Viessmann Boiler Documentation (Single Fuel CA3B) Vitocrossal 300, CA3B Instructions for use
إعلان
إعلان
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
2
Safety
Safety, Service and Warranty Requirements
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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. Ensure all requirements below are understood and fulfilled (including detailed information found in manual subsections).
Product documentation
Read all applicable documentation before commencing installation. Store documentation near boiler in a
readily accessible location for reference in the future by service personnel.
For a listing of applicable literature,
please see section entitled “Important
Regulatory and Safety Requirements”.
Warranty
Information contained in this and related product documentation must be read and followed. Failure to do so renders the warranty null and void.
Carbon monoxide
Improper installation, adjustment, service and/or maintenance can cause flue products to flow into living space. Flue products contain poisonous carbon
For information pertaining to the proper installation, adjustment, service and maintenance of this equipment to avoid formation of carbon monoxide, please see subsection entitled
“Mechanical room” and “Venting requirements” in this manual.
Licensed professional heating contractor
The installation, adjustment, service and maintenance of this equipment must be performed by a licensed
professional heating contractor.
Please see section entitled
“Important Regulatory and Installation
Requirements”.
Fresh air
This equipment requires fresh air for safe operation and must be installed ensuring provisions for adequate combustion and ventilation air exist.
For information pertaining to the fresh air requirements of this product, please see subsection entitled
“Mechanical room” in this manual.
Contaminated air
Air contaminated by chemicals can cause by-products in the combustion process, which are poisonous to inhabitants and destructive to
For a listing of chemicals which cannot be stored in or near the
boiler room, please see subsection entitled “Mechanical room” in this
manual.
equipment.
Equipment venting
Never operate boiler without an installed venting system. An improper venting system can cause carbon monoxide poisoning.
For information pertaining to
venting please see section entitled “Venting
All products of combustion must be safely vented to the outdoors.
Advice to owner
Once the installation work is complete, the heating contractor must familiarize the system operator/ ultimate owner with all equipment, as well as safety precautions/requirements, shutdown procedure, and the need for professional service annually before the
heating season begins.
WARNING
Installers must follow local regulations with respect to installation of carbon monoxide detectors. Follow the
Viessmann maintenance schedule of the boiler contained in this manual.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Safety, Service and Warranty Requirements
(continued)
Safety
Fiberglass wool and ceramic fiber materials
WARNING
Inhaling of fiberglass wool and/or ceramic fiber materials is a possible cancer hazard. These materials can also cause respiratory, skin and eye irritation.
First aid measures
- If eye contact occurs, flush eyes with water to remove
dust. If symptoms persist, seek medical attention.
- If skin contact occurs, wash affected areas gently
with soap and warm water after handling.
The state of California has listed the airborne fibers of these materials as a possible cancer hazard through inhalation. When handling these materials, special care must be applied.
Suppliers of ceramic fiber products recommend the following first aid measures:
- Respiratory tract (nose and throat) irritation:
If respiratory tract irritation develops, move the
person to a dust free location.
- Eye irritation: If eyes become irritated, flush immediately
with large amounts of lukewarm water for at least 15
minutes. Eyelids should be held away from the eyeball
to ensure thorough rinsing. Do not rub eyes.
- Skin irritation: If skin becomes irritated, remove soiled
clothing. Do not rub or scratch exposed skin.
Wash area of contact thoroughly with soap and cold
water (as warm or hot water may worsen the irritation).
Using a skin cream or lotion after washing may be
helpful.
- Gastrointestinal irritation: If gastrointestinal tract
irritation develops, move the person to a dust free
environment.
Suppliers of fiberglass wool products recommend the following precautions be taken when handling these materials:
- Avoid breathing fiberglass dust and contact with
skin and eyes.
- Use NIOSH approved dust/mist respirator.
- Wear long-sleeved, loose fitting clothing, gloves
and eye protection.
- Wash work clothes separately from other clothing.
Rinse washer thoroughly.
- Operations such as sawing, blowing, tear-out and
spraying may generate airborne fiber concentration
requiring additional protection.
WARNING
Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause serious injury or loss of life and which are known to the State of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby the appliance.
Codes
The installation of this unit shall be in accordance with local codes. In the absence of local codes, use:
CAN/CSA-B149.1 or .2 Installation Codes for Gas Burning
Appliances for Canada. For U.S. installations, use the
National Fuel Gas Code ANSI Z223.1. Always use latest editions of codes.
In Canada all electrical wiring is to be done in accordance with the latest edition of CSA C22.1 Part 1 and/or local codes. In the U.S., use the National Electrical Code ANSI/
NFPA 70.
The heating contractor must also comply with the Standard for Controls and Safety Devices for Automatically Fired
Boilers, ANSI/ASME CSD-1 where required by the authority having jurisdiction.
Mechanical room
Viessmann recommends installation of an additional electrical disconnect switch and a fuel shut-off valve (if possible) outside the mechanical room or enclosed area of installation.
The maximum room temperature of the mechanical room where the boiler is located must not exceed 104°F (40°C).
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4
Table of Contents
Safety
General Information
General Service Information
Commissioning
Operating
Service
Vitocrossal 300 CA3B - 3.5, 4.0, 5.0 and 6.0 Service
Page
Safety, Service and Warranty Requirements .................
2
About these Instructions .............................................
6
Product Information ....................................................
6
Service Equipment ......................................................
7
Important Regulatory Requirements ..............................
8
Safety Instructions ..................................................
9
Commissioning the System .....................................
11
Removing the Boiler Panels .....................................
11
Filling Condensate Trap with Water ..........................
11
Filling the Heating System with Water and Ventilating ..
12
Checking the Water Conditions ..................................
13
Checking Static and Connection Pressure ....................
15
Checking Heating Water Connections for Leakage .......
16
Checking for Flue Gas Leakage ..................................
16
Checking On-site Gas Connections for Leakage ............
17
Instructing the Operator of the System .......................
17
Operating and Service Documents ..............................
17
Operating the Burner Control Unit ...............................
18
Burner Control Unit ..................................................
20
Resetting Operating Parameters to Factory Settings ......
24
Manual Mode and Service Display ..............................
24
Burner Control Unit Flow Diagram ..............................
25
Burner Control Unit Faults .........................................
27
Burner Control Unit Fault Codes .................................
28
Burner Control Unit Faults Without Fault Display ..........
31
Operating the System ...............................................
32
Integrating the Control Unit into the LON.....................
34
Adjusting the Heating Curve ......................................
36
Boiler Water Temperature Control ...............................
38
Heating Circuit Control ............................................
39
DHW Tank Temperature Control .................................
43
Setting the Boiler Sequence (burner sequence) .............
45
Cascade Control Unit ...............................................
45
Installing the Boiler Panels ........................................
49
Turning the System Off .............................................
49
Preparing for Service Work ........................................
50
Burner Parts ...........................................................
52
Burner Interface Panel ...............................................
53
Display and Programming Unit of Burner Control Unit ...
54
Coding Card on Burner Control Unit ...........................
54
Burner Control Unit ..................................................
55
Fuel Conversion NG to LPG .......................................
55
Boiler Water Temperature Sensor ...............................
56
3A and 3B Boiler Temperature Sensor Description .......
57
Boiler Secondary Temperature Sensor .........................
58
Manual Reset Limits .................................................
59
Gas Valve ...............................................................
60
Air Pressure Switches ............................................
61
Ignition Unit ............................................................
63
Ignition Cables .........................................................
63
Rotary Damper and Servomotor .................................
64
Replacing the Solenoid Valve .....................................
65
Fan .........................................................................
65
Checking the Rotary Damper Setting ..........................
66
Measuring CO
2
Content ............................................
67
Displaying Ionization Current ....................................
69
Dismantling the Burner........................................
70
Checking and Cleaning the Burner Tube ......................
72
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Service
(continued)
Coding Levels
Coding Level 1
Coding Level 2
Service Scans
Troubleshooting
Connection and Wiring Diagrams
Parts
Specifications
Inspection and Maintenance
Table of Contents
Page
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
Taking Final Measurement Reading ............................
75
Checking Expansion Tank and System Pressure ..........
76
Mixing Valve Movement and Leak Check .....................
76
Checking Air Intake in the Installation Room (visual check) .
76
Sensors ................................................................
77
Cleaning of Condensate Drainage System ..................
78
Replacing the Supply Air Filter (for room air dependant operation) .............................................................
79
Calling up Coding Levels .......................................
80
Resetting Coding to their Factory Set Condition ...........
80
“General” Group .......................................................
81
“Combustion Controller” Group ..................................
83
“Boiler” Group .........................................................
83
“Cascade” Group ...................................................
84
“DHW” Group ..........................................................
86
“Solar” Group ....................................................
87
“Heating Circuit...” Group.........................................
88
“General” Group .......................................................
92
“Combustion Controller” Group ................................
100
“Boiler” Group .......................................................
101
“Cascade” Group ..................................................
101
“DHW” Group ........................................................
104
“Solar” Group ..................................................
106
“Heating Circuit...” Group.......................................
110
Calling up the Service Menu ...................................
116
Leaving the Service Menu .......................................
117
Change Passwords .................................................
117
Resetting all Passwords to Factory Settings .............
117
Scanning Operating Data ........................................
117
Resetting Operating Data .......................................
117
Brief Scan .............................................................
118
Carrying Out an Actuator Test ................................
119
Checking Sensors ...................................................
120
Maintenance Display ...............................................
120
Fault Display ..........................................................
121
Boiler System Fault Codes ........................................ 122
Burner Fault Codes ................................................
128
Burner Control unit Connection Diagram ....................
131
Boiler Connections ..................................................
132
Overview ..............................................................
134
PCB Extention for Heating Circuits 2 and 3 with
Mixing Valve .........................................................
135
PCB, Low Voltage ..................................................
135
PCB 120V~ ..........................................................
136
Parts Lists ...........................................................
137
Technical Data .......................................................
159
Requirements for Water Conditions ...........................
161
Maintenance Record ............................................
162
Maintenance Schedule ............................................
162
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6
General Information
About these Instructions
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include “WARNING”, “CAUTION”, and “IMPORTANT”. See below.
Warnings draw your attention to the presence of
potential hazards or important product information.
WARNING
Indicates an imminently hazardous situation which, if not avoided, could result in death, serious injury or substantial product/property damage.
CAUTION
Indicates an imminently hazardous situation which, if not avoided, may result in minor injury or product/ property damage.
Cautions draw your attention to the presence of
potential hazards or important product information.
IMPORTANT
Helpful hints for installation, operation or maintenance
which pertain to the product.
This symbol indicates that additional, pertinent
information is to be found.
This symbol indicates that other instructions must referenced.
Product Information
High efficiency gas-fired hot water condensing boiler.
For operation with modulating boiler water temperatures in closed loop, forced circulation hot water heating systems.
The Vitocrossal 300, CA3B boilers are CSA certified with
Viessmann burners which must be used in conjunction with this boiler series.
The proper burner size must be verified and the burners are factory adjusted so that the maximum input of the appropriate boiler size is always observed. The gas burners must always be installed according to the instructions provided by the burner manufacturer.
The boiler model selected should be based on an accurate heat loss calculation of the building. The boiler selected must be compatible with the connected radiation.
The Vitocrossal 300, CA3B boiler is suitable for a maximum operating pressure of 160 psig and a maximum boiler water temperature of 210°F (99°C).
This boiler does not require a flow switch.
WARNING
Exposing the boiler to pressures and temperatures in excess of those listed will result in damages, and will render warranty null and void.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Service Equipment
General Service Information
Tools
Assortment of flathead and Phillips screwdrivers
Pipe wrenches
Open-ended wrenches
Pipe sealant
Assortment of Hex keys
Flashlight
Approved leak detection fluid for natural gas and gas
Cleaning supplies
Plastic hand brush
Cleaning/service brush
Vacuum cleaner
Clean rags
Testing/analysis equipment
(use only calibrated equipment)
Flue gas analyzer to measure % CO
2
or O
2
(e.g. Bacharach fluid samplers or a suitable electronic
analyzer).
Multimeter to measure 0-120VAC, 0-25 amps AC and 0-100 microamps DC.
Pressure gage to measure gas pressure 0 - 28 "w.c.
A non-electric Magnehelic pressure gage (0 - 10 psig) may also be used.
Carbon monoxide measuring equipment (0 - 400 ppm).
Bacharach calculator or suitable tables to calculate
efficiency.
Stack thermometer dial settings range 0ºF to 250ºF
(0ºC to 121ºC).
d in. NPT male to ¼ in. barb adaptor fitting, as well as tubing for pressure measurement.
Technical information
The following is a list of literature applicable to the
Vitocrossal 300, CA3B boiler:
Installation Instructions
Service Instructions
Operating Instructions
Technical Data Manual
Wiring diagrams
For installation of the heating system, please refer also to the technical literature of other Viessmann System
Technology devices:
Installation Instructions for accessories
Installation Instructions for Viessmann indirect-fired hot water storage tank(s)
Replacement parts
For a complete listing of replacement components, please see Parts List starting on page 137 of these instructions.
Order replacement components from your Viessmann distributor.
CAUTION
Use only original Viessmann recommended components when replacing defective parts. Installation of incorrect replacement parts can cause hazardous operation and will void warranty.
7
8
General Service Information
Important Regulatory Requirements
Instructing the system user
The installer of the system is responsible to ensure the system operator/ultimate owner is made familiar with the functioning of the system, its activation, and its shutdown.
Initial start-up
Initial start-up must be performed by a qualified heating contractor. Completion of the Maintenance Record by the heating contractor is also required.
Working on the equipment
The installation, adjustment, service, and maintenance of this equipment must be done by a licensed professional heating contractor who is qualified and experienced in the installation, service, and maintenance of hot water heating systems. There are no user serviceable parts on this equipment.
Ensure main power supply to equipment, the heating system, and all external controls has been deactivated.
Close main gas supply valve. Take precautions in all instances to avoid accidental activation of power during service work.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
The following topics must be covered:
Proper system operation sequence. Explain the equipment as well as the need for combustion air.
Demonstrate an emergency shut-down, what to
do and what not.
Explain that there is no substitute for proper
maintenance to help ensure safe operation.
The Maintenance Record is located on page 162 of manual.
start-up, maintenance or service. Any warranty is null and void if these instructions are not followed.
For information regarding other Viessmann System
Technology componentry, please reference documentation of the respective product.
Viessmann offers frequent installation and service seminars to familiarize our partners with our products.
Please inquire.
The completeness and functionality of field supplied electrical controls and components must be verified by the heating contractor. These include low water cut-offs, flow switches (if used), staging controls, pumps, motorized valves, air vents, thermostats, etc.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Safety Instructions
General Service Information
Target group
These instructions are intended exclusively for qualified contractors.
■ Work on gas installations must only be carried out
by a licensed professional heating contractor.
■ Work on electrical equipment must only be carried
out by a qualified electrician.
■ The system must be commissioned by the system
installer or a qualified person authorised by the installer.
■ This appliance has not been designed to be operated
by individuals other than those qualified and trained.
Regulations
Observe the following when working on this system:
■ Statutory regulations regarding the prevention of accidents
■ Statutory regulations regarding environmental protection
■ Codes of practice of the relevant trade associations.
If you smell gas
WARNING
Escaping gas can lead to explosions which may result in serious injury.
■ Do not smoke. Prevent naked flames and sparks. Do
not press any switches for lights or electrical appliances.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Remove all people from the danger zone.
■ Notify your gas or electricity supply utility from outside
the building.
■ Shut off the electricity supply to the building from a
safe place (outside the building).
If you smell flue gas
WARNING
Flue gas can lead to life threatening poisoning.
■ Shut down the heating system.
■ Ventilate boiler room.
■ Close all doors in the living space
Working on the system
■ Where gas is used as the fuel, close the main gas
shut-off valve and safeguard it against unintentional
reopening.
■ Isolate the system from the power supply (e.g. at the
separate fuse or a main switch) and check that it is
de-energized.
■ Safeguard the system against reconnection.
