Viessmann VITOCROSSAL 300 Service Instructions Manual
Ct3 series
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- Service instructions manual (164 pages) ,
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Service Instructions
for use by heating contractor
Vitocrossal 300
CT3 Series
Gas-fired condensing boiler
Heating input:
638 to 3361 MBH
187 to 985 kW
VITOCROSSAL 300
5285 875 - 04
01/2016
Vitocrossal 300, CT3 boiler
with Vitotronic control
Product may not be exactly as shown
IMPORTANT
Read and save these instructions for
future reference.
Please file in Service Binder
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Table of Contents
Related Manuals for Viessmann VITOCROSSAL 300
Summary of Contents for Viessmann VITOCROSSAL 300
- Page 1 CT3 Series Gas-fired condensing boiler Heating input: 638 to 3361 MBH 187 to 985 kW VITOCROSSAL 300 Vitocrossal 300, CT3 boiler with Vitotronic control Product may not be exactly as shown IMPORTANT Read and save these instructions for future reference.
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Page 2: Safety
Installers must follow local regulations with respect to installation of carbon monoxide detectors. Warranty Follow the Viessmann maintenance schedule of the Information contained in this and boiler in the “Service Instructions” manual. related product documentation must be read and followed. Failure to do... -
Page 3: Fiberglass Wool And Ceramic Fiber Materials
Safety Vitocrossal 300, CT3 Series Service Safety, Installation and Warranty Requirements (continued) Suppliers of fiberglass wool products recommend the H Fiberglass wool and ceramic fiber materials following precautions be taken when handling these WARNING materials: Precautionary measures Inhaling of fiberglass wool and/or ceramic fiber - Avoid breathing fiberglass dust and contact with materials is a possible cancer hazard. -
Page 4: Table Of Contents
Table of Contents Vitocrossal 300, CT3 Series Service Page Safety Safety, Installation and Warranty Requirements ....2 Product documentation ...........2 Licensed professional heating contractor ....2 Contaminated air ...........2 Advice to owner ............2 Warranty ..............2 Carbon monoxide ...........2 Fresh air ...............2 Equipment venting ..........2 Fiberglass wool and ceramic fiber materials ....3... - Page 5 Check Proper Expansion Tank and System Pressures ..16 Check Flue Gas Collector for Leaks ......17 Close Combustion Chamber Door .......17 Check Thermal Insulation ..........18 Check Viessmann Mixing Service Valve for Proper Operation and Leaks ..........18 Adjust Burner ............18 Check Separate Heating System Controls ....18 Check for Proper DHW Production ......18...
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Page 6: Important Regulatory And Safety Requirements
This includes low water cut-offs, flow switches (if used), staging controls, pumps, motorized valves, air vents, thermostats, etc. Technical literature Literature for the Vitocrossal 300 CT3 boiler: - Technical Data Manual - Installation Instructions - Service Instructions - Operating Instructions and User’s Information Manual... -
Page 7: General Information
General Information Vitocrossal 300, CT3 Series Service About these Instructions Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below. Warnings draw your attention to the presence of WARNING potential hazards or important product information. -
Page 8: Necessary Tools
H Approved leak detection fluid for natural gas and to the technical literature of other System Technology propane gas devices: H Installation Instructions for Viessmann boiler control Cleaning supplies H Installation Instructions for Viessmann indirect-fired hot H Hand brush water storage tank(s) -
Page 9: Customer Site Information
General Information Vitocrossal 300, CT3 Series Service Customer Site Information Please complete the information below. Site Name: Street: City: Tel.: Boiler Mfr.: Viessmann Series: Heating Input: Serial No.: Burner Mfr.: Series: Heating Input: Serial No.: Installing Contractor Firm: Technician: Address: Tel.:... -
Page 10: Product Information
The Vitocrossal 300, CT3 boilers are CSA certified with Weishaupt and Riello burners which must be used in conjunction with this boiler series. See Installation and Operating Instructions The proper burner size must be verified and the burner for Vitotronic controls. -
Page 11: Inspection And Maintenance
Inspection and Maintenance Vitocrossal 300, CT3 Series Service Dispose of Condensate During the operation of the Vitocrossal 300 boiler, the amount of condensate as per the diagram can be expected. The values given are approximate amounts occurring under practical conditions. Not included in the chart is the amount of condensate occurring in the vent pipe and chimney system. -
Page 12: Start Up Heating System
Inspection and Maintenance Vitocrossal 300, CT3 Series Service Start up Heating System Reference operating instructions for control unit, 10. The start-up of the system will be automatically burner and neutralization system. Also reference initiated by the Vitotronic control. service instructions of control unit, as well as The gas burner should be calibrated immediately for burner manufacturer’s documentation. -
Page 13: Reduce Pulsation Noises
Inspection and Maintenance Vitocrossal 300, CT3 Series Service Reduce Pulsation Noises Gas-tight (positive pressure) flue systems may create pulsation noises, irrespective of the boiler, burner or flue gas system make. Pulsation noises may be reduced by rotating the damper fitted into the flue outlet (during start- up only). -
Page 14: Clean Combustion Chamber And Heat Exchanger Surfaces
