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

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Service Instructions
for use by heating contractor
Vitocrossal 300 with Graphical User Interface HI932
CA3B Series 2.5, 3.0, 3.5, 4.0, 5.0 and 6.0
Gas condensing boiler with cylinder burners
Heating input: 2500 to 6000 MBH
(733 to 1758 kW)
VITOCROSSAL 300
H
5838 946 - 13
01/2022
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

  • Page 1 Service Instructions for use by heating contractor Vitocrossal 300 with Graphical User Interface HI932 CA3B Series 2.5, 3.0, 3.5, 4.0, 5.0 and 6.0 Gas condensing boiler with cylinder burners Heating input: 2500 to 6000 MBH (733 to 1758 kW) VITOCROSSAL 300...
  • Page 2 Safety Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Safety, Service and Warranty Requirements Please ensure that these instructions are read and understood before commencing installation. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life.
  • Page 3 Safety Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Safety, Service and Warranty Requirements (continued) Fiberglass wool and ceramic fiber materials First aid measures - If eye contact occurs, flush eyes with water to remove WARNING dust. If symptoms persist, seek medical attention.
  • Page 4 Table of Contents Vitocrossal 300 CA3B - 3.5, 4.0, 5.0 and 6.0 Service Page Safety Safety, Service and Warranty Requirements ....2 General Information About these Instructions ..........6 Product Information ............6 General Service Information Service Equipment ............7 Important Regulatory Requirements ......8 Safety Instructions ..........
  • Page 5 Table of Contents Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Page Service (continued) Checking the Ignition Electrodes and Ionization Electrode ...73 Cleaning the Burners ..........73 Cleaning the Combustion Chamber and Heating Surfaces ...74 Burner Reassembly ..........75 Automatic Leakage Test for Valves of the Combined Gas Valve ...............75...
  • Page 6 Product Information High efficiency gas-fired hot water condensing boiler. The Vitocrossal 300, CA3B boiler is suitable for a maximum operating pressure of 160 psig and a maximum For operation with modulating boiler water temperatures boiler water temperature of 210°F (99°C).
  • Page 7 General Service Information Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Service Equipment Tools Technical information Assortment of flathead and Phillips screwdrivers The following is a list of literature applicable to the Pipe wrenches Vitocrossal 300, CA3B boiler: Installation Instructions...
  • Page 8 General Service Information Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Important Regulatory Requirements Instructing the system user The installer of the system is responsible to ensure the  T he following topics must be covered: system operator/ultimate owner is made familiar with Proper system operation sequence.
  • Page 9 General Service Information Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Safety Instructions Target group If you smell gas These instructions are intended exclusively for qualified WARNING contractors. ■ Work on gas installations must only be carried out Escaping gas can lead to explosions which may result by a licensed professional heating contractor.
  • Page 10 THAT THE FOLLOWING TEST PROCEDURE MAY RESULT IN BY OVERHEATING THE SYSTEM. 5. Observe temperature on the relative GW6C service The Vitocrossal 300, CA3B boilers are equipped with 2 display. RTD temperature sensors (per boiler section) that when 6. Once the temperature reached the fixed high limit activated on temperature rise (high fixed limit of 210°F...
  • Page 11 Commissioning Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Commissioning the System For room air dependant operation: WARNING Check that the ventilation facility in the installation room is open. CO build-up as a result of incorrect burner adjustment can Check the gas supply pressure (for set value refer to have serious health implications.
  • Page 12 Note: Store the handle in a safe place for future use. IMPORTANT See page 13 for water quality requirements. 1. Fill Vitocrossal 300, CA3B with fully softened water. Valve closed 2. Enter the fill quantity, water softness and pH-value in the chart provided on page 161.
  • Page 13 IMPORTANT pipework sections which are crucial. Check, clean and activate filters, dirt traps and other Fill Vitocrossal 300 CA3B with fully softened water only! blow-down or separating facilities in the heating water circuit frequently after commissioning and in new installations. Thereafter check and maintain as required, depending on the type of water treatment applied (e.g.
  • Page 14 Commissioning Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Checking the Water Conditions (continued) 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 212°F (100°C), VDI Guideline 2035 Part 1 “Prevention of damage in water heating...
  • Page 15 Commissioning Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Checking Static and Connection Pressure Static Pressure 1. Close gas shut-off valve. 2. Loosen screw in the measuring connector A do not remove. 3. Connect pressure measuring device at measuring connector A.
  • Page 16 Commissioning Commissioning Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Checking Heating Water Connections for Leakage WARNING Working on pressure loaded parts can be dangerous. Connections around the heating water should only be opened if the boiler is unpressurized. CAUTION Under-pressure in the boiler can lead to material damages.
