Viessmann Vitocrossal 300 Series Service Instructions Manual
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Viessmann Vitocrossal 300 Series Service Instructions Manual

Floor mounted, gas-fired condensing boiler with matrix gas burner and lambda pro control
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Service Instructions
for use by heating contractor
Vitocrossal 300 CU3A
Models 26, 35, 45, 57, 94, 125, 160, 199
Floor mounted, gas-fired condensing boiler with MatriX gas burner and Lambda Pro control
For operation with natural gas and liquid propane gas
Heating input
19 to 199 MBH
5.6 to 58 kW
VITOCROSSAL 300
5673 649 -18
10/2019
H
Product may not be exactly as shown
IMPORTANT
Read and save these instructions
for future reference.
Please file in Service Binder

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Summary of Contents for Viessmann Vitocrossal 300 Series

  • Page 1 Service Instructions for use by heating contractor Vitocrossal 300 CU3A Models 26, 35, 45, 57, 94, 125, 160, 199 Floor mounted, gas-fired condensing boiler with MatriX gas burner and Lambda Pro control For operation with natural gas and liquid propane gas Heating input 19 to 199 MBH 5.6 to 58 kW...

  • Page 2: Safety

    Follow the manufacturing facilities. Viessmann maintenance schedule of the boiler contained in this manual. Contaminated combustion air will damage the boiler and may lead to substantial property damage, severe Operating and Service Documentation personal injury and/or loss of life.

  • Page 3: Fiberglass Wool And Ceramic Fiber Materials

    Safety Vitocrossal 300 CU3A 26 to 199 Service Safety, Installation and Warranty Requirements (continued) Suppliers of fiberglass wool products recommend the Fiberglass wool and ceramic fiber materials following precautions be taken when handling these materials: WARNING - Avoid breathing fiberglass dust and contact with skin and eyes.

  • Page 4: Table Of Contents

    Table of Contents Vitocrossal 300 CU3A 26 to 199 Service Vitocrossal 300 CU3A 26 to 199 Service Page Page Safety, Installation and Warranty Requirements....2 Safety Product documentation..........2 Warranty..............2 Licensed professional heating contractor....2 Contaminated air...........2 Advice to owner............2 Operating and Service Documentation......2 Carbon monoxide...........2 Fresh air..............2 Equipment venting..........2...
  • Page 5 Table of Contents Vitocrossal 300 CU3A 26 to 199 Service Vitocrossal 300 CU3A 26 to 199 Service Page Page Service Removing the Burner and Checking the Burner Gasket...22 Placing the Burner Door in the Service Retainer....22 Checking Burner Mesh Assembly and Refractory..23 Check and Adjust Ignition and Ionization Electrodes..23 Cleaning the Combustion Chamber and Heating Surfaces..24 Separating the Neutralizing System (if installed)....24...

  • Page 6: General Information

    - Operating Instructions and User’s Information Manual The completeness and functionality of field supplied - Instructions of other Viessmann products utilized and electrical controls and components must be verified by installed the heating contractor. These include low water...

  • Page 7: For Installations On The Commonwealth Of Massachusetts

    CSD-1 Field Testing of High Limit Switches for boilers – where required by law. VIESSMANN IS NOT RESPONSIBLE FOR ANY DAMAGES THAT THE FOLLOWING TEST PROCEDURE MAY RESULT IN BY OVERHEATING THE SYSTEM. The fixed high limit, when tripped, produces a fault that will require manual reset of the boiler control.

  • Page 8: Applicability

    General Information Vitocrossal 300 CU3A 26 to 199 Service Applicability CAUTION The boiler serial number must be provided when ordering replacement parts. IMPORTANT When ordering replacement parts, provide the 16-digit boiler serial number (on the bar code label), located as shown underneath boiler front enclosure panel.

  • Page 9: Mechanical Room

    General Information Vitocrossal 300 CU3A 26 to 199 Service Mechanical Room During the early stages of designing a new home, we recommend that proper consideration be given to constructing a separate mechanical room dedicated to the gas- or oil-fired heating equipment and domestic hot water storage tank(s). The boiler must be located in a heated indoor area, near a floor drain, and as close as possible to a wall.

  • Page 10: Start-Up

    Start-up Vitocrossal 300 CU3A 26 to 199 Service Filling the Heating System CAUTION Unsuitable fill water increases the level of deposits and corrosion, and may lead to damage to the equipment. H Thoroughly flush the entire heating system prior to filling with water.

  • Page 11: Removing The Front Panels

    Start-up Vitocrossal 300 CU3A 26 to 199 Service Removing the Front Panel 1. Remove the retaining screw and set aside. 2. Pull the top of the boiler cover away from the boiler, lift off and set aside. Filling Siphon with Water 1.

