Viessmann VITOCROSSAL 300 Service Instructions Manual
Type ct3, 187 to 635 kw gas fired condensing boiler
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Also See for VITOCROSSAL 300:
- Service instructions manual (164 pages) ,
- Service instructions for contractors (148 pages) ,
- Service manual (108 pages)
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Summary of Contents for Viessmann VITOCROSSAL 300
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Page 1: Service Instructions
VIESMANN Service instructions for contractors Vitocrossal 300 Type CT3, 187 to 635 kW Gas fired condensing boiler VITOCROSSAL 300 Please keep safe. 5692 405 GB 2/2007... -
Page 2: Safety Instructions
Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained & the Code of Practice of relevant trade associations, Danger & all current safety regulations as This symbol warns against the defined by DIN, EN, DVGW, TRGI, risk of injury. - Page 3 Instal- charge static loads. ling non-authorised compo- nents and non-approved modifications/conversion can compromise safety and may invalidate our warranty. For replacements, use only ori- ginal spare parts from Viessmann or those which are approved by Viessmann.
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Page 4: Table Of Contents
Index Index Commissioning, inspection, maintenance Steps – commissioning, inspection and maintenance ........Further details regarding the individual steps ..........Parts lists ....................20 Commissioning/service reports ............... 28 Specification ..................... 29 Certificates Declaration of conformity ................33 Manufacturer's certificate according to the 1st BImSchV [Germany]..... 34... -
Page 5: Commissioning, Inspection, Maintenance
Commissioning, inspection, maintenance Steps – commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page • 1. Checking the high limit safety cut-out setting ... •... -
Page 6: Commissioning Steps
Commissioning, inspection, maintenance Steps – commissioning, inspection and . . . (cont.) Commissioning steps Inspection steps Maintenance steps Page • 21. Checking the boiler room ventilation • 22. Checking the function of the flue gas system • • 23. Adjusting the burner . -
Page 7: Further Details Regarding The Individual Steps
Commissioning, inspection, maintenance Further details regarding the individual steps Checking the high limit safety cut-out setting The high limit safety cut-out must not Control unit installation and be set higher than 110 °C; if required, service instructions set it to a maximum of 110 °C. Filling the heating system with water and venting the system Record the fill volume, water hard- Please note... -
Page 8: Minimising Pulsation Noise
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 7. Check the function of the neutralis- 8. Check all gaskets/seals and plugs ing system. and retighten, if necessary. Neutralising system operat- Note ing instructions We recommend you check all heat- ing water connections after approx. -
Page 9: Shutting Down The Heating System
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Undo M 10 nut A on lever B of 3. Lock the rotary damper with M 10 rotary damper C. nut. 2. Adjust the lever until all pulsating 4. Readjust the burner, if required. noises have ceased (the lever mir- rors the damper position). -
Page 10: Cleaning The Combustion Chamber And Heating Surfaces
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Clean the inside of the condensate 4. Connect the drain hose to the con- drain with a plastic brush. densate drain and run to a sewer. Cleaning the combustion chamber and heating surfaces Please note 2. -
Page 11: Checking Gaskets And Thermal Insulation Components
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking gaskets and thermal insulation components 1. Check gaskets and the packing 2. Check the thermal insulation com- cord in the boiler door for damage. ponents of the boiler door for possi- ble damage. -
Page 12: Checking The Diaphragm Expansion Vessel And System Pressure
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the diaphragm expansion vessel and system pres- sure Note Observe the diaphragm expansion vessel manufacturer's instructions. Carry out this test on a cold system. Pump controlled pressure maintaining systems Note Carry out all checks in accordance In heating systems with automatic... - Page 13 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Diaphragm expansion vessel 1. Drain the system or close the cap 2. If the inlet pressure of the dia- valve on the diaphragm expansion phragm expansion vessel is lower vessel and reduce the pressure, than the value calculated according until the pressure gauge indicates to the adjacent formula, top up with...