  • Page 17 Commissioning Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Checking On-site Gas Connections for Leakage WARNING Risk of explosion due to gas leakage. Check for gas leakage at the gauge connections. CAUTION Use of leak detection spray can lead to operational malfunctioning.
  • Page 18 500 hours initial run (refer to page 16). Gas type characteristics The Vitocrossal 300 CA3B boiler is for use with gases whose characteristics fall within the following ranges. Natural Gas Liquid Propane Gas...
  • Page 19 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Operating the Burner Control Unit (continued) Reducing Operational Output (if required) The burners heating output can be reduced via the individual burner control unit. As an alternative, the adjustment can be made via the burner control unit.
  • Page 20 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit Display and programming unit Standby A display and programming unit is integrated into each burner control unit. The display indicates the relevant operating conditions, the service and parameter conditions as well as all fault and error messages, relative to that boiler section.
  • Page 21 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit (continued) Operating display (continued) Maintenance program Pre-ignition no air pressure Ignition Maintenance program Safety time no gas pressure or Flame established mains under voltage Flame stabilization Forced ventilation...
  • Page 22 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit (continued) Information and configuration display The information display and the configuration display are activated from the operating display. The menu selection is activated by pressing button S for longer than 2 secs.
  • Page 23 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit (continued) Configurations: Menu item Description Changeover from the operating display of the burner control unit phase to other process information Configuration of control function operating parameters Menu item “5“ is used to display the following process information:...
  • Page 24 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit (continued) Example: to set the maximum operational burner input to between 0 and 100%, press the following buttons: 1. S longer than 2 seconds “ “ flashes. until “6“ is shown under Service.
  • Page 25 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit Flow Diagram...
  • Page 26 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit Flow Diagram (continued) State description: Phase Display Description Duration System start “A” System start 10 seconds Fan ramp-up, system start max. 20 seconds Forced ventilation, system start 20 seconds Fan ramp-up for valve test max.
  • Page 27 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit Faults Fault display Fault memory The fault display is activated automatically if the burner The ten most recent faults are saved and may be called up. control unit switches to a fault state. The most recent The order of scans ranges from the most recent to the fault will then be displayed.
  • Page 28 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit Fault Codes General process faults Fault display on the programming unit of the burner. Note: Carry out measures in the described order. All fault codes are saved to the fault memory and the last 10 can be called up.
  • Page 29 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit Fault Codes (continued) Displayed System Characteristics Cause Measures Fault Code Burner shuts down Multiple detection of under Check the power supply F E4 voltage Burner control unit in a fault...
  • Page 30 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit Fault Codes (continued) Displayed System Characteristics Cause Measures Fault Code No flame formation during Ignition electrode not set Adjust ignition electrodes (refer to F F4 safety time; ionization flame correctly;...
  • Page 31 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit Fault Codes (continued) Internal system fault Internal system faults are created if a fault-free program sequence can no longer be ensured. Displayed Fault Code System Characteristics Cause Measures Fan not running;...
  • Page 32 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Operating the System The control unit is pre-set, however several codings must Boiler model 2.5 to 4.0 be set individually. 1. Activate the main switch and all network switches on the control units.
  • Page 33 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Operating the System (continued) IMPORTANT During the initial start-up, the equipment can go into a fault state due to insufficient gas in the gas pipe (Fault lamp lights up on the control unit). Ventilate gas line once again and reset burner control unit.
  • Page 34 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Integrating the Control Unit into the LON Vitotronic 300 GW6C for CA3B 2.5, 3.0, 3.5 and 4.0 Remove terminal end resistor on A to carry on LON connection The LON communication module is factory installed.
  • Page 35 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Integrating the Control Unit into the LON (continued) Carrying out a LON participant check The participant check is used to test communication with the system devices connected to the fault manager.
  • Page 36 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Adjusting the Heating Curve The heating curves represent the relationship between the outdoor temperature and the boiler water or supply temperature. Simplified: The lower the outdoor temperature, the higher the boiler water or supply temperature.
  • Page 37 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Adjusting the Heating Curve (continued) Changing the standard set room temperature Reduced set room temperature Refer to the Vitocrossal 300 CA3B Operating Instructions. Adjustment of the reduced set room temperature from 37°F to 52°F (3°C to 14°C).
  • Page 38 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Boiler Water Temperature Control Brief description H The boiler water temperature is regulated by modulating the burner. H The set boiler water temperature is determined from the following coding: – Set supply temperature of the heating circuits...
  • Page 39 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Heating Circuit Control Only for single boiler and cascade control units Outdoor temperature Brief description A heating curve must be set for matching the control H The control unit features control circuits for one heating unit to the building and the heating system.