  • Page 12: Opening The Control Unit

    Start-up Vitocrossal 300 CU3A 26 to 199 Service Opening the Control Unit Vitotronic 200, type KW6B 1. Lift the programming unit A into the upright position (the angle of the programming unit can be adjusted using the push button on the side B). 2.

  • Page 13: Start-Up Wizard

    Start-up Vitocrossal 300 CU3A 26 to 199 Service Start-up Wizard Select Language At the commissioning stage, the display is in German. 1. “Sprache” (Language) Deutsch DE (German) 2. Select the required language with 3. Accept by pressing OK Set time and date 1.

  • Page 14: Selecting Zone Circuits

    Start-up Vitocrossal 300 CU3A 26 to 199 Service Start-up Wizard (continued) Select zone circuit type Each zone circuit can be operated either as a fixed setpoint or weather compensated (using the outdoor temperature sensor) thermostat, use to select and press OK. Select fixed setpoint For zone circuits with fixed setpoint operation select desired supply water temperature use...

  • Page 15: Select Pump Output

    Start-up Vitocrossal 300 CU3A 26 to 199 Service Start-up Wizard (continued) Confirm pump output Confirmation of selected pump output and press OK. Zone circuit temperature setting For the selected zone with fixed set point thermostat will display zone circuit temperature setting. Weather compensated operation For the selected zone circuit with weather compensated operation the current outdoor temperature and the current...

  • Page 16: Designating Heating Circuits

    Start-up Vitocrossal 300 CU3A 26 to 199 Service Designating Heating Circuits In the delivered condition, the heating circuits are designated "Heating circuit 1", "Heating circuit 2" and "Heating circuit 3" (if installed). If the system user prefers, the heating circuits can be designated differently to suit the specific system.

  • Page 17: Select Gas Type

    Start-up Vitocrossal 300 CU3A 26 to 199 Service Select Gas Type Note: the Vitocrossal 300 CU3A boiler is factory set to operate with natural gas . See following subsection for conversion instructions to liquid propane gas. 1. Ensure that the fuel type listed on the boiler rating plate is the correct type for the installation being attempted.

  • Page 18: Measuring The Static Pressure And Running Pressure

    Start-up Vitocrossal 300 CU3A 26 to 199 Service Measure Static Pressure and Running Pressure 1. To measure static and/or running pressure remove boiler enclosure panel as indicated page 11 in these instructions. 2. Close gas shutoff valve (field supplied). 3. Loosen screw at inlet gas pressure port A on the gas combination valve, do not remove completely.

  • Page 19: Set Maximum Output

    Start-up Vitocrossal 300 CU3A 26 to 199 Service Setting the Maximum Output You can limit the maximum output for heating operation. The limit is set via the modulation range. The max. adjustable output is limited upwards by the boiler coding card.

  • Page 20: Perform Combustion Analysis

    Legend A Flue gas test port Checking the Direct Vent (coaxial) System Tightness Viessmann strongly recommends that the heating contractor perform a simplified leak test during boiler start-up. For this purpose it is sufficient to measure the CO concentration of the combustion air in the coaxial gap of the air intake adaptor.

  • Page 21: Sequence Of Operation And Potential Faults During Each Start-Up Cycle

    Start-up Vitocrossal 300 CU3A 26 to 199 Service Sequence of Operation and Potential Faults During Each Start-up Cycle Function sequence and possible faults For further details on faults, see page 86.

  • Page 22: Removing The Burner And Checking The Burner Gasket

    Service Vitocrossal 300 CU3A 26 to 199 Service Removing the Burner and Checking the Burner Gasket 1. Switch OFF the main power supply and the ON/OFF switch at the control unit. 2. Close the gas shut-off valve and safeguard against reopening.

  • Page 23: Checking Burner Mesh Assembly And Refractory

    Service Vitocrossal 300 CU3A 26 to 199 Service Checking Burner Mesh Assembly and Refractory Replace the burner mesh assembly if the wire mesh is damaged. 1. Remove electrodes A. 2. Undo four nuts D and remove fan with gas valve C. 3.

  • Page 24: Cleaning The Combustion Chamber And Heating Surfaces

    Service Vitocrossal 300 CU3A 26 to 199 Service Cleaning the Combustion Chamber and Heating Surfaces Remove burner assembly as per instruction on page 22. WARNING Clean the combustion chamber by vacuuming loose debris out. Follow cleaning agent manufacturer‘s safety instructions Remove embedded sediment from the heat exchanger and wear appropriate protective equipment.

  • Page 25: Cleaning And Reconnecting The Condensate Drain System

    Service Vitocrossal 300 CU3A 26 to 199 Service Cleaning and Reconnecting the Condensate Drain System Flue collector, condensate drain, siphon, neutralizing system and all hoses or pipe runs in between are considered part of the condensate drain system. Note: Clean the inside of the condensate drain system at least annually.

