Viessmann Vitocrossal 300 Service Instructions For Contractors
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Viessmann Vitocrossal 300 Service Instructions For Contractors

Gas condensing boiler with matrix gas burner and lambda pro control, natural gas and lpg version open and balanced flue operation
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VIESMANN
Service instructions
for contractors
Vitocrossal 300
Type CU3A
Gas condensing boiler with MatriX gas burner and Lambda Pro Con-
trol,
Natural gas and LPG version
open and balanced flue operation
For applicability, see the last page
VITOCROSSAL 300
Please keep safe.
5692 860 GB
6/2010

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Summary of Contents for Viessmann Vitocrossal 300

  • Page 1 VIESMANN Service instructions for contractors Vitocrossal 300 Type CU3A Gas condensing boiler with MatriX gas burner and Lambda Pro Con- trol, Natural gas and LPG version open and balanced flue operation For applicability, see the last page VITOCROSSAL 300 Please keep safe.
  • Page 2 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.

  • Page 4: Table Of Contents

    Index Index Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance.......... Further details regarding the individual steps............Code 1 Calling up coding level 1..................56 General......................... 57 Boiler........................58 DHW........................59 Solar........................60 Heating circuit 1, heating circuit 2, heating circuit 3..........61 Code 2 Calling up coding level 2..................
  • Page 5 Index Index (cont.) Commissioning/service reports................ 138 Specification....................... 143 Certificates Declaration of conformity..................144 Manufacturer's certificate according to the 1st BImSchV [Germany]....144 Keyword index....................145...

  • Page 6: 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. Filling the heating system and checking the supply of ventilation air..............•...
  • Page 7 Commissioning, inspection, maintenance Steps - commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • • 20. Checking that the condensate drain and neutralising system (if installed) are not obstructed and that they are free from leaks............24 •...

  • Page 8: Further Details Regarding The Individual Steps

    (see Vitoset pricelist): – Vitocrossal 300 up to 45 kW: 16.8 °dH (3.0 mol/m – Vitocrossal 300 from 60 kW: 11.2 °dH (2.0 mol/m ■ An antifreeze additive suitable for heating systems can be added to the fill water.

  • Page 9: Filling Siphon With Water

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 5. Mark the set pressure at pressure 7. Return the check valves to their oper- gauge A. ating position. 6. Record the fill volume, water hard- ness and pH value on page 27. Note Observe the "Water quality require- ments"...

  • Page 10: Setting The Time And Date (If Required)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Setting the time and date (if required) During commissioning, or after pro- 2. "Settings" longed time out of use, the time and date need to be reset. 3. "Time / Date" Extended menu: 4.

  • Page 11: Removing The Front Panel

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Removing the front panel...

  • Page 12: Gas Type Conversion (Only For Operation With Lpg)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Gas type conversion (only for operation with LPG) 1. Only possible on appliances with 26 and 35 kW. Set adjusting screw A on the gas train to "2". 2. Turn ON/OFF switch 8 ON. 3.
  • Page 13 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Ignition Fault EE Check the ignition module (control voltage 230 V across plugs "X2.1" and "X2.2") Gas train opens Fault EE Check the gas train (control voltage 230 V); check the gas supply pres- sure Ionisation current...

  • Page 14: Checking The Static And Supply Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Automatic calibra- Fault E3 Ensure adequate tion of the com- heat transfer. bustion controller Press reset button Fault Eb Check gap between ionisation electrode and burner gauze assembly. Check allocation of gas type (coding address 82, gas train setting).
  • Page 15 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Check the supply (flow) pressure. Set value: ■ Natural gas: 20 mbar ■ LPG: 50 mbar Note Use suitable test equipment with a resolution of at least 0.1 mbar for test- ing the supply pressure.

  • Page 16: Setting The Maximum Output

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Supply pressure (flow pressure) Measures for natural gas for LPG below 17.4 mbar below 42.5 mbar Do not start the boiler. Notify your gas supply utility or LPG supplier. 17.4 to 25 mbar 42.5 to 57.5 mbar Start the boiler.

  • Page 17: Checking The Balanced Flue System Tightness (Annular Gap Check)

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the balanced flue system tightness (annular gap check) We recommend that your heating engi- neer carries out a simple leak/tightness test during the commissioning of your system. For this, it would be sufficient to check the CO or O concentration in the...

  • Page 18: Removing The Burner And Checking The Burner Gasket

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Removing the burner and checking the burner gasket...

  • Page 19: Checking Burner Gauze Assembly And Thermal Insulation Block

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Check burner gasket K for possible 1. Switch OFF the main power supply and the ON/OFF switch at the control damage; replace if necessary. unit. 2. Close the gas shut-off valve and safe- guard against reopening.
  • Page 20 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Remove electrodes A. 7. Insert thermal insulating mat E and thermal insulation block F accord- 2. Undo four nuts D and remove fan ing to the electrode position. with gas valve C. Note 3.

  • Page 21: Checking And Adjusting The Ignition And Ionisation Electrodes

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking and adjusting the ignition and ionisation electrodes A Ignition electrodes C Up to 35 kW B Ionisation electrode D From 45 kW 1. Check the electrodes for wear and 3.

