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Service instructions
for heating engineers
Vitocrossal 300
type CR3, 186 to 311 kW
Gas-fired condensing boiler
VITOCROSSAL 300
Please keep safe
5692 480 GB
9/2002

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Table of Contents
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Summarization of Contents

General Information
General Safety Instructions
Provides essential safety guidelines to prevent accidents and material losses during operation.
Operating and Service Document Management
Details on managing customer registration cards and service documents for user handover.
Initial start-up, inspection and maintenance
Initial Start-up and Maintenance Steps Overview
Outlines sequential steps for initial system start-up, inspection, and maintenance procedures.
High Limit Safety Cut-out Adjustment
Ensures the high limit safety cut-out is set correctly, not exceeding 110°C.
Heating System Filling and Ventilation
Procedure for filling the heating system with water and necessary ventilation steps.
Flue Outlet Damper Operation
Instructions for fully opening the flue outlet damper and securing it in the horizontal position.
System Start-up Procedure
Detailed steps for initiating the system start-up, including checks and switch-on sequence.
Addressing Pulsation Noises
Guidance on identifying and resolving pulsation noises by adjusting the flue outlet damper.
Boiler Door Opening Procedure
Steps for safely opening the boiler door, including gas supply pipe removal.
Neutralising System and Condensate Drain Connection
Procedure for disconnecting the neutralising system and connecting the condensate drain hose.
Combustion Chamber and Heating Surface Cleaning
Instructions for cleaning combustion chamber and heating surfaces using water jets and specific cleaning agents.
Heating Water Connections and Sensor Well Leak Check
Procedure to check heating water connections and sensor well for leaks after system depressurization.
Safety Equipment Function Check
Verifies the proper operation of safety valves, water level, and pressure limiters.
Expansion Vessel and System Pressure Check
Procedure for checking the expansion vessel and system pressure on a cold system.
Diaphragm Expansion Vessel Procedures
Detailed instructions on draining, checking, and refilling diaphragm expansion vessels.
Boiler Door Sight Glass Cleaning
Procedure for cleaning the sight glass in the boiler door and checking associated gaskets.
Boiler Door Closing Procedure
Steps for securely closing the boiler door, including tightening screws and checking gas supply.
Heating Water Quality Check
Guidelines for checking heating water quality and recording fill-up water parameters.
Thermal Insulation Check
Instructions for checking and adjusting the thermal insulation fit if necessary.
Flue Cover Leak Check
Procedure to check flue cover and clean-out cover gaskets for leaks.
Mixer Operation and Leak Check
Steps to ensure the mixer operates smoothly and check for any leaks.
Condensate Drain Cleaning and Reconnection
Procedure for cleaning the condensate drain system and reconnecting it properly.
Burner Adjustment Procedure
Guidance on performing burner adjustment according to the manufacturer's instructions.
Parts lists
Spare Parts List
Lists all available spare parts for the Vitocrossal 300, including item numbers for ordering.
Appendix
Heating Water Quality Requirements
Details essential heating water quality requirements to safeguard warranty rights and prevent corrosion.
Declaration of Conformity
States conformity of the Vitocrossal 300, type CR3, with relevant standards and guidelines.
Manufacturer's Certificate
Confirms product exceeds utilisation ratio requirements for boilers over 400 kW.
Commissioning and Service Report
Provides a template for recording initial start-up and subsequent maintenance/service activities.

Table of Contents