Viessmann VITOCROSSAL 300 Mode d'emploi
Service instructions
for contractors
VIESMANN
Vitocrossal 300
Type CU3A
Gas condensing boiler with MatriX gas burner and Lambda Pro Con-
trol,
Natural gas and LPG version
open and balanced flue operation
For applicability, see the last page
VITOCROSSAL 300
5692 860 GB 6/2010 Please keep safe.
2
Please follow these safety instructions closely to prevent accidents and mate-
rial 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 envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain 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 fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental protection,
■ the Code of Practice of relevant trade
associations,
■ all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never 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.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
5692 860 GB
3
If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the
living space.
Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply 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 unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged 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 ful-
fil a safety function can compro-
mise 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 com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
5692 860 GB
4
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 6
Further details regarding the individual steps....................................................... 8
Code 1
Calling up coding level 1...................................................................................... 56
General................................................................................................................. 57
Boiler.................................................................................................................... 58
DHW..................................................................................................................... 59
Solar..................................................................................................................... 60
Heating circuit 1, heating circuit 2, heating circuit 3............................................. 61
Code 2
Calling up coding level 2...................................................................................... 67
General................................................................................................................. 67
Boiler.................................................................................................................... 75
DHW..................................................................................................................... 76
Solar..................................................................................................................... 77
Heating circuit 1, heating circuit 2, heating circuit 3............................................. 84
Diagnosis and service scans
Calling up the service menu................................................................................. 91
Diagnosis.............................................................................................................. 91
Checking outputs (actuator test).......................................................................... 93
Troubleshooting
Fault display......................................................................................................... 95
Fault codes........................................................................................................... 96
Repairs................................................................................................................. 105
Function description
Weather-compensated control unit...................................................................... 113
Internal extensions (accessories)......................................................................... 114
External extension (accessory)............................................................................ 116
Control functions.................................................................................................. 118
Allocating heating circuits to the remote control................................................... 125
Electronic combustion controller.......................................................................... 125
Designs
Internal connection diagram................................................................................. 127
External connection diagram................................................................................ 130
Parts lists............................................................................................................ 132
Index
Index
5692 860 GB
5
Commissioning/service reports........................................................................ 138
Specification....................................................................................................... 143
Certificates
Declaration of conformity...................................................................................... 144
Manufacturer's certificate according to the 1st BImSchV [Germany]................... 144
Keyword index.................................................................................................... 145
Index
Index (cont.)
5692 860 GB
6
For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
•1. Filling the heating system and checking the supply of
ventilation air.................................................................. 8
•2. Filling siphon with water................................................ 9
•3. Checking the power supply
•4. Changing the language (if required)............................. 9
• • 5. Setting the time and date (if required).......................... 10
•6. Designating the heating circuits................................... 10
• • 7. Checking the gas type.................................................... 10
••• 8. Removing the front panel.............................................. 11
•9. Gas type conversion (only for operation with LPG).... 12
••• 10. Function sequence and possible faults....................... 12
••• 11. Checking the static and supply pressure..................... 14
•12. Setting the maximum output......................................... 16
•13. Checking the balanced flue system tightness (annular
gap check)....................................................................... 17
•14. Removing the burner and checking the burner
gasket.............................................................................. 18
•15. Checking burner gauze assembly and thermal
insulation block.............................................................. 19
•16. Checking and adjusting the ignition and ionisation
electrodes........................................................................ 21
• • 17. Separating the neutralising system (if installed) from
the boiler and connecting the drain hose.................... 22
• • 18. Cleaning the combustion chamber and heating
surfaces........................................................................... 22
• • 19. Cleaning and reconnecting the condensate drain
system............................................................................. 23
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
5692 860 GB
7
Commissioning steps
Inspection steps
Maintenance steps Page
• • 20. Checking that the condensate drain and neutralising
system (if installed) are not obstructed and that they
are free from leaks.......................................................... 24
• • 21. Checking gaskets and thermal insulation
components on the boiler.............................................. 25
• • 22. Checking the diaphragm expansion vessel and
system pressure............................................................. 26
• • 23. Checking the water quality............................................ 27
• • 24. Checking the mixer for obstructions and leaks........... 27
••• 25. Checking all connections on the heating water side
and DHW side for leaks
••• 26. Checking the function of safety valves
•27. Fitting the burner............................................................ 28
••• 28. Checking firm seating of electrical connections
••• 29. Checking all gas equipment for tightness at operating
pressure........................................................................... 29
• • 30. Checking the combustion quality................................. 29
• • 31. Checking the ventilation air apertures in the
installation room (only for open flue operation)
••• 32. Checking the external LPG safety valve (if installed)
•33. Matching the control unit to the heating system......... 30
•34. Adjusting the heating curves........................................ 49
•35. Connecting the control unit to the LON....................... 52
•36. Scanning and resetting the "Service" display............. 54
••• 37. Fitting the front panel..................................................... 55
•38. Instructing the system user........................................... 55
Commissioning, inspection, maintenance
Steps - commissioning, inspection and… (cont.)
