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

Viessmann VITOCROSSAL 300 Service Instructions Manual

Gas condensing boiler with matrix gas burner and lambda pro control, natural gas and lpg version open flue and room sealed operation
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VIESMANN
Service instructions
for contractors
Vitocrossal 300
Type CU3A, 13 to 60 kW
Gas condensing boiler with MatriX gas burner
and Lambda Pro Control,
Natural gas and LPG version
Open flue and room sealed operation
VITOCROSSAL 300
Please keep safe.
6192251 GB
4/2024

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Summary of Contents for Viessmann VITOCROSSAL 300

  • Page 1 VIESMANN Service instructions for contractors Vitocrossal 300 Type CU3A, 13 to 60 kW Gas condensing boiler with MatriX gas burner and Lambda Pro Control, Natural gas and LPG version Open flue and room sealed operation VITOCROSSAL 300 Please keep safe.

  • Page 2: Target Group

    Safety instructions Safety instructions Please follow these safety instruc- tions closely to prevent accidents and material losses. Safety instructions explained Danger Note This symbol warns against the risk Details identified by the word "Note" of injury. contain additional information. Please note This symbol warns against the risk of material losses and environmen- tal pollution.

  • Page 3: Safety Instructions

    Prior to commencing work, touch For installation and replacements, earthed objects such as heating or use only Viessmann original parts water pipes to discharge static or parts approved by Viessmann. loads. Repair work...

  • Page 4: If You Smell Flue Gas

    Safety instructions Safety instructions (cont.) Safety instructions for operating the system If you smell gas Condensate Danger Danger Escaping gas can lead to explo- Contact with condensate can be sions which may result in serious harmful to health. injury. Never let condensate touch your Do not smoke.
  • Page 5 Safety instructions Safety instructions (cont.) Danger The simultaneous operation of the boiler and appliances that exhausts air to the outside can result in life threatening poisoning due to a reverse flow of flue gas. Fit an interlock circuit or take suita- ble steps to ensure an adequate supply of combustion air.

  • Page 6: Table Of Contents

    Index Index 1. Information Symbols ....................Intended use ..................Product information ................10 System examples ................10 ■ Maintenance parts and spare parts ............ 10 ■ 2. Commissioning, inspec- Steps - commissioning, inspection and maintenance ......11 tion, maintenance 3. Code 1 Calling up coding level 1 ................
  • Page 7 Index Index b8 ......................62 ■ bA ....................... 63 ■ bb ......................63 ■ bC ....................... 63 ■ bd ......................63 ■ bE ....................... 63 ■ bF ....................... 64 ■ C1 ....................... 64 ■ C2 ....................... 64 ■ C3 ....................... 64 ■...

  • Page 8: Index Index

    Index Index (cont.) DHW heating ..................78 ■ Boosting DHW heating ............... 78 ■ Connecting the Vitoconnect 100 connecting cable (accessories) ..79 Installing the Vitoconnect 100 ............. 79 ■ Internal extensions (accessories) ............80 Internal H1 extension ................80 ■...

  • Page 9: Symbol Meaning

    Information Symbols The steps in connection with commissioning, inspec- Symbol Meaning tion and maintenance are found in the "Commission- Reference to other document containing ing, inspection and maintenance" section and identified further information as follows: Step in a diagram: Symbol Meaning The numbers correspond to the order in Steps required during commissioning...

  • Page 10: Product Information

    Vitocrossal 300, CU3A Conversion for other countries Preset for operation with natural gas E and LL The Vitocrossal 300 may only be delivered to the countries specified on the type plate. For deliveries to Conversion to LPG P other countries, approved contractors must arrange individual approval on their own initiative and in See service instructions.

  • Page 11: Commissioning, Inspec-Steps - Commissioning, Inspection And Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • 1. Filling the heating system and checking the supply of ventilation air......12 • 2. Checking the power supply • 3. Changing the language (if required)................. 12 •...