  • Page 26: Checking Gaskets And Thermal Insulation Components On The Boiler

    Service Vitocrossal 300 CU3A 26 to 199 Service Checking Gaskets and Thermal Insulation Components on the Boiler 1. Check the gasket/seal on the flue gas collector A between the flue gas collector C and the boiler body B for tightness. 2.

  • Page 27: Fitting The Burner

    Service Vitocrossal 300 CU3A 26 to 199 Service Fitting the Burner 1. Insert burner A and secure with four nuts B, tightening the nuts evenly and crosswise. Torque: 3 lb.ft (4 Nm). 2. Fit gas supply pipe C with new gasket D. Torque: 11 lb.ft (15 Nm).

  • Page 28: Check Co 2 Setting

    1. Connect a flue gas analyzer to test port A at boiler the Combustion Management System developed by vent pipe adaptor. Viessmann which ensures optimal combustion quality 2. Open gas shut-off valve, start up boiler and create independent of gas quality and type. (For a description of heat demand.

  • Page 29: Combustion Management System

    Service Vitocrossal 300 CU3A 26 to 199 Service Combustion Management System The combustion management system utilizes the physical The relationship between the CO or O content and air factor λ is illustrated in the table below. correlation between the level of the ionization current and the air factor λ.

  • Page 30: Check Electrical Connections

    Service Vitocrossal 300 CU3A 26 to 199 Service Check Electrical Connections Ensure all plug-in connectors and strain reliefs make positive contact and are seated properly. Refer to the Installation Instructions Check Gas Pipes and Fittings for Leaks Note: For the tightness test, use only suitable and approved leak detecting agents and devices.

  • Page 31: Example Layout 1

    Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 1 DHW heating by the solar thermal system Matching the control unit to the heating system Solar circuit pump wE starts and DHW tank qR is heated Subject to the equipment level, the control unit must up, if the temperature differential between collector be matched to the system.
  • Page 32 Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 1 (continued) Hydraulic installation scheme ID: 4605300_1006_01 Note: This scheme is a basic example without shut-off valves or safety equipment. This does not replace the need for local engineering.
  • Page 33 Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 1 (continued) Equipment required ID: 4605300_1006_01 Pos. Designation Boiler with Control unit Vitocrossal 300 with Vitotronic 200, type KW6B Outdoor temperature sensor ATS DHW heating by the boiler DHW tank Tank temperature sensor STS DHW recirculation pump ZP DHW pump UPSB...
  • Page 34 Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 1 (continued) Electrical installation diagram...

  • Page 35: Example Layout 2

    Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 2 System version 2 DHW heating by the solar thermal system One heating circuit without mixing valve, one heating Solar circuit pump wE starts and DHW tank qR is heated circuit with mixing valve and DHW heating (optional solar up, if the temperature differential between collector DHW heating)
  • Page 36 Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 2 (continued) Hydraulic installation scheme ID: 4605301_1006_02 Note: This scheme is a basic example without shut-off valves or safety equipment. This does not replace the need for local engineering.
  • Page 37 Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 2 (continued) Equipment required ID: 4605301_1006_02 Pos. Designation Boiler with Control unit Vitocrossal 300 with Vitotronic 200, type KW6B Outdoor temperature sensor ATS DHW heating by the boiler DHW tank Tank temperature sensor STS DHW recirculation pump ZP DHW pump UPSB...
  • Page 38 Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 2 (continued) Equipment required ID: 4605301_1006_02 Pos. Designation Accessories Internal extension H1: (integrated) Connection, external safety solenoid valve (LPG) Central fault message (alternative to extension EA1) Extension EA1 (integrated) External safety solenoid valve for LPG Central fault message External hook-up: External blocking...
  • Page 39 Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 2 (continued) Electrical installation diagram...

  • Page 40: Example Layout 3

    Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 3 System version 3 DHW heating by the solar thermal system One heating circuit without mixing valve and two heating Solar circuit pump wE starts and DHW tank qR is heated circuits with mixing valve and DHW heating (optional up, if the temperature differential between collector solar DHW heating)
  • Page 41 Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 3 (continued) Hydraulic installation scheme ID: 4605302_1006_01 Note: This scheme is a basic example without shut-off valves or safety equipment. This does not replace the need for local engineering.
  • Page 42 Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 3 (continued) Equipment required ID: 4605302_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 tank Tank temperature sensor STS DHW recirculation pump ZP DHW pump UPSB...
  • Page 43 Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 3 (continued) Equipment required ID: 4605301_1006_02 Pos. Designation Accessories Internal extension H1: (integrated) Connection, external safety solenoid valve (LPG) Central fault message (alternative to extension EA1) Extension EA1 (integrated) External safety solenoid valve for LPG Central fault message External hook-up: External blocking...
  • Page 44 Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 3 (continued) Electrical installation diagram...

