Viessmann VITOCROSSAL 300 Service Instructions Manual
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Summary of Contents for Viessmann VITOCROSSAL 300
- Page 1 VIESMANN Service instructions for contractors Vitocrossal 300 Type CR3, 787 and 978 kW Gas condensing boiler For applicability, see the last page VITOCROSSAL 300 Please keep safe. 5692 398 GB 2/2011...
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Page 2: Safety Instructions
Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate- rial losses. Safety instructions explained ■ all current safety regulations as defined by DIN, EN, DVGW, TRGI, Danger TRF, VDE and all locally applicable This symbol warns against the standards, risk of injury. - Page 3 ■ When using gas as fuel, also close the For replacements, use only orig- main gas shut-off valve and safeguard inal spare parts from Viessmann against unauthorised reopening. or those which are approved by ■ Isolate the system from the power sup- Viessmann.
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Page 4: Table Of Contents
Index Index Commissioning, inspection, maintenance Steps – commissioning, inspection and maintenance.......... Further details regarding the individual steps............Parts lists......................18 Commissioning/service reports................ 23 Specification....................... 24 Water quality Water quality requirements.................. 25 Certificates Declaration of Conformity..................27 Certificates Manufacturer’s certificate according to the 1st BImSchV........28... -
Page 5: Commissioning, Inspection, Maintenance
Commissioning, inspection, maintenance Steps – commissioning, inspection and maintenance 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..... • 2. Filling the heating system with water and venting the system................ - Page 6 Commissioning, inspection, maintenance Steps – commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • 21. Checking the flue system for leaks • • 22. Adjusting the burner............15 • • 23. Checking the gaskets/seals on the flue side....16 •...
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Page 7: Further Details Regarding The Individual Steps
Commissioning, inspection, maintenance Further details regarding the individual steps Checking the high limit safety cut-out setting The high limit safety cut-out must not be Control unit installation and serv- set higher than 110 °C; if required, set it ice instructions to a maximum of 110 °C. -
Page 8: Minimising Pulsation Noise
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Switch ON the mains isolator, the 8. Check all gaskets/seals and plugs, switch for the heating circuit pump and retighten if necessary. and the burner control switch, in that order. -
Page 9: Shutting Down The System
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Shutting down the system 1. Switch OFF the mains isolator or the 2. Pull plugs fA and lÖ from the power supply and safeguard against burner. unauthorised reconnection. 3. Close the gas shut-off valve. Opening the boiler door 1. -
Page 10: Checking Gaskets And Thermal Insulation Parts
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) ■ For normal cleaning, flush the heat- 2. Remove loose deposits from the ing surfaces thoroughly with a boiler; flush the heating surfaces and water jet. the flue gas collector thoroughly with ■... -
Page 11: Checking All Connections On The Heating Water Side And The Sensor Well For Leaks
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking all connections on the heating water side and the sen- sor well for leaks Danger Only drain the boiler with a suc- There is a risk of injury when tion pump when the boiler air vent working on pressurised compo- valve is open. -
Page 12: Checking The Safety Equipment Function
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the safety equipment function Check the safety valves, the water level and pressure limiters in accordance with manufacturer's details. Checking the diaphragm expansion vessel and system pressure Note Carry out all checks in accordance with Observe the diaphragm expansion ves- the manufacturer's instructions. -
Page 13: Cleaning The Sight Glass In The Boiler Door
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. If the pre-charge pressure of the dia- 4. Mark this value on the pressure phragm expansion vessel is lower gauge as the minimum filling pres- than the value calculated according sure. -
Page 14: Checking The Water Quality
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Check the mixer for leaks. Replace 4. Snap the motorised lever into place. the O-rings if the mixer leaks. Checking the water quality Enter the amount of top-up water and the total hardness of the feed and boiler water into the following table. -
Page 15: Adjusting The Burner
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Note Clean the inside of the condensate drain system at least annually. 1. Pull drain or cleaning hose C off. 6. Clean the inside of the pipes of the condensate drain system and the neutralising system. -
Page 16: Checking The Gaskets/Seals On The Flue Side
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the gaskets/seals on the flue side 2. Check gaskets A of the cleaning 1. Check the gasket/seal on the flue gas collector C between the flue gas col- cover for tightness. lector B and the boiler body D for tightness. -
Page 17: Instructing The System User
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Note 3. If required, retighten flue gas collec- tor seal C and seal A or replace. The seals/gaskets can also be checked under full load with an inspection mirror. If required, remove the thermal insulation components. -
Page 18: Parts Lists
012 Boiler door 220 Front thermal insulation mat 013 Sight and test pipe cover 221 2-fold strain relief 014 Sight glass (incl. gasket) 222 Vitocrossal 300 logo 015 Hose ferrule 223 Edge protector 016 Hose 224 Thermal insulation mat, back... - Page 19 Parts lists Parts lists (cont.)
- Page 20 Parts lists Parts lists (cont.)
- Page 21 Parts lists Parts lists (cont.)
- Page 22 Parts lists Parts lists (cont.)
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Page 23: Commissioning/Service Reports
Commissioning/service reports Commissioning/service reports Commissioning Service Service date: Service Service Service date: Service Service Service date: Service Service Service date: Service Service Service date:... -
Page 24: Specification
Specification Specification Rated heating output = 50/30 °C = 80/60 °C Rated heat input Product ID CE-0085 AU 0315 Product parameters (according to EnEV) Efficiency η ■ at 100 % of rated output 97.0 97.1 ■ at 30 % of rated output 108.3 108.5 Standby loss q... -
Page 25: Water Quality
Water quality Water quality requirements Heating systems with rated operating temperatures up to 100 ºC (VDI 2035) Prevent excessive scale build-up (cal- The build-up of limescale deposits on the cium carbonate) on the heating surfaces. heating surfaces will be minimised if For heating systems with operating tem- these instructions are observed. -
Page 26: Water Quality Water Quality Requirements
Water quality Water quality requirements (cont.) Prevention of damage due to corrosion on the water side The corrosion resistance of ferrous The pre-charge pressure of the dia- materials on the heating water side of phragm expansion vessel should be heating systems and boilers depends on checked at least during the annual serv- the absence of oxygen in the heating ice. -
Page 27: Certificates
Declaration of Conformity We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, declare as sole respon- sible body, that the product Vitocrossal 300, type CR3, 787 to 978 (720 to 895) kW with the Vitotronic boiler control unit conforms to the following standards:... -
Page 28: Certificates
Manufacturer’s certificate according to the 1st BImSchV We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm that the product Vitocrossal 300, type CR3, 787 to 978 (720 to 895) kW with boiler control unit Vitotronic complies with the following conditions specified by the 1st German Immis- sions Order: ■...