  • Page 12: Filling The Heating System And Checking The Supply Of Ventilation Air

    Viessmann accepts no liability for any resulting dam- Permiss. operating pressure: 3 bar (0.3 MPa) age or consequential losses. Minimum operating pressure: 0.5 bar (50 kPa)

  • Page 13: Setting The Time And Date (If Required)

    Commissioning, inspection, maintenance Changing the language (if required) (cont.) Sprache Deutsch ê ç Bulgarski ê Cesky ê Dansk ê Wählen mit Fig. 2 Setting the time and date (if required) The time and date need to be reset during commis- 4.

  • Page 14: Removing The Front Panel

    Commissioning, inspection, maintenance Removing the front panel Fig. 3...

  • Page 15: Converting The Gas Type (Only For Operation With Lpg)

    Commissioning, inspection, maintenance Converting the gas type (only for operation with LPG) 1. Set adjusting screw on the gas solenoid valve to "2". 2. Turn on the ON/OFF switch 3. Select the gas type in coding address "82": Call up code 2. ■...

  • Page 16: Testing The Static And Supply Pressure

    Commissioning, inspection, maintenance Function sequence and possible faults (cont.) Burner in operation Shuts down below the set Check the flue system for boiler water temperature and tightness (flue gas recircula- restarts immediately tion); check the gas flow pressure. Automatic calibration of Fault E3 Ensure adequate heat trans- the combustion controller...

  • Page 17: Commissioning, Inspection, Maintenance

    Commissioning, inspection, maintenance Testing the static and supply pressure (cont.) 3. Open the gas shut-off valve. 7. Record the actual value in the report on page 96. Implement measures as indicated in the table 4. Check the static pressure. Record the actual value below.

  • Page 18: Checking The Balanced Flue System For Leaks (Annular Gap Test)

    Commissioning, inspection, maintenance Checking the balanced flue system for leaks (annular gap test) Fig. 6 Combustion air aperture For balanced flue systems tested together with the If actual CO values are greater or O values are lower, heat generator, there is no requirement for a tightness then pressure test the flue pipe with a static pressure test (overpressure test) during commissioning by the of 200 Pa.

  • Page 19: Removing The Burner And Checking The Burner Gasket

    Commissioning, inspection, maintenance Removing the burner and checking the burner gasket Fig. 7 1. Turn off the ON/OFF switch on the control unit and the power supply. 2. Close the gas shut-off valve and safeguard against reopening. 3. Detach electrical cables/leads to burner: Fan motor , gas solenoid valve , ionisation...

  • Page 20: Checking The Burner Gauze Assembly And Thermal Insulation Block

    Commissioning, inspection, maintenance Removing the burner and checking the burner… (cont.) 6. Check burner gasket for damage and replace if required. Fig. 8 Undo 4 nuts . Remove burner and hook it into service retainer Please note Prevent damage to the burner. Always hook the burner into its service retainer.

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

    Commissioning, inspection, maintenance Checking the burner gauze assembly and thermal… (cont.) 5. Remove burner gauze assembly gasket 8. Insert new burner gauze assembly together with new gasket . Secure with 4 nuts. 6. Check thermal insulation block for damage and Torque: 5 Nm replace if required.

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

    Commissioning, inspection, maintenance Separating the neutralising system (if installed) from the boiler and connecting the drain hose 1. Detach hose to neutralising system from trap 2. Connect drain hose to trap and route it to the drainage system Fig. 11 Cleaning the combustion chamber and heating surfaces Please note 2.

  • Page 23: Checking The Condensate Drain And Neutralising System (If Installed) For Obstructions And Leaks

    Commissioning, inspection, maintenance Cleaning and reconnecting the condensate drain… (cont.) 3. Remove bottom part of trap , then clean and refit it. 4. Fill trap with water and refit to inlet connector Note There is a risk of flue gas escaping if the trap is not filled with water.

  • Page 24: Checking The Gaskets And Thermal Insulation Parts On The Boiler Side

    Commissioning, inspection, maintenance Checking the gaskets and thermal insulation parts on the boiler side Fig. 13 Danger 3. If required, remove flue gas collector and replace Leaking systems can cause life threatening poi- gaskets. soning from carbon monoxide in the flue gas. ■...

  • Page 25: Checking The Water Quality

    Commissioning, inspection, maintenance Checking the expansion vessel and system… (cont.) 3. Top up with water until the charge pressure of the cooled system is 0.1 to 0.2 bar (10 to 20 kPa) higher than the pre-charge pressure of the expan- sion vessel.

