VITOCROSSAL 300 Mode d'emploi
Service instructions
for contractors
VIESMANN
Vitocrossal 300
Type CT3U, 400 to 630 kW
Gas condensing boiler with MatriX cylinder burner
for natural gas E and LL
For applicability, see the last page
VITOCROSSAL 300
5783 337 GB 8/2017 Please keep safe.
2
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 intended for quali-
fied contractors.
■Work on gas installations may only be carried out by
a registered gas fitter.
■Work on electrical equipment may 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 to be observed
■National installation regulations
■Statutory regulations for the prevention of accidents
■Statutory regulations for environmental protection
■Codes of practice of the relevant trade associations
■All current safety regulations as defined by DIN, EN,
DVGW, TRGI, TRF, VDE and all locally applicable
standards
aÖNORM, EN, ÖVGW G K directives,
ÖVGW-TRF and ÖVE
cSEV, SUVA, SVGW, SVTI, SWKI, VKF and
EKAS guideline 1942: LPG, part 2
Safety instructions for working on the system
Working on the system
■Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■Isolate the system from the power supply, e.g. by
removing the separate fuse or by means of a mains
isolator, and check that it is no longer live.
■Safeguard the system against reconnection.
■Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces can cause burns.
■Before maintenance and service work, switch
OFF the appliance and let it cool down.
■Never touch hot surfaces on the boiler, burner,
flue system or pipework.
!Please note
Electronic assemblies can be damaged by elec-
trostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to dis-
charge static loads.
Repair work
!Please note
Repairing components that fulfil a safety func-
tion can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
Safety instructions
Safety instructions
5783 337 GB
3
Auxiliary components, spare and wearing parts
!Please note
Spare and wearing parts that have not been tes-
ted together with the system can compromise its
function. Installing non-authorised components
and making non-approved modifications or con-
versions can compromise safety and may inva-
lidate our warranty.
For replacements, use only original spare parts
supplied or approved by Viessmann.
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■Do not 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.
■Evacuate any people from the danger zone.
■Notify your gas or electricity supply utility from
outside the building.
■Have the power supply to the building shut off
from a safe place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■Shut down the heating system.
■Ventilate the installation site.
■Close doors to living spaces to prevent flue
gases from spreading.
What to do if water escapes from the appliance
Danger
If water escapes from the appliance there is a
risk of electrocution.
Switch OFF the heating system at the external
isolator (e.g. fuse box, domestic distribution
board).
Danger
If water escapes from the appliance there is a
risk of scalding.
Never touch hot heating water.
Condensate
Danger
Contact with condensate can be harmful to
health.
Never let condensate touch your skin or eyes
and do not swallow it.
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of conden-
sate or other external causes.
Avoid continuous condensate disposal with a wind pro-
tector.
Ensure an adequate supply of combustion air.
Inform system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inade-
quate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be non-
sealable.
Extractors
Operating appliances that exhaust air to the outside
(extractor hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to a reverse flow of flue
gas.
Danger
The simultaneous operation of the boiler and
appliances that exhausts air to the outside can
result in life threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Safety instructions
Safety instructions (cont.)
5783 337 GB
4
1. Information Symbols ................................................................................................. 5
Intended use .......................................................................................... 5
2. Commissioning, inspec-
tion, maintenance
Steps - commissioning, inspection and maintenance ............................ 6
3. Control unit Setting the codes at the control unit ...................................................... 25
4. Troubleshooting Diagnosis ............................................................................................... 32
■Faults displayed on the display and programming unit (fault codes) .. 32
■Faults without fault display ................................................................. 37
5. Burner control unit flow
chart
................................................................................................................ 38
6. Parts lists Overview of assemblies ......................................................................... 41
Boiler assembly ..................................................................................... 42
Thermal insulation assembly ................................................................. 44
Burner assembly .................................................................................... 46
Parts not shown ..................................................................................... 48
7. Component overview ................................................................................................................ 49
8. Connection and wiring dia-
gram
Burner control unit connection diagram ................................................. 50
■MatriX cylinder burner ........................................................................ 50
Mains filter unit connection diagram ...................................................... 51
9. Water quality requirements ................................................................................................................ 52
10. Reports Water quality .......................................................................................... 54
Settings and test values ......................................................................... 54
11. Specification ................................................................................................................ 56
12. Final decommissioning
and disposal
................................................................................................................ 57
13. Certificates EU Declaration of Conformity ................................................................ 58
Manufacturer's certificate ....................................................................... 59
14. Keyword index ................................................................................................................ 60
Index
Index
5783 337 GB
5
Symbol Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
Warning of material losses and environ-
mental pollution
Live electrical area
Pay particular attention.
