Viessmann VITOCROSSAL 300 Service Instructions Manual
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Viessmann VITOCROSSAL 300 Service Instructions Manual

Gas condensing boiler
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VIESMANN
Service instructions
for contractors
Vitocrossal 300
Type CR3B, 787 to 1400 kW
Gas condensing boiler
For applicability, see the last page
VITOCROSSAL 300
Please keep safe.
5692 910 GB
11/2013

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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 For applicability, see the last page VITOCROSSAL 300 Please keep safe. 5692 910 GB 11/2013...

  • Page 2: Safety Instructions

    Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and mate- rial losses. Safety instructions explained ■ The Code of Practice of relevant trade associations Danger ■ All current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury.
  • Page 3 Safety instructions Safety instructions (cont.) If you smell flue gas Danger The simultaneous operation of Danger the boiler and appliances that Flue gas can lead to life threat- extract air to the outside can ening poisoning. result in life threatening poison- ■...
  • Page 4 Please note Repairing components that fulfil a safety function can compromise the safe operation of the sys- tem. Faulty components must be replaced with original Viessmann spare parts. Auxiliary components, spare and wearing parts Please note Spare and wearing parts that...
  • Page 5 Index Index Product information Intended use......................Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance.......... Further details regarding the individual steps............Parts lists......................23 Commissioning/service reports ........................30 Reports Specification....................... 31 Water quality Water quality requirements.................. 32 Certificates Declaration of Conformity..................36 Certificates Manufacturer's certificate according to the 1st BImSchV........

  • Page 6: Intended Use

    Product information Intended use 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 as well as the details in the datasheet.
  • Page 7 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..•...
  • Page 8 Commissioning, inspection, maintenance Steps - commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • • 22. Checking the flue gas side for tightness...... 21 • 23. Instructing the system user........... 22 • 24. Operating and service documents........ 22...

  • Page 9: 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 10: Minimising Pulsation Noise

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Start the system in this order: 9. Check the boiler door and cleaning 1. Mains isolator cover a few days after commissioning 2. Switch for the heating circuit pump and retighten all screws.

  • Page 11: Shutting Down The System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Undo M 5 screw A on lever B of the damper lock. 2. Adjust the lever until no further pul- sation noise occurs. The lever indi- cates the position of rotary damper 3.

  • Page 12: Exchanger Module And Connecting The Drain Hose

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Please note Never put tools or other objects Scratches inside the combustion into the combustion chamber. chamber can lead to corrosion. Separating the neutralising system from the heat exchanger module and connecting the drain hose 2.

  • Page 13: Components

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) – Only use solvent-free cleaning Danger agents. Ensure that no cleaning Loose residues and residual agents enter between the boiler cleaning agents can lead to body and the thermal insulation. injury.
  • Page 14 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Ø = Ø B -10 A Boiler door D Burner plate B Flame tube E Thermal insulation block C Thermal insulation mat Check the thermal insulation mat at the flame tube. The blue side of the thermal insulation mat has to face the combus- tion chamber.

  • Page 15: Heating Water Side For Tightness

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking all connections and the sensor well on the heating water side for tightness Danger If draining with a suction pump, There is a risk of injury when only drain the boiler with the air working on pressurised compo- vent valve open.

  • Page 16: Checking The Function Of The Safety Equipment

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. Open the thermal insulation of the 5. Position the top panels and secure heat exchanger module until con- with screws. necting flange C is freely accessi- ble. Note The gaskets can also be checked under 3.
  • Page 17 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. If the pre-charge pressure of the 3. Refill with water until the charge pres- expansion vessel is lower than the sure is 0.2 (20 kPa) higher than the value calculated using the formula, pre-charge pressure of the expan- top up with sufficient nitrogen to ach- sion vessel when the system is cold.

  • Page 18: Cleaning The Sight Glass In The Boiler Door

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the sight glass in the boiler door Check gaskets A and hose connection B for leaks. Danger Leaks can result in a risk of poi- soning through escaping flue gas.

  • Page 19: System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Meter read- Fill and top- Total water Total hardness pH value Date up water volume Feedwater Boiler wa- The total hardness of the feed and top- The pH value should be between 8.2 and up water must not exceed the standard 9.5.