  • Page 26: Installing The Burner

    Commissioning, inspection, maintenance Installing the burner Fig. 14 1. Insert burner 4. Connect the electrical cables to the corresponding . Secure in place by tightening the 4 nuts diagonally. components. Torque: 4 Nm Danger 2. Fit gas connection pipe together with new gas- Leaks can result in poisoning by flue gas.

  • Page 27: Checking All Gas Equipment For Leaks At Operating Pressure

    Commissioning, inspection, maintenance Checking all gas equipment for leaks at operating pressure Danger Note Escaping gas leads to a risk of explosion. Only use suitable and approved leak detection agents Check gas equipment for leaks. (EN 14291) and devices for the leak test. Leak detec- tion agents with unsuitable constituents (e.g.

  • Page 28: Checking The External Lpg Safety Valve (If Installed)

    Commissioning, inspection, maintenance Checking the ventilation air apertures in the installation room (open flue operation) Checking the external LPG safety valve (if installed) Matching the control unit to the heating system The control unit must be matched to the system equip- For coding steps, see page 32.

  • Page 29: Connecting The Control Unit To The Lon

    Commissioning, inspection, maintenance Adjusting the heating curves (cont.) Standard set room temperature Changing the reduced set room temperature Operating instructions Changing the slope and level Individually adjustable for each heating circuit. Fig. 17 Example 1: Adjustment of the standard set room temperature from 20 to 26 °C Boiler water temperature or flow temperature in °C Outside temperature in °C...

  • Page 30: Checking And Resetting The "Service" Display

    Control unit receives outside — temperature. temperature. temperature. Set code "97:2". Set code "97:1". Set code "97:1". Viessmann system number. Viessmann system number. Viessmann system number. — Code "98:1" Code "98:1" Code "98:1" LON subscriber fault monitor- LON subscriber fault moni- LON subscriber fault moni- —...

  • Page 31: Mounting The Front Panel

    Commissioning, inspection, maintenance Checking and resetting the "Service" display (cont.) 2. "Service functions" Note An acknowledged service message that was not reset 3. "Service reset" reappears the following Monday. After a service has been carried out (resetting Note service) The selected service parameters for hours run and interval restart at 0.

  • Page 32: Code 1

    Code 1 Calling up coding level 1 On weather-compensated control units, codes are Calling up code 1 ■ displayed as plain text. Service menu: ■ Codes that are not assigned, due to the heating sys- tem equipment level or the setting of other codes, are not displayed.

  • Page 33: Boiler

    Code 1 General (cont.) Value, ad- Description dress 00: ... 1 heating circuit without mixer A1 (heating circuit 1), 1 heating circuit with mixer M2 (heating cir- cuit 2) and 1 heating circuit with mixer M3 (heating circuit 3), without DHW heating (code is set automatically) 1 heating circuit without mixer A1 (heating circuit 1), 1 heating circuit with mixer M2 (heating cir- cuit 2) and 1 heating circuit with mixer M3 (heating circuit 3), with DHW heating (code is set au-...

  • Page 34: Dhw

    Code 1 Boiler (cont.) Coding in the delivered condition Possible change Burner service in 100 hours 21:0 No service interval set (in hours 21:1 The number of hours run before the run) burner should be serviced is adjust- 21:100 able from 100 to 10,000 h One adjusting step ≙...
  • Page 35 Code 1 Solar (cont.) Coding Coding in the delivered condition Possible change Speed control solar circuit pump 02:... Coding dependent on the software 02:0 Solar circuit pump is not speed-con- version of solar control module trolled SM1/SM1A 02:1 With wave packet control function Never adjust 02:2 Solar circuit pump is speed-control-...

