Viessmann VITOCROSSAL 300 Service Instructions Manual
  1. Manuals
  2. Brands
  3. Viessmann Manuals
  4. Boiler
  5. VITOCROSSAL 300
  6. Service instructions manual

Viessmann VITOCROSSAL 300 Service Instructions Manual

Type ct3b, 187 to 635 kw gas condensing boiler
Hide thumbs Also See for VITOCROSSAL 300:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Service Manual, Instruction and Installation Manual
VIESMANN
Service instructions
for contractors
Vitocrossal 300
Type CT3B, 187 to 635 kW
Gas condensing boiler
For applicability, see the last page
VITOCROSSAL 300
Please keep safe.
5614 461 GB
1/2014

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the VITOCROSSAL 300 and is the answer not in the manual?

Questions and answers

Related Manuals for Viessmann VITOCROSSAL 300

Summary of Contents for Viessmann VITOCROSSAL 300

  • Page 1 VIESMANN Service instructions for contractors Vitocrossal 300 Type CT3B, 187 to 635 kW Gas condensing boiler For applicability, see the last page VITOCROSSAL 300 Please keep safe. 5614 461 GB 1/2014...

  • 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: Table Of Contents

    Index Index Product information Intended use......................Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance.......... Further details regarding the individual steps............Parts lists Overview of the assemblies................. 22 Boiler assembly....................23 Thermal insulation assembly................27 Boiler door assembly for third party burners............31 Commissioning/service reports................

  • Page 6: Product Information

    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

    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 system for tightness • • 23. Adjusting the burner............21 • 24. Instructing the system user........... 21 • 25. Operating and service documents........ 21...

  • 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.) 3. Check the gas supply pressure. 9. A few days after commissioning, check the boiler door and retighten 4. Check that the cleaning aperture on the screws (tightening torque the flue outlet is closed. 10 Nm).

  • Page 11: Shutting Down The System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Remove back panel C; for this undo quarter-turn closures E. 2. Undo nut A on lever B of rotary damper D. 3. Adjust the lever until all pulsation noise has ceased (the lever mirrors the position of the rotary damper).

  • Page 12: Separating The Neutralising System From The Boiler And Connecting The Drain Hose

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Separating the neutralising system from the boiler and connect- ing the drain hose 1. Separate hose A to the neutralising 4. Connect drain hose D to conden- system from siphon B. sate drain C and route it to drainage system E.

  • Page 13: Checking Gaskets And Thermal Insulation Components

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) For this, observe the following: Danger – Only use solvent-free cleaning Loose residues and residual agents. Ensure that no cleaning cleaning agents can lead to agents enter between the boiler injury.

  • Page 14: Checking The Function Of The Safety Equipment

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Undo cap A from the back of the boiler. 2. Check sensor well B for leaks. 3. Secure cap A. Checking the function of the safety equipment Check safety valves, water level and pressure limiter in accordance with man- ufacturer's details.
  • Page 15 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) The expansion vessel must have the fol- Expansion vessels lowing minimum size, subject to the boiler output: 1. Drain the system or close the cap ■ up to 300 kW: 50 l valve on the expansion vessel and ■...

  • Page 16: Checking The Flue Gas Collector For Tightness

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the flue gas collector for tightness 1. Traces of condensate on the outside of the flue gas collector indicate a leak. Danger Escaping flue gas can lead to a health hazard. Check gaskets on the flue gas collector and adjust if required.
  • Page 17 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Check gaskets A and hose connection B for leaks. Danger Leaks can result in a risk of poi- soning through escaping gas. Check gaskets carefully.

  • Page 18: Closing The Boiler Door

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Closing the boiler door 1. Tighten the screws on the boiler door 2. Mount the gas supply pipe and check evenly and diagonally. for tightness. Torque 10 Nm Danger Leaks can result in a risk of poisoning through escaping gas.

  • Page 19: Checking The Water Quality

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 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. For water quality requirements, see page 35. Meter read- Fill and top- Total water...

  • Page 20: Cleaning And Reconnecting The Condensate Drain System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning and reconnecting the condensate drain system The condensate drain system comprises Note the condensate drain, siphon, neutralis- Clean the inside of the condensate drain ing system and all hoses and pipes run- system at least annually.

  • Page 21: Adjusting The Burner

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Danger To stop flue gas from escaping, Escaping flue gas can lead to a always connect a condensate health hazard. drain with siphon. Adjusting the burner Observe the burner manufacturer's instructions.

  • Page 22: Parts Lists

    Parts lists Overview of the assemblies 0001 0003 0002 0001 Boiler assembly Parts not shown 0002 Thermal insulation assembly 0004 Fixings 0003 Boiler door assembly 0005 Touch-up spray paint, Vitosilver 0006 Touch-up paint stick, Vitosilver 0007 Sealant...

