Viessmann VITOCROSSAL 300 Operating Instructions Manual
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Viessmann VITOCROSSAL 300 Operating Instructions Manual

Ca3 series 2.5, 3.0, 3.5, 4.0, 5.0 and 6.0 with vitotronic 300 gw6c control 2500 to 6000 mbh (733 to 1758 kw)
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Operating Instructions

for use by heating contractor
Vitocrossal 300 CA3 Series 2.5, 3.0, 3.5, 4.0, 5.0 and 6.0
with Vitotronic 300 GW6C control
Gas condensing boiler with weather-compensated control unit
Heating input: 2500 to 6000 MBH
(733 to 1758 kW)
VITOCROSSAL 300
5790 737 - 01
03/2017
H
WARNING
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
Do not store or use gasoline or other
fl ammable liquids in the vicinity of this
or any other appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliances.
Do not touch any electrical switches,
do not use any phone in your building.
Immediately call your gas supplier
from a neighbor's phone. Follow
the gas supplier's instructions.
If you cannot reach your gas supplier,
call the fi re department.
Installation and service must be
performed by a qualifi ed installer,
service agency or the gas supplier.
WARNING
Improper installation, adjustment, and/
or operation could cause carbon monoxide
poisoning resulting in injury or loss of life.
This product must be installed and serviced
by a professional service technician who is
experienced and qualified in hot water boiler
installation and gas/oil combustion.
Product may not be exactly as illustrated.
IMPORTANT
Read and save these instructions for
future reference.
Please file in Service Binder

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Summary of Contents for Viessmann VITOCROSSAL 300

  • Page 1: Operating Instructions

    Operating Instructions for use by heating contractor Vitocrossal 300 CA3 Series 2.5, 3.0, 3.5, 4.0, 5.0 and 6.0 with Vitotronic 300 GW6C control Gas condensing boiler with weather-compensated control unit Heating input: 2500 to 6000 MBH (733 to 1758 kW)

  • Page 2: Safety, Installation And Warranty Instructions

    General Information Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Safety, Installation and Warranty Requirements Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life.

  • Page 3: About These Instructions

     This symbol indicates that other instructions must be referenced. Product Information The Viessmann Vitocrossal 300, CA3 boiler series is CSA The Vitocrossal 300, CA3 boiler must only be installed certified for Canada, is constructed in compliance with in closed loop hot water heating systems using a pre- CSA B51 Standard and carries Canadian Registration charged membrane expansion tank.

  • Page 4: Table Of Contents

    Table of Contents Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Page General Information Safety, Installation and Warranty Instructions ....2 About these Instructions ..........3 Product Information ........... 3 Safety For your Safety ............6 Operation ..............6 Gas Smell ............. 6 Flue gas Smell ............
  • Page 5 Table of Contents Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Page Central Heating Time Program ............19 Room Temperature ...........21 Operating Program ...........22 Time Program ............22 Heating Curve ............23 Stopping Central Heating ..........23 Comfort Function .............24 Energy Saving Function “Economy Mode” ....25 Energy Saving Function “Holiday Program”...

  • Page 6: For Your Safety

    Safety Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating For your Safety Working on the equipment  CAUTION All personnel working on the equipment or the heating system must have the proper qualifications and hold all Follow these safety instructions closely to avoid the risk necessary licenses.

  • Page 7: Frozen Water Pipe Hazard

    Safety Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating For your Safety (continued) Frozen water pipe hazard Boiler room conditions   - Do not use a room in which the air is polluted by WARNING halogenated hydro-carbons (e.g. as contained in aerosols,...

  • Page 8: Maintenance And Cleaning

    Safety Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating For your Safety (continued) Maintenance and cleaning  WARNING Regular inspection and service by a qualified heating contractor is important to the performance of the Improper installation, adjustment, service, or Viessmann Vitocrossal 300, CA3 boilers. Neglected maintenance can cause flue products to flow into maintenance impacts on warranty;...

  • Page 9: Description

    System Information Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Description CA3 2.5, 3.0, 3.5 and 4.0 CA3 5.0 and 6.0 Dimensions Dimensions Boiler Model 2.5 and 3.0 3.5 and 4.0 5.0 and 6.0 Boiler Model 2.5 and 3.0 3.5 and 4.0 5.0 and 6.0...