  • Page 22: Separating The Neutralising System (If Installed) From The Boiler And Connecting The Drain Hose

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Separating the neutralising system (if installed) from the boiler and connecting the drain hose 1. Separate the hose to the neutralising system from siphon A. 2. Connect the drain hose to siphon A and route it to the drainage sys- tem.

  • Page 23: Cleaning And Reconnecting The Condensate Drain System

    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 24: Checking That The Condensate Drain And Neutralising System (If Installed) Are Not Obstructed And That They Are Free From Leaks

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Undo fitting A on the siphon B and 5. Clean the insides of the condensate remove the siphon from the boiler. drain system and the neutralising system (if installed). 2.

  • Page 25: Checking Gaskets And Thermal Insulation Components On The Boiler

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking gaskets and thermal insulation components on the boiler 1. Check the gasket/seal on the flue gas 2. Check lip seal D of the boiler flue collector A between the flue gas col- connection for tightness.

  • Page 26: Checking The Diaphragm Expansion Vessel And System Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. If required, retighten the flue gas col- 5. Check the boiler thermal insulation lector seal A at the tensioning tog- for good fit and correct if required or gles E or replace. Replace lip seal replace if it is damaged.

  • Page 27: 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 139. Meter read- Fill and top- Total water...

  • Page 28: Fitting The Burner

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Fitting the burner...

  • Page 29: Checking Firm Seating Of Electrical Connections 29. Checking All Gas Equipment For Tightness At Operating Pressure

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Insert burner A and secure with four 3. Plug in ventilation air adaptor E. nuts B, tightening the nuts evenly 4. Connect the electrical cables/leads to and crosswise. the corresponding components. Torque: 4 Nm 2.

  • Page 30: Matching The Control Unit To The Heating System

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Note During commissioning, the combustion controller carries out an automatic calibration. Only test the emissions approx. 30 s after the burner has started. 5. Enter actual values into the report. 6.
  • Page 31 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) System version 1 Within the periods selected at control unit 2, DHW is heated with or without One heating circuit without mixer and priority. DHW heating (optional solar DHW heating) DHW heating by the solar thermal system Applications...
  • Page 32 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) DHW cylinder qR will only be heated by In the case of uninterrupted heating by collectors wP (> 2 h) boiler 1 will only boiler 1 when this set value is no longer reheat, if the set cylinder temperature achieved by the solar thermal system.
  • Page 33 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Hydraulic installation scheme ID: 4605300_1006_01 Flow --2/20-- Return -2/A1/21- ---26/24-- --2/28-- --26/5-- 10 / Note: This scheme is a basic example without shut-off valves or safety equipment. This does not replace the local technical engineering task.
  • Page 34 (cont.) Equipment required ID: 4605300_1006_01 Pos. Designation Boiler with Control unit Vitocrossal 300 with Vitotronic 200, type KW6A Outside temperature sensor ATS DHW heating by the boiler DHW cylinder Cylinder temperature sensor STS DHW circulation pump ZP Circulation pump for cylinder heating UPSB...
  • Page 35 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) ID: 4605300_1006_01 Pos. Designation Divicon Accessories (optional) Internal extension H1: ■ Connection, external safety solenoid valve (LPG) ■ Central fault message (alternative to extension EA1) Internal extension H2: ■ External extractor interlock ■...
  • Page 36 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Electrical installation diagram 230 V/ 50 Hz A1 / UPSB Ö X3.7 X3.6 KM BUS 65 66 X3.3 X3.2 X3.1 Ö 0-10V ID: 4605300_1006_01...
  • Page 37 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) System version 2 DHW heating without a solar thermal system One heating circuit without mixer, one heating circuit with mixer and If the temperature falls below the set DHW heating (optional solar DHW DHW temperature selected at control heating) unit 2, the burner of boiler 1 starts...
  • Page 38 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Demands for the auxiliary function are In the case of uninterrupted heating by met by circulation pump wR. collectors wP (> 2 h) boiler 1 will only reheat, if the set cylinder temperature Suppression of reheating of the DHW (coding address "67") selected at boiler cylinder by the boiler in conjunction...
  • Page 39 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Hydraulic installation scheme ID: 4605301_1006_02 --44/2-- --44/20-- Flow --44/20-- --2/20-- Return --44/52-- -2/21/A1- ---26/24-- --2/28-- --26/5-- 10 / Note: This scheme is a basic example without shut-off valves or safety equipment. This does not replace the local technical engineering task.
  • Page 40 (cont.) Equipment required ID: 4605301_1006_02 Pos. Description Boiler with Control unit Vitocrossal 300 with Vitotronic 200, type KW6A Outside temperature sensor ATS DHW heating by the boiler DHW cylinder Cylinder temperature sensor STS DHW circulation pump ZP Circulation pump for cylinder heating UPSB...
  • Page 41 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) ID: 4605301_1006_02 Pos. Description Components: ■ Mixer PCB and flow temperature sensor M2 (contact temperature sensor) Mixer motor Mixer motor M2 for flanged mixer and plug Temperature limiter for an underfloor heating circuit Heating circuit pump M2 and 3-way mixer Divicon Accessories (optional)
  • Page 42 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Electrical installation diagram 230 V/ 50 Hz A1 / UPSB Ö X3.7 X3.6 KM BUS 65 66 X3.3 X3.2 X3.1 Ö 0-10V VTS M2 ID: 4605301_1006_02...
  • Page 43 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) ID: 4605301_1006_02 System version 3 Heating mode One heating circuit without mixer and The boiler heating circuit controller reg- two heating circuits with mixer and ulates the boiler water temperature in DHW heating (optional solar DHW weather-compensated mode (= flow heating)
  • Page 44 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) In the case of absolute priority, heating Demands for the auxiliary function are circuit pumps eQ/rR/tR are switched off met by circulation pump wR. and mixers rT/tT are closed. With mod- ulating priority control of the heating cir- Suppression of reheating of the DHW cuits with mixer, heating circuit pumps...
  • Page 45 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Hydraulic installation scheme ID: 4605302_1006_01 --51/2-- --51/20-- --41/2-- Flow --51/20-- --2/20-- --41/20-- Return --51/52-- --41/52-- -2/21/A1- ---26/24-- --2/28-- --26/5-- Note: This scheme is a basic example without shut-off valves or safety equipment. This does not replace the local technical engineering task.
  • Page 46 Equipment required ID: 4605302_1006_01 Pos. Description Boiler with Control unit Vitocrossal 300 with Vitotronic 200, type KW6A Outside temperature sensor ATS DHW heating by the boiler DHW cylinder Cylinder temperature sensor STS DHW circulation pump ZP Circulation pump for cylinder heating UPSB...
  • Page 47 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) ID: 4605302_1006_01 Pos. Description Components: rW/tW Mixer PCB and flow temperature sensor (contact temperature sensor) rT/tT Mixer motor M2/M3 Temperature limiter for an underfloor heating circuit rR/tR Heating circuit pump M2/M3 and 3-way mixer Divicon Accessories (optional) Internal extension H1:...
  • Page 48 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Electrical installation diagram 230 V/ 50 Hz A1 / UPSB Ö X3.7 X3.6 KM BUS 65 66 X3.3 X3.2 X3.1 Ö 0-10V VTS M2 ID: 4605302_1006_01...