  • Page 40 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Heating Circuit Control (continued) DHW temperature System dynamics Priority control The mixing valve control characteristics can be influenced at coding “c4” in the “Heating circuit...” group. H With priority control: (coding address “a2:2” in the “Heating circuit...”...
  • Page 41 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Heating Circuit Control (continued) Supply temperature control single boiler control unit Differential temperature: The differential temperature can be set at coding “9f” in the “General”group, factory set condition: 15°F (8 K).
  • Page 42 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Heating Circuit Control (continued) Example using the settings in the factory set condition Raising the reduced room temperature During operation with reduced room temperature, the reduced set room temperature can be automatically raised subject to the outdoor temperature.
  • Page 43 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service DHW Tank Temperature Control Brief description H The tank temperature control is a constant temperature Priority control control function. This is achieved by starting and H With priority control: (coding stopping the DHW pump. The switching differential is “a2:2”...
  • Page 44 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service DHW Tank Temperature Control (continued) Controlled sequence single boiler control Tank temperature control with 2 tank temperature sensors Coding “55:0” in the “DHW” group; tank heating Coding “55:2” in the “DHW” group;...
  • Page 45 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Setting the Boiler Sequence (burner sequence) Setting the boiler sequence (burner sequence) Function Parameter Every boiler/burner can be blocked or enabled subject “Lead boiler or boiler to the outside temperature by means of the ECO sequence changeover”...
  • Page 46 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Cascade Control Unit (continued) Boilers connected in parallel Boilers connected in series H Without and with supply temperature sensor H Without and with supply temperature sensor (see the following table). (see the following table).
  • Page 47 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Cascade Control Unit (continued) Shutdown Shutdown criterion: The boilers are shut down via a shutdown integral. When the shutdown integral exceeds a limit set at coding “47” in the “Cascade” group, the shutdown criterion is met and the boiler started last will be shut down.
  • Page 48 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Cascade Control Unit (continued) Conventional boiler strategy 1 (coding “3c:1” in the “Cascade” group) Starting Shutdown Conventional boiler strategy 2 (coding “3c:2” in the “Cascade” group) Starting Shutdown...
  • Page 49 Operating Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Installing the Boiler Panels 1. Install the top front cover plate with 4 screws (for CA3B 5.0 and 6.0 only). 2. Install the lower front cover plate with 6 screws from the lower front cover plate.
  • Page 50 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Preparing for Service Work CA3B 2.5 to 4.0 WARNING Contact with hot surfaces can lead to burn injuries. Undertake work on the burner only when the system is cold. WARNING Escaping gas leads to a risk of explosion.
  • Page 51 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Preparing for Service Work (continued) Burner Identification Rear Front of boiler of boiler Section 1 Section 2 Section 3 Burner Combinations Burner Input MBH CA3B Boiler Section 1 (lead) Section 2 (lag 1)
  • Page 52 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Parts 1.25/1.5 MMBH (CA3B 2.5 and 3.0) 1.5/2.0 MMBH (CA3B 3.5 to 6.0) Legend Legend A Burner control unit A Burner control unit B Gas train B Gas train C Gas supply pipe...
  • Page 53 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Interface Panel 1. Close the gas shut-off valve. 2. Switch OFF the main circuit breaker or the power supply and safeguard against unauthorized reconnection. WARNING Mains voltage can be extremely dangerous.
  • Page 54 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Display and Programming Unit of Burner Control Unit 1. Disconnect KM-BUS connector avG. 2. Undo 2 mounting screws. Torque when installing: 9 lb.in (1 Nm). 3. Lift the display and programming unit and pull off the connector of the burner control unit connecting cable.
  • Page 55 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit 1. Disconnect KM-BUS connector avG. 2. Undo 2 mounting screws. Torque when installing: 9 lb.in (1 Nm). 3. Lift the display and programming unit and pull off the connector of the burner control unit connecting cable.
  • Page 56 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Boiler Water Temperature Sensor Note: There is a boiler water temperature sensor located on each boiler section. 1. Remove spring clip from the sensor well and set aside. 2. Remove the boiler water temperature sensor from the sensor well.
  • Page 57 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service 3A and 3B Boiler Temperature Sensor Description 3A sensor (NTC 10k ) terminals 1 & 2 3B sensor (NTC 20k ) terminals 3 & 4 3A sensor (NTC 10k ) Temperature...
  • Page 58 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Boiler Secondary Temperature Sensor Note: The boiler secondary temperature sensor is located on the boiler section pressure vessel. 1. Remove spring clip from the sensor well and set aside. 2. Remove the boiler secondary temperature sensor from the sensor well.
