Viessmann VITOCROSSAL 300 Service Instructions Manual

Brand: Viessmann

Model: VITOCROSSAL 300

Type: Service Instructions Manual

The Viessmann VITOCROSSAL 300 is a gas condensing boiler, designed for use in sealed unvented heating systems, providing both heating and hot water. It features advanced technology for efficient and reliable operation, with a focus on safety and environmental sustainability. With its compact design and user-friendly interface, the VITOCROSSAL 300 offers a convenient and efficient solution for your heating needs.

Service instructions

for contractors

VIESMANN

Vitocrossal 300

Type CM3, 87 to 142 kW

Gas condensing boiler

For applicability, see the last page

VITOCROSSAL 300

5692 501 GB 2/2013 Please keep safe.

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 inten-

ded for qualified contractors.

■ Work on gas installations must only be

carried out by a registered 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:

■ Statutory regulations regarding the

prevention of accidents

■ Statutory regulations regarding envi-

ronmental 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-TR Gas,

ÖVGW-TRF and ÖVE

cSEV, SUVA, SVGW, SVTI,

SWKI, VKF and EKAS guideline

1942: LPG, part 2

If you smell gas

Danger

Escaping gas can lead to explo-

sions which may result in serious

injury.

■ Do not smoke. Prevent naked

flames and sparks. Do not

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.

■ Shut off the electricity supply to

the building from a safe place

(outside the building).

Safety instructions

5692 501 GB

If you smell flue gas

Danger

Flue gas can lead to life-threat-

ening poisoning.

■ Shut down the heating system.

■ Ventilate the installation site.

■ Close all doors in the living

space.

Flue systems and combustion air

Ensure that flue systems are clear and

cannot be sealed, for instance due to

accumulation of condensate or other

causes. Ensure a sufficient supply of

combustion air.

Instruct system users that subsequent

modifications to the building characteris-

tics are not permissible (e.g. cable/pipe-

work routing, cladding or partitions).

Danger

Life-threatening poisoning

caused by carbon monoxide in

the flue gas occurs as a result of

leaking or blocked flue systems

or an insufficient supply of com-

bustion air.

Ensure the flue system is in

proper working order. It must not

be possible to close apertures for

interconnected combustion air

supply.

Extractors

Operating appliances that extract air to

the outside (cooker hoods, extractors, air

conditioning units, etc.) can create neg-

ative pressure. If the boiler is operated at

the same time, this can lead to reverse

flow of the flue gas.

Danger

The simultaneous operation of

the boiler and appliances that

extract air to the outside can

result in life threatening poison-

ing due to reverse flow of the flue

gas.

Fit an interlock circuit or take suit-

able steps to ensure a sufficient

supply of combustion air.

Working on the system

■ Where gas is used as the fuel, close

the main gas shut-off valve and safe-

guard it against unintentional reopen-

ing.

■ Isolate the system from the power sup-

ply (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 recon-

nection.

!Please note

Electronic assemblies can be

damaged by electrostatic dis-

charge.

Prior to commencing any 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 function can compromise

the safe operation of your sys-

tem.

Defective components must be

replaced with genuine

Viessmann spare parts.

Safety instructions

Safety instructions (cont.)

5692 501 GB

Auxiliary components, spare and

wearing parts

!Please note

Spare and wearing parts that

have not been tested together

with the system can compromise

its function. Installing non-author-

ised components and making

non-approved modifications or

conversions can compromise

safety and may invalidate our

warranty.

For replacements, use only orig-

inal spare parts supplied or

approved by Viessmann.

Safety instructions

Safety instructions (cont.)