  • Page 49: Adjusting The Heating Curves

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) VTS M2 ID: 4605302_1006_01 Adjusting the heating curves The heating curves illustrate the relation- Note ship between the outside temperature If the heating system includes heating and the boiler water or flow tempera- circuits with mixers, then the flow tem- ture.
  • Page 50 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Settings in the delivered condition: ■ Slope = 1.4 ■ Level = 0 Slope -5 -10 -15 -20 Outside temperature in °C A Heating curve slope for underfloor heating systems B Heating curve slope for low temper- ature heating systems (according to the Energy Savings Order [Ger-...
  • Page 51 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Changing the slope and level Adjusting the set room temperature Standard room temperature Outside temperature in °C Example 1: Adjustment of the standard A Changing the slope room temperature from 20 to 26°C B Changing the level (vertical parallel A Boiler water temperature or flow offset of the heating curve)

  • Page 52: Connecting The Control Unit To The Lon

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) C Set room temperature in °C Reduced room temperature D Heating circuit pump "OFF" E Heating circuit pump "ON" Adjustment of the reduced room tem- perature: Operating instructions Example 2: Adjustment of reduced room temperature from 5 °C to 14 °C A Boiler water temperature or flow temperature in °C...
  • Page 53 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Boiler control unit Vitotronic 200-H Vitotronic 200-H Vitocom Subscriber no. 1 Subscriber no. 10 Subscriber no. 11 Subscriber no. Code "77:1" Code "77:10" Set code "77:11" Control unit is fault Control unit is not Control unit is not Device is fault...

  • Page 54: Scanning And Resetting The "Service" Display

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 4. Select subscriber (e.g. subscriber Note 10). If the subscriber check is carried out The subscriber check for the selected by another control unit, the sub- subscriber is introduced. scriber number and "Wink" are ■...

  • Page 55: Fitting The Front Panel

    Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Fitting the front panel Instructing the system user The system installer must hand the oper- ating instructions to system users and instruct them in the operation of the sys- tem.

  • Page 56: Calling Up Coding Level 1

    Code 1 Calling up coding level 1 Note 4. Select coding address. ■ The codes are displayed as plain text. ■ Codes that have no function due to the 5. Select value according to the follow- heating system equipment level or the ing tables and confirm with OK.

  • Page 57: General

    Code 1 General Coding Coding in the delivered condition Possible change System design 00:1 System version 1: 00:2 For system schemes, see One heating circuit with- the following table: out mixer (heating circuit 00:10 1), without DHW heating Value System Description address version...

  • Page 58: Boiler

    Code 1 General (cont.) Coding in the delivered condition Possible change Subscriber no. 77:1 LON subscriber number, 77:2 LON subscriber number, if a LON communication adjustable from 1 to 99: module is installed 77:99 1 = Boiler 2 - 5 = Never adjust 10 - 98 = Vitotronic 200-H 99 = Vitocom Note...