  • Page 45: Example Layout 4

    Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 4 Vitocrossal 300 CU3A with... - DHW storage tank - three zone circuits Legend Vitocrossal 300 CU3A boilers Installation of different heating circuits... DHW storage tank DHW production ■ DHW pump [output 21] 3 zone circuits ■...

  • Page 46: Start-Up

    Service Vitocrossal 300 CU3A 26 to 199 Service Example Layout 4 (continued) Equipment required Pos. Designation Boiler with Control unit Vitocrossal 300 with Vitotronic 200, type KW6A Outside temperature sensor ATS DHW heating by the boiler DHW tank Tank temperature sensor STS DHW recirculation pump ZP DHW pump UPSB Zone circuit 1 [output 157]...

  • Page 47: Menu Heating Circuits

    Service Vitocrossal 300 CU3A 26 to 199 Service Menu Heating Circuits There are two control levels available, the “Standard menu” and the “Extended menu”. Standard menu Note: If your heating system has 2 or 3 heating circuits: You can select the heating circuit “HC1”, “HC2” or “HC3”...
  • Page 48 Service Vitocrossal 300 CU3A 26 to 199 Service Menu Heating Circuits (continued) Note: For any other connected heating circuits, use the settings in the extended menu. Call up the standard menu as follows: - If the screen saver is active - Press any key except If you are somewhere in the menu: Keep pressing...

  • Page 49: Functional Description

    Service Vitocrossal 300 CU3A 26 to 199 Service Functional Description Space heating mode For operation with heating circuits the control unit calculates a boiler water setpoint temperature based on the outdoor or room temperature (where a room temperature dependent remote control is connected) and on the slope/shift of the heating curve.

  • Page 50: Adjusting The Heating Curves

    Service Vitocrossal 300 CU3A 26 to 199 Service Adjusting the Heating Curves Changing the slope and shift The heating curves illustrate the relationship between the outdoor temperature and the boiler water or supply temperature. To put it simply, the lower the outside temperature, the higher the boiler water or supply temperature.
  • Page 51 Service Vitocrossal 300 CU3A 26 to 199 Service Adjusting the Heating Curves (continued) Reduced room temperature Adjusting the set room temperature Standard room temperature Example 1: Adjustment of the standard room temperature Example 2: Adjustment of reduced room temperature from 68°F to 79°F (20°C to 26°C) from 41°F to 57°F (5°C to 14°C) Legend Legend...
  • Page 52 Service Vitocrossal 300 CU3A 26 to 199 Service Adjusting the Heating Curves (continued) Raising the reduced room temperature During operation with reduced room temperature, the reduced set room temperature can be automatically raised subject to the outside temperature. The temperature is raised in accordance with the selected heating curve, but no higher than the set standard room temperature.

  • Page 53: Connecting The Boiler Tothe Lon System

    Service Vitocrossal 300 CU3A 26 to 199 Service Adjusting the Heating Curves (continued) 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 Vitotrol 200A 300A The remote control affects the heating...
  • Page 54 Service Vitocrossal 300 CU3A 26 to 199 Service Connecting the Boiler to a LON System (continued) Boiler control unit Vitotronic 200-H Vitotronic 200-H Vitocom (e.g. HK1B *1 mixing valve (e.g. HK1B *1 multiple *1 LON communication control) mixing valve control) module Participant no.

  • Page 55: General

    Coding 1 Vitocrossal 300 CU3A 26 to 199 Service General Accessing coding level 1 1. Press OK and simultaneously for approximately 4 seconds. Note: Codes are displayed as plain text. 2. “Coding level 1” Codes that have no function due to the heating 3.

  • Page 56: Boiler

    Coding 1 Vitocrossal 300 CU3A 26 to 199 Service General (continued) Coding in the factory set mode Possible change Participant no. Internal circulation pump function 51:0 System with low loss header: 51:1 System with low loss header: Internal circulation pump always When there is a heat demand, the starts when there is a heat internal circulation pump is only started...

  • Page 57: Dhw

    Coding 1 Vitocrossal 300 CU3A 26 to 199 Service Coding in the factory setting Possible change Enable DHW recirculation pump 67:40 For solar DHW heating: 67:0 Set DHW temperature adjustable from Set DHW temperature 32°F to 203°F (0°C to 95°C) (limited 104°F (40°C).
  • Page 58 Coding 1 Vitocrossal 300 CU3A 26 to 199 Service Heating Circuit 1, 2 and 3 Select “Heating circuit ...” Coding in the factory setting Possible change Priority DHW heating A2:2 DHW tank priority applicable to A2:0 Without DHW tank priority heating circuit pump and mixing applied to heating circuit pump valve...