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Page 14: Checking The Flue Gas Header For Soundness
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the flue gas header for soundness 1. Visually inspect the gasket through 2. If required, retighten the gasket at clean-out aperture A on the flue clamping clips B. gas collector. Traces of conden- sate on the outside of the flue gas header indicate a leak. -
Page 15: Cleaning The Sight Glass In The Boiler Door
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Cleaning the sight glass in the boiler door Check gaskets A and hose connec- tion B for leaks. Closing the boiler door 1. Tighten the screws on the boiler 2. Install the gas supply pipe and door evenly and diagonally. -
Page 16: Check The Water Quality
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Check the water quality Enter the volume of top-up water, the water hardness and the pH value in the tables. For water quality requirements, see page 30. Fill water Top-up water Count Total water Date... -
Page 17: Cleaning And Reconnecting The Condensate Drain System
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Total hardness pH value Water treatment Date Feedwater Boiler Boiler Medium Metering water water volume The pH value should be between 8.2 and 9.5. Cleaning and reconnecting the condensate drain system The condensate drain, siphon, neutralising system and all intermediate hoses and pipes are part of the condensate drain system. -
Page 18: Instructing The System User
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. For de-watering, remove drain 5. Connect the line with a U-bend to hose A from the condensate the condensate drain and fill with drain. water or fit a siphon and fill that with water. - Page 19 Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Operating and service documents 1. Complete and detach the customer 2. File all parts lists, operating and registration card: service instructions in the folder & Hand the system user this part and hand this over to the system for safekeeping.
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Page 20: Parts Lists
Parts lists Parts lists When ordering spare parts: 209 Front panel, centre Quote the type and serial no. (see 210 Front panel, bottom type plate) and the item no. of the 211 Back panel, top required part (as per this parts list). 214 Side panel, bottom Obtain standard parts from your local 215 Side panel, top... - Page 21 Parts lists Parts lists (cont.) A Type plate, optionally on the r.h. or l.h. side B Boiler circuit control, see separate parts list C Burner cable, see separate parts list...
- Page 22 Parts lists Parts lists (cont.)
- Page 23 Parts lists Parts lists (cont.)
- Page 24 Parts lists Parts lists (cont.)
- Page 25 Parts lists Parts lists (cont.)
- Page 26 Parts lists Parts lists (cont.)
- Page 27 Parts lists Parts lists (cont.)
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Page 28: Commissioning/Service Reports
Commissioning/service reports Commissioning/service reports Commissioning Service Service date: Service Service Service date: Service Service Service date: Service Service Service date: Service Service Service date:... -
Page 29: Specification
Specification Specification Rated output = 40/30 °C = 80/60 °C Rated thermal load 234.5 297 385.5 Product ID CE-0085 AQ 0257 Flue gas parameters Temperature (at return temp. 30 °C) & at rated output °C & at partial load °C Temperature (at return °C temp. - Page 30 Specification Water quality requirements (cont.) Prevention of damage due to scaling Excessive scale deposits (calcium carbonate) on the heating surfaces should be prevented. For heating systems with operating temperatures up to 100 °C, the VDI Directive 2035 sheet 1 "Prevention of heating system damage – scaling in DHW and hot water heating systems"...
- Page 31 Specification Water quality requirements (cont.) Operating information: & In multi-boiler systems, start all boi- & During expansion or repair work, lers simultaneously to prevent the only drain the necessary pipework entire lime deposit settling in the sections. heat transfer area of just one boiler. &...
- Page 32 Specification Water quality requirements (cont.) Prevention of damage due to corrosion on the water side The corrosion resistance of ferrous The use of permeable components, e. materials on the heating water side of g. plastic pipes that are permeable to heating systems and boilers depends gas in underfloor heating systems, on the absence of oxygen in the heat-...
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Page 33: Certificates
The product characteristics determined as system values for the product Vitocrossal 300 as part of EC type testing according to the Efficiency Directive (see specification table), can be utilised to assess the energy consumption of heating and ventilation equipment to DIN V 4701–10 which is specified by the EnEV [Germany]. -
Page 34: Manufacturer's Certificate According To The 1St Bimschv [Germany]
Certificates Manufacturer's certificate according to the 1st BImSchV [Germany] We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf confirm, that the fol- lowing product exceeds the efficiency of 91 % required by the 1st BImSchV paragraph 7 (3) [Germany] Boiler and burner unit... - Page 36 Viessmann Werke GmbH&Co KG Viessmann Limited D-35107 Allendorf 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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