  • Page 59: Dhw

    Code 1 Boiler (cont.) Coding in the delivered condition Possible change Burner service in 100 hours 21:0 No service interval (hours 21:1 Number of hours run run) selected before the burner should 21:100 be serviced is adjustable from 100 to 10,000 h One adjusting step ≙...

  • Page 60: Solar

    Code 1 Solar Note The solar group is only displayed if a solar control module, type SM1, is connected. Coding Coding in the delivered condition Possible change Speed control collector pump 02:0 Solar circuit pump is not 02:1 Solar circuit pump is speed-controlled speed-controlled with wave pack control (step-...

  • Page 61: Heating Circuit 1, Heating Circuit 2, Heating Circuit 3

    Code 1 Solar (cont.) Coding in the delivered condition Possible change Extended control functions 20:0 No extended control func- 20:1 Auxiliary function for DHW tions enabled heating 20:2 Differential temperature control 2 20:3 Differential temperature control 2 and auxiliary func- tion 20:4 Differential temperature...
  • Page 62 Code 1 Heating circuit 1, heating circuit 2, heating… (cont.) Parameter address With heating circuit pump logic function: Heating cir- A5:... cuit pump "Off" AT > RT + 5 K AT > RT + 4 K AT > RT + 3 K AT >...
  • Page 63 Code 1 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change Mixer eco function A7:0 Without mixer economy A7:1 With mixer economy func- function (only for heating tion (extended heating cir- circuits with mixer) cuit pump logic): Heating circuit pump also "Off":...
  • Page 64 Code 1 Heating circuit 1, heating circuit 2, heating… (cont.) Parameter With heating circuit pump logic function: address b5:... Heating circuit pump "Off" Heating circuit pump "On" > RT + 5 K < RT + 4 K actual actual > RT + 4 K <...
  • Page 65 Code 1 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change Screed function F1:0 Screed function disabled F1:1 Screed function adjustable in accordance with 6 F1:6 optional temperature/time profiles (see page 120) F1:15 Constant flow temperature 20 °C Party mode time limit F2:8...
  • Page 66 Code 1 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change Duration set flow temperature increase Fb:30 Duration for raising the Fb:0 Duration adjustable from 0 set boiler water tempera- to 300 min; 1 step ≙ 2 min ture or the set flow tem- Fb:150 perature (see coding...

  • Page 67: Calling Up Coding Level 2

    Code 2 Calling up coding level 2 Note 4. Select group of required coding ■ In coding level 2, all codes are acces- address: sible, including the codes from coding ■ "General" level 1. ■ "Boiler" ■ Codes that have no function due to the ■...
  • Page 68 Code 2 General (cont.) Value System Description address version 00: ... One heating circuit without mixer (heating circuit 1), without DHW heating One heating circuit without mixer (heating circuit 1), with DHW heating (code is adjusted automatically) One heating circuit with mixer (heating circuit 2), without DHW heating One heating circuit with mixer (heating circuit 2), with DHW heating...
  • Page 69 Code 2 General (cont.) Coding in the delivered condition Possible change 36:2 Function output aBJ: DHW circulation pump 3A:0 Function input DE1 at 3A:1 Function input DE1: Heat- extension EA1: Not ing program - changeover assigned 3A:2 Function input DE1: Exter- nal demand with set flow temperature.
  • Page 70 Code 2 General (cont.) Coding in the delivered condition Possible change DHW circulation pump run- time adjustment: Coding address 3d 3b:0 Function input DE2 at 3b:1 Function input DE2: Heat- extension EA1: Not ing program - changeover assigned 3b:2 Function input DE2: Exter- nal demand with set flow temperature.
  • Page 71 Code 2 General (cont.) Coding in the delivered condition Possible change DHW circulation pump run- time adjustment: Coding address 3d 3C:0 Function input DE3 at 3C:1 Function input DE3: Heat- extension EA1: Not ing program - changeover assigned 3C:2 Function input DE3: Exter- nal demand with set flow temperature.
  • Page 72 Code 2 General (cont.) Coding in the delivered condition Possible change DHW circulation pump run- time adjustment: Coding address 3d 3d:5 DHW circulation pump 3d:1 DHW circulation pump run- runtime for brief opera- time adjustable from 1 to tion: 5 min 3d:60 60 min 52:0...
  • Page 73 Code 2 General (cont.) Coding in the delivered condition Possible change Separate adjustment of holiday program and time program for DHW heating possible 80:6 A fault message is dis- 80:0 Immediate fault message played if a fault is active 80:2 The minimum fault duration for at least 30s before a fault message is...
  • Page 74 97:2 Control unit transmits the connected to the control outside temperature to the unit is utilised internally Vitotronic 200-H 98:1 Viessmann system num- 98:1 System number adjustable ber (in conjunction with from 1 to 5 monitoring several sys- 98:5 tems via Vitocom 300)

  • Page 75: Boiler

    Code 2 Boiler Coding Coding in the delivered condition Possible change 01:1 Never adjust 04:1 Minimum burner pause 04:0 Minimum burner pause set subject to the boiler load permanently (specified by (specified by boiler cod- boiler coding card) ing card) 06:...