  • Page 59: Heating Circuit 1, 2 And 3

    Coding 1 Vitocrossal 300 CU3A 26 to 199 Service Heating Circuit 1, 2 and 3 (continued) Coding in the factory setting Possible change Extended economy function mixing valve A7:0 Without mixing valve economy A7:1 With mixing valve economy function function (only with circuits with (extended heating circuit pump logic): mixing valve) Heating circuit pump also “OFF”:...
  • Page 60 Coding 1 Vitocrossal 300 CU3A 26 to 199 Service Heating Circuit 1, 2 and 3 (continued) Coding in the factory setting Possible change Minimum supply temperature heating circuit C5:20 Electronic minimum supply C5:1 Minimum limit adjustable from temp. limit 68°F (20°C) 34 to 260°F (1 to 127°C) C5:127 (limited by boiler-specific...
  • Page 61 Coding 1 Vitocrossal 300 CU3A 26 to 199 Service Heating Circuit 1, 2 and 3 (continued) Coding in the factory setting Possible change Start temperature raising F8:-5 Temperature limit for F8:+10 Temperature limit adjustable from terminating the reduced mode +50°F to -76°F 23°F (-5ºC);...

  • Page 62: General

    Coding 2 Vitocrossal 300 CU3A 26 to 199 Service General If the heating circuits were given individual designations, Calling up coding level 2 the selected designation and “HC1”, “HC2” or “HC3” Note: At coding level 2, all codes are accessible, including appear instead: the codes at coding level 1.
  • Page 63 Coding 2 Vitocrossal 300 CU3A 26 to 199 Service General (continued) Coding in the factory setting Possible change No access to the coding 11:9 Access open to the coding 11:g 9 addresses for the combustion addresses for the combustion controller parameters controller parameters.
  • Page 64 Coding 2 Vitocrossal 300 CU3A 26 to 199 Service General (continued) Coding in the factory setting Possible change 3A:0 Function input DE1 at extension 3A:1 Function input DE1: Heating EA1: Not assigned program - changeover. 3A:2 Function input DE1: External demand with set supply temperature.
  • Page 65 Coding 2 Vitocrossal 300 CU3A 26 to 199 Service General (continued) Coding in the factory setting Possible change 3C:0 Function input DE3 at extension 3C:1 Function input DE3: Heating EA1: Not assigned program - changeover. 3C:2 Function input DE3: External demand with set supply temperature.
  • Page 66 Coding 2 Vitocrossal 300 CU3A 26 to 199 Service General (continued) Coding in the factory setting Possible change 52:0 Without supply temperature 52:1 With supply temperature sensor sensor for low loss header for low loss header (automatic recognition). 53:1 53:0 Central fault message Function connection sK of the internal extension: DHW...
  • Page 67 Coding 2 Vitocrossal 300 CU3A 26 to 199 Service General (continued) Coding in the factory setting Possible change 79:1 With LON communication 79:0 Control unit is not fault manager. module: Control unit is fault manager 7B:1 With LON communication 7B:0 Does not transmit time.
  • Page 68 Vitotronic utilized internally 200-H. 98:1 With LON communication 98:1 System number adjustable from module: Viessmann system 1 to 5. number (in conjunction with 98:5 monitoring several systems via Vitocom 300) 99:0 DO NOT ADJUST...

  • Page 69: Boiler

    Coding 2 Vitocrossal 300 CU3A 26 to 199 Service Boiler Coding in the factory setting Possible change 06:95 Maximum limit of the boiler 06:20 Maximum limit of the boiler water water temperature, specified temperature within the ranges in °C by the boiler coding card 06:127 specified by the boiler.

  • Page 70: Dhw

    Coding 2 Vitocrossal 300 CU3A 26 to 199 Service Coding in the factory setting Possible change 56:0 Set DHW temperature 56:1 Set DHW temperature adjustable adjustable from 50 to 140°F from 50°F to over 140°F (10°C (10 to 60°C) to over 60°C). Note: Maximum value subject to boiler coding card.
  • Page 71 Coding 2 Vitocrossal 300 CU3A 26 to 199 Service (continued) Coding in the factory setting Possible change 65:0 65:0 DO NOT ADJUST 65:3 67:40 For solar DHW heating: 67:0 Set DHW temperature Set DHW temperature adjustable from 32°F to 203°F 104°F (40°C).