Note: Electronic assemblies can be damaged by electrostatic discharges. Before beginning work, touch grounded objects, such as heating or water pipes, to discharge static loads.
Repair work
Note: Repairing components that fulfil a safety function can compromise the safe operation of your system.
Replace faulty components only with original
Viessmann spare parts.
Auxiliary components, spare and wearing parts
Spare and wearing parts that have not been tested together with the system can compromise its function.
Installing non-authorized components and making non-approved modifications or conversions can compromise safety and may invalidate our warranty.
For replacements, use only original spare parts supplied or approved by Viessmann.
9
10
General Service Information
Safety Instructions
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Checking the high limit safety cut-out setting
The high limit safety cut-out is preset to 210°F (99°C).
If this temperature needs to be changed, this can only be done by changing the coding card.
Refer to the control section of the Installation
Instructions.
CSD-1 Field Testing of High Limit Switches for Vitocrossal
300, CA3B boilers – where required by law.
As per ASME Boiler and Pressure Vessel Code, section IV, subsection HG-613 TEMPERATURE CONTROL requirements, Vitocrossal 300, CA3B hot water boilers are protected from over-temperature by two temperatureoperated controls. These temperature control devices conform to Standards for Limit Controls, and are accepted by CSA, a nationally recognized testing agency.
Each boiler is equipped with a manual reset high temperature limit control and a temperature control that will cut off fuel supply when the system water temperature reaches a preset operating temperature.
VIESSMANN IS NOT RESPONSIBLE FOR ANY DAMAGES
THAT THE FOLLOWING TEST PROCEDURE MAY RESULT
IN BY OVERHEATING THE SYSTEM.
The Vitocrossal 300, CA3B boilers are equipped with 2
RTD temperature sensors (per boiler section) that when activated on temperature rise (high fixed limit of 210°F
(99°C) disable the burners to operate.
The fixed high limit, when tripped, produces a fault that will require manual reset of the boiler control.
Note: Each boiler section is equipped with its own fixed high limit. Each fixed high limit must be tested individually.
Fixed High Limit test procedure:
1. Use the emission test switch on each boiler section to generate call for heat.
Refer to Vitocrossal 300 CA3B Operating
Instructions.
2. As described in the table on page 23, adjust item #4 boiler water temperature” under menu 6 of each
burner control (GC310) to a max. setting of 243°F
(117°C), as an example, higher than fixed high limit temperature setting [factory default setting is 203°F
(95°C)].
For testing of the adjustable limit ‘Max. boiler temperature’ for a reduced temp. value as required
[e.g. 122°F (50°C)].
3. Press/activate emission test switch of the applicable boiler section, the burner will start.
4. Gradually and slowly throttle the water flow to the
boiler.
5. Observe temperature on the relative GW6C service
display.
6. Once the temperature reached the fixed high limit setting, burner control will have a hard lock out with
F F2 fault displayed. Burner fan stays on for 10 min.
The fault can only be manually reset once the water temperature in the boiler drops.
7. Reset to original settings as needed (item #4 under
5
6
Menu item “6“ is used to change the following operating parameters: (refer to page 23 for more detail)
Sub-menu
Item
3
4
1
2
Parameter
Maximum operational input
Gas type
Not assigned
Maximum boiler water temperature
Units/Scale
% of rated input
0=NG (natural gas)
1=LPG (liquid propane gas)
-from 41°F to 260°F (5°C to 127°C)
Factory set condition
100%
0
--
203°F (95°C)
Integral threshold value of controller
Runtime optimization
In Kmin from 1 to 255
0=minimum pause
1=integral method
30 Kmin
1
0 Reset all operating parameters to their factory set condition.
---
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Commissioning the System
Commissioning
WARNING
CO build-up as a result of incorrect burner adjustment can have serious health implications. Always carry out a CO test before and after work on gas appliances.
Leak test
Gaskets on the burner plate and components routing flue gas can be checked during operation with an inspection mirror.
If required, remove the thermal insulation components.
Condensate traces on the outside of the flue gas collector or on thermal insulation components also indicate leaks.
Note: The burner adjustment has to be checked with the
boiler heated to operating temperature (min. 40°C).
Perform checks in the partial load range as well.
1. Check the heating system pressure.
Maximum operating pressure: .............. 160 psi (11 bar)
Minimum operating pressure: ..................8 psi (0.6 bar)
2. For room air dependant operation:
Check that the ventilation facility in the installation room is open.
3. Check the gas supply pressure (for set value refer to
15).
4. Open the gas line shut-off valves.
5. Check the function of the neutralising system (if installed), including the hydraulic seal in the trap.
Refer to the control Instructions and
Neutralizing system Operating Instructions.
6. Check all gaskets and plugs, and retighten if necessary.
Note: Check all connections on the heating water side
for leaks approx. every 500 operating hours.
7. Switch ON the mains isolator (outside the installation
room).
8. Start the control unit.
Removing the Boiler Panels
1. Remove the screws from the right side of the top panels.
2. Lift and remove the top right side panels.
3. Slide the top panels toward the right side and remove.
4. Lift and remove the top left side panels.
5. Lift and remove the bottom left side panels.
6. Tilt forward, lift and remove lower front panel.
7. Remove the screws from the lower front cover plate
and remove plate.
8. Lift and remove the top front panel (for CA3B 5.0 and
9. Remove the screws from the top front cover plate and
remove plate (for CA3B 5.0 and 6.0 only).
Filling Condensate Trap with Water
1. Remove the siphon cup A and fill with water
(otherwise flue gas may escape).
2. Check that the condensate can drain freely.
3. Refit the siphon cup A .
Note: The hose connection to the on-site condensate
system or to the neutralizing system must not
be permitted to sag; support hose where required.
11
12
Commissioning
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Filling the Heating System with Water and Ventilating
Installing the isolation valve handle
Remove the isolation valve handle A from the accessory pack and insert it into the receiver handle B of the isolation valve until it locks into place. Repeat for all valves.
Note: The handle is only used for initial installation and for service. The handle must be removed prior to putting the boiler into operation.
Note: Store the handle in a safe place for future use.
To open valve
Valve closed
IMPORTANT
See page 13 for water quality requirements.
1. Fill Vitocrossal 300, CA3B with fully softened water.
2. Enter the fill quantity, water softness and pH-value in the chart provided on page 161.
3. Before filling push the actuator release button and open each isolation valve (located near the return header of each boiler section).
4. When fill is complete push the actuator release button and close each isolation valve (located near the return header of each boiler section).
To close valve
Valve open
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Checking the Water Conditions
Commissioning
Water Quality
The lifetime of the entire heating system is influenced by the water quality. A water treatment system will protect against damages caused by corrosion and lime formation.
Hard water conditions (i.e. calcium carbonate) must be avoided as it will cause deposits to accumulate on the heat exchanger surfaces.
If in any doubt about the water quality, please have a proper water analysis done. Check with regional chemical suppliers for boiler water treatment or with Viessmann
Manufacturing Company Inc. directly.
Total output (MBH) Total Hardness (ppm of CaCO
3
)
> 2050 <150
The pH value of the heating water should be between 8.2 and 9.5
Only fill the boiler with water that conforms with water quality guidelines of VDI 2035-1.
IMPORTANT
Fill Vitocrossal 300 CA3B with fully softened water only!
Water quality requirements
Note: Observing the following requirements is necessary to safeguard your warranty rights. The warranty excludes damage due to corrosion and scaling.
The standard values assume the following:
The total volume of fill and top-up water during its service life will not exceed three times the water content of the heating system.
Soften the fill and top-up water in heating systems operating under the following conditions:
The total of alkaline earths in the fill and top-up water exceeds the standard value.
Higher fill and top-up water volumes are expected.
In systems > 170 MBH (50 kW), install a water meter to capture the amount of fill and top-up water.
Enter the volume of fill water and the water hardness into the boiler maintenance checklists.
Operating information:
During expansion or repair work, only drain the pipework sections which are crucial.
Check, clean and activate filters, dirt traps and other 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. water softening).
If the heating system is filled with fully softened water, no other measures for start-up are required.
If the heating system is not filled with fully softened water but with water which fulfils the requirements given in the table above, the following should also be considered for commissioning:
Start the system step by step with a high heating water flow rate, starting with the lowest boiler output. This prevents localized concentration of lime scale deposits on the boiler heating surfaces.
In multiple boiler systems, start all boilers simultaneously to prevent the entire lime scale deposit settling in the heat exchanger of just one boiler.
Where water treatment is required, treat the first fill of the heating system prior to start-up. This also applies to any subsequent filling, e.g. when adding top-up water or after a repair, or for any system
expansion.
The build-up of lime scale deposits on the heating surfaces will be minimised if these instructions are
followed.
13
14
Commissioning
Checking the Water Conditions
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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 installations – Scale formation in domestic hot water supply installations and water heating installations” applies together with the following standard values.
See the explanations in the original text of the Guideline.
Avoiding damage caused by water corrosion
The corrosion-resistance on the heating-water side of ferrous materials used in heating systems and heat generators depends on the absence of oxygen in the heating water. The oxygen that enters the heating system upon initial and subsequent filling reacts with the system materials without causing damage.
The characteristic blackening of the water after a certain operating time is a sign that there is no longer any free oxygen.
During operation, oxygen can enter due to:
Open vented expansion vessels due to flow through
Negative pressure in the system
Through permeable components
Correctly sized sealed unvented systems operating at the correct pressure, e.g. systems with expansion vessel, offer good protection against the ingress of airborne oxygen. The pressure must be above the pressure of the ambient atmosphere at all times during operation and at every point in the heating system, including the suction side of the pump. Check the precharge pressure of the expansion vessel at least during the annual service.
Avoid the use of components permeable to gas, e.g. permeable plastic pipes in underfloor heating systems.
If they are used, system separation should be provided.
This system separation must separate the water flowing through the plastic pipes from other heating circuits,e.g. from the boiler, by the provision of a corrosion resistant heat exchanger. No other protective measures against corrosion are necessary in corrosion-resistant closed hot water heating systems in which the previous points have been taken into account. However, take additional precautions where there is a risk of oxygen ingress, for example by adding oxygen binder sodium sulphite
5 to 10 ppm (5 to 10 mg/L) into the excess. The pH value of the heating water should be 8.2–9.5.
Different conditions apply to systems that contain aluminium components.
Where chemicals are used as part of the corrosion protection, we recommend that the manufacturer of the chemicals issues a certificate of suitability of the additives with regard to the boiler materials and the materials of other components. Please refer questions regarding water treatment to an appropriate contractor.
Further details can be found in the VDI guideline
2035-2 and EN 14868.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Checking Static and Connection Pressure
Commissioning
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 .
4. Open gas shut-off valve.
5. Measure static pressure max. 14 “w.c.
6. Record measurement reading in the maintenance record
(on page 162).
IMPORTANT
The burner is automatically ignited and starts operation after a safety time has elapsed.
During initial start-up, the unit may indicate a fault because of air in the gas supply pipe.
After approximately 5 seconds, press the reset button R to reset the burner. The ignition procedure is repeated.
This boiler employs a direct spark ignition system.
WARNING
Never purge a gas line into a combustion chamber. Never use matches, candles, flame, or other sources of ignition for purpose of checking leakage. Use a soap-and-water solution to check for leakage. Failure to follow this warning could result in fire, explosion, personal injury, or death.
IMPORTANT
A CO
2
measurement (see page 67) must be taken before and after working on gas appliances to eliminate risks to health and to guarantee the satisfactory condition of the system.
Supply pressure for NG/LPG
1.
Start the burner.
Note: Switch the burner to maximum heating output.
For this, activate the emissions test switch at the
boiler control unit.
2. Measure the supply pressure (running pressure).
Use suitable measuring instruments calibrated with a minimum resolution of 0.04 “w.c. Value must be as per the chart below:
Note: The supply pressure should be between 4 “w.c. and 14 ”w.c. for NG and 10” w.c. to 14” w.c. for LPG. The gas pressure switch for the inlet pressure test/check is factory set to 4 ”w.c.
Never alter this setting.
3. Record the actual value in the maintenance record
(on page 162).
4. Close the gas shut-off valve.
5. Remove the pressure tester and close test nipple A .
WARNING
Ensure that there is no open flame in the room.
Supply pressure with:
Natural gas Liquid propane gas under 4 ”w.c.
4 to 14 “w.c.
under 10 ”w.c.
10 to 14 ”w.c. over 14 ”w.c
over 14 ”w.c.
Corrective action
Do not attempt adjustment. Call local gas utility
Start up boiler.
Do not attempt adjustment. Call local gas utility to decrease pressure.
Boiler valve must not be exposed to pressure over 14 ”w.c.
15
16
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. Only empty boiler with open ventilation with a suction pump.
IMPORTANT
Ensure that connections for control equipment and minimum pressure monitor (low-water indicator) are also leakage-free.
Checking for Flue Gas Leakage
CAUTION
Failure to ensure that all flue gases have been safely vented to the outdoors can cause property damage, severe personal injury or loss of life. Flue gases may contain deadly carbon monoxide.
Check flue gas collector and boiler body for leakage.
IMPORTANT
Gaskets can be checked with a dew point hygrometer at full load operation. Detach thermal insulation parts if necessary. Traces of condensed water on the exterior of the glue gas collector or on the thermal insulation parts also indicate leakages.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Checking On-site Gas Connections for Leakage
Commissioning
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. Leak detection spray must not come into contact with electrical contacts.
1. Insert and tighten new gaskets at all detached on-site connections.
2. Open gas shut-off valve.
3. Check sealing points at input side of the combination gas valve for leakage.
4. Put boiler into operation (refer to page 18).
5. Check output-side sealing points of combination gas valve, sealing points between fan and burner plate and sealing points between fan and Venturi-tube for leakage.
Instructing the Operator of the System
The system manufacturer must hand over the operating instructions to the system operator and instruct him in its operation.
This includes all accessories that have been installed as components, such as remote controls. The system manufacturer must also provide instruction regarding maintenance work.
Operating and Service Documents
1.
Complete customer information file and separate:
Hand over segment for system operator to system
operator.
Retain segment for heating contractor in files.
2.
Assemble all parts lists, operating and service instructions in a file and deliver to the system operator.
After installation, the installation instructions will no longer be required and do not need to be retained.
17
18
Operating
Operating the Burner Control Unit
WARNING
Failure to ensure that all flue gases have been safely vented to the outdoors can cause property damage, severe personal injury, or loss of life. Flue gases may contain deadly carbon monoxide.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
See the neutralizing system instructions.
1. Check the heating system pressure.
Max. permissible boiler operating pressure: .... 160 psi.
Min. permissible boiler operating pressure: .........8 psi.
2. Check the gas supply pressure. Permissible gas pressure 4-14 “w.c. (NG) and 10-14 “w.c. (LPG).
3. Open the gas line shut-off valves.
4. Switch ON the internal power disconnect switch.
5. Switch ON the main power (breakers).
6. Switch ON system ON/OFF switch at the control unit.
If fault indicator on the control unit illuminates and burner control unit display A flashes, first press
reset R B on the burner control unit.
Note: The system can enter a fault state during commissioning if there is insufficient gas in the supply line (the fault indicator on the control unit illuminates). Purge the gas supply line again and reset the burner control unit.
Remove air from the gas line with an approved gas purge burner or vent outdoors.
7. Switch ON the individual section control power switches (the control display will show system
activation).
8. Match the coding card at the burner control unit, refer to page 55.
9. Check the function of the neutralizing system.
Note: Neutralizing system operating instructions.
See the control section of the Installation
Instructions and neutralizing system
Instructions.
10. Check all gaskets and plugs, and retighten if necessary.
Note: We recommend you check all connections on the heating water side for leaks after approximately
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.
Liquid Propane Gas Natural Gas
Heating value
(gross) Btu/ft 3 970 to 1100
Specific gravity 0.57 to 0.70
Ultimate carbon dioxide (CO
2
) % 11.7 to 12.2
2466 to 2542
1.522 to 1.574
13.73 to 13.82
1. The burners are factory set for operation with
natural gas.