  • Page 36: Heating Circuit 1, Heating Circuit 2, Heating Circuit 3

    Code 1 Heating circuit 1, heating circuit 2, heating circuit 3 Coding Coding in the delivered condition Possible change Priority DHW heating A2:2 Cylinder priority for heating circuit A2:0 No cylinder priority for heating circuit pump pump A2:1 Cylinder priority for mixers: The mix- er is closed during cylinder heating.
  • Page 37 Code 1 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change Extended economy function mixer A7:0 Without mixer economy function A7:1 With mixer economy function (exten- (only for heating circuits with mix- ded heating circuit pump logic): Heating circuit pump also "OFF": If the mixer has been trying to ■...
  • Page 38 Code 1 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change Max. flow temperature heating circuit C6:74 Electronic maximum flow tempera- C6:10 Maximum limit adjustable from 10 to ture limit set to 74 °C 127 °C (limited by boiler-specific pa- C6:127 rameters)

  • Page 39: Code 2 Calling Up Coding Level 2

    Code 2 Calling up coding level 2 In coding level 2 all codes are accessible. Calling up code 2 ■ Codes that are not assigned, due to the heating sys- ■ Service menu: tem equipment level or the setting of other codes, are not displayed.
  • Page 40 Code 2 General (cont.) System examples Coding in the delivered condition Possible change 11:≠9 No access to the coding addresses 11:9 Access to the coding addresses for for the parameters of the combus- the parameters of the combustion tion controller controller open 2A:0 Do not adjust.
  • Page 41 Code 2 General (cont.) Coding in the delivered condition Possible change 3b:3 Function of input DE2: External blocking Function, circulation pump for cylin- der heating: Coding address 5F Function, heating circuit pumps: Coding address D7 3b:4 Function of input DE2: External blocking with fault message input Function, circulation pump for cylin- der heating: Coding address 5E...
  • Page 42 Code 2 General (cont.) Coding in the delivered condition Possible change 51:0 Only if the low loss header sensor 51:1 Do not adjust. is connected: Boiler circuit pump 51:2 When there is demand, the boiler (output A1/21) always runs. circuit pump only starts if the burner is operational.
  • Page 43 The control unit transmits the out- unit is used internally. side temperature to the LON sub- scribers. 98:1 Viessmann system number (in 98:1 System no. adjustable from 1 to 5 conjunction with monitoring of sev- eral systems via Vitocom 300)

  • Page 44: Boiler

    Code 2 Boiler Coding Coding in the delivered condition Possible change 04:1 Minimum burner pause time sub- 04:0 Minimum burner pause time set per- ject to the boiler load (specified by manently (specified by coding card) coding card) 06:... Maximum limit of boiler water tem- 06:20 Maximum limit of boiler water tem- perature, specified in °C by coding...

  • Page 45: Solar

    Code 2 (cont.) Coding in the delivered condition Possible change 59:0 Cylinder heating: 59:1 Start point adjustable from 1 to 10 K Start point -2.5 K below set value Stop point +2.5 K 59:10 5E:0 Circulation pump for cylinder heat- 5E:1 Circulation pump for cylinder heating ing stays in control mode at "Exter-...
  • Page 46 Code 2 Solar (cont.) Coding Coding in the delivered condition Possible change Not allocated to any function mode 00:8 The solar circuit pump starts if the 00:2 The differential between the actual collector temperature exceeds the cylinder temperature and the start actual cylinder temperature by 8 K.
  • Page 47 Calculation of solar yield with water Viessmann heat transfer medium as heat transfer medium (do not se- lect as operation is only possible with Viessmann heat transfer medi- 0E:0 Calculation of solar yield switched 0F:70 The flow rate in the collector circuit...
  • Page 48 Code 2 Solar (cont.) Coding in the delivered condition Possible change 20:0 No extended control function ac- 20:1 Auxiliary function for DHW heating tive 20:2 Differential temperature control 2 20:3 Differential temperature control 2 and auxiliary function 20:4 Differential temperature control 2 for central heating backup 20:5 Thermostat function...