  • Page 76: Dhw

    Code 2 Coding Coding in the delivered condition Possible change 56:0 Set DHW temperature 56:1 Set DHW temperature adjustable from 10 to adjustable from 10 to 60 °C above 60 °C Note Maximum value subject to boiler coding card. Observe the max. permis- sible DHW temperature.

  • Page 77: Solar

    Code 2 (cont.) Coding in the delivered condition Possible change 62:15 65:0 No diverter valve 67:40 For solar DHW heating: 67:0 Set DHW temperature Set DHW temperature adjustable from 0 to 95 °C 40 °C. Reheating is sup- 67:95 (limited by boiler-specific pressed above the selec- parameters) ted set temperature.
  • Page 78 Code 2 Solar (cont.) Coding Coding in the delivered condition Possible change Not allocated to any function mode 00:8 The solar circuit pump 00:2 The differential between starts when the collector the actual cylinder temper- temperature exceeds the 00:30 ature and the start point for actual cylinder tempera- the solar circuit pump can ture by 8 K.
  • Page 79 5 K. 0b:0 Collector frost protection 0b:1 Collector frost protection function switched off function switched on (not required with Viessmann heat transfer medium). 0C:1 Delta T monitoring 0C:0 Delta T monitoring switched on. switched off. No flow rate captured in the collector circuit, or flow rate too low.
  • Page 80 Calculation of solar yield with Viessmann heat with water as heat transfer transfer medium medium (do not select as operation is only possible with Viessmann heat trans- fer medium) 0E:0 Calculation of solar yield switched off 0F:70 The flow rate in the col-...
  • Page 81 Code 2 Solar (cont.) Coding in the delivered condition Possible change 12:20 Minimum collector tem- 12:0 Minimum collector temper- perature 20 °C. ature function switched off The solar circuit pump is 12:1 The minimum collector not started until the mini- temperature is adjustable mum collector tempera- 12:90...
  • Page 82 Code 2 Solar (cont.) Coding in the delivered condition Possible change 23:4 Stop temperature differ- 23:2 Stop temperature differen- ential for central heating tial for central heating backup: 4 K. 23:30 backup is adjustable from 1 Switching output sS is to 29 K switched off when the temperature at sen-...
  • Page 83 Code 2 Solar (cont.) Coding in the delivered condition Possible change 25:50 Stop temperature for 25:0 Start temperature for ther- thermostat function mostat function is adjusta- 50 °C. 25:100 ble from 0 to 100 K Start temperature for thermostat function ≤ stop temperature for ther- mostat function: Thermostat function e.g.

  • Page 84: Heating Circuit 1, Heating Circuit 2, Heating Circuit 3

    Code 2 Solar (cont.) Coding in the delivered condition Possible change 27:15 Alternate heating time 27:5 The alternate heating time 15 min. is adjustable from 5 to The DHW cylinder with- 27:60 60 min out priority is heated at most for the duration of the set alternate heating time if the DHW cylinder with priority is heated up.
  • Page 85 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Please note If a value below 1 °C is selected, there is a risk that pipes outside the thermal envelope of the building could freeze up. The standby mode, in particular, should be taken into consideration, e.g. dur- ing holidays.
  • Page 86 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Parameter address With heating circuit pump logic function: Heating cir- A5:... cuit pump "Off" AT > RT + 5 K AT > RT + 4 K AT > RT + 3 K AT >...
  • Page 87 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change A9:7 With pump idle time: A9:0 Without pump idle time Heating circuit pump A9:1 With pump idle time; "Off" in case of set value adjustable from 1 to 15 modification by changing A9:15...
  • Page 88 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Parameter With heating circuit pump logic function: address b5:... Heating circuit pump "Off" Heating circuit pump "On" > RT < RT - 1 K actual actual > RT - 1 K <...
  • Page 89 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change d8:0 No heating program d8:1 Heating program change- changeover via extension over via input DE1 at exten- sion EA1 d8:2 Heating program change- over via input DE2 at exten- sion EA1 d8:3...
  • Page 90 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change +10 to -60 °C FA:20 Raising the set boiler FA:0 Temperature rise adjusta- water temperature or the ble from 0 to 50 % set flow temperature FA:50 when changing from...

  • Page 91: Diagnosis And Service Scans

    Diagnosis and service scans Calling up the service menu Press OK and å simultaneously for approx. 4 s. Service menu overview Service General Diagnosis Heating circuit 1 Heating circuit 2 Actuator test Heating circuit 3 Domestic hot water Coding level 1 Solar Brief scan Coding level 2...
  • Page 92 Diagnosis and service scans Diagnosis (cont.) The value "Adjusted outside temp" is reset to the actual value. 1. Press OK and å simultaneously 3. "Reset data" for approx. 4 s. 4. Select required value (e.g. "Burner 2. "Diagnosis" starts") or "All details". Brief scan In the brief scan, you can scan temperatures, software versions and connected com- ponents, for example.