  • Page 59 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Manual Reset Limits Temperature limit switch If the temperature at the probe exceeds the set limit, the snap-action switch is operated, the circuit is opened or closed and the snap-action switch is locked out mechanically.
  • Page 60 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Gas Valve Note: Reinstalled gas valve in the same orientation as originally installed. 1. Undo screws and pull connectors from the gas valve and both gas pressure switches. 2. Pull the compensation line from the gas valve.
  • Page 61 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Air Pressure Switches Fan pressure monitoring function (LDW1) The switching threshold of the air pressure switch 1, (LDW1) is monitored in all fan start-up phases and tested during modulating operation of the burner.
  • Page 62 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Air Pressure Switches (continued) 1. Undo 2 mounting screws. Torque when installing: 9 lb.in (1 Nm) 2. Remove the display and programming unit from the burner control unit. 3. Pull connector aCA (LDW1) and connector aCAA (LDW2) from the plug-in strip on the burner control unit.
  • Page 63 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Air Pressure Switches (continued) Legend Line Hose length in. (mm) Hose Dia. A Gas train 11f (296) 7 6 mm B Air pressure switch 1 22f (575) 7 6 mm C Air pressure switch 2...
  • Page 64 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Rotary Damper and Servomotor For CA3B models 3.5 to 6.0 IMPORTANT 1. Pull the connector from the servomotor. 2. Undo 4 screws from the retaining bracket of the rotary An incompletely opened rotary damper can cause damper.
  • Page 65 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Replacing the Solenoid Valve For CA3B models 2.5 and 3.0 1. Undo the hose clips and remove the hoses. Unscrew 2 plastic brackets from the 2/2 directional valve. 2. Unscrew 2 fixing screws and remove 2/2 directional valve.
  • Page 66 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Checking the Rotary Damper Setting 1. Open gas shut-off valve. 2. Check the rotary damper setting when burners are off. The rotary damper window B must be fully opened. The scale ring D must be set at “0” on the air damper actuator relative to the marking C.
  • Page 67 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Measuring CO Content Preparing for measurement IMPORTANT When adjusting a burner only this one burner may be in operation. The other boiler unit burners must be at standstill. Take measurement readings of burners one after the other.
  • Page 68 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Measuring CO Content (continued) Measuring CO at lower heating output 1. Press button D until the service indicator has dropped down to “0” (lower heating output). 2. Measure CO content at the flue gas pipe.
  • Page 69 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Displaying Ionization Current IMPORTANT Ionization current must be queried via the burner control unit. An ionization current measurement with Testomatic Gas or a multimeter is not possible. 1. Press button S for approx. 2 sec., „ “ will blink.
  • Page 70 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Dismantling the Burner IMPORTANT Please observe section “Preparing for service work” on page 50. Detach upper burner section 1. Disconnect the burner gas line. 2. Disconnect the connectors from the burner control unit.
  • Page 71 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Dismantling the Burner (continued) IMPORTANT A lifting mechanism is required to remove the burner. Refer to the Instructions provided with the lifting device. Secure lifting mechanism chains at 3 points A on the frame of the upper burner section.
  • Page 72 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Checking and Cleaning the Burner Tube CAUTION WARNING Gas leakage can lead to risk of explosion. Close gas Scratches in the combustion chamber can lead to shut-off valve. corrosion. Do not allow any tools or other objects to fall into the combustion chamber.
  • Page 73 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Checking the Ignition Electrodes and Ionization Electrode Electrodes 1. The electrode block can be tested or dismounted once the burner plate has been dismounted. 2. Check ignition electrodes and ionization electrode for damages and that they are situated at the correct distance from the burner tube.
  • Page 74 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Cleaning the Combustion Chamber and Heating Surfaces Cleaning the combustion chamber and heating surfaces CAUTION Clean the combustion chamber by vacuuming loose debris out. Scratches in the combustion chamber can lead to corrosion.
  • Page 75 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Reassembly WARNING Escaping gas leads to a risk of explosion. Check the fitting for gas tightness. 1. Position the burner plate with burner mesh assembly on the 8 studs on the boiler section. Tighten nuts with a torque of 29.5 lb.ft (40 Nm).
  • Page 76 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Checking Expansion Tank and System Pressure Check proper expansion tank and system pressures CAUTION See expansion tank manufacturer’s instructions. Damage on boiler or other system components may result if these recommendations are not followed.
  • Page 77 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Sensors Tank, supply and room temperature sensors IMPORTANT The supply temperature sensor can be used as a surface contact temperature sensor or immersion temperature sensor. Refer to the Vitotrol 300 Installation and Service...