  • Page 49: Heating Circuit 1, Heating Circuit 2, Heating Circuit 3

    Code 2 Solar (cont.) Coding in the delivered condition Possible change 25:50 Stop temperature for the thermo- 25:0 Start temperature for thermostat stat function 50 °C. function is adjustable from Start temperature for thermostat 25:100 0 to 100 K. function stop temperature for ≤...
  • Page 50 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change A2:2 Cylinder priority for heating circuit A2:0 No cylinder priority for heating circuit pump pump A2:1 Cylinder priority for mixer. The mixer is closed during cylinder heating. The heating circuit pump is running.
  • Page 51 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Parameter address A5:... With heating circuit pump logic function: Heating circuit pump "OFF" + 5 K > + 4 K > + 3 K > + 2 K > + 1 K >...
  • Page 52 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change b2:1 Room influence factor adjustable from 1 to 64 b2:64 b5:0 With remote control: No room tem- b5:1 For heating circuit pump logic func- perature-dependent heating circuit tion, see the following table: pump logic function (change code...
  • Page 53 Code 2 Heating circuit 1, heating circuit 2, heating… (cont.) Coding in the delivered condition Possible change d8:2 Operating program changeover via input DE2 at EA1 extension d8:3 Operating program changeover via input DE3 at EA1 extension E1:1 Do not adjust. E2:50 With remote control: No display E2:0...

  • Page 54: Diagnosis And Service Calling Up The Service Menu

    Diagnosis and service checks Calling up the service menu Press OK and simultaneously for approx. 4 s. å Service menu overview Service General Diagnosis Heating circuit 1 Heating circuit 2 Actuator test Heating circuit 3 Coding level 1 Solar Brief scan Coding level 2 Reset data Fault history...

  • Page 55: Checking Outputs (Actuator Test)

    Diagnosis and service checks Diagnosis (cont.) For an explanation of the relevant values in the individual rows and fields, see the following table: Row (brief Field scan) System scheme 01 to 10 Software version Software version Control unit Programming unit Appliance version Appliance ID (CU-ID) Number of KM-BUS subscrib-...
  • Page 56 Diagnosis and service checks Checking outputs (actuator test) (cont.) Display Explanation "Htg circ pump HC2" Output for heating circuit pump active (extension heating circuit with mixer) "Mixer HC2" Open Output for "Mixer open" active (extension heating circuit with mix- "Mixer HC2" Close Output for "Mixer close"...