  • Page 72: Solar

    Coding 2 Vitocrossal 300 CU3A 26 to 199 Service Solar Note: The solar group is only displayed if a solar control module, type SM1, is connected. Coding in the factory setting Possible change 00:8 The solar circuit pump starts 00:2 The differential between when the collector temperature the actual DHW tank temperature...
  • Page 73 0B:0 Collector frost protection 0B:1 Collector frost protection function function switched off switched on (not required with Viessmann heat transfer medium). 0C:1 0C:0 t monitoring switched on. t monitoring switched off. No flow rate captured in the solar circuit, or flow rate too low.
  • Page 74 Coding 2 Vitocrossal 300 CU3A 26 to 199 Service Solar (continued) Coding in the factory setting Possible change 11:50 Set DHW tank temperature for 11:10 The set DHW tank temperature for solar 122°F (50°C). solar can be adjusted from 50°F to - Target temperature control 11:90 194°F (10°C to 90°C).
  • Page 75 Coding 2 Vitocrossal 300 CU3A 26 to 199 Service Solar (continued) Coding in the factory setting Possible change 23:4 Stop temperature differential 23:2 Stop temperature differential for central heating for central heating backup is backup: 4 K. 23:30 adjustable from 1 to 29 K. (code 20:4 must be selected) 24:40 Start temperature for thermostat...

  • Page 76: Heating Circuit 1, 2 And 3

    Coding 2 Vitocrossal 300 CU3A 26 to 199 Service Heating Circuit 1, 2 and 3 Coding in the factory setting Possible change A0:0 Without remote control A0:1 With Vitotrol 200A (automatic recognition). A0:2 With Vitotrol 300A (automatic recognition). A1:0 All possible settings at the A1:1 Only party mode can be set at the remote control can be accessed...
  • Page 77 Coding 2 Vitocrossal 300 CU3A 26 to 199 Service Heating Circuit 1, 2 and 3 (continued) Coding in the factory setting Possible change A4:0 With frost protection A4:1 No frost protection; this setting is only possible if code “A3:-9” has been selected.
  • Page 78 Coding 2 Vitocrossal 300 CU3A 26 to 199 Service Heating Circuit 1, 2 and 3 (continued) Coding in the factory setting Possible change A9:0 With pump idle time: A9:0 Without pump idle time. Heating circuit pump “OFF” if A9:1 With pump idle time, adjustable the set value is altered through from 1 to 15.
  • Page 79 Coding 2 Vitocrossal 300 CU3A 26 to 199 Service Heating Circuit 1, 2 and 3 (continued) Coding in the factory setting Possible change C5:20 Electronic minimum supply C5:1 Minimum limit adjustable from 1°F temperature limit 68°F to 260°F (-17°C to 127°C) (limited (20°C) C5:127 by boiler-specific parameters).
  • Page 80 Coding 2 Vitocrossal 300 CU3A 26 to 199 Service Heating Circuit 1, 2 and 3 (continued) Coding in the factory setting Possible change E5:0 Without external variable speed E5:1 With external variable speed heating heating circuit pump circuit pump. E6:... Maximum speed of the variable E6:0 Maximum speed adjustable...

  • Page 81: Zone Heating Circuit 1, 2 And 3

    Coding 2 Vitocrossal 300 CU3A 26 to 199 Service Zone Circuit 1, 2 and 3 Coding in the factory setting Possible change 1B:14 Heating curve slope = 1.4 1B:2 Heating curve slope adjustable from 0.2 to 3.5. 1B:35 Zone circuit 1 1C:0 Heating curve level = 0 1C:–13...

  • Page 82: Calling Up The Service Level

    Diagnosis and Service Scans Vitocrossal 300 CU3A 26 to 199 Service Calling up the Service Level Press OK and simultaneously for approximately 4 sec. Service menu overview Service General Heating circuit 1 HC1 Diagnosis Heating circuit 2 HC2 Heating circuit 3 HC3 Actuator test Zone circuit 1 Zone circuit 2...

  • Page 83: Diagnosis

    Diagnosis and Service Scans Vitocrossal 300 CU3A 26 to 199 Service Diagnosis Brief scan Scanning operating data In the brief scan, you can call up temperatures, software - Operating data can be scanned in six areas. versions and connected components, for example: See “Diagnosis”...

  • Page 84: Checking Outputs (Relay Tests)

    Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Checking Outputs (relay tests) 1. Press OK and simultaneously for approximately 4 sec. 2. “Actuator test” The following relay outputs can be controlled subject to system design: Display Explanation Base load Start Burner operated at minimum output;...