5692 501 GB

Product information

Intended use......................................................................................................... 6

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance.......................................... 7

Further details regarding the individual steps....................................................... 9

Parts lists............................................................................................................ 18

Commissioning/service reports........................................................................ 21

Specification....................................................................................................... 22

Certificates

Declaration of conformity...................................................................................... 27

Manufacturer's certificate according to the 1st BImSchV [Germany]................... 28

Keyword index.................................................................................................... 29

Index

5692 501 GB

The appliance is only intended to be

installed and operated in sealed unven-

ted heating systems that comply with

EN 12828, with due attention paid to the

associated installation, service and

operating instructions. It is only designed

for the heating of water that is of potable

water quality.

Intended usage presupposes that a fixed

installation in conjunction with permissi-

ble, system-specific components has

been carried out.

Commercial or industrial usage for a pur-

pose other than heating the building or

DHW does not comply with regulations.

Any usage beyond this must be

approved by the manufacturer for the

individual case.

Incorrect usage or operation of the appli-

ance (e.g. the appliance being opened

by the system user) is prohibited and

results in an exclusion of liability. Incor-

rect usage also occurs if the components

in the heating system are modified from

their intended function (e.g. if the flue

gas and ventilation air paths are

sealed).

Product information

Intended use

5692 501 GB

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............. 9

•2. Filling the heating system with water and venting the

system............................................................................. 9

•3. Filling the siphon with water......................................... 9

••• 4. Commissioning the system........................................... 10

• • 5. Shutting down the system............................................. 10

• • 6. Opening the boiler door................................................. 10

• • 7. Separating the neutralising system (if installed) from

the boiler and connecting the drain hose.................... 11

• • 8. Cleaning the combustion chamber and heating

surfaces........................................................................... 11

• • 9. Checking components exposed to flue gas for

corrosion damage

• • 10. Checking the gaskets, packing cords and thermal

insulation components of the boiler door.................... 12

• • 11. Checking gaskets and thermal insulation

components on the boiler.............................................. 13

• • 12. Checking the function of safety valves

• • 13. Checking the mixer for ease of operation and

tightness.......................................................................... 14

• • 14. Checking the water quality............................................ 14

• • 15. Cleaning and reconnecting the condensate drain

system............................................................................. 15

• • 16. Checking the condensate drain and the neutralising

system (if installed)........................................................ 16

• • 17. Closing the boiler door.................................................. 16

•18. Checking the installation room ventilation

•19. Checking the flue system for leaks

Commissioning, inspection, maintenance

Steps - commissioning, inspection and maintenance

5692 501 GB

Commissioning steps

Inspection steps

Maintenance steps Page

• • 20. Adjusting the burner...................................................... 16

•21. Instructing the system user........................................... 17

•22. Operating and service documents................................ 17

Commissioning, inspection, maintenance

Steps - commissioning, inspection and… (cont.)

5692 501 GB

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 serv-

ice instructions

Filling the heating system with water and venting the system

Enter the amount of fill water, water

hardness and pH value into the table on

page 15.

Permissible boiler operating pressure: 4

bar (0.4 MPa)

Minimum operating pressure: 0.5 bar

(50 kPa)

Note

The minimum operating pressure is

essential for safe operation and can be

ensured with a minimum pressure switch

(one per system for multi boiler sys-

tems).

!Please note

Unsuitable water quality can

result in damage to the boiler

body and the heating system.

Observe the "Water quality

requirements" on page 23.

Filling the siphon with water

1. Undo the siphon and fill it with

water.

!Please note

Risk of escaping flue gas.

Fill the siphon with water.

2. Check that the condensate can drain

freely.

3. Remount the siphon.

Commissioning, inspection, maintenance

Further details regarding the individual steps

5692 501 GB

Commissioning the system

Operating and service instruc-

tions of the control unit, burner

and neutralising system, as well

as documentation from the

burner manufacturer.

1. Check the heating system pressure.

Permissible boiler operating pres-

sure: 4 bar (0.4 MPa)

Minimum operating pressure:

0.5 bar (50 kPa)

Note

The minimum operating pressure is

essential for safe operation and can

be ensured with a minimum pressure

switch (one per system for multi boiler

systems).