  • Page 57: Troubleshooting Fault Display

    Troubleshooting Fault display In the event of a fault, red fault indicator flashes. Calling up acknowledged faults " " flashes on the display and "Fault" is shown. In the standard menu, select "Fault". Current faults will be listed. Calling up fault codes from the fault memory (fault history) The 10 most recent faults (including those remedied) are saved and can be called up.
  • Page 58 Troubleshooting Fault codes (cont.) System characteristics Measures Regulates as if the outside temperature were 0 °C. Set code 2A:0. Cause Configuration fault System characteristics Measures Burner locked out Check the boiler water temperature sensor (see page 73) Cause Short circuit, boiler water temperature sensor System characteristics Measures Burner locked out...
  • Page 59 Troubleshooting Fault codes (cont.) Cause Measures Lead break, flow temperature sensor, heating circuit 2 Check flow temperature sensor. (with mixer) System characteristics Measures Mixer is being closed. Check flow temperature sensor. Cause Lead break, flow temperature sensor, heating circuit 3 (with mixer) System characteristics Measures...
  • Page 60 Troubleshooting Fault codes (cont.) System characteristics Measures No solar DHW heating Check temperature sensor on the solar control & module or the sensor on the Vitosolic. Cause Short circuit, collector temperature sensor System characteristics Measures Normal operation Check temperature sensor at connection S3 on the Vitosolic 100.
  • Page 61 Troubleshooting Fault codes (cont.) Measures Check temperature sensor on the solar control & module or the sensor on the Vitosolic. System characteristics Measures Normal operation Check temperature sensor at connection S3 on the Vitosolic 100. Cause Lead break, cylinder temperature sensor System characteristics Measures No solar DHW heating...
  • Page 62 Troubleshooting Fault codes (cont.) System characteristics Measures Normal operation as per delivered condition Replace the programming unit. Cause Programming unit faulty System characteristics Measures Burner locked out Check flue gas temperature sensor. Cause Short circuit, flue gas temperature sensor System characteristics Measures Normal operation as per delivered condition Check connections and replace programming unit if...
  • Page 63 Troubleshooting Fault codes (cont.) Measures Check flue gas temperature sensor. System characteristics Measures Mixer regulates to 20 °C flow temperature Check extension kit connections and code. Cause Communication error, extension kit for heating circuit 2 (with mixer) System characteristics Measures Mixer regulates to 20 °C flow temperature Check extension kit connections and code.
  • Page 64 Troubleshooting Fault codes (cont.) Measures Check connections, cable, coding address "A0" in the "Heating circuit" group and remote control settings (see page 88). For wireless remote control units: Check connection; place remote control close to the boiler. System characteristics Measures Normal operation Replace LON communication module.
  • Page 65 Troubleshooting Fault codes (cont.) System characteristics Measures Normal operation Replace LON communication module. Cause Communication error, LON communication module System characteristics Measures Normal operation Remedy fault at affected appliance. Cause Input DE1 at EA1 extension reports a fault. System characteristics Measures Normal operation Remedy fault at affected appliance.
  • Page 66 Troubleshooting Fault codes (cont.) Measures Check room temperature sensor, heating circuit 2. System characteristics Measures Normal operation without room influence Check room temperature sensor, heating circuit 3. Cause Short circuit, room temperature sensor, heating circuit 3 (with mixer) System characteristics Measures Normal operation without room influence Check room temperature sensor, heating circuit 1 and...
  • Page 67 Troubleshooting Fault codes (cont.) System characteristics Measures Burner in a fault state Check gap between ionisation electrode and burner gauze assembly (see page 21). Cause In open flue operation, prevent high levels of dust in the combustion air. Ionisation current too high during calibration Press reset button R.
  • Page 68 Troubleshooting Fault codes (cont.) System characteristics Check assignment of gas type (see page 15). Burner in a fault state Check ionisation electrode for the following: ■ Distance to burner gauze assembly (see page 21) Cause Contamination on electrode. ■ Ionisation current lies outside the permissible range Press reset button R.
  • Page 69 Troubleshooting Fault codes (cont.) System characteristics Check gas solenoid valve. Check ionisation electrode and connecting cable. Burner in a fault state Check ignition: Cause Connecting cables to ignition module and ignition ■ electrode Flame signal is not present or insufficient at burner Ignition electrode gap and contamination (see ■...
  • Page 70 Troubleshooting Fault codes (cont.) Measures Press reset button R. Check heating system fill level. Check circulation pump. Vent the system. Check temperature limiter and connecting cables. System characteristics Measures Burner in a fault state Check ionisation electrode and connecting cable. Press reset button R.
  • Page 71 Troubleshooting Fault codes (cont.) System characteristics Measures Burner in a fault state and additional fault b7 is dis- Insert coding card. Press reset button R. played. Replace control unit if fault persists. Cause Coding card missing. System characteristics Measures Burner in a fault state Check ignition electrodes and connecting cables.
  • Page 72 Maintenance Checking the outside temperature sensor Fig. 24 Boiler top panel Control unit enclosure cover panel 1. Disconnect plug "X3" from the control unit. 2. Test the resistance of the outside temperature sen- sor across terminals "X3.1" and "X3.2" on the dis- connected plug and compare it with the curve.

  • Page 73: Checking The Cylinder Temperature Sensor

    Maintenance Checking the cylinder temperature sensor 1. Cylinder temperature sensor Disconnect plug and measure the resistance. 2. Check the sensor resistance. Compare the meas- ured value with the curve. Fig. 26 3. In the event of severe deviation replace the sensor. Temperature in °C Fig.

  • Page 74: Checking The Flue Gas Temperature Sensor

    Maintenance Checking boiler water temperature sensor (cont.) 3. In the event of severe deviation replace the sensor. Temperature in °C Fig. 29 Sensor type: NTC 10 k Ω Checking the flue gas temperature sensor The flue gas temperature sensor locks out the boiler if the permissible flue gas temperature is exceeded.

  • Page 75: Checking The Temperature Limiter

    Maintenance Checking the flue gas temperature sensor (cont.) 2. Check the sensor resistance. Compare the meas- ured value with the curve. 3. In the event of severe deviation replace the sensor. Temperature in °C Fig. 31 Sensor type: NTC 10 k Ω...

  • Page 76: Mixer Extension Kit

    Maintenance Checking the fuse Fig. 33 1. Switch off the power supply. 3. Check fuse F1. Replace if necessary (see connec- tion diagram figure 50 on page 90). 2. Remove top panel and cover Danger Incorrect or improperly fitted fuses can lead to an increased risk of fire.