  • Page 78 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Cleaning of Condensate Drainage System Note: Clean the inside of the condensate drain system at least annually. 1. Pull drain or cleaning hose D off. 2. Clean the inside of the condensate drain system (hose, pipe).
  • Page 79 Service Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Replacing the Supply Air Filter (for room air dependant operation) 1. Remove screws from the top panel. 2. Lift and remove the top right panel. 3. Remove screws from the air filter frame.
  • Page 80 Coding Levels Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Calling up Coding Levels H The coding indicators are preset by the configuration of From the home screen tap the following buttons: the heating system. H Coding is split into the following groups: 2.
  • Page 81 Coding Level 1 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “General” Group Coding Coding in the factory set condition Possible change System design 00:1 System version 1: 00:2 For system schemes, see the following One heating circuit without mixing valve...
  • Page 82 Coding Level 1 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “General” Group (continued) Coding in the factory set condition Possible change “Automatic summer/wintertime changeover” 81:1 Automatic summer/wintertime changeover. 81:0 Manual summer/wintertime changeover 81:2 Do not adjust! 81:3 With LON communication module: The control unit receives the time.
  • Page 83 Coding Level 1 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Combustion Controller” Group Coding Coding in the factory set condition Possible change “Max operational output” 02:100 100% of rated heating output. 02:0 Adjustable from 0% to 100% (0% represents burner minimum firing rate).
  • Page 84 Coding Level 1 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Cascade” Group Coding Coding in the factory set condition Possible change “Number of boilers connected to the cascade” 35:2 Boiler sections 35:1 1 to 8 boiler sections connected to lead control...
  • Page 85 Coding Level 1 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Cascade” Group (continued) Coding in the factory set condition Possible change “Type of control” 3b:1 Standalone parallel boiler circuit: 3b:0 Standalone parallel boiler circuit: With supply temperature sensor Without supply temperature sensor (refer to page 45).
  • Page 86 Coding Level 1 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Cascade” Group (continued) Coding in the factory set condition Possible change “Stop differential” 47:15 Set to 27°F (15 K). 47:2 Adjustable from 4°F to 54°F (2 K to 30 K).
  • Page 87 Coding Level 1 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “DHW” Group (continued) Coding in the factory set condition Possible change “For solar DHW heating: DHW temperature target” 67:40 DHW setpoint temperature 104°F (40°C). 67:0 Adjustable from 32°F to 203°F (0°C to 95°C) Reheating is suppressed above the selected (limited by boiler-specific coding).
  • Page 88 Coding Level 1 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Solar” Group (continued) Coding in the factory set condition Possible change “Extended control function” 20:0 No extended control function enabled. 20:1 Additional function for DHW heating. 20:2 Differential temperature control 2.
  • Page 89 Coding Level 1 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Heating Circuit ...” Group (continued) Coding in the factory set condition Possible change “Extended economy mode” a6:36 Extended economy mode disabled. a6:5 Extended economy mode enabled, i.e. the burner and heating circuit pump...
  • Page 90 Coding Level 1 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Heating Circuit ...” Group (continued) Coding address With heating circuit pump logic function: b5:... Heating circ pump OFF Heating circuit pump on RTactual > RTset +9°F (+ 5 K) RTactual <...
  • Page 91 Coding Level 1 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Heating Circuit ...” Group (continued) Coding in the factory set condition Possible change “Time limit for comfort mode” f2:8 Time limit for comfort mode or external f2:0 No time limit operating program changeover via push button: 8 h.
  • Page 92 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “General” Group Coding Coding in the factory set condition Possible change System design 00:1 System version 1: 00:2 For system schemes, see the following One heating circuit without mixing valve...
  • Page 93 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “General” Group (continued) Coding in the factory set condition Possible change “Function output A1 at AM1 extension” 34:0 DHW recirculation pump. 34:1 Heating circuit pump without mixing valve A1 (Heating circuit 1).
  • Page 94 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “General” Group (continued) Coding in the factory set condition Possible change “Function output 157 at EA1 extension” 5c:0 5c:1 Feed pump Function output aBJ at EA1 extension: Central fault message...
  • Page 95 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “General” Group (continued) Coding in the factory set condition Possible change “Function input DE3 at EA1 extension” 5f:0 No function 5f:1 Operating program changeover. 5f:2 External demand with minimum set supply temperature Set value adjustment at coding “9b”...
  • Page 96 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “General” Group (continued) Coding in the factory set condition Possible change “With LON communication module” 79:1 Control unit is fault manager. 79:0 Control unit is not fault manager IMPORTANT Must be set for boiler section 2/boiler section 3, refer to page 34.
  • Page 97 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “General” Group (continued) Coding in the factory set condition Possible change “Summer time starts: Week of the selected month” 83:2 Week 2 of the selected month. 83:1 Week 1 to week 5 of the selected month.