2. Record gas type in the maintenance record on page 162.
Note: To change gas type refer to page 55.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Operating the Burner Control Unit
(continued)
Operating
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.
If required, the maximum heating output of the burners can be set at 70% to 100% of the rated heating output.
1. Press button S E for longer than 2 sec. will blink.
2. Press button F until “6” appears in the display C
under Service.
3. Press button S E , “6” appears in the display C
under Status.
4. Press button S E , “1” appears in the display C
under Status and the actual value for the maximum
heating output will be indicated in % under Service.
5. Press button F or D for the desired maximum
heating output.
6. Press button S E to confirm. If successfully completed, “1” appears in the display C under
Service, a failed attempt results in a “0”.
7. Press button S E to make a change in operating
status indicator.
8. Press button R G . A system reboot will be initiated.
19
20
Operating
Burner Control Unit
Display and programming unit
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.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Standby
Idle state check
System tests
Fan ramp-up
The display comprises four elements of seven segments each. Four buttons enable adjustments to be made at the different operating levels.
A Status display
B Service display
C Reset button
D LEDs, from left: heat demand, flame,
F Selection button
E / G Cursor button
Operating display
In standard mode, the status display shows the current operating conditions. The same applies in a fault state after pressing reset button R C .
The following displays are scrolled through automatically.
In case of faults, see the fault codes starting at page 28.
You can exit at any time by pressing and holding the reset button R C for 0.5 to 10 seconds.
Section start-up after power supply is switched ON.
Gas valve and/or relay test
Pre-purge
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Burner Control Unit
(continued)
Operating display (continued)
Pre-ignition
Ignition
Safety time
Flame established
Flame stabilization
Operation with flame
Reheat
Post-purge
Operating
Maintenance program no air pressure
Maintenance program no gas pressure or mains under voltage
Forced ventilation when no flame was recognized
Safety shutdown due to flame tear-off
Safety shutdown due to reaching maximum boiler water temperature
21
22
Operating
Burner Control Unit
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
You can scroll through the menu items with
Y / B buttons .
A menu item is selected by pressing button S again and will be displayed under Service.
This mode is automatically terminated if no other button is pressed within 20 secs.
Information regarding current meter readings, such as the start counter and permanent hours run meter, can be called up via the information display.
Information
Menu item Description
1
2
Continuous meters for start-ups and hours run
Meters for start-ups and hours run that can be reset
3
4
Software version
Fault history for the last 10 fault codes
Example: to delete the hours run meter, press the following buttons:
1. S longer than 2 seconds “ “ flashes
2. Y until “2“ is shown under Service.
3. S “1“ will be displayed under Status
4. Y Scroll through Status until “6“ is shown under
Status:
Status Description
1 Display of start-up meter with reset, 1 digit
2
3
4
5
6
Display of start-up meter with reset, 1000 digit
Menu item for deleting the start-up meter reading
Display of hours run meter with reset, 1 digit
Display of hours run meter with reset, 1000 digit
Menu item for deleting the hours run meter reading
5. S to confirm the deletion. If deleted successfully, “1“
will be shown under Service, “ 0“ if it failed.
6. S to change to the operating display.
Menu items “ 5“ and “ 6“ are used to adjust configuration settings of the burner control unit.
Note: Only make adjustments when the burner control
unit is on standby.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Burner Control Unit
(continued)
Operating
Configurations:
Menu item Description
5 Changeover from the operating display of the burner control unit phase to other process information
6 Configuration of control function operating parameters
Menu item “5“ is used to display the following process information:
Sub-menu Item
0
1
2
Process Information
Phase
Boiler water temperature
Secondary boiler water temperature
6
7
8
3
4
5
9
A
B
Ionization current
Set speed
PWM actuating variable
Actual speed
Gas pressure switch 1, GDW1
Gas pressure switch 2, GDW2
Air pressure switch 1, LDW1
Gas valve 1
Gas valve 2
Units/Scale
1
°C
°C
I in 1/10 μ A
%
%
RPM x10/min
0 or 1
0 or 1
0 or 1
0 or 1
0 or 1
Example: to display the ionization current, press the following buttons:
1. S longer than 2 seconds “ “ flashes.
2. Y until “5“ is shown under Service.
3. S “5“ will be displayed under Status
4. Y until “3“ is shown under Service.
5. S “3“ is shown under Status and during operation
the ionization current is shown under Service
(e.g. 30 = 3.0 μ A).
6. To exit the process information menu, press and
7.
Y
S longer than 2 seconds “_“ flashes.
until “5“ is shown under Service.
8. S “5“ will be displayed under Status
9.
B until “0“ is shown under Service.
10. S to change to the operating display.
Menu item “6“ is used to change the following operating parameters:
Sub-menu
Item
1
2
Parameter
Maximum operational input
Gas type
Units/Scale
% of rated input
0=NG (natural gas)
1=LPG (liquid propane gas)
3
4
5
6
7
8
0
Not assigned
Maximum boiler water temperature
Integral threshold value of controller
Runtime optimization
Not assigned
Behavior in case of low gas level
Reset all operating parameters to their factory set condition.
-from 41°F to 260°F (5°C to 127°C)
In K min from 1 to 255
0=minimum pause
1=integral method
--
0=delayed lockout fault shutdown
1= delayed safety shutdown
--
Factory set condition
100%
Coding card dependent
--
203°F (95°C)
30 K min
1
--
0
--
23
24
Operating
Burner Control Unit
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Example: to set the maximum operational burner input to between 0 and 100%, press the following buttons:
1. S longer than 2 seconds “ “ flashes.
2. Y until “6“ is shown under Service.
3. S “6“ will be displayed under Status.
4. S “1” will be shown under Status and the current value for the maximum operational output in % is shown under Service.
5. Y / B for required maximum operational output.
Note: Observe the modulation range (refer to page 67).
6. S to confirm. If applied successfully, “1“ will be
shown under Service, “0“ if it failed.
7. S to change to the operating display.
Resetting Operating Parameters to Factory Settings
To reset all operating parameters to factory settings, press the following buttons:
1. S longer than 2 seconds “ “ flashes.
2. Y until “6“ is shown under Service.
3. S “6“ will be displayed under Status.
4.
Y until “0“ is shown under Service.
5. S “1“ is shown under Status and “dEL“ under Service.
6. S to confirm. If reset successfully, “1“ will be shown
under Service, “0“ if it failed.
7. S to change to the operating display.
Manual Mode and Service Display
The burner must be running to call up the service display and for manual mode. The service display shows the current level of modulation in %.
Press the following buttons:
1.
B
/ S together for longer than 2 seconds. The burner changes to manual mode, a “P“ will be shown under
Status and the current modulation level will flash
2.
B
for lower heating output, until “0“ is shown under
Service.
3. Y for upper heating output, until “100“ is shown
Service.
4.
B
/ S together for longer than 2 seconds. The burner returns to modulating mode.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Burner Control Unit Flow Diagram
Wait state parameterization of the valve test.
Subsequent state depends on the
Operating
Air pressure switch 1 LDW1 Gas pressure switch 1 GDW1 Air pressure switch 2 LDW2
Input evaluation
Auxiliary valve/ Servomotor
Output activation
25
26
Operating
Burner Control Unit Flow Diagram
(continued)
State description:
Phase Display
System start “A”
Relay test
Standby
Start-up
Operation
Shutdown
”P“
”0“
”1“
“2“
“3”
“4”
“5”
“6”
“7”
“8”
Waiting
Fault states
”U“
”C“
“9”
“10”
“11”
“F”
Adjusting shutdown load
Reheat, test WD2
Fan ramp-up, post-purge
Post-purge
Waiting for restart
Waiting mains, gas pressure
Forced ventilation fault
Flame tear-off
Safety shutdown
Fault shutdown
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Description
System start
Fan ramp-up, system start
Forced ventilation, system start
Fan ramp-up for valve test
Safety relay test
Relay/valve test V1
Test time V1
Relay/valve test V2
Test time V2
Start-up meter, initialization
Standby
Flame signal amplifier, test
Gas fan, air pressure switch and boiler water temperature sensor test
Fan ramp-up
Pre-purge
Adjusting start-up load, test WD1
Pre-ignition
Ignition safety time
Flame detection safety time
Flame stabilizing time
Start-up partial load
Modulating operation
Duration
10 seconds max. 20 seconds
20 seconds max. 20 seconds
0.9 second
2 seconds
1.1 seconds
2 seconds
1.1 seconds
0.1 second
0 ... seconds max. 50 seconds max. 20 seconds max. 20 seconds
10 seconds
1.9 seconds
2 seconds
2.3 seconds max. 0.51 second
15 seconds
20 seconds
0 to 24 hours (burner will restart after 24 hours of continuous operation)
0.1 seconds min. 10 seconds max. 60 seconds max. 20 seconds
10 seconds
5 minutes
5 minutes
20 seconds
0 ... seconds
0 ... seconds
0 ... seconds
Operating
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Burner Control Unit Faults
Fault display
The fault display is activated automatically if the burner control unit switches to a fault state. The most recent fault will then be displayed. The fault LED is also illuminated in case of a non-lockout shutdown or flashes together with the fault code in case of a lockout shutdown. Fault codes are also displayed on the boiler section service display.
A
F b
A
Fault code of the most recent fault (refer to table starting at page 28).
1. Correct the fault. For fault codes and measures (refer to
2. Press reset button R for longer than 0.5 seconds
The operating display is shown again and the burner
control unit is reset.
Fault memory
The ten most recent faults are saved and may be called up.
The order of scans ranges from the most recent to the earlier fault codes. The fault memory display is terminated automatically if no key is pressed within 20 seconds.
Note: If the burner does not start up due to a non-lockout fault without displaying a fault code, the fault memory may be able to indicate the cause.
To call up the fault codes, press the following buttons:
1. S longer than 2 seconds “ “ flashes.
2.
Y until “4“ is shown under Service.
3. S “4“ will be displayed under Status.
4.
Y
/
B to scroll through the fault memory display.
Service
1
2
3
Description
Display fault codes
Detail fault codes
Clear fault memory
5. S the selected fault memory display will appear
Status.
6.
Y
/
B to scroll through the fault codes.
To clear the fault memory from the operating display, press the following buttons:
1. S longer than 2 seconds “ “ flashes.
2.
Y until “4“ is shown under Service.
3. S “4“ will be displayed under Status.
4.
Y until “3” is shown under Service.
5. S “1“ is shown under Status and “dEL“under Service.
6. S to confirm the deletion. If deleted successfully,
“1“ will be shown under Service, “0“ if it failed.
7. S to change to the operating display.
Note: For the fault display on the burner display and control unit, every fault code is stored in the fault memory and the last 10 can be read.
27
28
Operating
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.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Displayed
Fault Code
F 80
F 81
F 88
F b7
F b7
F d0
F E1
F E2
F E2
System Characteristics Cause Measures
Burner control unit in a fault state; system cools down; burner control unit locked out
Burner control unit in a fault state
Burner control unit in a fault state
Burner control unit in a fault state; system cools down; burner control unit locked out
Type of coding card
Short circuit, boiler water temperature sensor, burner control unit
Sensor drift, boiler water temperature sensor, burner control unit
Lead break, boiler water temperature sensor, burner control unit
Coding card not inserted in the burner control unit; incorrect or faulty coding card
Coding card does not match burner control unit
Check lead and dual sensor; replace sensor if required
Check lead and dual sensor; replace sensor if required
Check lead and dual sensor; replace sensor if required
Insert coding card; check coding card; replace if required
Replace coding card or burner control unit
Danger Plug-in terminals on the burner control unit are ‘live‘. Only replace the coding card when the power has been isolated from the burner control unit (via the internal power disconnect inside the GW6C).
Check line, check wiring, replace burner control unit, if required.
Burner control unit in a fault state
Gas pressure switch 2, GDW2 activated (closed on pressure rise)
Gas pressure switch 2, GDW2 did not close during control self diagnostics
Shortage of gas to gas pressure switch 2; valve leak test
Simultaneous selection of multiple gas types at the burner control unit via plug lÖ
1st gas valve seat leaking/
GDW2. Gas pressure switch 2 activated/burner test firing valve closed.
Gas valve does not open, gas valve leaking, gas pressure switch faulty
Gas valve does not open; gas valve leaking; gas pressure switch 2 faulty.
Check setting of gas pressure switch 2; check connecting cable; replace gas valve.
Check setting of gas pressure switch 2; check connecting cable; replace gas valve
Replace gas valve
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Burner Control Unit Fault Codes
(continued)
Operating
Displayed
Fault Code
F E4
F E5
F E7
F E8
F E9
F EA
F Eb
F EE
F EF
F F0
F F2
F F3
F F4
System Characteristics Cause Measures
Burner shuts down
Burner control unit in a fault state
Burner control unit in a fault state
Burner control unit in a fault state
Burner control unit in a fault state
Burner control unit in a fault state
Burner blocked
Burner control unit in a fault state
Burner control unit in a fault state
Emergency operation according to internal default
Burner control unit in a fault state; system cools down
Ionization flame monitor reports faulty flame signal during startup or after the post-purge
No flame formation during safety time; ionization flame monitor reports no flame signal
Multiple detection of under voltage
Internal fault of the burner control unit and during test of ionization input
Short circuit on boiler temperature sensor 2, burner control unit
Sensor drift on boiler temperature sensor 2, burner control unit
Lead break, boiler temperature sensor 2, burner control unit
For boilers with multiple gas types, 1 or more main gas valves leaking.
Burner not enabled by external blocking device
Internal error in feedback from gas safety valves; output relay does not respond
Internal error in feedback from gas safety valves; output relay does not respond
Communication error KM BUS burner control unit
Excessive boiler water temperature
Gas valve leaking (flame present); incorrect coding card
Check the power supply
Replace burner control unit
Check connecting cable and dual sensor; replace sensor if required.
Check connecting cable and dual sensor; replace sensor if required.
Check connecting cable and dual sensor; replace sensor if required.
Check connection line and main gas valves, replace if required.
Check blocking device, e.g. flue gas damper.
Reset burner control unit; replace burner control unit
Reset burner control unit; replace burner control unit
Check the KM BUS cable plug for firm seating; check all KM BUS cables
Wait until the boiler water temperature falls below the maximum permissible boiler water temperature. If the burner fan is active check sensor 3A/3B.
If the burner fan is not active check sensor 15A/15B.
Reset burner control unit.