  • Page 10: Fuel

    Boiler control air, such as barber shops and beauty salons, printing The Vitocrossal 300, CA3 boiler series is operated with shops, chemical cleaners, laboratories etc. a Vitotronic control and microcomputer indoor/outdoor control system for boiler operation without low temperature CAUTION limit.

  • Page 11: Operation

     gas shut-off valve, ventilation apertures Domestic hot water production The Vitocrossal 300, CA3 boiler may be used to supply 1. Check the heating system pressure at the pressure domestic hot water heating by means of an indirect-fired gauge. If the pressure of the heating system is too hot water storage tank.

  • Page 12: Commissioning

    Upon powering Central heating up the Vitocrossal 300, CA3 boiler and burners may H Between 12:00 am and 12:00 am (00:00 h and 24:00 h), be initially commissioned or temporarily operated with the rooms are heated to 68°F (20°C) “Room temp set...

  • Page 13: Energy Saving Tips

    System Information Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Energy Saving Tips H Holiday: Central heating If you are going away, select the “Holiday program”: H Standard room temperature The room temperature will be reduced, and DHW (“Room temp target”): heating will be turned off.

  • Page 14: General Boiler Information

    General Boiler Information Single boiler application Boiler model 2.5 and 3.0 Each Vitocrossal 300 CA3 boiler section is equipped with it’s own control unit. The CA3 models 2.5 and 4.0 each have two boiler sections and the CA3 models 5.0 and 6.0 each have three boiler sections.

  • Page 15: System And Lead Control Boiler Section 1 Programming Unit

    Operation Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating System and Lead Control Boiler Section 1 Programming Unit You can change any settings on your heating system centrally at the programming unit of the system and lead control boiler section 1.

  • Page 16: Service Display Lag Boiler Sections

    Operation Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Service Display Lag Boiler Sections A screensaver appears after opening the control unit, or if there has not been any operation for some time: Each service display unit is equipped with a touchscreen.

  • Page 17: Starting The Heating System

    Operation Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Starting the Heating System Ask your heating contractor about the following: Legend H Boiler and relevant control unit type A ON/OFF switch B ON indicator (green) H Level of the required system pressure...

  • Page 18: Shutting Down The Heating System

    Operation Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Shutting Down the Heating System With frost protection monitoring Without frost protection monitoring (shutdown) For every heating circuit select the “Standby mode” 1. Switch OFF the ON/OFF switch on every system and operating program lead control unit (see page 17).

  • Page 19: Time Program

    Central Heating Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Time Program Time programs are set at the system and lead boiler section control. The following explains how to input the settings for a time program. The special features of individual time programs are allotted to the relevant chapters.
  • Page 20 Central Heating Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Time Program (continued) Transferring the time program to other days of the week You can copy this time program for any other days of the week. You want to copy this time program for Monday to the period Tuesday to Friday.

  • Page 21: Room Temperature

    Central Heating Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Room Temperature Note: Further information can be found in chapter “Terminology” in this manual. You can make the following settings only at the system and lead control boiler section 1.

  • Page 22: Operating Program

    Central Heating Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Operating Program Note: Further information can be found in chapter “Terminology” in this manual. Setting the operating program You can make the following settings only at the system and lead control boiler section 1.

  • Page 23: Heating Curve

    Central Heating Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Heating Curve Note: Further information can be found in chapter “Terminology” in this manual. You can make the following settings only at the system and lead control boiler section 1.

  • Page 24: Comfort Function

    Central Heating Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Comfort Function You can make the following settings only at the system and lead control boiler section 1. Setting “Comfort mode” From the home screen tap the following buttons: 1. “Menu”...

  • Page 25: Energy Saving Function "Economy Mode

    Central Heating Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Energy Saving Function “Economy Mode” You can make the following settings only at the system and lead control boiler section 1. Setting “Economy mode” From the home screen tap the following buttons: 1.

  • Page 26: Energy Saving Function "Holiday Program

    Central Heating Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Energy Saving Function “Holiday Program” You can make the following settings only at the system and lead control boiler section 1. Setting “Holiday program” Note: The holiday program affects all heating circuits.