  • Page 93: Checking Outputs (Actuator Test)

    Diagnosis and service scans Diagnosis (cont.) Line (brief Field scan) Software Software Software Software version, version, version, version, program- mixer solar con- ming unit exten- trol mod- module sion M2 ule SM1 0: No mixer exten- sion Software version, Type, Appliance type burner control unit burner control unit...
  • Page 94 Diagnosis and service scans Checking outputs (actuator test) (cont.) The following relay outputs can be controlled subject to system design: Display Explanation Base load start Burner operates at minimum output; heating circuit pump A1 is on Full load start Burner operates at maximum output; heating circuit pump A1 is on Output Internal start Internal output sA (cylinder primary pump) enabled...

  • Page 95: Troubleshooting

    Troubleshooting Fault display If there is a fault, the red fault indicator Calling up acknowledged faults A flashes. The following flash on the display: " " and "Fault" appears. Select "Fault" in the standard menu. The current faults will be displayed in a list.

  • Page 96: Fault Codes

    Troubleshooting Fault codes Displayed System characteris- Cause Measures fault code tics Controls as if outside Short circuit, out- Check outside tempera- temperature was side temperature ture sensor (see 0 °C sensor page 105) Controls as if outside Lead break, out- Check outside tempera- temperature was side temperature...
  • Page 97 Troubleshooting Fault codes (cont.) Displayed System characteris- Cause Measures fault code tics No solar DHW heat- Short circuit, col- Check temperature sen- lector temperature sor & on solar control sensor module or Vitosolic sen- Control mode Short circuit, cylin- Check temperature sen- der temperature sor at connection S3 to sensor...
  • Page 98 Troubleshooting Fault codes (cont.) Displayed System characteris- Cause Measures fault code tics Control mode as per Communication Check connections and delivered condition error, program- replace programming unit ming unit if required Control mode as per Internal fault Replace control unit delivered condition Burner blocked Boiler coding card...
  • Page 99 Troubleshooting Fault codes (cont.) Displayed System characteris- Cause Measures fault code tics Control mode Communication Check solar control mod- error, solar control ule or Vitosolic module or Vitosolic Control mode Communication Check Open Therm error, Open Therm extension extension Control mode, max. Communication Check setting of coding pump speed...
  • Page 100 Troubleshooting Fault codes (cont.) Displayed System characteris- Cause Measures fault code tics Control mode without Lead break, room Check room temperature room influence temperature sen- sensor for heating circuit 1 sor, heating circuit and remote control set- 1 (without mixer) tings (see page 125) Control mode without Lead break, room...
  • Page 101 Troubleshooting Fault codes (cont.) Displayed System characteris- Cause Measures fault code tics Burner in a fault Ionisation current Check ionisation elec- state too low during cali- trode: bration ■ Distance to burner gauze assembly (see page 21) ■ Contamination of elec- trode ■...
  • Page 102 Troubleshooting Fault codes (cont.) Displayed System characteris- Cause Measures fault code tics Burner in a fault Repeated flame Check gap between ioni- state loss during calibra- sation electrode and tion burner gauze assembly (see page 21). Check allocation of gas type (see page 12).
  • Page 103 Troubleshooting Fault codes (cont.) Displayed System characteris- Cause Measures fault code tics Burner in a fault Flame is lost imme- Check gas supply (gas state diately after it has pressure and gas flow lim- built (during the iter). safety time) Check flue gas/ventilation air system for flue gas recirculation.
  • Page 104 Troubleshooting Fault codes (cont.) Displayed System characteris- Cause Measures fault code tics Burner in a fault Fan speed too low Check fan, fan connecting state during burner start cables and power supply; check fan control. Press reset button R Burner in a fault Fan not at stand- Check fan, fan connecting state...

  • Page 105: Repairs

    Troubleshooting Repairs Checking the outside temperature sensor A Boiler top panel B Control unit enclosure cover panel...
  • Page 106 Troubleshooting Repairs (cont.) 2. Test the resistance of the outside temperature sensor across terminals "X3.1" and "X3.2" on the disconnec- ted plug and compare it with the curve. 3. Where actual values deviate severely from the curve values, disconnect the wires at the sensor and repeat test on the sensor itself.
  • Page 107 Troubleshooting Repairs (cont.) 3. Replace the sensor in the case of severe deviation. 10 30 50 70 90 110 Temperature in °C Checking the boiler water temperature sensor 1. Boiler water temperature sensor Pull plug § and measure the resist- ance.
  • Page 108 Troubleshooting Repairs (cont.) 3. Replace the sensor in the case of severe deviation. 10 30 50 70 90 110 Temperature in °C Checking the flue gas temperature sensor The flue gas temperature sensor locks out the boiler when the permissible flue gas temperature is exceeded.
  • Page 109 Troubleshooting Repairs (cont.) 2. Check the sensor resistance and compare it with the curve. 3. Replace the sensor in the case of severe deviation. 10 30 50 70 90 110 Temperature in °C Checking the temperature limiter If the burner control unit cannot be reset after a fault shutdown, although the boiler water temperature is below approx.
  • Page 110 Troubleshooting Repairs (cont.) Checking the fuse 1. Switch off the power. 3. Check fuse F1 (see connection and wiring diagram). 2. Remove top panel A and cover...
  • Page 111 Troubleshooting Repairs (cont.) Extension kit for heating circuit with mixer Checking the setting of rotary selec- Note the rotational direction of the mixer tor S1 motor during its self-test. Then set the mixer manually to "Open" The rotary selector on the PCB of the again.
  • Page 112 Troubleshooting Repairs (cont.) 3. Refit the casing cover. Checking the Vitotronic 200-H (accessories) The Vitotronic 200-H is connected to the control unit via the LON cable. To test the connection, carry out a subscriber check at the boiler control unit (see page 53).

