Viessmann Vitocrossal 300 Service Instructions For Contractors
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Viessmann Vitocrossal 300 Service Instructions For Contractors

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VIESMANN
Service instructions
for contractors
Vitocrossal 300
Type CR3B, 787 to 1400 kW
Gas condensing boiler
VITOCROSSAL 300
Please keep safe.
5692910 GB
9/2018

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Summary of Contents for Viessmann Vitocrossal 300

  • Page 1 VIESMANN Service instructions for contractors Vitocrossal 300 Type CR3B, 787 to 1400 kW Gas condensing boiler VITOCROSSAL 300 Please keep safe. 5692910 GB 9/2018...
  • Page 2 Danger system. Hot surfaces and fluids can lead to burns or Replace faulty components only with genuine scalding. Viessmann spare parts. Before maintenance and service work, switch ■ OFF the appliance and let it cool down. ■ Never touch hot surfaces on the boiler, burner,...
  • Page 3 For replacements, use only original spare parts supplied or approved by Viessmann. Safety instructions for operating the system If you smell gas Condensate Danger...
  • Page 4 Index Index Information Symbols ....................Intended use ..................Product information ................Commissioning, inspec- Steps - commissioning, inspection and maintenance ......tion, maintenance Parts lists Ordering parts ..................19 Parts ...................... 20 Casing ....................22 Thermal insulation ................. 24 Miscellaneous ..................26 Water quality Water quality requirements ..............
  • Page 5 Information Symbols The steps in connection with commissioning, inspec- Symbol Meaning tion and maintenance are found in the "Commission- Reference to other document containing ing, inspection and maintenance" section and identified further information as follows: Step in a diagram: Symbol Meaning The numbers correspond to the order in Steps required during commissioning...
  • Page 6 Information Product information Vitocrossal 300, type CR3B ■ Fuel: Natural gas E and natural gas LL ■ Rated heating output 787 kW and 1400 kW ■ Permissible operating pressure 6 bar (0.6 MPa)

  • Page 7: Table Of Contents

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • 1. Checking the high limit safety cut-out setting..............• 2. Filling the heating system with water and venting............• 3. Fully opening the rotary damper in the flue outlet and securing it....... •...

  • Page 8: Checking The High Limit Safety Cut-Out Setting

    Commissioning, inspection, maintenance Checking the high limit safety cut-out setting The high limit safety cut-out must not be set higher Control unit installation and service instructions than 110 °C. If required, set it to a maximum of 110 °C. Filling the heating system with water and venting Record the volume filled, water hardness and pH value Please note on page 30.

  • Page 9: Minimising Pulsation Noise

    Commissioning, inspection, maintenance Minimising pulsation noise Whatever the make of boiler, burner or flue system, 1. Undo M 5 screw on lever of the damper gas-tight flue systems can still create pulsation noise. lock. A change of resonance may be affected by rotating the damper fitted into the flue outlet.

  • Page 10: Separating The Neutralising System From The Heat Exchanger Module And Connecting The Drain Hose

    Commissioning, inspection, maintenance Separating the neutralising system from the heat exchanger module and connecting the drain hose 1. Separate hose or pipework to the neutralising system from siphon 2. Undo siphon from condensate drain 3. Clean condensate drain on the inside using a plastic brush.

  • Page 11: Checking All Connections And The Sensor Well On The Heating Water Side For Tightness

    Commissioning, inspection, maintenance Checking gaskets and thermal insulation… (cont.) Ø = Ø B -10 Fig. 3 Boiler door Burner plate Flame tube Thermal insulation block Thermal insulation mat Check the thermal insulation mat at the flame tube. The blue side of the thermal insulation mat has to face the combustion chamber.

  • Page 12: Checking The Function Of The Safety Equipment

    Commissioning, inspection, maintenance Checking all connections and the sensor well on… (cont.) Fig. 4 1. Undo the fixing screws in top panels . Remove 4. Close the thermal insulation of the heat exchanger the panels. module. 2. Open the thermal insulation of the heat exchanger 5.

  • Page 13: Checking The Temperature Controller Setting If A Building Management System Is Used (Dcc System)

    Commissioning, inspection, maintenance Checking the temperature controller setting if a building management system is used (DCC system) Please note Shutting down from full load can result in high material stress and material damage. If a system with a higher ranking building man- agement system takes over the temperature control of the boiler, adjust the settings at the temperature controller TR.

  • Page 14: Cleaning The Sight Glass In The Boiler Door

    Commissioning, inspection, maintenance Cleaning the sight glass in the boiler door Check gaskets and hose connection for leaks. Danger Leaks can result in a risk of poisoning through escaping flue gas. Check gaskets carefully. Fig. 5 Closing the boiler door 1.

  • Page 15: Checking The Installation Room Ventilation

    Commissioning, inspection, maintenance Cleaning and reconnecting the condensate drain… (cont.) Fig. 6 1. Disconnect drain or cleaning hose 6. Clean the inside of the pipes of the condensate drain system and the neutralising system. 2. Clean condensate drain again from the inside using a plastic brush.