2. Check that the installation room vent

is open.

3. Check the gas supply pressure.

4. Check that the cleaning aperture on

the flue outlet is closed.

5. Open the gas line shut-off valves.

6. Switch ON the mains isolator, the

switch for the heating circuit pump

and the burner ON/OFF switch, in

that order.

Burner manufacturer's oper-

ating instructions

7. Check the function of the neutralising

system.

Neutralising system operating

instructions

8. Check all gaskets and plugs, and

retighten if necessary.

Note

We recommend you check all con-

nections on the heating water side for

leaks approx. every 500 hours run.

9. Check the boiler door and cleaning

cover a few days after commissioning

and retighten all screws.

Shutting down the system

1. Isolate the system from the power

supply and safeguard against re-con-

nection.

2. Pull plug fA and lÖ from the

burner.

3. Close the gas shut-off valve.

Opening the boiler door

1. Remove the gas supply pipe. 2. Undo six screws on boiler door and

open the door.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 501 GB

!Please note

Scratches inside the combustion

chamber can lead to corrosion.

Never put tools or other objects

into the combustion chamber.

Separating the neutralising system (if installed) from the boiler

and connecting the drain hose

1. Separate hose A to the neutralising

system from siphon B.

2. Remove siphon B from the conden-

sate drain.

3. Clean the inside of the condensate

drain with a plastic brush.

4. Connect drain hose C to the con-

densate drain.

Connect drain hose C to the on-site

drain connection.

Cleaning the combustion chamber and heating surfaces

!Please note

Contact with unalloyed iron and

scratches on parts in contact with

flue gases can lead to corrosion.

Only use plastic brushes, NOT

wire brushes or sharp objects.

1. Clean the combustion chamber and

heating surfaces.

■ For normal cleaning, flush the heat-

ing surfaces thoroughly with a

water jet.

■ However, you may use cleaning

agents if you notice stubborn resi-

dues, surface discolouration or

soot deposits.

For this, observe the following:

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 501 GB

– Only use solvent-free cleaning

agents. Ensure that no cleaning

agents enter between the boiler

body and the thermal insulation.

– Remove soot deposits with alka-

line cleaning agents with addi-

tional surfactants (e.g. Fauch

600).

– Remove coatings and surface

discolouration (yellow-brown)

with slightly acidic, chloride-free

cleaning agents based on phos-

phoric acid (e.g. Antox 75 E).

2. Remove loose deposits from the

boiler; flush the heating surfaces and

the flue gas collector thoroughly with

a water jet.

Danger

Loose residues and residual

cleaning agents can lead to

injury.

Wear goggles, protective gloves

and protective clothing.

Cleaning agent manufacturer's

details.

Note

"Fauch 600" and "Antox 75 E"

Manufacturer:

Hebro Chemie GmbH

Rostocker Straße 40

D -41199 Mönchengladbach

Checking the gaskets, packing cords and thermal insulation

components of the boiler door

1. Check gaskets and packing cord in

the boiler door for damage.

2. Check thermal insulation compo-

nents on the boiler door for damage.

3. Replace any damaged parts.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 501 GB

Checking gaskets and thermal insulation components on the

boiler

D E

1. Check flue gas collector seal A

between flue gas collector C and

boiler body B for tightness.

2. Check lip seal D on the boiler flue

connection for tightness.

Note

■ The seals/gaskets can also be

checked under full load with an

inspection mirror. If required,

remove the thermal insulation com-

ponents.

■ Traces of condensate on the out-

side of flue gas collector C indi-

cate a leak.

3. If required, retighten flue gas collec-

tor seal A at tensioning toggles E

or replace. Replace lip seal D if it

leaks.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 501 GB

4. Check the fittings on the water side

for leaks and replace the seals/gas-

kets if required.

Danger

There is a risk of injury when

working on pressurised com-

ponents.

Only open the connections on

the heating water side after

the boiler has been depres-

surised.