  • Page 77: Checking The Vitotronic 200-H (Accessories)

    Maintenance Mixer extension kit (cont.) Checking the rotational direction of the mixer Observe the rotational direction of the mixer motor dur- motor ing its self-test. Then manually set the mixer back to "Open". After being switched on, the boiler implements a self- The flow temperature sensor must now capture a test.

  • Page 78: Heating Mode

    Function description Weather-compensated control unit 21°C 14°C Boiler temperature 48 °C Fig. 36 Heating mode The control unit determines a set boiler water tempera- The electronic temperature limiter inside the burner ture subject to outside temperature or room tempera- control unit limits the boiler water temperature. ture (if a room temperature-dependent remote control is connected) and to the slope level of the heating...

  • Page 79: Connecting The Vitoconnect 100 Connecting Cable (Accessories)

    Function description Connecting the Vitoconnect 100 connecting cable (accessories) Fig. 37 Installing the Vitoconnect 100 "Vitoconnect 100" installation and commission- ing instructions...

  • Page 80: Internal Extensions (Accessories)

    Function description Internal extensions (accessories) Internal H1 extension Fig. 38 The internal extension is integrated into the control unit A central fault message facility can be connected to ■ enclosure. relay output "A1". An external safety valve can be connected to con- ■...

  • Page 81: Function Description

    Function description Internal extensions (accessories) (cont.) Internal H2 extension Fig. 39 The internal extension is integrated into the control unit A central fault message facility can be connected to ■ enclosure. relay output "A1". ■ An extractor fan can be switched off via connection when the burner starts.

  • Page 82: External Extension (Accessories)

    Function description External extension (accessories) EA1 extension Fig. 40 Digital input 1 Power supply fÖ Digital input 2 Power supply for additional accessories fÖ Digital input 3 Central fault message/feed pump/DHW circu- Fuse lation pump (potential-free) 0 - 10 V 0 to 10 V input KM-BUS Digital data inputs DE1 to DE3 Input function assignment...

  • Page 83: Control Functions

    Function description External extension (accessories) (cont.) Effect of the "External blocking" function on the Note circulation pumps If the 0 - 10 V signal is not transmitted correctly, an iso- lating amplifier must be used for galvanic separation. The effect on the relevant heating circuit pump is selected with code d6.

  • Page 84: External Blocking

    Function description Control functions (cont.) Operating program changeover Code Changeover towards "Permanently reduced" or "Permanent standby mode" (ac- d5:0 cording to the selected set value) Changeover towards "Continuous heating mode" d5:1 The duration of the operating program changeover can be adjusted in coding address "F2": Operating program changeover Code No operating program changeover...

  • Page 85: External Demand

    Function description Control functions (cont.) External demand When the contact is closed, burner operation is load- Plug dependent. The boiler water is heated to the set value selected in coding address "9b" in the "General"/1 The function is selected via code 4b:1 in the "Gen- ■...
  • Page 86 Function description Control functions (cont.) Temperature profile 2: (acc. to ZV parquet and flooring technology) code "F1:2" ϑ/°C Fig. 42 Temperature profile 3 (to ÖNORM): Code "F1:3" ϑ/°C Fig. 43 Temperature profile 4: Code "F1:4" ϑ/°C Fig. 44 Temperature profile 5: Code "F1:5" ϑ/°C Fig.

  • Page 87: Raising The Reduced Room Temperature

    Function description Control functions (cont.) Raising the reduced room temperature During operation at reduced room temperature, the The outside temperature limits for the start and end of reduced set room temperature can be automatically the temperature raising can be adjusted via coding raised subject to the outside temperature.

  • Page 88: Assigning Heating Circuits To The Remote Control

    Function description Control functions (cont.) Example using the settings in the delivered condition Time Fig. 49 Start of operation at standard room temperature Set boiler water or flow temperature in accordance Set boiler water or flow temperature in accordance with coding address "FA": with the selected heating curve 50 °C + 20 % = 60 °C Duration of operation with raised set boiler water...
  • Page 89 Function description Electronic combustion control unit (cont.) To check the combustion quality, the CO content or the O content of the flue gas is measured. The pre- vailing air ratio is determined with the measured val- ues. The relationship between the CO or O content and air ratio...