  • Page 85: Fault Codes

    Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Fault Codes  In the event of a fault, red fault indicator A flashes. “ “ flashes on the display and “Fault” is shown. The fault code is displayed with OK. For an explanation of the fault code, see the following pages.
  • Page 86 Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Fault Codes (continued) Fault code on display System behavior*1 Cause Corrective action Boiler operates based on outdoor Short circuit on outdoor Check the outdoor temperature temperature of 32°F (0°C) temperature sensor sensor (see page 93). Boiler operates based on outdoor Outdoor temperature Check the outdoor temperature...
  • Page 87 Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Fault Codes (continued) Fault code on display System behavior*1 Cause Corrective action No solar DHW heating Collector temperature Check the sensor & at the sensor & cable solar control module. broken Control mode Tank temperature Check temperature sensor at DO NOT USE...
  • Page 88 Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Fault Codes (continued) Fault code on display System behavior*1 Cause Corrective action Control mode without remote Communication error, Check connections, cable, control remote control Vitotrol coding address “A0” in “Heating heating circuit 2 circuit”...
  • Page 89 Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Fault Codes (continued) Fault code on display System behavior*1 Cause Corrective action Control mode Input DE3 reports a Remove fault at appliance fault at extension EA1 concerned. Control mode without Short circuit on room Check the room temperature room influence temperature sensor,...
  • Page 90 Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Fault Codes (continued) Fault code on display System behavior*1 Cause Corrective action Burner blocked Fault, supply voltage Replace the control unit. Burner blocked Fault flame amplifier Replace control unit. Burner in a fault mode Ionization current too Check ionization electrode: low during calibration...
  • Page 91 Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Fault Codes (continued) Fault code on display System behavior*1 Cause Corrective action Burner in a fault mode At burner start, flame Check gas supply (gas pressure signal is missing or too and gas regulator). Check gas weak train.
  • Page 92 Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Fault Codes (continued) Fault code on display System behavior*1 Cause Corrective action Burner in fault mode Gas valve closes too Check the gas valve. late Check both control wiring/ connections. Press reset button R. Burner in fault mode Fan speed too low Check the fan, the fan cables...

  • Page 93: Corrective Action

    Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Corrective Action Accessing the Control Electrical Connections Box 1. Remove the screws from the top panel and set aside. 2. Slide the top panel to the rear of the boiler and lift up. 3.
  • Page 94 Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Corrective Action (continued) Checking the DHW / low loss header / heating circuit / room temperature sensor 1. Pull the leads from temperature sensor. 2. Check the sensor resistance and compare it with the curve.
  • Page 95 Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Corrective Action (continued) Checking the flue gas temperature sensor The flue gas temperature sensor locks out the boiler when the permissible flue gas temperature is exceeded. Reset the interlock after the flue system has cooled down by pressing reset button R.
  • Page 96 Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Corrective Action (continued) Legend A Integrate EA1 module B Power/pump connection interface C Fuse F1 (Integrate EA1 module) D Fuse F2 (Power/pump connection interface) E Fuse F1 (Power/pump connection interface) Checking the electrical connect module fuse 1.
  • Page 97 Troubleshooting Vitocrossal 300 CU3A 26 to 199 Service Corrective Action (continued) Extension kit for heating circuit with mixing valve Checking the setting of rotary selector S1 The rotary selector on the PCB of the extension kit defines the assignment to the relevant heating circuit. Heating circuit Rotary selector S1 setting Heating circuit with mixing...

  • Page 98: Internal Extensions Ea1

    Function Description Vitocrossal 300 CU3A 26 to 199 Service Internal Extensions EA1 Legend Refer to main wiring diagram on page 101. Digital input 1 Digital input 2 Digital input 3 0 – 10V 0 - 10V input Power supply fÖ fÖ...
  • Page 99 Function Description Vitocrossal 300 CU3A 26 to 199 Service Internal Extensions EA1 (continued) Digital data inputs DE1 to DE3 Effect of the external blocking function on the pumps The following functions can be connected alternatively: The effect on the respective heating circuit pump is selected in coding address D6 in the “Heating circuit”...

  • Page 100: Control Functions

    Function Description Vitocrossal 300 CU3A 26 to 199 Service Control Functions External heating program changeover External blocking The “External blocking” and “External blocking and fault The “External heating program changeover” function is message input” functions are connected via extension connected via extension EA1. There are 3 inputs available EA1.

  • Page 101: Wiring Diagram

    Additional Information Vitocrossal 300 CU3A 26 to 199 Service Wiring Diagram CAUTION WARNING DISCONNECT POWER BEFORE Label all wires prior to disconnection SERVICING BOILER. when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation If any of the original wires as after servicing.
  • Page 102 Additional Information Vitocrossal 300 CU3A 26 to 199 Service Wiring Diagram (continued) Legend IMPORTANT Outdoor Temperature Sensor Supply Temperature Sensor/Low Loss Header Electrical installations must comply with the latest edition of: Boiler Temperature Sensor #1 Boiler Temperature Sensor #2 In the U.S.A., the National Electrical Code (NEC), DHW Temperature Sensor ANSI/NFPA 70 and any other state, local codes and/or Ionization Electrode...

  • Page 103: Fitting The Front Panel

    Additional Information Vitocrossal 300 CU3A 26 to 199 Service Fitting the Front Panel 1. Place the front cover onto the locating pegs. 2. Push the top of the panel in place. 3. Secure in place with the retaining screw.