Combustion It is recommended to service, clean and inspect the chamber Observation heating system at least once a year. Viessmann door bolts port recommends a service contract with a mechanical firm. Neglected service on the unit presents a risk, service... -
Page 15: Clean Observation Port In Combustion Chamber Door
Inspection and Maintenance Vitocrossal 300, CT3 Series Service Clean Combustion Chamber and Heat Exchanger Surfaces (continued) CAUTION Ensure that no cleaning agent is entering between the pressure vessel and the insulation enclosure. 8. With a good light source (flash light, trouble light) examine combustion chamber and flue gas collector area for discoloration of the stainless steel. -
Page 16: Check All Connections And Sensor Well For Leaks
Inspection and Maintenance Vitocrossal 300, CT3 Series Service Check all Connections and Sensor Well for Leaks CAUTION Only open the heating water connections after the boiler has been depressurized. Only drain the boiler with a vacuum pump when the boiler air vent valve is open. -
Page 17: Check Flue Gas Collector For Leaks
Inspection and Maintenance Vitocrossal 300, CT3 Series Service Check Flue Gas Collector for Leaks 1. Visually check the gasket through clean-out opening A on the flue gas collector. Traces of condensate on the outside of the flue gas collector indicate a leak. -
Page 18: Check Thermal Insulation
Replace the O-rings if the mixing valve leaks. 4. Snap the motorized lever back into place. Adjust Burner The input of the burner used with the Vitocrossal 300 boiler must be adjusted so that the maximum boiler input of the particular boiler model is not exceeded. -
Page 19: Maintenance Schedule
Inspection and Maintenance Vitocrossal 300, CT3 Series Service Maintenance Schedule The following is an overview of scheduled service steps. Regular service work ensures reliable, energy-efficient, and environmentally friendly operation. IMPORTANT Keep boiler and boiler room clear and free from combustible materials, gasoline and other flammable vapors and liquids. - Page 20 Inspection and Maintenance Vitocrossal 300, CT3 Series Service Maintenance Schedule (continued) Frequency Performed by Service Annually Owner / Ensure service work/test is conducted at least annually by qualified personnel, and that any deficiencies are corrected immediately. Operator Heating Test functionality of safety high limits.
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Page 21: Additional Information
If in any doubt about the water quality, please have a proper water analysis done. Check with regional chemical suppliers for boiler water treatment or with Viessmann Manufacturing Company Inc. directly. Total output (MBH) Total Hardness (ppm as CaCO >... -
Page 22: Technical Data
Additional Information Vitocrossal 300, CT3 Series Service Technical Data Boiler Model CT3- 1071 1389 1726 2160 2702 3361 Input (kW) (187) (248) (314) (407) (506) (633) (792) (985) Output 1044 1350 1675 2094 2616 3252 (kW) (183) (242) (306) (396) - Page 23 30% of rated input. Calculate the flue gas mass flow rate accordingly when the partial load differs from that stated above (subject to the burner mode). For information regarding other Viessmann System Technology componentry, please reference documentation of respective product.
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Page 24: Parts List
Additional Information Vitocrossal 300, CT3 Series Service Parts List When ordering replacement parts Please provide boiler Model and Serial Number from rating plate when ordering replacement parts. Order replacement parts from your Viessmann distributor. Parts 082 Gasket, PN6 200 Insulation blanket-front, top... - Page 25 Additional Information Vitocrossal 300, CT3 Series Service Parts List (continued) Parts 087 Gasket, PN6 090 Condensate pan (with items 091, 092 and 094) 091 Cover for condensate pan 092 Cleanout gasket (order with 304 sealant) 093 Retaining clip 094 Condensate pan gasket (order with 405 sealant)
- Page 26 Additional Information Vitocrossal 300, CT3 Series Service Parts List (continued) Parts 208 Front panel, top 209 Front panel, middle 210 Front panel, bottom 216 Side panel (left/right) 217 Lamellar panel-bottom right 220 Lamellar panel-bottom left 222 Strain relief (6-channel) 234 Lamellar panel-center left...
- Page 27 Additional Information Vitocrossal 300, CT3 Series Service Parts List (continued) Parts 211 Rear panel, top 214 Side panel, bottom 215 Side panel, top 221 Cover, round access 223 Console casing-rear 224 Console case-front 232 Rear panel, right 233 Rear panel, left...
- Page 28 Additional Information Vitocrossal 300, CT3 Series Service Parts List (continued) Parts 069 Burner plate 070 Combustion chamber door 071 Glass fiber gasket 9 x 7 x l=2000 mm 072 Support bracket (hinges) 073 Glass fiber gasket 20 x 15 x l=2000 mm...
- Page 29 Additional Information Vitocrossal 300, CT3 Series Service Parts List (continued) Parts 080 Counter flange 081 Gasket, PN6 083 Counter flange 084 Gasket, PN6 086 Counter flange 087 Gasket, PN6 Other parts (not illustrated) 300 Access. pack (insulation) 301 Installation Instructions 302 Service Instructions 303 Access.
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Page 30: Maintenance Record
Additional Information Vitocrossal 300, CT3 Series Service Maintenance Record Maintenance/ Maintenance/ Maintenance/ Maintenance/ Maintenance/ Service Service Service Service Service Maintenance/ Maintenance/ Maintenance/ Maintenance/ Maintenance/ Service Service Service Service Service Maintenance/ Maintenance/ Maintenance/ Maintenance/ Maintenance/ Service Service Service Service Service Maintenance/... - Page 31 Vitocrossal 300, CT3 Series Service...
- Page 32 Vitocrossal 300 CT3 Series Service...