  • Page 113: Function Description

    Function description Weather-compensated control unit Boiler temperature 48 °C Heating Solar energy Information Select with Heating mode The control unit determines a set boiler The electronic temperature limiter inside water temperature subject to outside the burner control unit limits the boiler temperature or room temperature (if a water temperature.

  • Page 114: Internal Extensions (Accessories)

    Function description Weather-compensated control unit (cont.) Boosting DHW heating The booster heating function is activated The set temperature value for the heat- if a switching period is selected for the ing boost is adjustable in coding address fourth time phase. "58".
  • Page 115 Function description Internal extensions (accessories) (cont.) The internal extension is integrated into ■ A central fault message facility can be the control unit casing. connected to relay output "A1". ■ An external safety valve can be con- nected to gD Internal extension H2 The internal extension is integrated into ■...

  • Page 116: External Extension (Accessory)

    Function description External extension (accessory) Extension EA1 Digital input 1 Central fault message/feed Digital input 2 pump/DHW circulation pump Digital input 3 (potential-free) 0 - 10 V 0 - 10 V input KM BUS fÖ Power supply fÖ A Power supply terminal for addi- tional accessories...
  • Page 117 Function description External extension (accessory) (cont.) Digital data inputs DE1 to DE3 Effect on the pumps of external block- ing function The following functions can be connec- ted alternatively: The effect on the relevant heating circuit ■ External heating program changeover pump is selected with code d6.

  • Page 118: Control Functions

    Function description External extension (accessory) (cont.) Function assignment Select the function of output aBJ via code 36 at the boiler control unit. Control functions External heating program changeover The "External heating program change- The function is selected via the following over"...
  • Page 119 Function description Control functions (cont.) Heating program - changeover Code No heating program changeover F2:0 Duration of the heating program changeover 1 to 12 hours F2:1 to F2:12 The heating program changeover stays enabled for as long as the contact remains closed, but at least as long as the duration selected in coding address "F2".
  • Page 120 Function description Control functions (cont.) External demand Code Input DE1 3A:2 Input DE2 3b:2 Input DE3 3C:2 The effect on the circulation pump for The minimum set boiler water tempera- cylinder heating is selected with code ture in case of external demand is selec- ted in coding address "9b".
  • Page 121 Function description Control functions (cont.) Temperature profile 2: (ZV parquet and flooring technology) code "F1:2" Days Temperature profile 3: Code "F1:3" Days Temperature profile 4: Code "F1:4" Days Temperature profile 5: Code "F1:5" Days...
  • Page 122 Function description Control functions (cont.) Temperature profile 6: Code "F1:6" Days Temperature profile 7: Code "F1:15" Days Raising the reduced room temperature During operation with reduced room The outside temperature limits for the temperature, the reduced set room tem- start and end of the temperature raising perature can be automatically raised can be adjusted via coding addresses subject to the outside temperature.
  • Page 123 Function description Control functions (cont.) Example using the settings in the delivered condition -5 -10 -15 Outside temp. in °C A Heating curve for operation with B Heating curve for operation with standard room temperature reduced room temperature Reducing the heat-up time During the transition from operation with The value and duration of the additional reduced room temperature to operation...
  • Page 124 Function description Control functions (cont.) Example using the settings in the delivered condition Time in h A Start of operation with standard D Duration of operation with raised set room temperature boiler water or flow temperature in B Set boiler water or flow temperature accordance with coding address in accordance with the selected "Fb":...

  • Page 125: Allocating Heating Circuits To The Remote Control

    Function description Allocating heating circuits to the remote control The heating circuit allocation must be configured when commissioning the Vitotrol 200A or Vitotrol 300A. Heating circuit Configuration Vitotrol 200A Vitotrol 300A The remote control affects the heating circuit with- out mixer A1 The remote control affects the heating circuit with mixer M2 The remote control affects the heating circuit with...
  • Page 126 Function description Electronic combustion controller (cont.) Air factor λ – CO content Air factor λ O content (%) CO content (%) for nat- content (%) for ural gas H LPG P 1.24 10.9 1.27 10.6 1.30 10.3 1.34 10.0 1.37 1.40 1.44 To achieve an optimum combustion con-...