Check ionization path; replace coding card; replace gas valve
Ionization electrode incorrectly adjusted; ionization electrode not plugged in. Ground fault of electrode or cable
Insert plug of ionization electrode; check cables; adjust ionization electrode (refer to page 73)
29
30
Operating
Burner Control Unit Fault Codes
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Displayed
Fault Code
F F4
F F4
F F4
F F4
F F4
F F4
F F5
F F5
F F6
F F7
F F7
F F8
F F8
System Characteristics
No flame formation during safety time; ionization flame monitor reports no flame signal
No flame formation during safety time; ionization flame monitor reports no flame signal
Poor start-up characteristics, rotary damper does not close, solenoid valve does not switch
No flame builds during safety time; ionization flame monitor reports no signal
No flame builds during safety time; ionization flame monitor reports no signal
No flame builds during safety time; ionization flame monitor reports no signal
Fan pressure is created during the idle state check of air pressure switch 1, LDW1
Contact of air pressure switch
1, LDW1 not closed in idle state
Flame extinguishes during operation
Flame extinguishes during operation
Cause
Ignition electrode not set correctly; electrodes grounded; ignition unit faulty; burner control unit faulty
Insulation body of ignition or ionization electrode cracked
Servomotor faulty, servomotor connecting cable faulty, solenoid valve faulty, burner control unit output relay faulty
Incorrect gas type selected
Gas valve does not open
Combustion characteristics not ideal
Air pressure switch 1, LDW1 shows no air pressure, fan does not operate
Air pressure switch 1, LDW1 switches off during operation
Gas pressure switch 1, GDW1 shows no gas pressure
Air pressure switch 1, LDW1 faulty, incorrectly connected or incorrectly set
Flue gas back pressure; condensate built up; air pressure switch 1, LDW1 hose faulty; connecting hose leaking
Gas shut-off valve closed; gas pressure switch faulty; multiple problems with gas supply
Wind influence on fan
Air pressure switch 1, LDW1 faulty
Burner gauze assembly faulty
Combustion characteristics not ideal
Measures
Adjust ignition electrodes (refer to page 73); replace ignition unit; replace burner control unit
Replace ignition or ionization electrode
Replace connecting cable; replace servomotor; replace solenoid valve; replace burner control unit
Adjust gas type (refer to page 23)
Check the connecting cable; check the gas valve and replace if required
Adjust the burner (refer to pages
67 and 68, if necessary, also adjust the setting screws when the burner is OFF to be able to start the burner)
Replace air pressure switch 1, connect or set correctly
Remove flue gas back pressure; check if condensate banked up; reset burner control unit; replace hose
Open gas shut-off valve; check gas flow pressure; replace gas filter if required; reset burner control unit; replace gas valve
Check flue outlet or (chimney)
Replace air pressure switch 1,
LDW1
Check burner gauze assembly; replace if damaged
Adjust burner
(refer to pages 67 and 68)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Burner Control Unit Fault Codes
(continued)
Operating
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
F F9
F F9
F F9
F F9
Fan not running; fan speed not reached
Status duration too long, fan ramp-up
Varying fan speed
No fan feedback
Fan faulty; cables are faulty or broken
Internal fault; fan cannot reach its set value
Fan faulty, cable “ a-Ö A“ faulty or broken
Fan faulty; external power supply to fan not connected or faulty; cable “ a-Ö A“ faulty or broken; fan blocked
(possibly by a foreign object)
F FA
F Fb
F Fb
F E5
F Fd
,
,
F EC
F FF
, F Ed ,
Fan runs without demand; burner control unit in a fault state
Burner not starting.
Combustion chamber pressure too high; burner control unit in a fault state
Burner not starting.
Combustion chamber pressure too high; burner control unit in a fault state
Fault around burner control unit
Fan has not stopped; cable
“ a-Ö A“ faulty; fan faulty; burner control unit faulty
Flue gas path or condensate path blocked off. Excessive combustion chamber pressure (air pressure switch
2, LDW2)
Motorized burner damper does not open/close
Internal system fault and
EMC
Measures
Check cables; replace fan if required
Replace fan or burner control unit
Check cable; replace cable “ a-Ö A“ or fan if required
Check cable “ a-Ö A“, check external power supply; replace cable or fan; remove foreign object
Wind influence on fan; check flue outlet and fan; replace cable “ a-Ö A“, replace fan; replace burner control unit
Check flue gas path or condensate path and clean if required
Check motorized burner damper
Reset burner control unit. Replace the burner control unit if the fault persists.
Burner Control Unit Faults Without Fault Display
Fault Cause
Combustion fault through pulsation
Excessive gas input
Insufficient or excessive air
Condensate build up in flue system
Thermoacoustics/ combustion noise
Incorrect flue outlet
Incorrect CO
2
settings; insufficient or excessive air
CO
2
content too low Incorrect setting
Measures
Adjust gas input in accordance with rated boiler heating output
Check condensate drain.
Check flue outlet and flue system.
Adjust burner in accordance with the details on pages 67 and 68.
CO is formed or burner is very sooty
Flame extinguishes during operation
Insufficient or excessive air
Insufficient draught in flue system
Inlet strainer of gas valve contaminated
Check that burner has been adjusted and adjust burner in accordance with the details on pages 67 and 68.
Adjust correctly. Check ventilation of installation room.
Check flue system.
Remove flange and clean strainer.
31
Operating
Operating the System
Boiler model 2.5 to 4.0
Legend
A System and lead boiler section 1 control unit
B Boiler section 2 control unit
Boiler model 5.0 and 6.0
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
The control unit is pre-set, however several codings must be set individually.
1. Activate the main switch and all network switches on the control units.
2. Activate switch on the control unit. Start-up begins automatically.
The following settings may be changed
“Language”
“Date and time”
“Temperature units”
“System layout”
“Elevation”
3. Confirm with , after which the prompt will appear:
“Do you want to make further changes”.
IMPORTANT
With , you can switch between codes.
After you have scrolled through all the codes, a message appears to end operations.
IMPORTANT
Control unit A assumes the function of the boiler and heating circuit control and of the system boiler section 1 control unit. Referred to below as Cascade control unit.
“Lead boiler + cascade” appears on the display.
The other control units assume the function of a lag boiler control unit. Referred to as Boiler section 2/boiler section
3 control unit.
32
Legend
A System and lead boiler section 1 control unit
B Boiler section 2 control unit
C Boiler section 3 control unit
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Operating the System
(continued)
Operating
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. See “Burner control unit” chapter.
IMPORTANT
Burner will start up after a 3 min delay.
Adjusting the coding
Check all addresses in Coding level 1 and adjust if required. See “Coding Levels”.
If the fault indicator lights up on the control unit and the display on the burner control unit is blinking, reset burner control unit. To reset, press the reset button R on the burner control unit.
If the fault continues, the supply side of the combination gas valve may be blocked due to work on the gas pipe.
See the following chapter to adjust coding levels.
Check the following coding addresses in Coding level 2 and adjust accordingly.
See Chapter “Coding Levels” for procedural steps and overview on code setting.
Function
“Connection at plug 29”
“Viessmann system number”
“With LON communication module: LON Participants monitoring”
“With LON communication module” (lead control unit is fault manager)
“Central control of heating circuits”
“Viessmann system number”
“With LON communication module: Monitoring LON participants”
“Storage tank heating, hysteresis”
Group
“General”
“General”
“General”
“General”
“General”
“General”
“General”
“DHW”
Coding
4D
98
9C
79
7A
98
9C
55
33
34
Operating
Integrating the Control Unit into the LON
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Vitotronic 300 GW6C for CA3B 2.5, 3.0, 3.5 and 4.0
Vitotronic 300 GW6C for CA3B 5.0 and 6.0
Legend
A Boiler section 1/ lead control unit
B Boiler section 2/ lag control unit 1
C Boiler section 3/ lag control unit 2 (CA3B 5.0 and 6.0 only)
D External control unit (Vitotronic 200-H HK1B)
Note: Cascade combination of CA3B boilers cannot exceed
8 boiler sections.
Remove terminal end resistor on A to carry on LON
connection
The LON communication module is factory installed.
Vitotronic 200-H:
The LON communication module (accessory) must be plugged in.
Refer to the Vitotronic 200-H Installation and
Service Instructions.
The same participant number may not be assigned twice within a LON.
Example for a multiple-boiler system:
Within a LON, the system numbers (Coding “98” in
the “General” group) must be the same.
Only one control unit may be encoded as fault manager.
The data transfer via LON can take up to several minutes.
A
Multiple boiler system
Set coding “01:2” in the
“Boiler” group.
Boiler number 1
Coding “07:1” in the
“Boiler” group
Number of connected boilers.
Set coding “35:1” to “35:8” in the “Cascade” group.
Participant No. 1.
Coding “77:1” in the
“General” group.
Control unit is fault manager.
Coding “79:1” in the
“General” group.
Control unit transmits time.
Coding “7b:1” in the
“General” group.
manager.
B
Multiple boiler system
Set coding “01:2” in the
“Boiler” group
Boiler number 2
Set coding “07:2” in the
“Boiler” group.
--
Participant No. 2.
Coding “77:2” in the
“General” group.
Control unit is not fault
Coding “79:0” in the
“General” group.
--
C
Multiple boiler system
Set coding “01:2” in the
“Boiler” group.
Boiler number 3
Set coding “07:3” in the
“Boiler” group
--
Participant No. 3.
Set coding “77:3” in the
“General” group.
Control unit is not fault manager.
Coding “79:0” in the
“General” group.
--
D
--
--
--
Participant No. 10.
Coding “77:10” in the
“General” group.
Control unit is not fault manager.
Coding “79:0” in the
“General” group.
Control unit receives time.
Set coding “81:3” in the
“General” group.
Control unit transmits outdoor temperature.
Coding “97:2” in the
“General” group.
Viessmann system number, coding “98:1” in the
“General” group.
--
Viessmann system number, coding “98:1” in the
“General” group.
LON Participant fault monitoring
Coding “9C:20” in the
“General” group.
LON Participant fault monitoring
Coding “9C:20” in the
“General” group.
--
Viessmann system number, coding “98:1” in the
“General” group.
LON Participant fault monitoring
Coding “9C:20” in the
“General” group.
Control unit receives outdoor temperature.
Set coding „97:1“ in the
“General” group.
Viessmann system number, coding “98:1” in the
“General” group.
LON Participant fault monitoring
Coding “9C:20” in the
“General” group.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Integrating the Control Unit into the LON
(continued)
Operating
Carrying out a LON participant check
The participant check is used to test communication with the system devices connected to the fault manager.
Preconditions:
H
The control unit must be programmed as fault manager
(coding “79:1” in the “General” group).
H
The LON participant no. must be programmed in all control units.
H
The LON participant list in the fault manager must be up to date.
From the home screen tap the following buttons:
1.
2. “Service”
3. Enter “viservice” password.
4. “Service functions”
5. “LON participant check”
The list of all connected LON participants appears.
6. Select participant and start participant check with “OK”.
“Participant ...” appears on the display” Check running”.
Note: During the participant check, the display for the relevant participant flashes for approx. 1 min. and
displays
H
Successfully tested participants are designated with “OK”.
H
Unsuccessfully tested participants are designated with
“Subscribe ... Check not OK”.
Update the participant list with “New list” in order to
carry out another participant check.
35
36
Operating
Adjusting the Heating Curve
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
The boiler water or supply temperature in turn affects the room temperature.
Settings in the factory set condition:
H
Slope = 1.4
H
Shift = 0
Example for outdoor temperature 5°F ( − 15°C)
A Underfloor heating system, slope 0.2 to 0.8
B Low temperature heating system, slope 0.8 to 1.6
C Heating systems with a boiler water temperature in excess of 167°F (75°C), slope greater than 1.6
Standard set room temperature Selecting the set room temperature
Individually adjustable for each heating circuit. The heating curve is offset along the set room temperature axis. With the heating circuit pump logic function enabled, the curve modifies the starting and stopping characteristics of the heating circuit pump.
Changing the standard set room temperature
Refer to the Vitocrossal 300 CA3B
Operating Instructions.
Adjustment of the standard set room temperature from 68°F to 79°F (20°C to 26°C).
Legend
A Boiler water temperature or supply temperature
B Outdoor temperature
C Set room temperature
D Heating circuit pump “Off”
E Heating circuit pump “On”
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Adjusting the Heating Curve
(continued)
Reduced set room temperature Changing the standard set room temperature
Refer to the Vitocrossal 300 CA3B
Operating Instructions.
Operating
Adjustment of the reduced set room temperature from 37°F to 52°F (3°C to 14°C).
Legend
A Boiler water temperature or supply temperature
B Outdoor temperature
C Set room temperature
D Heating circuit pump “Off”
E Heating circuit pump “On”
Outdoor temperature
Legend
A Changing the slope
B Changing the shift (vertical parallel offset of the heating curve)
Changing the slope and shift
Individually adjustable for each heating circuit.
From the home screen tap the following buttons:
1. .
2.
3. “Heating circuit 1”, “Heating circuit 2” or “
Heating circuit 3” as the required heating circuit.
4. “Heating curve”.
5. for the required value for “Slope” or “Shift”.
6. to confirm.
37
38
Operating
Boiler Water Temperature Control
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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
connected to the control unit and the heating circuits
connected via the LON BUS
– External demand
– DHW temperature target
H
When the DHW tank is heated, the default set boiler water temperature is 36°F (20 K) above the set DHW temperature (adjustable via coding “60” in the group).
Emissions test function
Enable the emissions test function on all control units.
The following functions are activated:
H
Burner start
H
Starting all pumps
Note: Only the heating circuit pump is switched ON in the case of boiler section 2/boiler section 3 control
(this can be achieved through the relay test function of the lead boiler control).
H
Mixing valve remains set to control function
Function duration <30 min:
The burner operates at 100% output until the
temperature limiter in the burner control unit switches
off. The burner then cycles, with 100% output, around
the value at the temperature limiter.
Function duration >30 min (continuous):
Boiler water temperature at max. set value,
e.g. 194°F (90°C).
The burner is operated in modulating mode.
This prevents excessive cycling if emissions testing
is carried out over an extended period.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Heating Circuit Control
Operating
Only for single boiler and cascade control units
Brief description
H
The control unit features control circuits for one heating circuit without mixing valve A1 (heating circuit 1) and two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3).
H
The set supply temperature of each boiler is determined from the following coding:
– Outdoor temperature
– Set room temperature
– Operating mode
– Heating curve slope and shift
H
The supply temperature of the heating circuit without mixing valve corresponds to the common system supply temperature.
H
The supply temperature of the heating circuits with mixing valve is regulated by the stepped opening or closing of the mixing valves.
The mixing valve motor control changes the actuating
and pause times subject to the control differential deviation).
Functions
The heating circuit without mixing valve is subject to the boiler water temperature and its control range limits.
The heating circuit pump is the only actuator.
The supply temperature of the heating circuits with mixing valve is captured by the supply temperature sensor of the relevant heating circuit.
H
Upper control limit:
Electronic maximum supply temperature limit
coding address “c6” in the “Heating circuit...” group.
H
Lower control range limit:
Electronic minimum supply temperature limit
coding address “c5” in the “Heating circuit...” group.
Time program
The control unit switches over according to the time program. In the “Heating and DHW” operating program, the control unit switches between “Central heating with standard room temperature” and “Central heating with reduced room temperature”.
Every operating mode has its own set level. 4 time phases per day can be selected.
Outdoor temperature
A heating curve must be set for matching the control unit to the building and the heating system.
The heating curve characteristics determine the set boiler water temperature subject to outdoor temperature.
The control unit uses an average outdoor temperature.
This comprises the actual and the adjusted outdoor temperature.
Room temperature
In conjunction with a remote control and room temperature hook-up (coding “b0” in the “Heating circuit...”) group:
Compared with the outdoor temperature, the room temperature has a greater influence on the set boiler water temperature (changed at coding “b2” in the
“Heating circuit...” group).
In conjunction with heating circuits with mixing valve:
For control differentials (actual value deviation) above
4°F (2 K) room temperature, the influence can be increased further (coding “b6” in the “Heating circuit...” group):
H
Quick heat-up
The set room temperature must be raised by at least
4°F (2 K) by the following measures:
– Enabling comfort mode
– Changing from central heating with reduced
temperature to central heating with standard
temperature
– Start optimization (coding “b7” in the “Heating
circuit...” group) Quick heat-up will stop when the
set room temperature has been reached.
H
Quick setback
The set room temperature must be reduced by at least
4°F (2 K) by the following measures:
– Activating economy mode
– Changing from central heating with standard
temperature to central heating with reduced
temperature
– Shutdown time optimization (coding address “c1”
in the “Heating circuit...” group)
Quick setback ends when the set room temperature
has been reached.
39
40
Operating
Heating Circuit Control
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
DHW temperature
Priority control
H
With priority control: (coding address “a2:2” in the
“Heating circuit...” group):
The set supply temperature will be adjusted to 32°F during tank heating. The mixing valve closes
and the heating circuit pump is switched off.
H
Without priority control:
The heating circuit control unit continues to operate
with the same set value.
H
With modulating priority control in conjunction with heating circuits with mixing valve:
The heating circuit pump remains switched on.
During tank heating the set supply temperature
of the heating circuit will be reduced until the set
boiler water temperature has been reached.
The set supply temperature is determined from the coding:
– Outdoor temperature
– Differential between the set and the actual boiler temperature
– Heating curve slope and shift
– Set coding “a2” in the “Heating circuit...” group
Heating circuit pump logic – Economy circuits
The heating circuit pump is switched OFF [set supply temperature set to 32°F (0°C)] if one of the following criteria is met:
H
The outdoor temperature selected in coding “a5”
in the “Heating circuit...” group exceeds the set value.