  • Page 104: Burner Program Sequence Of Operation

    Additional Information Vitocrossal 300 CU3A 26 to 199 Service Burner Program Sequence of Operation Phase 0: Stand-by Phase 6: Burner modulation operation or calibration Complete shutdown until the next call for heat. In this At the end of the flame stabilization period (4.5 seconds.), phase both the combination gas valve and the blower a release for modulation occurs and the burner temperature are not energized.

  • Page 105: Parts Lists

    A Rating Plate and Serial Number B Enclosure Assembly C Control Assembly D Boiler Assembly E Burner Assembly F Other Parts (see your Viessmann distributor) Other Parts (not illustrated) 0300 Installation Set *1 0404 Parts List, Vitocrossal boiler 0410 Conversion kit, NG > LP 0411 Conversion kit, LP >...
  • Page 106 Additional Information Vitocrossal 300 CU3A 26 to 199 Service Parts Lists (continued) Model No. Serial No. CU3A 26, 94 Boiler 7553000jjjjjjjjj CU3A 35, 125 Boiler 7553001jjjjjjjjj CU3A 45, 160 Boiler 7553002jjjjjjjjj CU3A 57, 199 Boiler 7553003jjjjjjjjj Parts for Main Enclosure Assembly 0001 Spring clip for insulation (set of 4) 0009 Mid panel, control 0002 Cover, edge molding...
  • Page 107 Additional Information Vitocrossal 300 CU3A 26 to 199 Service Parts Lists (continued) Model No. Serial No. CU3A 26, 94 Boiler 7553000jjjjjjjjj CU3A 35, 125 Boiler 7553001jjjjjjjjj CU3A 45, 160 Boiler 7553002jjjjjjjjj CU3A 57, 199 Boiler 7553003jjjjjjjjj Parts for Control Assembly 0001 Boiler control 0002 Hinge for control housing (each) 0003 Coding plug...
  • Page 108 Additional Information Vitocrossal 300 CU3A 26 to 199 Service Parts Lists (continued) Model No. Serial No. CU3A 26, 94 Boiler 7553000jjjjjjjjj CU3A 35, 125 Boiler 7553001jjjjjjjjj CU3A 45, 160 Boiler 7553002jjjjjjjjj CU3A 57, 199 Boiler 7553003jjjjjjjjj Parts for Boiler Assembly 0001 Sensor well, G½...
  • Page 109 Additional Information Vitocrossal 300 CU3A 26 to 199 Service Parts Lists (continued) Model No. Serial No. CU3A 26, 94 Boiler 7553000jjjjjjjjj CU3A 35, 125 Boiler 7553001jjjjjjjjj CU3A 45, 160 Boiler 7553002jjjjjjjjj CU3A 57, 199 Boiler 7553003jjjjjjjjj Parts for Burner Assembly 0001 Burner gasket 0014 Accessory pack for burner parts 0002 Ground terminal (set of 10)

  • Page 110: Installation Fittings

    Ordering Parts: Please provide Model and Serial Number A when ordering replacement parts. Order replacement components from your Viessmann distributor. Parts (Installation Set 7560 593) 0301 Air vent with shut-off base, e in. 0302 Hex bushing, c in. x e in.

  • Page 111: Technical Data

    Additional Information Vitocrossal 300 CU3A 26 to 199 Service Technical Data Boiler Model No. CU3A 26, 94 35, 125 45, 160 57, 199 Natural Gas / Liquid Propane Gas CSA input 19-94 25-125 43-160 43-199 (kW) (5.6-27.5) (7.3-36.6) (12.6-47) (12.6-58) CSA output / DOE heating capacity*1 17.7-87 23.3-116...
  • Page 112 For details refer to the Installation Instructions for the Vitocrossal 300 CU3A Venting System. Standby losses measured from the boiler temperature sensor well based on a boiler water temperature of 158°F (70°C) and a room temperature of 68°F (20°C). For information regarding other Viessmann System Technology componentry, please reference documentation of respective product.

  • Page 113: Maintenance Record

    Additional Information Vitocrossal 300 CU3A 26 to 199 Service Maintenance Record...

  • Page 114: Lighting And Operating Instructions

    Additional Information Vitocrossal 300 CU3A 26 to 199 Service Lighting and Operating Instructions FOR YOUR SAFETY READ BEFORE OPERATING W A R N I N G: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A.
  • Page 115 Vitocrossal 300 CU3A 26 to 199 Service...
  • Page 116 Vitocrossal 300 CU3A 26 to 199 Service...

This manual is also suitable for:

Vitocrossal 300 cu3a seriesVitocrossal 300 cu3a 26Vitocrossal 300 cu3a 35Vitocrossal 300 cu3a 57Vitocrossal 300 cu3a 94Vitocrossal 300 cu3a 125 ... Show all

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