  • Page 20: Adjusting The Burner

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 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 A again Neutralising system operating from the inside using a plastic instructions brush.
  • Page 21 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the flue gas side for tightness...

  • Page 22: Instructing The System User

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Check flue gas collector A and the 2. If required, tighten flue gas collector A with a torque of 7 Nm or replace boiler body for tightness. the gasket. Note The gaskets can also be checked under full load with an inspection mir-...

  • Page 23: Parts Lists

    Parts lists Parts lists Serial no. (see type plate) Pos. Spare part 7436409 7436410 7436411 7436412 Part no. of spare part Flue gas cover with gasket and 7837525 7837525 7837530 7837530 rotary damper Gasket set comprising Z001525 Z001525 Z001525 Z001525 Gasket DN 125, PN 6 7815443 7815443 7815443 7815443...
  • Page 24 Trim strip (1 roll = 10 m) 7819535 7819535 7819535 7819535 Touch-up spray paint, Vitosil- 7819545 7819545 7819545 7819545 ver, 150 ml can Touch-up paint stick, Vitosilver 7819546 7819546 7819546 7819546 Vitocrossal 300 installation in- 5719748 5719748 5719748 5719748 structions...
  • Page 25 Parts lists (cont.) Serial no. (see type plate) Pos. Spare part 7436409 7436410 7436411 7436412 Part no. of spare part Vitocrossal 300 service instruc- 5681910 5681910 5681910 5681910 tions Vitocrossal 300 logo 7841102 7841102 7841102 7841102 Viessmann ND18 logo 7841104 7841104 7841104...
  • Page 26 Parts lists Parts lists (cont.)
  • Page 27 Parts lists Parts lists (cont.) 208 241...
  • Page 28 Parts lists Parts lists (cont.)
  • Page 29 Parts lists Parts lists (cont.)

  • Page 30: Reports

    Commissioning/service reports Reports Commissioning Service Service date: Service Service Service date: Service Service Service date: Service Service Service date: Service Service Service date:...

  • Page 31: Specification

    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) Efficiency η ■ At 100 % of rated heating 97.0 97.1 97.0 97.0 output ■...

  • Page 32: Water Quality Water Quality Requirements

    Water quality Water quality requirements Note The warranty excludes damage due to Observing the following requirements is corrosion and scaling. necessary to safeguard your warranty rights. 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 sheet 1 "Prevention of heating system damage –...
  • Page 33 Water quality Water quality requirements (cont.) ■ In systems > 50 kW, install a water ■ Commission the system step by step, meter to capture the amount of the fill starting with the lowest boiler output and top-up water. Enter the volume of and a high heating water flow rate.
  • Page 34 Water quality Water quality requirements (cont.) Prevention of damage due to corrosion on the water side The corrosion resistance of ferrous Sealed unvented systems – e.g. those materials on the heating water side of equipped with an expansion vessel – heating systems and heat generators offer good protection against the ingress depends on the absence of oxygen in the...
  • Page 35 Water quality Water quality requirements (cont.) Where chemicals are used as part of the corrosion protection, we recommend that the manufacturer of the chemicals issues a certificate of suitability of the additives with regard to the boiler mate- rials and the materials of the other heat- ing system components.

  • Page 36: Declaration Of Conformity

    Declaration of Conformity We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, declare as sole respon- sible body, that the product Vitocrossal 300, type CR3B, 787 to 1400 (720 to 1280) kW with the Vitotronic boiler control unit conforms to the following standards:...

  • Page 37: Manufacturer's Certificate According To The 1St Bimschv

    Manufacturer's certificate according to the 1st BImSchV We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm that the product Vitocrossal 300, type CR3B, 787 to 1400 (720 to 1280) kW, complies with the following conditions stipulated by the 1st German Immissions Order (BImSchV): ■...

  • Page 38: Keyword Index

    Keyword index Keyword index Boiler door Neutralising system......12 – Closing..........18 – Opening..........11 – Sight glass, cleaning.......18 Operating and service documents..22 Boiler water quality requirements..32 Burner adjustment......20 Pressure maintaining system.....17 Pulsation noise........10 Checking tightness – Flue gas side........21 Combustion chamber Reports..........30 –...
  • Page 40 Applicability Serial No.: 7436409 7436410 7436411 7436412 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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