  • Page 127: Designs

    Designs Internal connection diagram Main PCB Coding card Programming unit Connection adaptor Burner control unit LON communication module...
  • Page 128 Designs Internal connection diagram (cont.) Reset button Temperature limiter X ... Electrical interfaces a-Ö Fan motor Outside temperature sensor a-ÖA Fan motor control § Boiler water temperature sensor Gas pressure switch Cylinder temperature sensor KM BUS Plug on the cable harness a:Ö...
  • Page 129 Designs Internal connection diagram (cont.) Internal extension H1 or H2 External safety solenoid valve X ... Electrical interfaces (LPG) Ionisation electrode Ignition unit Circulation pump for cylinder Power supply of accessories heating a-Ö Fan motor Gas solenoid valve a-ÖA Fan motor control fÖ...

  • Page 130: External Connection Diagram

    Designs External connection diagram Main PCB X ... Electrical interfaces PCB SA 104 Outside temperature sensor On/off switch Ionisation electrode...
  • Page 131 Designs External connection diagram (cont.) sÖ fÖ Circulation pump for heating circuit Power supply Ignition unit Circulation pump for cylinder heat- Power supply of accessories a-Ö Fan motor DHW circulation pump aVG KM BUS Gas solenoid valve aBJ External extractor interlock...

  • Page 132: Parts Lists

    209 Thermal insulation mat, front 004 Adjustable foot 210 Retaining bracket 005 Siphon 211 Thermal insulation jacket 006 Boiler flue connection 212 Vitocrossal 300 logo 007 Flue gas gasket 213 Edge protector 008 Ventilation air gasket 214 Decorative cap 009 Thermal circuit breaker...
  • Page 133 Parts lists Parts lists (cont.) 410 Cable harness 100/54/35 418 Cylinder temperature sensor NTC 411 Cable harness, connection exten- sion X7 419 Mating plug 416 Outside temperature sensor NTC 417 Boiler water temperature sensor A Type plate NTC 10k...
  • Page 134 Parts lists Parts lists (cont.)
  • Page 135 Parts lists Parts lists (cont.)
  • Page 136 Parts lists Parts lists (cont.)
  • Page 137 Parts lists Parts lists (cont.)

  • Page 138: Commissioning/Service Reports

    Commissioning/service reports Commissioning/service reports Setting and test val- Set value Commis- Mainte- sioning nance/serv- Date: Static pressure mbar max. 57.5 Supply pressure (flow pressure) = for natural gas E mbar 17.4-25 = for natural gas LL mbar 17.4-25 = for LPG mbar 42.5-57.5 Tick gas type...
  • Page 139 Water quality requirements Note Maintaining the following requirements is necessary to safeguard your warranty rights. The manufacturer's 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 Directive 2035 Sheet 1 "Prevention of damage to hot water heating systems –...
  • Page 140 Water quality requirements (cont.) ■ In systems > 50 kW, install a water ■ Commission the system step by step, meter to capture the volume of the fill starting with the lowest boiler output & top-up water. Enter the amount of fill and at a high heating water flow rate.
  • Page 141 Water quality requirements (cont.) Prevention of damage due to corrosion on the water side The corrosion resistance of ferrous Sealed unvented systems – e.g. sys- materials on the heating water side of tems with a diaphragm expansion vessel heating systems and boilers depends on –...
  • Page 142 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 equipment components.

  • Page 143: Specification

    Specification Specification Rated voltage 230 V Electronic tempera- Rated frequency 50 Hz ture limiter setting 90 °C Rated current Temperature limiter 110 °C (perma- Protection class setting nent) IP rating IP X 2 D to Backup fuse (power EN 60529 supply) max.

  • Page 144: Certificates

    Declaration of conformity Declaration of conformity for Vitocrossal 300, CU3A We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm as sole respon- sible body that the product Vitocrossal 300 complies with the following standards: EN 297 EN 55 014 EN 298...

  • Page 145: Keyword Index

    Keyword index Keyword index Fault manager........53 Acknowledging a fault display....95 Fault memory........95 Actuator test........93 Faults..........95 Allocating heating circuits....125 Fill and top-up water......27 Fill water..........8 Fitting the burner........28 Boiler water quality requirements..139 Flue gas temperature sensor...108 Boiler water temperature sensor..107 Function descriptions.......113 Boosting DHW heating.....114 Fuse..........110 Brief scans.........92...
  • Page 146 Keyword index Keyword index (cont.) Setting the date........10 Parts list...........132 Setting the time........10 Small softening system......8 Specification ........143 Reduced room temperature....52 Standard room temperature....51 Reduced room temperature raising. 122 Static pressure........15 Reducing the heat-up output....122 Supply pressure.........14 Reducing the heat-up time....123 System schemes......30, 56 Relay test...........93 Remote control.........125...
  • Page 148 Applicability Gas condensing boiler Vitocrossal 300, type CU3A from serial no. 5.2 to 26 kW 7439 242 ... 7.0 to 35 kW 7439 243 ... 9.0 to 45 kW 7439 244 ... 12.0 to 60 kW 7439 245 ... Viessmann Werke GmbH&Co KG...

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