5692 860 GB
8
Filling the heating system and checking the supply of ventilation
air
!Please note
Unsuitable fill water increases the level of deposits and corrosion and may
lead to boiler damage.
■ Thoroughly flush the entire heating system prior to filling it with water.
■ Only use fill water of potable quality.
■ Fill water, the hardness of which exceeds the following values, must be
softened, for example with a small softening system for heating water (see
Vitoset pricelist):
–Vitocrossal 300 up to 45 kW: 16.8 °dH (3.0 mol/m3)
–Vitocrossal 300 from 60 kW: 11.2 °dH (2.0 mol/m3)
■ An antifreeze additive suitable for heating systems can be added to the fill
water. The antifreeze manufacturer must verify its suitability, since other-
wise damage to gaskets and diaphragms can occur as well as noise during
heating operation. Viessmann accepts no liability for damage or conse-
quential damage.
1. Check whether the ventilation air
supply is unrestricted.
2. Check the pre-charge pressure of the
diaphragm expansion vessel when
the system is still cold.
Note
If the pre-charge pressure of the dia-
phragm expansion vessel is lower
than the static pressure of the sys-
tem, top up with nitrogen until the pre-
charge pressure (0.1 to 0.2 bar) is
higher than the static system pres-
sure. The static pressure corre-
sponds to the static head.
3. Open any installed check valves.
4. Fill the heating system with water and
vent it, until the fill pressure (0.1 to 0.2
bar) is higher than the pre-charge
pressure of the diaphragm expansion
vessel.
Permiss. operating pressure: 3 bar
Min. operating pressure: 1 bar
Commissioning, inspection, maintenance
Further details regarding the individual steps
5692 860 GB
9
5. Mark the set pressure at pressure
gauge A.
6. Record the fill volume, water hard-
ness and pH value on page 27.
Note
Observe the "Water quality require-
ments" on page 139.
7. Return the check valves to their oper-
ating position.
Filling siphon with water
1. Undo fitting A of siphon B, remove
the siphon and fill it with water.
Note
There is a risk of flue gas escaping if
the siphon is not filled with water.
2. Refit siphon B.
Changing the language (if required)
Note
At the commissioning stage, the display
is in German (default setting)
Extended menu:
1. å
2. "Settings"
3. "Language"
Sprache
Cesky CZ
Deutsch DE
Dansk
English
DK
GB
Wählen mit
Ø
ç
4. Set the required language with /.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 860 GB
10
Setting the time and date (if required)
During commissioning, or after pro-
longed time out of use, the time and date
need to be reset.
Extended menu:
1. å
2. "Settings"
3. "Time / Date"
4. Set current time and date.
Designating the heating circuits
In the delivered condition, the heating
circuits are designated "Heating circuit
1", "Heating circuit 2" and "Heating
circuit 3" (if installed).
If the system user prefers, the heating
circuits can be designated differently to
suit the specific system.
Enter names for heating cir-
cuits:
Operating instructions
Checking the gas type
The boiler is equipped with an electronic combustion controller that adjusts the burner
for optimum combustion in accordance with the prevailing gas quality.
■ Consequently, for natural gas there is no adjustment required across the entire
Wobbe index range.
The boiler can operate in the Wobbe index range 9.5 to 15.2 kWh/m3(34.2 to
54,7 MJ/m3).
■ Convert the burner for operation with LPG (see "Gas type conversion" on
page 12).
1. Determine the gas type and Wobbe
index by asking your local gas supply
utility or LPG supplier.
2. Only possible on appliances with
26 and 35 kW.
Convert the burner for operation with
LPG (see page 12).
3. Record the gas type in the report on
page 138.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 860 GB
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