  • Page 23: Boiler Assembly

    Parts lists Overview of the assemblies (cont.) 0008 Installation instructions Standard parts are available from your 0009 Service instructions local supplier. Boiler assembly Boiler for Vitocrossal 170 to 285 kW Pos. Component Serial no. (see type plate) 750138 750138 7501384 750140 750140 7501408...
  • Page 24 Parts lists Boiler assembly (cont.) Boiler 170 to 285 kW 0006 0005 0005 0001 0002 0004 0003 0005 0006 0003 0007 0008 0009...
  • Page 25 Parts lists Boiler assembly (cont.) Boiler for Vitocrossal 370 to 575 kW Description Serial no. (see type plate) 7501385 7501386 7501387 7501409 7501410 7501411 Part no. 0001 Burner plate 7222517 7222517 7222517 0002 Hose packing d=18, L=1520 7836745 7836745 7836745 0003 Boiler door CT3B 370-575kW 7836865 7836865...
  • Page 26 Parts lists Boiler assembly (cont.) Boiler 370 to 575 kW 0014 0013 0013 0010 0017 0008 0018 0007 0019 0020 0011 0018 0020 0006 0012 0021 0019 0013 0014 0020 0009 0021 0010 0020 0001 0015 0002 0003 0004 0005 0016 0022 0023...

  • Page 27: Thermal Insulation Assembly

    Parts lists Thermal insulation assembly Thermal insulation for Vitocrossal 170 to 285 kW Pos. Component Serial no. 7501382 7501383 7501384 7501406 7501407 7501408 Part no. 0001 Side panel 7836518 7836574 7836621 0002 Side panel, top 7836521 7836576 7836622 0003 Side panel, control unit 7836522 7836582 7836631 0004...
  • Page 28 Cable trunking FB 60 x 150, upper section 7836551 7836612 7836644 0041 Corner rail, front right 7839741 7839742 7839742 0042 Viessmann logo 7841104 7841104 7841104 0043 Vitocrossal 300 logo 7841102 7841102 7841102 Thermal insulation for Vitocrossal 370 to 575 kW Pos. Component Serial no. 7501385 7501386 7501387 7501409...
  • Page 29 Cable trunking FB 60 x 150, lower section 7836679 7836689 7836700 0040 Cable trunking FB 60 x 150, upper section 7836680 7836690 7827375 0041 Corner rail, front right 7839743 7839743 7839743 0042 Viessmann logo 7841104 7841104 7841104 0043 Vitocrossal 300 logo 7841102 7841102 7841102...
  • Page 30 Parts lists Thermal insulation assembly (cont.) 0027 0026 0025 0015 0013 0013 0016 0007 0017 0012 0007 0002 0002 0008 0033 0024 0014 0032 0023 0030 0019 0020 0001 0009 0018 0012 0028 0011 0002 0039 0010 0003 0004 0034 0038 0031 0001...

  • Page 31: Boiler Door Assembly For Third Party Burners

    Parts lists Boiler door assembly for third party burners Boiler door for Vitocrossal 170 to 285 kW Pos. Component Serial no. 7501382 7501383 7501384 7501406 7501407 7501408 Part no. 0001 Burner plate 7222516 7222516 7222516 0002 Packing GF 7x9 L= 950 7836722 7836722 7836722 0003...
  • Page 32 Parts lists Boiler door assembly for third party burners (cont.) 0008 0006 0009 0010 0011 0007 0012 0012 0006 0013 0010 0011 0012 0013 0014 0015 0001 0002 0003 0004 0005 0012...

  • Page 33: 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 34: Specification

    Specification Specification Rated heating output = 40/30 °C = 80/60 °C Rated heat input 234.5 385.5 CE designation CE-0085AQ0257 Flue gas parameters Temperature (at 30 °C return temperature) ■ At rated heating out- °C ■ At partial load °C Temperature (at 60 °C °C return temperature) Product parameters (according to EnEV)
  • Page 35 Water quality requirements 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 36 Water quality requirements (cont.) ■ In systems > 50 kW, install a water ■ In multi boiler systems, start all boilers meter to capture the amount of the fill simultaneously to prevent the entire and top-up water. Enter the volume of limescale deposit settling in the heat the fill water and the water hardness transfer area of just one boiler.
  • Page 37 Water quality requirements (cont.) The characteristic blackening of the No further anti-corrosion measures are water after a certain time in operation required for sealed hot water heating indicates that there is no more free oxy- systems, subject to the above points gen present.

  • Page 38: Certificates

    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 CT3B, 170-575 (187-635) kW ■ with the Vitotronic boiler control unit and ■ with the Vitotronic boiler control unit and MatriX radiant burner...

  • Page 39: Certificates

    Certificates Manufacturer's certificate We, Viessmann Werke GmbH & Co KG, D-35107 Allendorf, confirm that this product meets the conditions specified by the 1st German Immissions Order (1. BImSchV): ■ NO limits in accordance with paragraph 6(1). ■ Flue gas loss of max. 9 % in accordance with paragraph 10 (1).

  • Page 40: Keyword Index

    Keyword index Keyword index Boiler door Neutralising system......12 – Closing..........18 – Opening..........11 Boiler door gaskets, checking....13 Operating and service documents..21 Boiler door sight glass, cleaning..16 Boiler door thermal insulation, check- ing............13 Pressure maintaining systems, pump- Boiler water quality requirements..35 controlled...........14 Burner adjustment......21 Rotary damper in the flue outlet...9 Combustion chamber, cleaning..12...
  • Page 44 7501385 7501386 7501387 7501406 7501407 7501408 7501409 7501410 7501411 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...

Table of Contents