H
The adjusted outdoor temperature exceeds the value
set in coding“a6” in the “Heating circuit...” group.
H
The mixing valve has been attempting to close for more than 12 min. (mixing valve economy function, coding
“a7” in the “Heating circuit...” group).
H
The pump idle time selected in coding “a9”
in the “Heating circuit ...” group is reached.
Requirements:
– There is no risk of frost.
– Coding “b0” in the “Heating circuit...” group
must be set to 0.
Note: If, during the pump idle time, the system
is switched to heating mode or the set room
temperature is increased, the heating circuit
pump is switched ON,even if the time has
not
H
The actual room temperature exceeds the value
set in coding “b5” in the “Heating circuit ...” group.
System dynamics
The mixing valve control characteristics can be influenced at coding “c4” in the “Heating circuit...” group.
Central control
Coding “7a” in the “General” group enables you to program central control to one heating circuit.
The operating and holiday program then applies to all additional heating circuits of the system.
For these heating circuits, when the operating and holiday program is enabled,“Central control” is displayed.
Any holiday programs that may have been set will be deleted.
Party and economy modes cannot be enabled on all control units.
Frost protection
The supply temperature is held in accordance with the heating curve for the reduced set room temperature, but at least at 50°F (10°C).
A variable frost limit can be set in line with coding address “a3” in the “Heating circuit...” group.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Heating Circuit Control
(continued)
Operating
Legend
A Max. boiler water temperature
B Slope = 1.8 for heating circuit without mixing valve
C Slope = 1.2 for heating circuit with mixing valve
D Boiler water temperature [with a differential temperature = 15°F (8 K)]
E Lower boiler water temperature, defaulted by the boiler coding card
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).
The differential temperature is the minimum value by which the boiler water temperature should be higher than the highest currently required supply temperature of the heating circuit with mixing valve.
H
System with only one heating circuit with mixing valve:
The set boiler water temperature will be automatically
regulated to 15°F (8 K) above the set supply temperature.
H
System with heating circuit without mixing valve and heating circuit with mixing valve:
The set boiler water temperature operates in
accordance with its own heating curve. The differential
temperature of 15°F (8 K) towards the set supply
temperature is set at the factory.
Legend
A Maximum supply temperature limit
(coding “37” in the “Cascade” group)
B Slope = 1.8 for heating circuit without mixing valve
C Slope = 1.2 for heating circuit with mixing valve
D Common supply temperature [at a differential temperature = 15°F (8 K)]
E Lower common supply temperature
Supply temperature control cascade control unit
Differential temperature:
The differential temperature can be set at coding “9f”
in the “General” group, factory set condition 15°F (8 K).
The differential temperature is the value by which the common supply temperature should be higher than the highest currently required supply temperature of the heating circuit with mixing valve.
H
System with only one heating circuit with mixing valve:
The common set supply temperature is regulated
automatically to 15°F (8 K) above the set supply
temperature of the heating circuit with mixing valve.
H
System with heating circuit without mixing valve and heating circuits with mixing valve:
The common set supply temperature operates in
accordance with its own heating curve. The differential
temperature of 15°F (8 K) towards the set supply
temperature of the heating circuits with mixing valve
is set at the factory.
41
42
Operating
Heating Circuit Control
(continued)
Example using the settings in the factory set condition
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Legend
A Heating curve for operation with standard room
temperature
B Heating curve for operation with reduced room
temperature
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.
The temperature is raised in accordance with the selected heating curve, but no higher than the set standard room temperature.
The outdoor temperature limits for the start and end of temperature raising can be set in coding “f8” and “f9” in the “Heating circuit...” group.
Reducing the heat-up time
During the transition from operation with reduced room temperature to operation with standard room temperature, the boiler water or supply temperature will be raised in accordance with the selected heating curve. The boiler water or supply temperature increase can be automatically raised.
The value and duration for the additional raising of the boiler water temperature or set supply temperature can be set in coding “fa” and “fb” in the “Heating circuit...” group.
Control sequence
Mixing valve circuit
The mixing valve motor will not be switched within the
“neutral zone” ±2°F (±1 K).
Supply temperature drops
(Set value -2°F (-1 K)
The mixing valve motor receives the signal “mixing valve open”. The signal duration lengthens with an increasing control differential. The duration of pauses reduces with an increasing control differential.
Supply temperature rises
(set value +2°F (+1 K)
The mixing valve motor receives the signal “mixing valve close”. The signal duration lengthens with an increasing control differential. The duration of pauses reduces with an increasing control differential.
Legend
A Start of operation with standard room temperature
B Set boiler water or supply temperature in accordance with the selected heating curve
C Set boiler water or supply temperature in accordance with coding “fa”:
122°F (50°C) + 20% = 146°F (60°C)
D Duration of operation with higher boiler water or set supply temperature in accordance with coding
“fb”: 60 min
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
DHW Tank Temperature Control
Operating
Brief description
H
The tank temperature control is a constant temperature control function. This is achieved by starting and stopping the DHW pump. The switching differential is
±5°F (±2.5 K).
H
When the DHW tank is heated, a set supply temperature is specified that is 36°F (20 K) higher than
the set DHW temperature (adjustable at coding
“60” in the “DHW” group).
Functions
Time program
An automatic or an individual time program may be selected for DHW pump and the DHW recirculation pump.
Compared with the heating circuit heatup phase, DHW heating starts 30 min earlier in automatic mode.
The individual time program enables up to 4 time phases per day to be set for DHW pump and the DHW recirculation pump for every day of the week.
All tank heating sequences will be completed independently of the time program.
In conjunction with coding “7f” in the “General” group
H
Detached house
Coding
– Automatic mode
The heating times for heating circuit 1 are applied
to systems with two or three heating circuits.
– Individual time program
The time phases for DHW pump and the DHW
recirculation pump have the same effect on all
H
Apartment building
“7f:0”:
– Automatic mode
For systems with two or three heating circuits, the
heating times for the respective heating circuit will applied.
– Individual time program
The time phases for DHW pump and the DHW
recirculation pump can be adjusted individually
for each heating circuit.
Frost protection
The DHW tank will be heated to 68°F (20°C) if the DHW temperature falls below 41°F (5°C).
Forth phase heating function
(auxiliary function for DHW heating)
This function is activated by providing a second set DHW temperature at coding “58” in the “DHW” group and activating the fourth DHW phase for DHW heating.
Set DHW temperature
The set DHW temperature can be adjusted between 50°F and 140°F (10°C and 60°C).
Coding “56” in the “DHW” group enables the set range to be extended to 203°F (95°C).
Coding “66” in the “DHW” group enables the set value of the programming unit and/or remote control Vitotrol 300 to be assigned.
Priority control
H
With priority control: (coding
“a2:2” in the “Heating circuit...” group):
The set supply temperature will be adjusted to 32°F during tank heating. The mixing valve closes
and the heating circuit pump is switched off.
H
Without priority control:
The heating circuit control unit continues to operate
with the same set value.
H
With modulating priority control in conjunction with heating circuits with mixing valve:
The heating circuit pump remains switched on.
During tank heating the set supply temperature of the
heating circuit will be reduced until the set boiler water
temperature has been reached.
The set supply temperature is determined from the coding:
– Outdoor temperature
– Differential between the set and the actual boiler
water
– Heating curve slope and shift
– Set coding “a2” in the “Heating circuit...” group
DHW recirculation pump
This delivers hot water to the draw-off points at adjustable times. Four time phases can be selected at the control unit for every day.
Auxiliary circuits
DHW heating in conjunction with the heating circuits can be disabled or enabled by changing over the operating program (see coding “d5” in the “Heating circuit...” group).
System with tank loading system
The above functions also apply in conjunction with tank loading systems.
Set the following coding:
“55:3” in the “DHW” group; “4c:1”,
“4e:2” in the “General” group.
The DHW tank is only reheated by the boiler if the temperature falls below this value.
System with solar control unit
A third set DHW temperature can be assigned at coding
“67” in the “DHW” group.
The DHW tank is only reheated by the boiler if the temperature falls below this value.
43
44
Operating
DHW Tank Temperature Control
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Controlled sequence single boiler control
Coding “55:0” in the “DHW” group; tank heating
The DHW tank goes cold [set value -5°F (-2.5 K), adjustable via coding “59”]:
H
The set boiler water temperature is set 36°F (20 K) higher than the set DHW temperature (adjustable via
coding “60”).
H
Pump on:
– Starting the DHW pump is subject to boiler water
(coding
The DHW pump starts when the boiler water
temperature is 14°F (7 K) higher than the DHW
temperature.
– Starting the DHW pump for tank heating
(coding
The DHW tank is hot [set value +5°F (+2.5 K)]:
H
The set boiler water temperature is reset to the weather-compensated set value.
H
Pump delay off:
The DHW pump runs on after tank heating
until one of the following criteria is met:
– The differential between the boiler water temperature
and the DHW temperature is less than 13°F (7 K).
– The weather-compensated set boiler water
temperature has been reached.
– The set DHW temperature is exceeded by 10°F (5 K).
– The set max. delay off time is reached (coding “62”).
H
Without pump delay off (coding “62:0”).
Adaptive tank heating
Coding “55:1” in the “DHW” group;
With adaptive tank heating, the speed of the temperature rise during DHW heating is taken into account.
The DHW tank goes cold [set value -5°F (-2.5 K), adjustable via coding “59”]:
H
The set boiler water temperature is set 36°F (20 K) higher than the set DHW temperature (adjustable via coding “60”).
H
Pump on:
– Starting the DHW pump is subject to boiler water
temperature (coding “61:0”):
The DHW pump starts when the boiler water
temperature is 13°F (7 K) higher than the DHW
temperature.
– Starting the DHW pump immediately (coding “61:1”).
The DHW tank is hot:
H
The control unit checks whether the boiler will still
be required to supply heating energy after the tank
has been heated up or whether residual boiler heat
should be transferred to the DHW tank.
Accordingly, the control unit determines the burner
and DHW pump stop times to prevent the set
DHW temperature being substantially exceeded after
the tank has been heated up.
Tank temperature control with 2 tank temperature sensors
Coding “55:2” in the “DHW” group;
Tank temperature sensor 1 enables the DHW pump and is evaluated for stop conditions during the pump delay off time.
Tank temperature sensor 2:
Tank heating will start early if a lot of hot water is drawn off. Tank heating will terminate early if no hot water is drawn off.
DHW tank goes cold:
H
Set value -5°F (-2.5 K), change at coding “59”
or...
H
Actual DHW temperature at sensor 2 < set DHW temperature x factor for start time (adjustment at coding “69”)
The DHW tank is hot:
H set value 5°F (2.5 K)
and...
H
Actual DHW temperature at sensor 2 > set DHW temperature x factor for stop time (adjustment at coding “68”)
Coding “55:3” in the “DHW” group; tank temperature control tank loading system
The DHW tank goes cold [set value -5°F (–2.5 K); change at coding “59”]:
H
The set boiler water temperature is set 36°F (20 K) higher than the set DHW temperature (adjustable via coding “60”).
H
The primary pump in the tank loading system starts.
H
The 3-way mixing valve opens and then regulates to
the specified set value.
H
The DHW pump cycles (briefly switches on and off) until the set supply temperature has been reached [set
DHW temperature +10°F (+5 K)].
Then it runs constantly. If, during heating, the actual
value falls below the required set temperature, the
DHW pump will temporarily cycle again.
The DHW tank is hot:
H
Tank temperature sensor 1:
Actual set value
and...
Tank temperature sensor 2:
Actual value > set value -3°F (-1.5 K):
H
The set boiler water temperature is reset to the weather-compensated set value.
H
The DHW pump stops immediately when the 3-way mixing valve is fully opened.
or...
H
The DHW pump stops after expiry of the delay off time that is selected at coding “62”.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Setting the Boiler Sequence
(burner sequence)
Function
“Lead boiler or boiler sequence changeover”
“Permanent lead boiler”
“Permanent last boiler”
“Boiler ECO threshold”...
Parameter
38
39
3A
41 to 44, 65, 6F, 74, 7D
Operating
Setting the boiler sequence (burner sequence)
Every boiler/burner can be blocked or enabled subject
to the outside temperature by means of the ECO
threshold.
The ECO threshold has no effect if a boiler is
required to achieve the set flow temperature in the
case of enabled boilers failing.
At least the lead boiler remains in operation when all
boilers in a system would otherwise be blocked by
the ECO threshold.
Tap the following buttons:
1.
2. “Boiler sequence”
3. Select the required boiler sequence (burner sequence). with .
Cascade Control Unit
Brief description
The supply temperature is regulated by starting or stopping the burners or by starting/stopping individual burner stages.
H
Standalone control
H
Sequential control
H
Subject to system version, a difference is made between the condensing strategy
and 2 conventional boiler strategies
Set supply temperature
The set supply temperature is determined from the following coding:
H
Set supply temperature of heating circuit without mixing valve A1 (heating circuit 1) and heating circuits with mixing valve M2 (heating circuit 2) and M3
(heating circuit 3).
H
Set supply temperature of further consumers.
H
DHW temperature target.
H
External demands.
Upper control range limits:
Maximum system supply temperature limit
(coding “37” in the “Cascade” group).
Lower control range limits:
Minimum system supply temperature limit
(coding “36” in the “Cascade” group).
Standalone control
Note: Vitocrossal 300, type CA3B, operate in parallel and with condensing strategy
45
46
Operating
Cascade Control Unit
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Boilers connected in parallel
H
Without and with supply temperature sensor
(see the following table).
H
The cascade control specifies the set boiler water temperature for all currently active boilers. Every boiler control unit regulates to the specified set value.
The following control strategies are available:
H
Condensing strategy (refer to page 47)
H
Conventional boiler strategy 1 (refer to page 47)
H
Conventional boiler strategy 2 (refer to page 47)
Boilers connected in series
H
Without and with supply temperature sensor
(see the following table).
H
The control strategy is set automatically to conventional boiler strategy 2, coding “3c:2” in the
“Cascade” group (refer to page 84).
H
The cascade control specifies the set boiler water temperature for all currently active boilers. Every boiler control unit regulates to the specified set value. If the boiler section 1 (condensing boiler) does not achieve the specified set value, it will only act to control the return temperature of the conventional boiler downstream. The conventional boiler is started late and is also shut down late.
With supply temperature sensor
Set coding “3b:1” or “3b:3” in the “Cascade” group.
The control deviation is calculated from the set supply temperature and the actual supply temperature to determine the start and shutdown criteria.
Starting
Without supply temperature sensor
Set coding “3b:0” or “3b:2” in the “Cascade” group.
To determine the start and stop criteria, the control deviation is calculated from the set boiler water temperature and the estimated average actual boiler water temperature of the currently active boilers.
Only boilers with open motorized isolation valves are taken into consideration.
Sequential control
H
With supply temperature sensor.
H
Set coding “3b:4” in the “Cascade” group.
H
The control strategy is set automatically to
conventional boiler strategy 2, coding “3c:2”
in the “Cascade”group (refer to page 84).
H
The cascade control unit regulates to the specified set supply temperature by stipulating the output for each individual boiler. The boiler section 1 can be operated in modulating mode. All other boilers are operated in two stages via a specified output (incl. modulating burners).
Control strategies
Condensing strategy
Benefit:
Optimal utilization of the condensing effect and long burner run-times.
Set coding “3C:0“ in the “Cascade” group. It is the aim of the condensing strategy to operate as many boilers as possible at the lowest output level.
Starting criterion:
An output statement causes the boilers to start
(Coding “3d:1” in the “Cascade” group).
An additional boiler will start if the current heat demand
can be covered by the currently active boilers plus the
next boiler in the boiler sequence.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Cascade Control Unit
(continued)
Shutdown
Operating
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.
Example (coding “3C:0” in the “Cascade” group)
Two-boiler system with modulating burners:
Boiler 1: 100% rated heating output
(base load set to 33%)
Boiler 2: 100% rated heating output
(base load set to 33%)
Conventional boiler strategies
Benefit
Conventional boiler strategy 1
The number of boilers in operation is the lowest possible.