  • Page 98 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “General” Group (continued) Coding in the factory set condition Possible change “Connection at terminals 1 and 2 in plug 143” 91:0 Connection disabled (external operating 91:1 Contact affects the following heating program changeover).
  • Page 99 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “General” Group (continued) Coding in the factory set condition Possible change “Connection at terminals 2 and 3 in plug 143” 99:0 Connection disabled 99:1 No function 99:2 External “mixing valve closed”...
  • Page 100 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “General” Group (continued) Coding in the factory set condition Possible change “With LON communication module: Monitoring LON participants” 9c:20 Monitoring LON participants 9c:0 No monitoring. If there is no response from a participant...
  • Page 101 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Boiler” Group Coding Coding in the factory set condition Possible change “Single boiler and multi boiler system” 01:2 Multi-boiler system with Viessmann-cascade 01:1 Do not adjust! or LON-cascade. 01:3 Do not adjust! “Consecutive boiler number in multi boiler systems”...
  • Page 102 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Cascade” Group (continued) Coding in the factory set condition Possible change “Minimum system supply temperature limit” 36:0 Set to 32°F (0°C). 36:1 Adjustable from 32°F to 261°F (0°C to 127°C) (only when operating 36:127 with standard room temperature).
  • Page 103 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Cascade” Group (continued) Coding in the factory set condition Possible change “System pump” 3e:0 System pump will only run if there is a 3e:1 System pump always runs; shutdown heat demand.
  • Page 104 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Cascade” Group (continued) Coding in the factory set condition Possible change “ECO threshold boiler 6” 6f:31 No ECO threshold boiler 6. 6f:−30 Adjustable from -22°F to 86°F Do not adjust! (-30°C to +30°C).
  • Page 105 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “DHW” Group (continued) Coding in the factory set condition Possible change “Boiler temperature during DHW heating” 60:20 During DHW heating, the boiler water 60:10 The differential between the common temperature is up to 36°F (20 K) higher...
  • Page 106 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “DHW” Group (continued) Coding in the factory set condition Possible change “With 2 tank temperature sensors: Tank heating start point” 69:7 With 2 tank temperature sensors (coding 69:1 Factor adjustable from 0.1 to 0.9 “55:2”): Tank heating start point at set...
  • Page 107 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Solar” Group (continued) Coding in the factory set condition Possible change “Temperature differential between the collector temperature and actual DHW temperature” 03:10 Temperature differential for the start of 03:5 Adjustable from 9°F to 36°F...
  • Page 108 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Solar” Group (continued) Coding in the factory set condition Possible change “Night circulation monitoring” 0d:1 Night circulation monitoring switched on. 0d:0 Night circulation monitoring switched off. Unintentional flow in the solar circuit is captured (e.g.
  • Page 109 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Solar” Group (continued) Coding in the factory set condition Possible change “Extended control function” 20:0 No extended control function enabled. 20:1 Additional function for DHW heating. 20:2 Differential temperature control 2.
  • Page 110 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Solar” Group (continued) Coding in the factory set condition Possible change “Alternate heating time” 27:15 Alternate heating time 15 min The 27:5 Adjustable from 5 to 60 min. DHW tank without priority is heated at...
  • Page 111 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Heating Circuit ...” Group (continued) Coding address Heating circuit pump a3:... Heating circuit pump “ON” Heating circuit pump “OFF” 14°F (–10°C) 18°F (–8°C) 16°F (–9°C) 19.5°F (–7°C) 18°F (–8°C) 21°F (–6°C)
  • Page 112 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Heating Circuit ...” Group (continued) Coding in the factory set condition Possible change “Extended economy mode” a6:36 Extended economy mode disabled. a6:5 Extended economy mode enabled, i.e. the burner and heating circuit pump...
  • Page 113 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Heating Circuit ...” Group (continued) Coding address With heating circuit pump logic function: b5:... Heating circuit pump “OFF” Heating circuit pump “ON” RTactual > RTset +9°F (+5 K) RTactual < RTset +7°F (+4 K) RTactual >...
  • Page 114 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Heating Circuit ...” Group (continued) Coding in the factory set condition Possible change “Mixing valve runtime” c3:125 Only for heating circuits with mixing c3:10 Adjustable from 10 sec. to 255 sec.
  • Page 115 Coding Level 2 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service “Heating Circuit ...” Group (continued) Coding in the factory set condition Possible change “Slab curing” f1:0 Slab curing function not active. Do not adjust! “Time limit for comfort mode”...
  • Page 116 Service Scans Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Calling up the Service Menu From the home screen tap the following buttons: 2. “Service” 3. Enter “viservice” password. 4. Select the required menu range. Overview of menu structure “Service main menu”...