■Component must audibly click into place.
or
■Acoustic signal
■Fit new component.
or
■In conjunction with a tool: Clean the sur-
face.
Dispose of component correctly.
Dispose of component at a suitable collec-
tion point. Do not dispose of component in
domestic waste.
The steps in connection with commissioning, inspec-
tion and maintenance are found in the "Commission-
ing, inspection and maintenance" section and identified
as follows:
Symbol Meaning
Steps required during commissioning
Not required during commissioning
Steps required during inspection
Not required during inspection
Steps required during maintenance
Not required during maintenance
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instruc-
tions as well as the details in the datasheet.
It is only designed for the heating up of heating water.
Commercial or industrial usage for a purpose other
than the heating up of heating water shall be deemed
inappropriate.
Intended use presupposes that a fixed installation in
conjunction with permissible components designed for
this purpose has been carried out.
Every other use will be deemed to be inappropriate.
Any resulting losses are excluded from the manufac-
turer's liability.
Any usage beyond this must be approved by the man-
ufacturer for the individual case.
Intended use also includes the adherence to mainte-
nance and inspection intervals.
Information
Symbols
5783 337 GB
Information
6
Commissioning steps
Inspection steps
Maintenance steps Page
• • 1. Information on maintenance work.................................................................................... 8
•2. Checking the high limit safety cut-out setting................................................................ 8
•3. Filling the heating system with water and venting......................................................... 8
•4. Filling the trap with water.................................................................................................. 8
••• 5. Commissioning the system............................................................................................... 9
•6. Checking the gas type....................................................................................................... 10
•7. Converting to natural gas LL............................................................................................ 10
••• 8. Checking static pressure and supply pressure.............................................................. 11
••• 9. Checking the CO2 content................................................................................................. 12
••• 10. Checking the CO content
••• 11. Checking the flue gas temperature
• • 12. Checking the ionisation current....................................................................................... 14
• • 13. Shutting down the system................................................................................................. 14
• • 14. Opening the boiler door..................................................................................................... 15
• • 15. Separating the neutralising system from the boiler, connecting the drain hose......... 16
• • 16. Cleaning the combustion chamber and heating surfaces............................................. 17
• • 17. Checking the gaskets and thermal insulation sections................................................. 17
• • 18. Checking all connections on the heating water side for tightness............................... 17
• • 19. Cleaning and reconnecting the condensate drain system............................................. 17
• • 20. Checking the condensate drain and neutralising system (if installed)......................... 18
• • 21. Checking the burner gauze assembly.............................................................................. 18
• • 22. Checking the ignition and ionisation electrodes............................................................ 19
• • 23. Cleaning the burner........................................................................................................... 19
•24. Installing the burner........................................................................................................... 20
• • 25. Closing the boiler door...................................................................................................... 20
• • 26. Automatic tightness test on the two gas train valves.................................................... 20
• • 27. Checking the filter element in the gas line (if installed) and replacing if required
••• 28. Checking all gas connections for tightness.................................................................... 21
••• 29. Checking the rotary damper setting................................................................................. 21
•30. Performing final checks..................................................................................................... 22
• • 31. Checking the water quality................................................................................................ 22
••• 32. Checking the function of the safety valves
••• 33. Checking the temperature controller setting if a building management system is
used (DCC system)............................................................................................................ 22
• • 34. Checking the expansion vessel and system pressure................................................... 22
• • 35. Checking the flue gas collector for tightness................................................................. 23
• • 36. Checking the mixer for ease of operation and leaks...................................................... 23
••• 37. Checking the thermal insulation for firm seating
•38. Checking the flue system for leaks
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5783 337 GB
7
Commissioning steps
Inspection steps
Maintenance steps Page
• • 39. Checking the ventilation air apertures in the installation room (only for open flue
operation)
•40. Instructing the system user.............................................................................................. 23
•41. Operating and service documents................................................................................... 24
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
5783 337 GB
8
The product contains ceramic fibres. Danger
When working with high temperature insulation
materials that contain zirconium or aluminium
silicate ceramic fibres, fibre dust may
develop. This fibre dust can be harmful to
health.