Set coding “3C:1“ in the “Cascade” group.
It is preferable to operate conventional boilers at their upper output range, to reliably prevent formation of condensate when return temperatures are low.
An additional boiler will only be started if the maximum output of all currently active burners is insufficient to achieve the supply temperature set value.
A boiler will be shut down when the remaining boilers can achieve the required output on their own.
Starting criterion The boilers are started via a starting integral.
The next boiler in the boiler sequence will be started if the value set in coding ”45” in the
“Cascade” group is exceeded.
Shutdown criterion A reduction in output causes the boilers to shut down (Coding “3d:1“ in the “Cascade“ group). A boiler will be shut down when the currently required output can be achieved without the most recently started boiler.
Conventional boiler strategy 2
Long burner run times.
Set coding “3C:2“ in the “Cascade” group
(factory set condition).
An additional boiler will only be started if the maximum output of all currently active burners is insufficient to achieve the supply temperature set value.
A boiler will be shut down if the burners were ramped down to their minimum output because of a major negative control deviation and the output is still too high.
The boilers are started via a starting integral.
The next boiler in the boiler sequence will be started if the value set in coding ”45” in the
“Cascade” group is exceeded.
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.
Examples
Two-boiler system with modulating burners:
Boiler 1: 100% rated heating output
(base load set to 33%)
Boiler 2: 100% rated heating output
(base load set to 33%)
47
48
Operating
Cascade Control Unit
(continued)
Conventional boiler strategy 1 (coding “3c:1” in the “Cascade” group)
Starting
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Shutdown
Conventional boiler strategy 2 (coding “3c:2” in the “Cascade” group)
Starting Shutdown
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Installing the Boiler Panels
Operating
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.
3. Install the top front panel (for CA3B 5.0 and 6.0 only).
4. Insert the bottom of the lower front panel in place and
push into place.
5. Install the bottom left side and top left side panels.
6. Install the top right side panels.
7. Slide the top panels toward the left side.
8. Install with screws to the right side of the top panels.
Turning the System Off
1. Turn off main power switch or power supply voltage and ensure against being unintentionally switched on again.
WARNING
Power supply voltage is dangerous and may cause life-threatening injury. The system must be disconnected from the power supply before maintenance work is performed.
2. Close central gas shut-off valve.
49
50
Service
Preparing for Service Work
CA3B 2.5 to 4.0
CA3B 5.0 and 6.0
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
Close the gas shut-off valve.
IMPORTANT
Disconnect power and close the gas shut-off valve to ensure system is shut down during any service work on the burner.
1. Remove the 4 screws from the right side of the top panels.
2. Lift and remove the top right side panels.
3. Slide the top panels toward the right side and remove.
4. Lift and remove the top left side panels.
5. Remove the nut and bolt from each side of the lower
portion of the upper frame profiles.
Note: Removal of the upper frame profiles are required when removing the burner.
6. Remove the upper frame profiles.
7. Reinstall upper frame profiles and panels once
service is completed.
1. Remove the 6 screws from the right side of the top panels.
2. Lift and remove the top right side panels.
3. Slide the top panels toward the right side and remove.
4. Lift and remove the top left side panels.
5. Remove the nut and bolt from each side of the lower
portion of the upper frame profiles.
Note: Removal of the upper frame profiles are required when removing the burner.
6. Remove the upper frame profiles.
7. Reinstall upper frame profiles and panels once
service is completed.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Preparing for Service Work
(continued)
Burner Identification
Rear of boiler
Front of boiler
Section 3
Section 2
Section 1
Service
Burner Combinations
CA3B Boiler
2.5
3.0
3.5
4.0
5.0
6.0
Section 1 (lead)
1250 (compact)
1500 (compact)
1500
2000
1500
2000
Burner Input MBH
Section 2 (lag 1)
1250 (compact)
1500 (compact)
2000
2000
1500
2000
Section 3 (lag 2)
--
--
--
--
2000
2000
51
Service
Burner Parts
1.25/1.5 MMBH (CA3B 2.5 and 3.0)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
1.5/2.0 MMBH (CA3B 3.5 to 6.0)
52
Legend
A Burner control unit
B Gas train
C Gas supply pipe
D Air pressure switch 1
E Air pressure switch 2
F Ignition electrodes
G Burner gauze assembly
H Burner frame
K Gas pressure switch
L Venturi mixing pipe
M Burner fan
Legend
A Burner control unit
B Gas train
C Gas supply pipe
D Air pressure switch 1
E Air pressure switch 2
F Ignition electrodes
G Burner gauze assembly
H Burner frame
K Gas pressure switch
L Venturi mixing pipe
M Burner fan
N Rotary damper with servomotor
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Burner Interface Panel
Service
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.
For maintenance work, isolate the system from the power supply.
3. Remove the boiler left side panels (refer to page 50).
4. Disconnect power cable with plug fÖ . Then disconnect the burner cables with plugs § A/ § B, aG A/ aG B, fA , gD and in addition to plug avG from the burner control unit and pull out of the burner
casing.
53
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.
Remove the display and programming unit.
4. Install new display and programming unit in reverse order.
Coding Card on 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.
Remove the display and programming unit.
4. Pull the coding card from the burner control unit.
5. Insert new coding card.
Note: If fault code “ card.
F b7 ” is displayed, check the coding
Refer to the Installation Instructions supplied with the burner coding card.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Burner Control Unit
Service
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.
Remove the display and programming unit.
4. Remove all connecting cables from the burner control unit.
5. Pull the coding card from the burner control unit.
6. Undo 4 mounting screws on the burner control unit.
7. Remove the burner control unit.
8. Install the new burner control unit in reverse order.
Fuel Conversion NG to LPG
For more information, refer to the Installation
Instructions supplied with the Conversion kit.
55
56
Service
Boiler Water Temperature Sensor
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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
3. Disconnect sensor cable plugs 3 A/ 3 B.
4. Connect new sensor to sensor cable plugs 3 A/ 3 B
and install into the sensor well.
5. Reinstall spring clip.
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 )
Service
3B sensor (NTC 20k )
Temperature
Temperature
57
Service
Boiler Secondary Temperature Sensor
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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
3. Disconnect sensor cable plugs 15A/15B.
4. Connect new sensor to sensor cable plugs 15A/15B and install into the sensor well.
5. Reinstall spring clip.
Legend
A Temperature sensor
B Connecting plugs 15A/15B
C Burner control plug
the connecting plug is located at the burner control
unit, for that boiler section.
58
Temperature
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Manual Reset Limits
Service
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.
After the temperature has fallen below the limit temperature by about 14°F (8°C), the snap-action switch can be reset manually.
Legend
A Probe well
B Supply water temperature limit switch
C Flue gas temperature limit switch
IMPORTANT
The switches are preset fom the factory, do not adjust.
To reset the switch;
1. Unscrew the reset cap and set aside.
2. Reset the switch.
3. Reinstall the reset cap.
Note: If the switch cannot be reset, replace the switch.
59
60
Service
Gas Valve
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Note: Reinstalled gas valve in the same orientation as 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.
3. Undo nuts on the gas line flange. Remove the flange.
4. Undo nuts on the Venturi flange. Remove the flange.
Assembly
Assembly in reverse order
Check for correct orientation when fitting.
Replace the gaskets on the inlet and outlet sides.
Secure the gas valve free from stress on the flange
using screws. Torque: 13 lb.in (1.5 Nm)
Note: Never interchange the connecting cables of the two
gas pressure switches (GDW 1 and GDW 2).
CAUTION
The use of leak detection spray can result in faulty operation. Leak detection spray must not come into contact with electrical contacts.
WARNING
Escaping gas leads to a risk of explosion.
Check the fitting for gas tightness.
Legend
A GDW1 - gas inlet pressure monitoring switch
B GDW2 - valve seat gas pressure monitoring switch
Gas inlet pressure monitoring switch - GDW1
The factory default setting for the gas inlet pressure switch is 10 mbar (4” w.c.). This is the minimum gas pressure required for the burner to operate with natural gas fuel.
For liquid propane gas the switch can be left at factory default setting of 10 mbar (4” w.c.) or increased to
22.4 mbar (9” w.c.). This setting can be changed by removing the GDW1 cover and manually setting the dial.
The inlet gas switch GDW1 will trigger a stand still (waiting) state of the burner control unit when the gas pressure drops below the setpoint. The burner will retry after 5 minutes if the gas pressure returns to the setpoint threshold.
Valve seat gas pressure monitoring switch - GDW2
(outlet pressure at first valve seat)
The factory default setting for valve seat gas pressure switch is 10 mbar (4” w.c.).
The switch will trigger an E1 (pressure) or E2 (open circuit during control self diagnostics) faults on the burner control,
if activated.
IMPORTANT
Do not adjust this switch.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Air Pressure Switches
Service
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.
This way a minimum amount of pre-aeration will be ensured, among other things.
The air pressure switch A triggers a fault shutdown on the burner control unit in the following situations:
If the system cold-state checkup is not successful
after approx. 5 minutes,
If the air pressure during the pre-aeration phase is outside of the permissible range (tolerance period approx. 5 minutes),
If the air pressure switch fails during normal operation
or the air pressure is outside of the permissible range.
A fault shutdown is registered on the burner control unit display (refer to page 30) with fault indicators “ F F5 ” and
“ F F7 ”.
The fault shutdown can be released by pressing the reset button R .
CA3B Boiler
2.5 and 3.0
3.5 to 6.0
Burner model Setting value LDW1
1.25 MMBTU 0.4 ”w.c. (1 mbar)
1.5 MMBTU
1.5 MMBTU
2.0 MMBTU
0.4 ”w.c. (1 mbar)
0.4 ”w.c. (1 mbar)
0.4 ”w.c. (1 mbar)
Combustion chamber pressure monitoring function (LDW2)
In order to monitor the pressure in the combustion chamber, the switching threshold of the air pressure switch 2 (LDW2) is monitored in all operational phases
(with the exception of safety and stabilization times).
The air pressure monitor B will generate a fault shutdown at the burner control unit in the following situations:
If the combustion chamber pressure lies outside of
the permissible range after two attempts during the
pre-aeration phase, normal operation, or the post- phase.
The fault shutdown is registered with the fault indicator
“ F Fb ” in the burner control unit display.
The fault shutdown can be released by pressing the reset button R .
CA3B Boiler
2.5 and 3.0
3.5 to 6.0
Burner model
1.25 MMBTU
1.5 MMBTU
1.5 MMBTU
2.0 MMBTU
Setting value LDW2 preset* preset* preset* preset*
* Equipped with a non adjustable pressure switch.
61
62
Service
Air Pressure Switches
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Legend
A Air pressure switch, fan (LDW1, compensation line on connector marked “-”)
B Air pressure switch, combustion chamber (LDW2, compensation line on connector marked “+”)
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 aCA A (LDW2) from the plug-in strip on the burner control unit.
4. Pull compensation hose from connector.
5. Undo the mounting screw(s) on the air pressure switch.
Remove the air pressure switch cover.
Torque when installing: 9 lb.in (1 Nm).
6. Undo the base mounting screws and remove the base.
7. Install new air pressure switch in reverse order.
Observe torque settings.
Note: Attach the connection hose to the corresponding
connector.
Note: Set the new air pressure switch to exactly the same
value as that of the replaced air pressure switch.
Air pressure switch settings
CA3B Boiler
Burner model
2.5 and 3.0
1.25 1.5
LDW1 mbar
(“w.c.)
MMBTU
1
(0.4)
MMBTU
1
(0.4)
LDW2 mbar
(“w.c.) preset * preset *
1
3.5 to 6.0
1.5
MMBTU
(0.4) preset *
2.0
MMBTU
1
(0.4) preset *
* Equipped with a non adjustable pressure switch.
Compensation lines (burners for CA3B 2.5 and 3.0)
Replacement lines must be cut to length. See following table for required length.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Air Pressure Switches
(continued)
Service
Legend
A Gas train
B Air pressure switch 1
C Air pressure switch 2
D Solenoid valve
E Venturi mixing pipe
F Burner frame
G Gas feed nozzles
Ignition Unit
Ignition Cables
Line
1
2
3
4
5
6
7
8
9
Hose length in. (mm)
11 f (296)
22 f (575)
2 (72)
24 a (615)
8 b (214)
11 a (285)
8 (201)
6 b (167)
5 (125)
Hose Dia.
7 6 mm
7 6 mm
7 6 mm
7 6 mm
7 6 mm
7 4 mm
7 4 mm
7 4 mm
7 4 mm
1. Pull the connecting cable from the ignition unit.
2. Pull the ignition cables from the ignition unit.
3. Undo the ignition unit mounting screws. Remove the unit.
4. Install new ignition unit in reverse order.
Torque for mounting screws: 13 lb.in (1.5 Nm).
1. Pull the ignition cables from the ignition unit.
2. Pull the ignition connectors from the ignition electrodes.
3. Install new ignition cables in reverse order.
63
64
Service
Rotary Damper and Servomotor
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
IMPORTANT
An incompletely opened rotary damper can cause malfunctions or indicate incorrect adjustment of the servomotor. The rotary damper must be fully open when the burner is off and during operation. If necessary, adjust it via the articulated rod. See service instructions for servomotor settings.
For CA3B models 3.5 to 6.0
1. Pull the connector from the servomotor.
2. Undo 4 screws from the retaining bracket of the rotary damper. Torque when installing: 13 lb.in (1.5 Nm).
Remove rotary damper together with the retaining
bracket.
3. Undo 2 screws on the servomotor axis.
Torque when installing: 3 lb.ft (4 Nm).
4. Remove the servomotor.
5. Release the articulated rod on the rotary damper with an open-ended wrench.
6. Install new rotary damper, air pressure switch and servomotor in reverse order.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Replacing the Solenoid Valve
Service
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.
Assemble in reverse order. Torque to: 1.1 lb.ft (1.5 Nm)
Screw the plastic brackets into the new 2/2 directional valve. Fit the hoses and secure with hose clips (observe the mark on the valve: 1 left, 2 right).
Fan
1. Disconnect both connectors from the fan.
2. Remove 6 nuts on the Venturi pipe. Remove the
Venturi pipe with the fitted gas valve.
Torque when installing: 4.5 lb.ft (6 Nm).
3. Undo the hexagon nuts from the 4 studs.
4. Remove the fan, noting how the gasket is positioned.
5. Installation in reverse order.
Note: Fit gasket in the correct position.
65
66
Service
Checking the Rotary Damper Setting
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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 .
3. Check whether the compensating tubing A has been connected between the gas valve and venturi mixing pipe.
4. Put burners into operation.
5. Check the setting of the rotary damper during the startup phase. The rotary damper window B must nearly close for approx. 5 sec. The scale ring D must be set as follows during this time:
Boiler model Burner model
2.5 and 3.0
1.25 MMBTU
1.5 MMBTU
3.5 to 6.0
1.5 MMBTU
2.0 MMBTU
Rotary damper setting
Not equipped
Not equipped
20° (close) 0° open
20° (close) 0° open
Checking the functioning of the burner damper
Angle position of the switch cams: The servomotor is at setting “0” during standstill. The factory-installed settings may not be changed.
Putting burners into operation
Servomotor moves to 105°, levers and rods move to the left. Burner damper E is opened.
Turning burners off
Servomotor moves to setting “0”, burner damper E is closed.
The spring on the rod is compressed approx. 0.08 in. to 0.12 in. (2 mm to 3 mm).
The burner damper E is pressed against the seat ensuring tightness.
If the actual measurement of dimension is not within tolerance as shown below, loosen lock nut F , and rotate the rod G to attain the dimension shown below. Tighten lock nut F to 22 lb.in (2.5 Nm).
Legend
A Tubing
B Damper window
C Marking
D Scale ring
E Burner damper
F Lock nut
G Rod
H Retaining ring
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Measuring CO
2
Content
CA3B Boiler
2.5 and 3.0
3.5 to 6.0
Burner models
1.25 MMBTU
1.5 MMBTU
1.5 MMBTU
2.0 MMBTU
Service
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.