  • Page 90: Connection Diagram Internal Connection Diagram

    Connection diagram Internal connection diagram Fig. 50 Heating circuit pump A1 A6 Coding card sÖ DHW circulation pump A7 Adaptor A1 Main PCB A8 LON communication module A3 Programming unit Vitotronic 200 KW6A A9 Internal extension SA100B10 (accessories) A5 Connection extension SA104A10 H1 or H2...
  • Page 91 Connection diagram Internal connection diagram (cont.) Fig. 51 Main PCB Ignition unit Boiler water temperature sensor Fan motor control § a¢Ö A Ionisation monitoring Modulation coil aY\YA a:Ö Flue gas temperature sensor Connection extension Temperature limiter...

  • Page 92: External Connection Diagram

    Connection diagram External connection diagram Fig. 52 A1 Main PCB Flow temperature sensor A2 Power supply unit Cylinder temperature sensor A3 Programming unit/Optolink Circulation pump for cylinder heating A4 Burner control unit Solenoid valve A5 Coding card Power supply fÖ A6 Connection adaptor Network accessories A7 LON communication module (Vitotronic 200)

  • Page 93: Water Quality Requirements

    Water quality Requirements Water quality requirements Prevention of damage due to scaling Note Prevent excessive scale build-up (calcium carbonate) Observing the following requirements is necessary to on the heating surfaces. For heating systems with operating temperatures up to 100 °C, VDI Guideline safeguard your warranty rights.
  • Page 94 Water quality Requirements (cont.) This measure must be carried out by a qualified con- No further anti-corrosion measures are required for tractor. Inspect the heating system for possible dam- sealed unvented hot water heating systems, subject to age prior to returning it into use. It is essential that the above points being observed.

  • Page 95: Commissioning/Service

    Commissioning/service reports Meter reading Fill and top- Total water Total hardness pH value Date up water volume Feedwater Boiler water...

  • Page 96: Reports Settings And Test Values

    Commissioning/service reports Settings and test values Settings and test values Set value Commissioning Maintenance/ service Static pressure 57.5 mbar ≤ 5.75 ≤ Supply pressure (flow pres- sure) for natural gas E 17.4-25 mbar 1.74-2.5 for natural gas LL 17.4-25 mbar 1.74-2.5 for LPG mbar...

  • Page 97: Specification

    Specification Specification Gas boiler, types B and C Rated heating output range = 50/30 °C 2.6 to 13 2.6 to 19 5.2 to 26 7 to 35 12 to 45 12 to 60 = 80/60 °C 2.4 to 2.4 to 4.7 to 6.3 to 10.9 to...

  • Page 98: Shutdown And Disposal Final Decommissioning And Disposal

    Shutdown and disposal Final decommissioning and disposal Viessmann products can be recycled. Components For decommissioning, isolate the system from the and substances from the system are not part of ordi- power supply and allow components to cool down nary domestic waste.

  • Page 99: Certificates Declaration Of Conformity

    Manufacturer's certificate according to the 1st BImSchV [Germany] We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, confirm that the product Vitocrossal 300 complies with the NO limits specified by the 1st BImSchV paragraph 6 [Germany].

  • Page 100: Keyword Index

    Keyword index Keyword index Fault manager............30 Acknowledging a fault display........57 Fault memory............. 57 Actuator test............... 55 Fault message call-up..........57 Faults................. 57 Fill and top-up water...........25 Boiler water requirements.......... 93 Fill water..............12 Boiler water temperature sensor........ 73 Flue gas temperature sensor........74 Boosting DHW heating..........78 Front panel Brief scans..............
  • Page 101 Keyword index Keyword index (cont.) Service menu, calling up..........54 Power supply Set room temperature selection......... 28 – Checking..............12 Shutdown..............98 Small softening system..........12 Standard set room temperature......... 29 Reduced room temperature Static pressure............. 16, 17 – Raising..............87 Supply pressure............
  • Page 104 Viessmann Climate Solutions SE Viessmann Limited 35108 Allendorf / Germany Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040 E-mail: info-uk@viessmann.com...

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