  • Page 117 Service Scans Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Leaving the Service Menu From the service main menu tap the following buttons: Note: The system exits the service menu automatically after 30 min. 1. “Exit service” Change Passwords In the factory set condition, the following passwords have...
  • Page 118 Service Scans Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Brief Scan From the home screen tap the following buttons: 6. An overview of brief scans appears with 11 lines and 6 fields. for the required brief scan in line with the 2.
  • Page 119 Service Scans Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Carrying Out an Actuator Test Note: Before an actuator is selected, all actuators are From the home screen tap the following buttons: switched off. The actuators listed in the table can be tested at the relay 2.
  • Page 120 Service Scans Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Checking Sensors From the home screen tap the following buttons: 2. “Service” 3. Enter “viservice” password. 4. “Diagnosis” 5. Select group. 6. Scan actual temperature of the relevant sensor. Maintenance Display Set limits in coding “21”...
  • Page 121 Troubleshooting Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Fault Display In the event of a fault, the red fault display flashes at the control unit. The display shows symbol and “Fault”. Note: If a central fault message facility is connected, this is started.
  • Page 122 Troubleshooting Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Boiler System Fault Codes Displayed System characteristics Cause Measures fault code Control mode. Service “0f” is only displayed in Service required the fault history. Note: After servicing, set code “24:0”. Operates as if the outdoor...
  • Page 123 Troubleshooting Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Boiler System Fault Codes (continued) Displayed System characteristics Cause Measures fault code Mixing valve is being closed. Lead break, supply temperature Check supply temperature sensor, heating circuit with mixing sensor. valve M3 (heating circuit 3).
  • Page 124 Troubleshooting Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Boiler System Fault Codes (continued) Displayed System characteristics Cause Measures fault code Burner control unit in a fault state Lead break, boiler water Check connection cable and temperature sensor, burner dual sensor; replace sensor if control unit required.
  • Page 125 Troubleshooting Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Boiler System Fault Codes (continued) Displayed System characteristics Cause Measures fault code Control mode Lead break, temperature sensor, Check sensor at the solar control connection to S3 of the Vitosolic. unit (see separate installation and service instructions).
  • Page 126 Troubleshooting Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Boiler System Fault Codes (continued) Displayed System characteristics Cause Measures fault code Constant mode Invalid hardware recognition Check coding address “92” in the “General” group; H 161: Single boiler system H 190: Cascade control unit...
  • Page 127 Troubleshooting Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Boiler System Fault Codes (continued) Displayed System characteristics Cause Measures fault code Boiler cools down. Fault, maximum pressure limiter Check system pressure, at “X3” of plug-in adapter 1 for reset maximum pressure limiter.
  • Page 128 Troubleshooting Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Boiler System Fault Codes (continued) Displayed System characteristics Cause Measures fault code Control mode without room Short circuit, room temperature Check room temperature sensor influence. sensor, heating circuit with mixing (refer to page 77).
  • Page 129 Troubleshooting Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Fault Codes (continued) Displayed System characteristics Cause Measures fault code Burner control unit in a fault Excessive boiler water Wait until the boiler water state; system cools down. temperature. temperature falls below the maximum permissible boiler water temperature.
  • Page 130 Troubleshooting Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Fault Codes (continued) Displayed System characteristics Cause Measures fault code Air pressure switch shows no air Air pressure switch is faulty, Replace air pressure switch, pressure, fan not running. incorrectly connected or connect or set correctly.
  • Page 131 Connection and Wiring Diagrams Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Burner Control Unit Connection Diagram WARNING CAUTION Disconnect power inside the boiler junction box, before Provide disconnect means and overload protection as servicing boiler. required. Legend Boiler temperature sensor 1 §A Flame sensor aA Boiler temperature sensor 2 §B...
  • Page 132 Connection and Wiring Diagrams Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Boiler Connections Connection overview for CA3B 2.5 to 4.0 models Legend A Supply temperature sensors heating circuits M2/M3 B External LON participants (i.e. Vitotronic 200-H) C Low voltage/sensor connections...
  • Page 133 Connection and Wiring Diagrams Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Boiler Connections (continued) Connection overview for CA3B 5.0 to 6.0 models Legend A Supply temperature sensors heating circuits M2/M3 B External LON participants (i.e. Vitotronic 200-H) C Low voltage/sensor connections...
  • Page 134 Connection and Wiring Diagrams Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Overview Legend PCB extension for heating circuits 2 and 3 with mixing valve, boiler section 1 control only Coding card PCB, low voltage A10 LON communication module PCB, 120 V~...