Only trained personnel may adapt or replace the
insulation. Wear suitable protective clothing,
especially breathing equipment and safety gog-
gles.
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 service instructions
Filling the heating system with water and venting
Record the fill volume, water hardness and pH value in
the table on page 54. !Please note
Unsuitable water quality can result in damage to
the boiler shell and the heating system.
Observe the "Water quality requirements" on
page 52 onwards.
Filling the trap with water
AB
Fig. 1
1. Remove lower back panel A by undoing the 4
quarter-turn rotary latches B.
2. Undo the siphon and fill with water, otherwise flue
gas may escape.
Commissioning, inspection, maintenance
Information on maintenance work
5783 337 GB
9
3. Check that the condensate can drain freely. 4. Refit the siphon.
Commissioning the system
Control unit operating and service instructions,
and neutralising system operating instructions
01. Check the heating system pressure.
Permissible boiler operating pressure: 5.5 bar
(550 kPa)
02. For open flue operation: Check that the ventilation
facility in the installation room is open.
03. Check the gas supply pressure.
04. Open the gas line shut-off valves.
05. Switch ON the mains isolator (outside the installa-
tion room).
06.
A B
D
C
Fig. 2
Switch ON system ON/OFF switch B at the con-
trol unit. If fault indicator A on the control unit illu-
minates and display C on the burner control unit
flashes, first reset the system. For this, press reset
button D on the burner control unit.
Note
The system can enter a fault state during commis-
sioning due to a lack of gas in the gas line. The
fault indicator on the control unit then illuminates.
Purge the gas line again and reset the burner con-
trol unit.
07. Adjust the codes on the boiler control unit in
accordance with the table on page 25.
Control unit installation and service instruc-
tions
08. Check the function of the neutralising system and
the hydraulic seal in the trap.
Neutralising system operating instructions
09. Check all gaskets and plugs, and retighten if nec-
essary.
Note
We recommend checking all connections on the
heating water side for leaks approx. every 500
hours run. See page 17.
10. Check the boiler door and flue gas collector cover
a few days after commissioning and retighten all
screws.
Danger
For safe operation, a minimum operating pres-
sure of 0.5 bar (50 kPa) is absolutely essential.
A minimum pressure switch can be used to
safeguard this.
Commissioning, inspection, maintenance
Filling the trap with water (cont.)
5783 337 GB
10
1. Check with your gas supply utility regarding the
gas type and Wobbe index (Wo).
■With the natural gas E setting, the boiler can be
operated in the Wobbe index range 12.0 to
16.1 kWh/m3 (43.2 to 58.0 MJ/m3).
■With the natural gas LL setting, boilers can be
operated in the Wobbe index range 10.0 to
13.1 kWh/m3 (36.0 to 47.2 MJ/m3) (not in a or
c).
2. In the delivered condition, the burner is preset for
natural gas E. If necessary, convert the burner to
the other gas type (see page 10) in accordance
with the details provided by the gas supply utility.
3. Record the gas type in the report (on page 54).
Converting to natural gas LL
(Not in a and c)
01. Close the gas shut-off valve.
02. Switch OFF the system ON/OFF switch on the
control unit.
03. Switch OFF the mains isolator (outside the instal-
lation room) or isolate the mains power and
secure against unintentional reconnection.
04. Pull connecting cables from the gas train.
05. Undo fitting A.
A
B
C
D
G
F
E
Fig. 3
06. Pull compensation hose G from the gas train.
07. Release the gas train from flange E.
08. Remove restrictor C with rubber cork gasket D.
09. Secure the gas train (without restrictor C and
without rubber cork gasket D, but with O-ring B)
at flange E. Replace the factory-fitted screws
M 5 × 16 with the supplied screws M 5 × 12.
10. Secure fitting A.
11. Fit compensation hose G onto the gas train.
12. Affix supplied label "Set to..." F over the existing
label.
13. Start the burner (see page 9).
Danger
Escaping gas leads to a risk of explosion.
Check the fitting for gas tightness.
!Please note
The use of leak detection spray can result in
faulty operation.
Leak detection spray must not come into contact
with electrical contacts.
Commissioning, inspection, maintenance
Checking the gas type
5783 337 GB
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