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
VITOCROSSAL 300
Please keep safe.
5836858 GB
9/2020

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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 VITOCROSSAL 300 Please keep safe. 5836858 GB 9/2020...
  • Page 2 Safety instructions Safety instructions Please follow these safety instruc- tions closely to prevent accidents and material losses. Safety instructions explained Danger Note This symbol warns against the risk Details identified by the word "Note" of injury. contain additional information. Please note This symbol warns against the risk of material losses and environmen- tal pollution.
  • Page 3 Viessmann. water pipes to discharge static loads. Repair work Please note Repairing components that fulfil a safety function can compromise the safe operation of the system. Replace faulty components only with genuine Viessmann spare parts.
  • Page 4 Safety instructions Safety instructions (cont.) Safety instructions for operating the system If you smell gas Condensate Danger Danger Escaping gas can lead to explo- Contact with condensate can be sions which may result in serious harmful to health. injury. Never let condensate touch your Do not smoke.
  • Page 5 Safety instructions Safety instructions (cont.) Danger The simultaneous operation of the boiler and appliances that exhausts air to the outside can result in life threatening poisoning due to a reverse flow of flue gas. Fit an interlock circuit or take suita- ble steps to ensure an adequate supply of combustion air.
  • Page 6 Commissioning/service Water quality ..................24 reports Maintenance/service ................24 Specification ........................ 26 Final decommissioning ........................ 27 and disposal Certificates EU Declaration of Conformity ..............28 Manufacturer's certificate ............... 28 Vitocrossal 300, type CR3B ..............28 ■ Keyword index ........................ 29...
  • Page 7 Information Key to date of manufacture Year Week Fig. 1 Digits Internal Viessmann information Digits 0 and 5 = calendar week 05 = 5th calendar week 1 and 5 = year 2015 Digits Digit 2 = 2nd day of the working week (Monday = 1, Tuesday = 2, etc.)
  • Page 8 Intended use presupposes that a fixed installation in conjunction with permissible components designed for this purpose has been carried out. Product information Vitocrossal 300, type CR3B ■ Fuel: Natural gas E, natural gas LL and LPG ■ Rated heating output 787 kW and 1400 kW Permissible operating pressure 6 bar (0.6 MPa)

  • Page 9: Table Of Contents

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • 1. Checking the high limit safety cut-out setting..............10 • 2. Filling the heating system with water and venting............10 • • • 3.

  • Page 10: Checking The High Limit Safety Cut-Out Setting

    Commissioning, inspection, maintenance Checking the high limit safety cut-out setting The high limit safety cut-out must not be set higher Control unit installation and service instructions than 110 °C. If required, set it to a maximum of 110 °C. Filling the heating system with water and venting Record the volume filled, water hardness and pH value Please note on page 24.

  • Page 11: Filling The Trap With Water

    Commissioning, inspection, maintenance Filling the trap with water Fig. 2 Lower part of trap Condensate drain hose 1. Fill the trap with water. To do this, pour water into 2. Check that the condensate can drain freely from the boiler via the combustion chamber or the the condensate drain hose.

  • Page 12: Commissioning The System

    Commissioning, inspection, maintenance Fully opening and locking the butterfly valve… (cont.) Butterfly valve Fig. 3 Screw for locking the adjusting lever Adjusting lever Commissioning the system Operating instructions for control unit, burner 6. Check the function of the neutralising system and and neutralising system, service instructions for the hydraulic seal in the trap.

  • Page 13: Minimising Pulsation Noise

    Commissioning, inspection, maintenance Commissioning the system (cont.) Danger For safe operation, a minimum operating pres- sure of 0.5 bar (50 kPa) is essential. A minimum pressure switch can be used for this purpose. See EN 12828. Minimising pulsation noise Pressure-tight flue systems can generate pulsation 2.

  • Page 14: Separating The Neutralising System From The Heat Exchanger Module And Connecting The Drain Hose

    Commissioning, inspection, maintenance Separating the neutralising system from the heat exchanger module and connecting the drain hose 1. Separate hose or pipework to the neutralising system from siphon 2. Undo siphon from condensate drain 3. Clean all components on the inside with plastic brush.
  • Page 15 Commissioning, inspection, maintenance Checking the boiler door/burner gaskets and… (cont.) Ø = Ø B -10 Fig. 5 Boiler door Burner plate Flame tube Thermal insulation block Thermal insulation mat Check the thermal insulation mat at the flame tube. The blue side of the thermal insulation mat has to face the combustion chamber.