  • Page 135 Connection and Wiring Diagrams Vitocrossal 300 CA3B Series 2.5 to 6.0 Service PCB Extension for Heating Circuits 2 and 3 with Mixing Valve PCB, extension for heating circuits 2 and 3 with mixing valve ? M2/M3 Supply temperature sensors sÖ M2/M3...
  • Page 136 Connection and Wiring Diagrams Vitocrossal 300 CA3B Series 2.5 to 6.0 Service PCB 120V~ Legend sÖ Heating circuit pump aBÖ External connections (remove jumper when connecting) primary pump, tank loading system Safety chain (potential free) Circulation pump for DHW tank heating...
  • Page 137 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists Model No. Serial No. CA3B 2.5 Boiler 7745189 CA3B 3.0 Boiler 7745190 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate A when ordering replacement parts.
  • Page 138 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 2.5 Boiler 7745189 CA3B 3.0 Boiler 7745190 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 139 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 2.5 Boiler 7745189 CA3B 3.0 Boiler 7745190 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 140 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 3.5 Boiler 7745191 CA3B 4.0 Boiler 7745192 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate A when ordering replacement parts.
  • Page 141 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 3.5 Boiler 7745191 CA3B 4.0 Boiler 7745192 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 142 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 3.5 Boiler 7745191 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor.
  • Page 143 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 4.0 Boiler 7745192 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor.
  • Page 144 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 5.0 Boiler 7745193 CA3B 6.0 Boiler 7745194 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate A when ordering replacement parts.
  • Page 145 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 5.0 Boiler 7745193 CA3B 6.0 Boiler 7745194 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 146 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 5.0 Boiler 7745193 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor.
  • Page 147 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 6.0 Boiler 7745194 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts. Order replacement components from your Viessmann distributor.
  • Page 148 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 2.5 Boiler 7745189 CA3B 3.0 Boiler 7745190 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 149 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 2.5 Boiler 7745189 CA3B 3.0 Boiler 7745190 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 150 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 3.5 Boiler 7745191 CA3B 5.0 Boiler 7745193 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 151 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 3.5 Boiler 7745191 CA3B 5.0 Boiler 7745193 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 152 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 3.5 Boiler 7745191 CA3B 4.0 Boiler 7745192 CA3B 5.0 Boiler 7745193 CA3B 6.0 Boiler 7745194 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 153 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 3.5 Boiler 7745191 CA3B 4.0 Boiler 7745192 CA3B 5.0 Boiler 7745193 CA3B 6.0 Boiler 7745194 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 154 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 2.5 Boiler 7745189 CA3B 3.0 Boiler 7745190 CA3B 3.5 Boiler 7745191 CA3B 4.0 Boiler 7745192 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 155 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 5.0 Boiler 7745193 CA3B 6.0 Boiler 7745194 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 156 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 5.0 Boiler 7745193 CA3B 6.0 Boiler 7745194 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 157 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 5.0 Boiler 7745193 CA3B 6.0 Boiler 7745194 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 158 Parts Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Parts Lists (continued) Model No. Serial No. CA3B 5.0 Boiler 7745193 CA3B 6.0 Boiler 7745194 Ordering Replacement Parts: Please provide Model and Serial Number from CSA rating plate when ordering replacement parts.
  • Page 159 Specifications Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Technical Data Boiler Model CA3B Input 2500 3000 3500 4000 5000 6000 (kW) (733) (879) (1026) (1172) (1465) (1758) Minimum Input NG (kW) (73) (88) (88) (117) (88) (117) Minimum Input LPG...
  • Page 160 Specifications Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Technical Data (continued) Boiler Model CA3B Boiler Water Content (410) (410) (570) (540) (860) (825) Heat Exchanger Surface 142.7 142.7 170.2 192.5 244.1 288.8 (13.3) (13.3) (15.8) (17.9) (22.7) (26.8) Maximum Operating Temperature °F...
  • Page 161 Inspection and Maintenance Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Requirements for Water Conditions Counter reading Fill and make-up water Total quantity of water Total hardness pH-value Date Feed water Boiler water...
  • Page 162 Inspection and Maintenance Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Maintenance Record Setting and Test Values Commissioning Maintenance/Service Static Pressure mbar (”w.c.) Section 1 Section 2 Section 3 Section 1 Section 2 Section 3 Supply Pressure (running pressure) mbar (”w.c.) ...
  • Page 163 Inspection and Maintenance Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Maintenance Schedule (continued) Frequency Performed by Service  Monthly Owner / Check the system pressure frequently. Operator Ensure proper operation of the boiler control. Refer to operating instructions of the control.
  • Page 164 Vitocrossal 300 CA3B Series 2.5 to 6.0 Service Scan for digital copy of this document...