Checking the CO
2
level
Preparing the test
1. Open the gas shut-off valve.
2. Start the burner with the emissions test switch enabled at the boiler control unit.
3. At the same time, press button S E and button
B D and hold for longer than 2 seconds.
The display will then show the following:
■ Under Status C : “P“ (= relay test)
■ Under Service C : Modulation level in %
“100“ = 100% = upper heating input
“0“ = 0% = lower heating input
CO
2
Test at the upper heating input
1. Press button Y F until the service display C has incremented to “100“(= 100%).
2. Check the CO
2
level at the flue pipe.
3. If the CO
2
level must be adjusted:
■ Remove cap B .
■ Turn adjusting screw A in small increments
(3 mm Allen key) until the CO specified range:
- Turning clockwise → CO
2
2
level falls within the
level falls (less gas)
- Turning counter-clockwise → CO
2
level rises
4. Record the actual value in the maintenance report on
162.
Permissible CO
2
content (%)
Natural Gas Liquid Propane Gas
8.8 - 9.2
10.8 - 11.0
8.8 - 9.2
10.8 - 11.0
8.8 - 9.2
8.8 - 9.2
10.8 - 11.0
10.8 - 11.0
67
68
Service
Measuring CO
2
Content
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Measuring CO
2
at lower heating output
1.
Press button D until the service indicator has dropped down to “0” (lower heating output).
2.
Measure CO
2
content at the flue gas pipe.
IMPORTANT
CO
2
content in partial load must always be at least 0.6% lower than in full load.
3. If the CO
2
content must be changed:
Unscrew cover cap B . Turn adjustment screw A in
small increments (Torx 40) until CO
2
content is at the
indicated
Turning clockwise → CO
2
content increases,
Turning counter-clockwise → CO
2
content decreases.
4. Record measurement reading in maintenance record on
page
Check measurement readings again.
Start up the upper and lower heating output via the
burner control unit. If the values do not correspond
with the permissible CO
2
contents as per the tables,
the steps for the upper and lower heating output must repeated.
5. Press buttons S E and D simultaneously for longer than 2 sec. Burner changes to operating mode.
CA3B Boiler
2.5 and 3.0
3.5 to 6.0
Burner models
1.25 MMBTU
1.5 MMBTU
1.5 MMBTU
2.0 MMBTU
Permissable CO
2
content (%)
Natural Gas Liquid Propane Gas
8.1 - 8.4
8.9 - 9.3
8.1 - 8.4
8.1 - 8.4
8.1 - 8.4
8.1 - 8.4
8.1 - 8.4
8.5 - 8.9
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Displaying Ionization Current
Service
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.
2. Press button until “5” appears under Service.
3. Press button S. “5” will appear under Status.
4. Press button until “3” appears under Service.
5. Press button S. “3” will appear under Status and the
ionization current in operation will be indicated under
Service (i.e. 30 = 3,0 μ A).
6. Put burners into operation with the emissions test-
switch on the GW6C control.
Refer to the Operating Instructions.
7. Take ionization current reading.
IMPORTANT
The ionization current must reach a minimum of 3 μ A for approximately 2 to 3 sec. after opening of the combination gas valve and while in operation.
8. Record the measurement reading in the maintenance record on page 162.
9. Press button S approx. 2 sec, „ “ will blink.
10. Press button until “5” appears under Service.
11. Press button S. “5” will appear under Status.
12. Press button until “0” appears under Service.
13. Press button S. The operating status indicator again.
69
70
Service
Dismantling the Burner
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
3. Pull off the ignition electrode connectors.
4. Remove 2 screws on the ignition electrode block.
Lift the electrode block upwards to remove.
5. Remove the 6 nuts around the burner mounting plate.
6. Remove upper burner section.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Dismantling the Burner
(continued)
Service
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.
1. Remove 8 nuts from the combustion chamber cover
plate.
2. Lift out mounting plate with burner tube.
71
Service
Checking and Cleaning the Burner Tube
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
72
CAUTION
Scratches in the combustion chamber can lead to corrosion. Do not allow any tools or other objects to fall into the combustion chamber.
CAUTION
Contamination of the burner tube can lead to malfunctions.
When exchanging the burner tube, ensure that no fibres from the heat insulation block stick to the burner tube.
CAUTION
Improperly executed exchange of the burner tube can lead to contamination of the combustion chamber.
Ensure that the combustion chamber is maintained free of insulation fibers.
WARNING
Gas leakage can lead to risk of explosion. Close gas shut-off valve.
WARNING
Contact with hot surfaces can lead to burn injuries.
Undertake work on the burner only when the system is cold.
1. Dismantle the burner. Refer to section starting on page 70.
2. Undo 6 screws from the insulation ring.
Torque when installing: 13 lb.in (1.5 Nm.)
3. Remove the insulation ring.
4. Unscrew the burner gauze assembly.
You can now vacuum or replace the burner gauze assembly. Torque when installing: 7.5 lb.ft (10 Nm.)
5. Replace all gaskets. Reassemble burner tube and
burner in reverse order. Torque: 7.5 lb.ft (10 Nm).
6. Remove the insulation ring.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Checking the Ignition Electrodes and Ionization Electrode
Service
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. Replace electrodes if
necessary.
3. Install the electrode block in reverse order.
Fit new gaskets. Torque: 4.4 lb.ft (6 Nm).
Cleaning the Burners
Compact burner 1.25/1.5
Legend
A Combination gas valve
B Gas connector pipe
C Fitting at gas connector pipe
D Venturi-mixing tube
E Burner fan
F Burner tube
Burner 1.5/2.0
IMPORTANT
Close the central gas shut-off valve for all dismantlement work on the burners.
For dismantling the burners refer to section starting on page 70.
1. Disconnect Venturi mixing tube D from fan E .
2. Detach Venturi mixing tube D with combination gas
valve A and gas connector pipe B and if applicable,
detach connector pipes.
3. Detach connector a-Ö and a-Ö A from fan E and
dismantle fan.
4. Clean fan housing and fan impeller with compressed air.
5. If necessary, vacuum clean burner tube F from
inside and out.
6. Reassemble in reverse order.
IMPORTANT
Ensure correct positioning of gasket between fan housing and burner plate. Replace gasket if damaged.
WARNING
Risk of explosion due to gas leakage. Check for gas leakage at screws and the gasket between the fan housing and the burner plate.
73
74
Service
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Cleaning the Combustion Chamber and Heating Surfaces
CAUTION
Scratches in the combustion chamber can lead to corrosion. Do not allow any tools or other objects to fall into the combustion chamber.
CAUTION
Scratches on parts that come into contact with flue gas can lead to corrosion. Use only plastic brushes; do not use metal brushes or sharp objects.
Cleaning the combustion chamber and heating surfaces
1. Clean the combustion chamber by vacuuming loose debris out.
2. Remove embedded sediment from the stainless steel heat exchanger surface by thoroughly rinsing with water or solvent free cleaning agents such as citric acid based cleaners. Consult a cleaning agent manufacturer for a suitable product.
Avoid getting the refractory wet during cleaning.
Note: Discoloration of the heat exchanger surface is the normal result of the combustion process.
It has no impact on the functionality or the longevity of the heat exchanger.
3. Use a non-metallic brush if necessary, with a gentle brushing motion to remove the embedded
sediment.
It is not recommended to use chemicals to clean the heat exchanger surface.
4. Flush the combustion chamber with water until it runs clear through the condensate trap.
5. Remove and clean out any accumulated debris from condensate trap. Reinstall condensate trap.
See page 78 for details.
Checking gaskets and thermal insulation parts
1. Check gaskets and the sealing rope for damage.
2. Check the thermal insulation components for possible
damage.
3. Replace any damaged parts.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Burner Reassembly
Service
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).
2. Position the upper burner section above the burner plate.
Tighten the M10 nuts with a torque of 7.3 lb.ft (10 Nm).
3. Push on the ignition and ionization electrode connectors.
4. Insert connectors at the plug-in panel and at the burner control unit; insert mains plug fÖ last.
5. Fit the gas connection pipe.
Note: The use of leak detection spray can result in faulty operation. Leak detection spray must not come into contact with electrical contacts.
6. Start the burner and carry out a function test. Vitocrossal
CA3B installation and service instructions.
Automatic Leakage Test for Valves of the Combination Gas Valve
WARNING
Risk of explosion due to gas leakage. Check for gas leakage at the gauge connections.
The burner control unit triggers an automatic leakage check of both valves at burner start-up.
If valves are leak-free the burner shifts into normal operating mode and the burner ignites.
If the first valve leaks, the error code “ F E1 ” will appear in the burner control unit display, if the second valve leaks, “ F E2 replaced.
” will appear.
In both cases, the combination gas valve should be
Taking Final Measurement Reading
1. Take CO
2
measurement reading after each burner
dismantling in accordance with the items shown on
pages 67 and 68.
2. Record the measurement readings in the maintenance
record on page 162.
75
76
Service
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Checking Expansion Tank and System Pressure
CAUTION
Damage on boiler or other system components may result if these recommendations are not followed.
Check proper expansion tank and system pressures
See expansion tank manufacturer’s instructions.
CAUTION
Carry out all check in accordance with the expansion tank manufacturer’s instructions. Limit pressure fluctuations to the lowest possible differential. Cyclical pressure fluctuations and greater pressure differentials indicate a system fault. Immediately remedy such faults, otherwise other heating system components may become faulty.
IMPORTANT
The diaphragm expansion tank must be able to hold the heating water expansion volume inside the boiler, and must be properly sized for the system.
This diaphragm expansion vessel reduces the frequency and severity of pressure fluctuations; the service life of the circulating pump is improved and therefore the operational reliability and service life of system components increased.
IMPORTANT
Carry out this test on a cold system.
1. Drain system or close cap valve on the diaphragm
expansion tank and reduce the pressure until the
pressure gauge indicates “0”.
2. 60°F (15.5°C) water fill pressure must equal diaphragm expansion tank pressure.
Mixing Valve Movement and Leak Check
1. Remove motor lever from mixing valve handle.
2. Check mixing valve for ease of movement.
3. Check leak tightness of mixing valve. Replace O-ring if there is a leakage.
4. Engage motor lever.
Checking Air Intake in the Installation Room
(visual check)
Check filter and air intake during room-air-dependent operation.
Check the air intake outside the installation room as well during room-air-dependent operation.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Sensors
Viessmann NTC 10 k Ω (blue ID label)
Service
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
Instructions
DHW Tank, supply and room temperature sensor
Note: The supply temperature sensor can be used as a contact or immersion temperature sensor.
Refer to the Installation and service instructions
for Vitotrol 300.
1. Pull corresponding plug.
2. Check the sensor resistance and compare it with the
curve.
3. In the case of severe deviation, check the installation and replace the sensor if required.
Temperature
Viessmann NTC 10 k Ω Outdoor temperature sensor
1. Pull plug !
.
2. Check the sensor resistance across plug terminals “1” and “2” and compare with the curve.
3. If the results are very different from the curve, disconnect the wires from the sensor and repeat the test on the sensor.
4. Depending on the result, replace the lead or the outdoor temperature sensor.
Temperature
77
78
Service
Cleaning of Condensate Drainage System
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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 pipe).
3. Clean the neutralizing system (if installed) in accordance with the manufacturer‘s instructions.
See Neutralization System Operating
Instructions.
Note: You can obtain the neutralizing granulate from
Viessmann.
4. Release and flush lower part C of siphon cup B .
5. Fill lower part C of siphon cup B with water and
reassemble.
6. Install hose A of the neutralizing system to the siphon.
Checking the condensate drain and the neutralizing system (if installed)
Add water to the flue gas collector through the inspection port E .
Note: The water must flow from the condensate drain without back pressure.
If necessary, clean the condensate drain again.
IMPORTANT
If the condensate does not drain freely, the condensate will accumulate in the bottom part of the boiler, resulting in burner shut-down (fault message).
Check neutralization unit (if installed)
1. Check the pH value of the condensate with a pH measuring strip (field supplied). If the pH value is less than 6.5, replace granulate.
2. If contaminated - rinse the neutralization unit with water.
3. Add granulate as marked.
IMPORTANT
The granulate is consumed as it neutralizes the condensate.
The red marking indicates the minimum filling level.
See Neutralization Unit ”Installation Instructions”.
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.
4. Disassemble the air filter frame.
5. Replace air filter.
6. Reassemble panel in reverse order.
Service
79
80
Coding Levels
Calling up Coding Levels
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
H
The coding indicators are preset by the configuration of the heating system .
H
Coding is split into the following groups:
“General”
– “Burner control unit”
–
“Solar”
– “Heating circuit 1/2/3”
“Cascade”
– “All coding”
In this group, all coding in the coding levels is listed in ascending order (except the coding in the “Solar” group).
H
Heating systems with one heating circuit without mixing valve and one or two heating circuits with mixing valve:
In the following, the heating circuit without mixing valve is designated “Heating circuit 1” and the heating circuits with mixing valve as “Heating circuit 2” or
“Heating circuit 3”.
H
The selected designation appears if the heating circuits have been designated individually.
From the home screen tap the following buttons:
1.
2. “Service”
3. Enter “viservice” password.
4. “System configuration”
5. “Coding level 1”
or...
“Coding level 2”:
Enter “viexpert” password.
6.
Select group.
7.
8. for the required value in line with the following tables.
9. to accept.
Resetting Coding to their Factory Set Condition
From the home screen tap the following buttons:
1.
2. “Service”
3. Enter “viservice” password.
4. “System coding”
5. “Coding level 1”
or...
“Coding level 2”:
Enter “viexpert” password.
6. “Reset coding”
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“General” Group
Coding Level 1
Coding
Coding in the factory set condition
System design
00:1 System version 1:
One heating circuit without mixing valve
A1 (heating circuit 1), without DHW heating
Possible change
00:2 to
00:10
For system schemes, see the following table:
3
4
5
Value address 00:
...
2
6
7
8
9
10
Description
One heating circuit without mixing valve A1 (heating circuit 1), with DHW heating; recognized automatically.
One heating circuit with mixing valve M2 (heating circuit 2), without DHW heating.
One heating circuit with mixing valve (heating circuit 2), with DHW heating
One heating circuit without mixing valve A1 (heating circuit 1), one heating circuit with mixing valve M2 (heating circuit 2), without DHW heating; recognized automatically.
One heating circuit without mixing valve A1 (heating circuit 1), one heating circuit with mixing valve M2 (heating circuit 2), with DHW heating; recognized automatically.
Two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), without DHW heating.
Two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), with DHW heating.
One heating circuit without mixing valve A1 (heating circuit 1), two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), without DHW heating; recognized automatically.
One heating circuit without mixing valve A1 (heating circuit 1), two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), with DHW heating; recognized automatically.
Coding in the factory set condition
Servomotor runtime
40:125 Actuator runtime at plug
Do not adjust!
gS A1 125 sec.
Possible change
40:5 to
40:199
LON participant no.
77:1 LON Participant number
Boiler section 1 set to 1, boiler section 2 set to 2 boiler section 3 set to 3.
77:1 to
77:99
IMPORTANT
If coding is to be set to the factory set condition, the participant number must be reset.
Adjustable from 5 to 199 sec.
Adjustable from 1 to 99:
1 to 8 = Boiler section
10 - 96 = Vitotronic 200-H
97 = Vitogate 300
98 = Vitogate
99 = Vitocom
“Detached house/apartment building”
7f:1 Detached house 7F:0 Apartment building
Separate adjustment of holiday program and time program for DHW heating possible.
81
82
Coding Level 1
“General” Group
(continued)
Coding in the factory set condition
“Automatic summer/wintertime changeover”
81:1 Automatic summer/wintertime changeover.
“Summer time starts: Month”
82:3 March
“Summer time starts: Week of the selected month”
83:2 Week 2 of the selected month.
“Summer time starts: Day of the selected week”
84:7 Last Sunday of the selected month.
“Wintertime starts: Month”
85:11 November
“Wintertime starts: Week of the selected month”
86:1 Week 1 of the selected month.