Only drain the boiler with a

suction pump with the boiler

air vent valve open.

5. Check the boiler thermal insulation

for good fit and correct if required or

replace if it is damaged.

Checking the mixer for ease of operation and tightness

1. Remove the motorised lever from the

mixer handle.

2. Check the mixer for ease of opera-

tion.

3. Check the mixer for leaks. Replace

the O-rings if the mixer leaks.

4. Snap the motorised lever into place.

Checking the water quality

Enter the amount of top-up water and the

total hardness of the feed and boiler

water into the table.

For water quality requirements, see

page 23.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 501 GB

Meter

reading

Fill and

top-up

water

Total wa-

ter vol-

ume

Total hardness pH val-

Date

Feed-

water

Boiler

water

m3m3m3°dH °dH

The total hardness of the feed and top-

up water must not exceed the standard

values specified by the VDI 2035 (see

page 23).

The pH value should be between 8.2 and

9.5.

Cleaning and reconnecting the condensate drain system

The condensate drain, siphon, neutralis-

ing system (if installed) and all intermedi-

ate hoses and pipes are part of the con-

densate drain system.

Note

Clean the inside of the condensate drain

system at least annually.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 501 GB

1. Undo and flush lower section A of

siphon B; clean the inlet connector

of siphon B with a brush.

2. Fill lower section A of the siphon

with water and refit.

3. Clean the neutralising system (if

installed) in accordance with the

manufacturer's instructions.

Neutralising system operating

instructions

Note

The neutralising agent can be

obtained from Viessmann by quoting

part no. 9524 670.

4. Pull off hose C and fit siphon B to

the condensate drain.

5. Refit hose D of the neutralising sys-

tem to the siphon.

Checking the condensate drain and the neutralising system (if

installed)

Add water to the combustion chamber.

The water must flow from the conden-

sate drain pipe without back pressure.

If necessary, clean the condensate drain

pipe again.

Closing the boiler door

1. Tighten the screws on the boiler door

evenly and diagonally.

2. Mount the gas supply pipe and check

for tightness.

Adjusting the burner

Observe the burner manufacturer's

instructions.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 501 GB

Instructing the system user

The installer should instruct the user in

the operation of the system.

Operating and service documents

1. Complete and detach the customer

registration card:

■ Hand system users their section for

safekeeping.

■ Retain the heating contractor's

section.

2. File all parts lists, operating and serv-

ice instructions in the folder and hand

this over to the system user.

Commissioning, inspection, maintenance

Further details regarding the individual steps (cont.)

5692 501 GB

When ordering spare parts:

Quote the part no. and serial no. (see

type plate) and the position number of

the required part (as per this parts list).

Standard parts are available from your

local supplier.

001 Flue gas collector

002 Flue gas collector gasket

003 Adjustable foot

004 Siphon

005 Flue gasket

200 Fascia

201 Top panel

202 Side panel, l.h. and r.h. side

203 Front panel

204 Back panel

205 Thermal insulation jacket

206 Thermal insulation mat, front

207 Thermal insulation mat, back

208 Bottom cover plate

209 Thermal insulation pack

210 Vitocrossal 300 logo

211 Edge protector

Parts not shown

300 Decorative adhesive tape

301 Spray paint, Vitosilver

302 Touch-up paint stick, Vitosilver

303 Installation instructions

304 Service instructions

AType plate

BBoiler control unit, see separate

parts list

Parts lists

5692 501 GB

210

201

200

202

211

206

203

Parts lists

Parts lists (cont.)

5692 501 GB

211

001

204207

209

004

005

003003

003

208

209

002

209

205209

Parts lists

Parts lists (cont.)

5692 501 GB

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Viessmann VITOCROSSAL 300 Service Instructions Manual

Viessmann VITOCROSSAL 300 Service Instructions Manual

Viessmann VITOCROSSAL 300 Service Instructions Manual

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