  • Page 16: Checking All Connections And The Sensor Well On The Heating Water Side For Tightness

    Commissioning, inspection, maintenance Checking all connections and the sensor well on the heating water side for tightness Removing the casing panels Fig. 6 6. Open the thermal insulation jacket if necessary. Danger There is a risk of injury when working on pres- surised components.
  • Page 17 Commissioning, inspection, maintenance Checking all connections and the sensor well on… (cont.) Checking gaskets Fig. 7 Boiler return 2 Sleeve for control equipment Boiler return 1 Drain outlet Safety connection (safety valve) Condensate drain Sleeve for pressure limiter Connecting flanges for heat exchanger/combustion Boiler flow chamber module Note...

  • Page 18: Checking The Function Of The Safety Equipment

    Commissioning, inspection, maintenance Checking the function of the safety equipment Check safety valves, water level and pressure limiter in accordance with manufacturer's details. Checking the pressure switch function Installation instructions in the "pressure switch set" Checking the temperature controller setting if a building management system is used (DCC system) Please note Shutting down from full load can result in high...

  • Page 19: Cleaning The Sight Glass In The Boiler Door

    Commissioning, inspection, maintenance Expansion vessel and system pressure (cont.) Pump controlled pressure maintaining systems Note Check the pressure maintaining system in line with the In heating systems with automatic pressure maintain- manufacturer's instructions. Limit pressure fluctuations ing equipment or deaeration systems (operating to the lowest possible differential.

  • Page 20: Checking The Water Quality

    Commissioning, inspection, maintenance Checking the water quality Enter the amount of top-up water and the total hard- The total hardness of the feed and top-up water must ness of the feed and boiler water into the table in the not exceed the standard values specified by VDI 2035 appendix on page 24.

  • Page 21: Checking The Flue Gas Side Tightness

    Commissioning, inspection, maintenance Checking the flue gas side tightness Fig. 10 Flue gas temperature sensor on flue gas collector Test port 1. Check the flue gas collector and boiler body for 2. If required, tighten the flue gas collector with a tor- leaks.
  • Page 22 Water quality Water quality requirements Note Observing the following requirements is necessary to safeguard your warranty rights. The warranty excludes damage due to corrosion and scaling. 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 Part 1 "Prevention of damage in water heating installations - Scale formation in domestic hot water...
  • Page 23 Water quality Water quality requirements (cont.) Failure to observe the requirements of VDI Guideline This measure must be carried out by a qualified con- 2035 can result in damaging limescale deposits. In tractor. Inspect the heating system for possible dam- such cases, the service life of the installed boilers will, age prior to returning it into use.
  • Page 24 Commissioning/service reports Water quality Meter reading Fill and top-up water Total water volume Total hardness pH value Date Feedwater Boiler water Maintenance/service Commissioning Maintenance/service Maintenance/service Date: Maintenance/service Maintenance/service Maintenance/service Date: Maintenance/service Maintenance/service Maintenance/service Date: Maintenance/service Maintenance/service Maintenance/service Date:...
  • Page 25 Commissioning/service reports Maintenance/service (cont.) Maintenance/service Maintenance/service Maintenance/service Date:...
  • Page 26 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) Standard seasonal efficiency [to DIN] At heating system temperature Up to 98 (H ) [gross cv] 40/30 °C At heating system temperature...
  • Page 27 Final decommissioning and disposal Final decommissioning and disposal Viessmann products can be recycled. Components For decommissioning the system, isolate the system and substances from the system are not part of ordi- from the power supply and allow components to cool nary household waste.
  • Page 28 Manufacturer's certificate Vitocrossal 300, type CR3B We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, confirm that this product meets the following required conditions: In accordance with the 1st German Immissions Ordinance (BImSchV) ■...
  • Page 29 Keyword index Keyword index Boiler door Operating and service documents......21 – Closing..............19 – Opening..............13 – Sight glass, cleaning..........19 Pressure maintaining system........19 Boiler water requirements.......... 22 Pressure switch function, checking......18 Building management system DCC......18 Product information............8 Burner adjustment............20 Pulsation noise............13 Butterfly valve.............
  • Page 32 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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Cr3b

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