  • Page 27: Dhw Temperature

    DHW Heating Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating DHW Temperature You can make the following settings only at the system and lead control boiler section 1. Factory setting: 122°F (50°C) Setting range: 50°F to 140°F (10°C to 60°C) If you want to make changes to this, contact your local heating contractor.
  • Page 28 DHW Heating Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Time Program (continued) Note: DHW is not heated between the time phases. Frost  protection for the DHW tank is enabled. When setting time programs, bear in mind that your ...

  • Page 29: Setting The Display Backlighting

    Further Adjustments Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Setting the Display Backlighting From the home screen tap the following buttons: 1. “Menu” 2. “Settings” 3. “Screen” 4. “Brightness standby” or “Brightness control” for the required value 6. Press OK to confirm...

  • Page 30: Language Selection

    Further Adjustments Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Language Selection From the home screen tap the following buttons: 1. “Menu” 2. “Settings” 3. “Language” 4. Required language 5. Tap OK to confirm Setting the Measuring Units From the home screen tap the following buttons: 1.

  • Page 31: Scanning Information

    Scanning Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Scanning Information Subject to the components connected and the settings made, you can scan current temperatures and operating conditions. Information in the main menu is split into groups: H “General” H “Combustion controller”...
  • Page 32 Scanning Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Scanning Information (continued) Resetting data You can reset the following data: H Burner hours run H Fuel consumption H In conjunction with a solar thermal system: Solar energy yield, solar circuit pump hours run...
  • Page 33 Scanning Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Scanning Information (continued) Scanning fault messages Your display indicates that your heating system has developed faults by showing symbol and “Faults”. The red fault indicator flashes on the control unit enclosure (see chapter “Starting the heating system”).

  • Page 34: Main Menu Overview

    Scanning Options Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Main Menu Overview Lead control unit...
  • Page 35 Scanning Options Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Main Menu Overview (continued) Service control display boiler section 2 or 3...

  • Page 36: Scanning Options Under "Information

    Scanning Options Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Scanning Options under “Information” Note: Subject to the actual heating system equipment level, not all of the scans listed here may be available. You can scan more details on information marked with .

  • Page 37: Emissions Test Mode

    Emissions Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Emissions Test Mode Emissions test mode for testing the flue gas with briefly Boiler model 2.5 and 3.0 raised boiler water temperature. Emissions test mode should only be activated by your heating contractor during the annual inspection.

  • Page 38: Rooms Are Too Cold

    Troubleshooting Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Rooms are Too Cold Cause Remedy The heating system is off H Switch ON the ON/OFF switch on the control units (see page 17). H Switch ON the mains isolator, if installed (outside the boiler room).

  • Page 39: Rooms Are Too Hot

    Troubleshooting Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Rooms are Too Hot Cause Remedy H Control unit incorrectly adjusted. Check the settings and correct if required: H The remote control (if installed) is set incorrectly. H Operating program (see pages 18 or 22)

  • Page 40: The Dhw Is Too Hot

    Troubleshooting Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating The DHW is Too Hot Cause Remedy The control unit is set incorrectly. Check and correct the DHW temperature, if required (see page 27). The DHW is being heated by the solar thermal system.

  • Page 41: Inspection And Maintenance

    Maintenance Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Inspection and Maintenance Cleaning Safety valve (DHW tank) All equipment can be cleaned with a commercially The function of the safety valve must be checked every available domestic cleaning agent (non-scouring).

  • Page 42: Additional Maintenance Information

    Maintenance Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Additional Maintenance Information Water quality Danger of freezing The lifetime of the entire heating system is influenced by If the system is subject to freezing temperatures and the water quality. A water treatment system will protect is not filled with antifreeze for protection, the system against damages caused by corrosion and lime formation.
  • Page 43 Additional Information Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Terminology (continued) Heating curve Heating curves illustrate the relationship between the outdoor temperature, the set room temperature and the boiler water temperature or supply temperature. The lower the outdoor temperature, the higher the boiler water temperature or supply temperature.
  • Page 44 Additional Information Vitocrossal 300 CA3 Series 2.5 to 6.0 Operating Terminology (continued) Open flue operation Summer mode Operating program “DHW only”. In warmer months, you Combustion air is drawn from the room where the boiler can switch off heating mode. The boiler remains operational is installed.

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