  • Page 16: Checking The Flue Gas Side Tightness

    Commissioning, inspection, maintenance Checking the flue gas side tightness Fig. 7 1. Check flue gas collector and the boiler body for 2. If required, tighten flue gas collector with a tor- tightness. que of 7 Nm or replace the gasket. Note In full load operation, the gaskets can be checked with an inspection mirror.
  • Page 17 Commissioning, inspection, maintenance Operating and service documents (cont.) 2. File all parts lists, operating and service instruc- tions in the folder and hand this over to the system user. The installation instructions are no longer required after the installation and, therefore, do not need to be retained.
  • Page 18 Commissioning, inspection, maintenance Operating and service documents (cont.)
  • Page 19 Trim strip (1 roll = 10 m) 0302 Touch-up spray paint, Vitosilver, 150 ml can 0303 Touch-up paint stick, Vitosilver 0304 Vitocrossal 300 installation instructions 0305 Vitocrossal 300 service instructions 0308 Spring clip, short (10 pce) 0310 Flue system collar...
  • Page 20 Parts lists Parts Fig. 8...
  • Page 21 Parts lists Parts (cont.) Pos. Part 0003 Gasket DN 125 PN 6 0005 Boiler door 0006 Sight glass 0007 Sight glass frame 0008 Hose nozzle 0009 Plastic hose 800 mm 0010 Sensor well 0011 Thermal insulation mats 0012 Thermal insulation block 0013 Packing 15 x 25, L = 2500 with adhesive 0014...
  • Page 22 Parts lists Casing 208 241 Fig. 9...
  • Page 23 Back panel, top 0224 Top panel, centre back 0225 Top panel, back 0226 Top panel, centre 0227 Top panel, left 0228 Top panel, centre, connector 0229 Top panel, right 0241 Corner rail, right 0306 Vitocrossal 300 logo 0307 Viessmann logo...
  • Page 24 Parts lists Thermal insulation Fig. 10 Type plate, either right or left Boiler control unit (see parts list in the service instructions of the boiler control unit) Burner cable (see parts list in the service instruc- tions of the boiler control unit)
  • Page 25 Parts lists Thermal insulation (cont.) Pos. Part 0019 Coding card 0200 Top front r.h. rail 0201 Top back r.h. rail 0204 Bottom front r.h. rail 0205 Bottom back r.h. rail 0211 Support plate 0212 Side panel, right front 0213 Side panel, control unit 0214 Side panel, centre 0215...
  • Page 26 Parts lists Miscellaneous Fig. 11...
  • Page 27 Parts lists Miscellaneous (cont.) Pos. Part 0001 Flue gas cover with gasket and rotary damper 0002 Gasket set comprising 0003 Gasket DN 125 PN 6 0004 Gasket DN 100 PN 6, 1100/1280 kW only 0017 Stench trap...
  • Page 28 Water quality Water quality requirements Note Observing the following requirements is necessary to safeguard your warranty rights. The warranty excludes damage due to corrosion and scaling. Prevention of damage due to scaling Prevent excessive scale build-up (calcium carbonate) on the heating surfaces. For heating systems with operating temperatures up to 100 °C, VDI Guideline 2035 Part 1 "Prevention of damage in water heating installations - Scale formation in domestic hot water...
  • Page 29 Water quality Water quality requirements (cont.) Failure to observe the requirements of VDI Guideline This measure must be carried out by a qualified con- 2035 can result in damaging limescale deposits. In tractor. Inspect the heating system for possible dam- such cases, the service life of the installed boilers will, age prior to returning it into use.
  • Page 30 Commissioning/service reports Water quality Meter reading Fill and top-up water Total water volume Total hardness pH value Date Feedwater Boiler water Maintenance/service Commissioning Maintenance/service Maintenance/service Date: Commissioning Maintenance/service Maintenance/service Date: Commissioning Maintenance/service Maintenance/service Date: Commissioning Maintenance/service Maintenance/service Date:...
  • Page 31 Commissioning/service reports Maintenance/service (cont.) Commissioning Maintenance/service Maintenance/service Date:...
  • Page 32 Specification Specification Rated heating output = 50/30 °C 1100 1400 = 80/60 °C 1006 1280 Rated heat input 1038 1320 Product ID CE-0085AU0315 Product parameters (according to EnEV) Standard seasonal efficiency [to DIN] At heating system temperature 40/30 Up to 98 (H ) [gross cv] °C At heating system temperature 75/60...
  • Page 33 Final decommissioning and disposal Final decommissioning and disposal Viessmann products can be recycled. Components For decommissioning the system, isolate the system and substances from the system are not part of ordi- from the power supply and allow components to cool nary household waste.
  • Page 34 Manufacturer's certificate We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, confirm that the product Vitocrossal 300, type CR3B, complies with the following conditions stipulated by the 1st German Immissions Order (BImSchV): ■ limits according to paragraph 6 (1).
  • Page 35 Keyword index Keyword index Boiler door Operating and service documents......16 – Closing..............14 Ordering parts............19 – Opening..............9 – Sight glass, cleaning..........14 Boiler water requirements.......... 28 Parts..............19, 20 Burner adjustment............15 Pressure maintaining system........13 Pressure switch function, checking......12 Product information............
  • 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...

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Cr3b

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