“Wintertime starts: Day of the selected week”
87:7 Last Sunday of the selected month.
“Operation enabled/blocked”
8f:0 Do not adjust!
“Set supply temperature for external demand”
9b:70 Set to 158°F (70°C)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Possible change
81:0
81:2
81:3
Manual summer/wintertime changeover
Do not adjust!
With LON communication module:
The control unit receives the time.
82:1 to
82:12
83:1 to
83:5
83:6
83:7
83:8
83:9
83:10 to
83:14
January to December
Week 1 to week 5 of the selected month.
Last week - 1 week
Last week - 2 weeks
Last week - 3 weeks
Last week - 4 weeks
Special function
86:1 to
86:5
87:1 to
87:7
84:1 to
84:7
85:1 to
85:12
Monday to Sunday.
January to December
Week 1 to week 5 of the selected month.
Monday to Sunday
---
9b:0 to
9b:127
Adjustable from 32°F to 261°F (0°C to 127°C)
(limited by boiler specific coding).
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“Combustion Controller” Group
Coding
Coding in the factory set condition
“Max operational output”
02:100 100% of rated heating output.
“Gas type”
03:0 Natural gas
“Altitude”
04:0 LA: ≤ 5000 ft. (1500 m) above sea level
“Max boiler temperature”
06:95 Set to 203°F (95°C).
“Integral threshold value of controller”
08:30
09:1
Set to 30 Kmin.
“Runtime optimization”
Integral method
Coding Level 1
Possible change
02:0 to
02:100
Adjustable from 0% to 100%
(0% represents burner minimum firing rate).
03:1 Liquid Propane Gas
04:1
06:5 to
06:127
HA: > 5000 ft. (1500 m) above sea level
Adjustable from 41°F to 261°F (5°C to 127°C).
IMPORTANT
Supply temperature limit switch common supply,
[set to 210°F (99°C)] [tolerance -11°F (-6K)].
Adjustable from 1 to 255 K min 08:1 to
08:255
09:0 Minimum pause
“Boiler” Group
Coding in the factory set condition
“Single boiler and multi boiler system”
01:2 Multi-boiler system with Viessmann-cascade or LON-cascade.
Possible change
01:1
01:3
Do not adjust!
Do not adjust!
“Consecutive boiler number in multi boiler systems”
07:1 Consecutive boiler section number in multi boiler systems.
07:2 to
07:8
Adjustable from 1 to 8
7:1 Lead boiler section
7:2-8 Lag boiler sections
“Flue gas temperature sensor”
1f:0 Do not adjust!
“Service interval”
21:0 No service interval (hours run) selected.
--
21:1 to
21:100
--
The number of hours run before the burner should be serviced is adjustable from 100 to
10000 h; 1 step 100 h.
“Interval for service”
23:0 No interval for service.
23:1 to
23:24
Adjustable from 1 to 24 months.
”Service” display”
24:0 No “Service” display 24:1 “Service” is displayed (the address is automatically set and must be manually reset after a service has been carried out).
83
84
Coding Level 1
“Cascade” Group
Coding
Coding in the factory set condition
“Number of boilers connected to the cascade”
35:2 to 3
Boiler sections
Factory set conditions:
CA3B 2.5/3.0/3.5/4.0: 2
CA3B 5.0/6.0: 3
“Minimum system supply temperature limit”
36:0 Electronic minimum system supply temperature limit set to 32°F (0°C).
“Maximum system supply temperature limit”
37:80 Electronic maximum system supply temperature limit set to 176°F (80°C).
“Boiler section 1 or boiler sequence changeover”
38:0 No boiler section boiler sequence changeover
Do not adjust!
“Permanent boiler section 1”
39:0 No permanent lead boiler section.
Do not adjust!
“Permanent last boiler”
3a:0 No permanent last boiler section.
Do not adjust!
Possible change
35:1 to
35:8
1 to 8 boiler sections connected to lead control
36:1 to
36:127
37:20 to
37:127
38:1
38:2 to
38:200
39:1 to
39:3
3a:1 to
3a:3
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Adjustable from 32°C to 261°C (0°C to 127°C)
(only when operating with standard room temperature).
Adjustable from 68°F to 261°F (20°C to 127°C).
Note: Value must be lower than the lowest value of coding “06” in the “Combustion controller” group of every control unit.
Boiler section 1 changeover:
Every first day of the month, the boiler with the shortest number of hours run by its burner becomes the boiler section 1.
Boiler section 1 changeover after 200 to
20,000 hours run
1 step 100 hours run.
Permanent lead boiler section is 1, 2, 3, 4, 5,
6, 7 or 8.
Permanent last boiler section is 1, 2, 3, 4, 5, 6,
7 or 8.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“Cascade” Group
(continued)
Coding Level 1
Coding in the factory set condition
“Type of control”
3b:1 Standalone parallel boiler circuit:
With supply temperature sensor
(refer to page 45).
3b:4
“Control strategy”
3c:0 Condensing strategy (see page 46).
3c:1
3c:2
“Output statement”
3d:1 Output statement for condensing strategy and conventional boiler strategy 1.
3d:0
Possible change
3b:0
3b:2
3b:3
Standalone parallel boiler circuit:
Without supply temperature sensor
(refer to page 45).
Standalone serial boiler circuit:
Without supply temperature sensor
(refer to page 45).
Standalone serial boiler circuit:
With supply temperature sensor (refer to page
45).
Sequential control method with supply temperature sensor (refer to page 45).
Conventional boiler strategy 1 (refer to page 47).
Conventional boiler strategy 2 (refer to page 47).
No output statement
Note: Control only in accordance with conventional boiler strategy 2.
“ECO threshold boiler 1”
41:31 No ECO threshold boiler 1.
Do not adjust!
“ECO threshold boiler 2”
42:31 No ECO threshold boiler 2.
Do not adjust!
“ECO threshold boiler 3”
43:31 No ECO threshold boiler 3.
Do not adjust!
“ECO threshold boiler 4”
44:31 No ECO threshold boiler 4.
Do not adjust!
41: to
− 30
41:+30
42: − 30 to
42:+30
43: to
43:+30
44: to
−
−
30
30
44:+30
Adjustable from -22°F to 86°F
(-30°C to +30°C).
Adjustable from -22°F to 86°F
(-30°C to +30°C).
Adjustable from -22°F to 86°F
(-30°C to +30°C).
Adjustable from -22°F to 86°F
(-30°C to +30°C).
85
86
Coding Level 1
“
Cascade” Group
(continued)
Coding in the factory set condition
“Stop differential”
47:15 Set to 27°F (15 K).
“ECO threshold boiler 5”
65:31 No ECO threshold boiler 5.
Do not adjust!
“ECO threshold boiler 6”
6F:31 No ECO threshold boiler 6.
Do not adjust!
“ECO threshold boiler 7”
74:31 No ECO threshold boiler 7.
Do not adjust!
“ECO threshold boiler 8”
7d:31 No ECO threshold boiler 8.
Do not adjust!
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Possible change
47:2 to
47:30
Adjustable from 4°F to 54°F (2 K to 30 K).
Note: One boiler or one burner stage will be shut down if the actual supply temperature exceeds the set supply temperature by this value.
Adjustable from -22°F to 86°F
(-30°C to +30°C).
65: − 30 to
65:+30
6F: − 30 to
6F:+30
Adjustable from -22°F to 86°F
(-30°C to +30°C).
74: − 30 to
74:+30
7d: − 30 to
7d:+30
Adjustable from -22°F to 86°F
(-30°C to +30°C).
Adjustable from -22°F to 86°F
(-30°C to +30°C).
“
DHW” Group
Coding
Coding in the factory set condition
“Storage tank heating, hysteresis”
55:0 Tank heating hysteresis ± 5°F (2.5 K).
Possible change
55:1
55:2
55:3
Adaptive storage tank heating enabled
(refer to page 44).
Storage tank temperature control with 2 temperature sensors (refer to page 44).
Storage tank temperature control, storage tank loading system.
Do not adjust!
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“DHW” Group
(continued)
Coding Level 1
Coding in the factory set condition
“For solar DHW heating: DHW temperature target”
67:40 DHW setpoint temperature 104°F (40°C).
Reheating is suppressed above the selected set temperature (DHW heating blocked by the boiler).
“DHW recirculation pump”
73:0 ON according to time program
Possible change
67:0 to
67:95
73:1 to
73:6
73:7
Adjustable from 32°F to 203°F (0°C to 95°C)
(limited by boiler-specific coding).
“ON” from once per hour for 5 min up to 6 times per hour for 5 min during the time program.
Permanently ON
“Solar” Group
Note: The “Solar” group is only displayed if a solar control module, type SM1, is connected.
Coding
Coding in the factory set condition
“Solar circuit pump speed control”
02:0 Solar circuit pump is not speed controlled.
Possible change
02:1
02:2
“Maximum storage tank temperature”
08:60 DHW setpoint temperature (maximum tank temperature) 140°F (60°C).
“Stagnation time reduction”
0a:5 Temperature differential for stagnation time reduction (reduction in the speed of the solar circuit pump to protect system components and heat transfer medium) 11°F (5 K).
08:10 to
08:90
0a:0
0a:1 to
0a:40
“Solar circuit flow rate”
0f:70 Solar circuit flow rate at maximum pump speed 1.8 USG/min (7 L/min).
0f:1 to
0f:255
Variable speed solar circuit pump with wave packet control.
Solar circuit pump speed controlled with PWM control.
Adjustable from 50°F to 194°F
(10°C to 90°C).
Stagnation time reduction disabled.
Temperature differential adjustable from
2°F to 72°F (1 K to 40 K).
Adjustable from 0.02 USG/min to 6.7 USG/min
(0.1 L/min to 25.5 L/min),
1 step 0.02 USG/min (0.1 L/min).
87
88
Coding Level 1
“Solar” Group
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Coding in the factory set condition
“Extended control function”
20:0 No extended control function enabled.
20:1
20:2
20:3
20:4
20:5
20:6
20:7
20:8
20:9
Possible change
Additional function for DHW heating.
Differential temperature control 2.
Differential temperature control 2 and auxiliary function.
Differential temperature control 2 for central heating backup.
Thermostat function
Thermostat function and auxiliary function.
Solar heating via external heat exchanger without additional temperature sensor.
Solar heating via external heat exchanger with additional temperature sensor.
Solar heating of two DHW storage tanks.
“Heating Circuit ...” Group
Coding
Coding in the factory set condition
“Storage tank priority” a2:2 Tank priority control for heating circuit pump and mixing valve.
Possible change a2:0 a2:1 a2:3 to a2:15
“Heating circuit pump logic function (economy control)” a5:5 With heating circuit pump logic function
(economy control): heating circuit pump
OFF when the outdoor temperature (OT) is 2°F (1 K) higher than the set room temperature (RTset) OT > RTset +2°F
(1 K).
a5:0 a5:1 to a5:15
Without storage tank priority applicable to heating circuit pump and mixing valve.
Storage tank priority only applicable to mixing valve.
Modulating priority applies to mixing valves, i.e. the heating circuit receives a reduced amount of heat.
Without heating circuit pump logic function.
With heating circuit pump logic function:
Heating circuit pump OFF, see the following table.
3
4
5
6
7 to
15
1
2
Coding address a5:...
With heating circuit pump logic function:
Heating circ pump OFF
OT > RTset +9°F (+ 5 K)
OT > RTset +7°F (+ 4 K)
OT > RTset +5°F (+ 3 K)
OT > RTset +4°F (+ 2 K)
OT > RTset +2°F (+ 1 K)
OT > RTset
OT > RTset –2°F (– 1 K)
OT > RTset –16°F (– 9 K)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“Heating Circuit ...” Group
(continued)
Coding Level 1
Coding in the factory set condition
“Extended economy mode” a6:36 Extended economy mode disabled.
Possible change a6:5 to a6:35
Extended economy mode enabled, i.e. the burner and heating circuit pump will stop and the mixing valve will be closed at a variable value, adjustable between 41°F to 95°F (5°C and 35°C) plus 2°F (1°C). The base value is the adjusted outdoor temperature. This value is based on the actual outdoor temperature and a time constant, which takes the cooling down of an average building into consideration.
“Mixing valve economy function” a7:0
“Pump idle time” a9:0
Only for heating circuits with mixing valve:
Without mixing valve economy function.
Without pump idle time.
a7:1 a9:7 a9:1 to a9:15
With mixing valve economy function:
Heating circuit pump also OFF:
H
Mixing valve tries closing for more than
20 min.
Heating circuit pump ON:
H
Mixing valve in control mode.
H
If there is a risk of frost
With pump idle time (heating circuit pump turned off).
Refer to function description on page 40.
Note: The maximum idle time is 10 h.
Pump idle time adjustable from 1 to 15.
1: Short idle time
15: Long idle time
“Room temperature hook-up” b0:0 With remote control:*
Heating mode/reduced mode:
Weather-compensated
1 b0:1 b0:2
Heating mode: Weather-compensated
Reduced mode: with room temperature hook-up
Heating mode: with room temperature hook-up
Reduced mode: Weather-compensated b0:3 Heating mode/reduced mode: with room temperature hook-up.
“Room temperature-dependent heating circuit pump logic function” b5:0 With remote control:
No room temperature-dependent heating circuit pump logic function.
b5:1 to b5:8
For heating circuit pump logic function, see the following table:
* 1 Only change the coding for the heating circuit without mixing valve A1 for boilers without lower temperature limit or for heating circuits with mixing valve if a remote control is connected to them.
89
90
Coding Level 1
“Heating Circuit ...” Group
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
5
6
3
4
7
8
1
2
Coding address b5:...
With heating circuit pump logic function:
Heating circ pump OFF
RTactual > RTset +9°F (+ 5 K)
RTactual > RTset +7°F (+ 4 K)
RTactual > RTset +5°F (+ 3 K)
RTactual > RTset +4°F (+ 2 K)
RTactual > RTset +2°F (+ 1 K)
RTactual > RTset
RTactual > RTset -2°F (– 1 K)
RTactual > RTset -4°F (– 2 K)
Heating circuit pump on
RTactual < RTset +7°F (+ 4 K)
RTactual < RTset +5°F (+ 3 K)
RTactual < RTset +4°F (+ 2 K)
RTactual < RTset +2°F (+ 1 K)
RTactual < RTset
RTactual < RTset -2°F (-1 K)
RTactual < RTset -4°F (-2 K)
RTactual < RTset -5°F (-3 K)
Coding in the factory set condition
“Minimum supply temperature limit” c5:20 Electronic supply temperature minimum limit 68°F (20°C) (only for operation with standard room temperature).
“Maximum supply temperature limit” c6:75 Electronic maximum supply temperature limit set to 167°F (75°C).
Possible change c5:1 to c5:127 c6:10 to c6:127
“External operating program changeover” d5:0 With external operating program changeover
(observe setting of coding “5d”, “5e”, “5f” and
“91” in the “General” group).
Changeover “Constant central heating with reduced room temperature” or “Standby mode”
(subject to set reduced room temperature).
“EA1 extension: Operating program changeover” d8:0 No operating program changeover.
d5:1 d8:1 d8:2 d8:3
Adjustable from 34°F to 261°F (1°C to
127°C) (limited by boiler specific coding).
Adjustable from 50°F to 261°F (10°C to
127°C) (limited by boiler specific coding).
Changeover to “Constant operation with standard room temperature”.
Operating program changeover via input
DE1.
Operating program changeover via input
DE2.
Operating program changeover via input
DE3.
“Slab curing” f1:0 Slab curing function not active.
Do not adjust!
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“Heating Circuit ...” Group
(continued)
Coding Level 1
Coding in the factory set condition
“Time limit for comfort mode” f2:8 Time limit for comfort mode or external operating program changeover via push button: 8 h.
Possible change f2:0 No time limit
Note: Observe setting of coding “5d”,
“5e”, “5f” in the “General” group, as well as “d5” and “d8” in the “Heating circuit...” group.
“Temperature limit for terminating reduced mode” f8:–5 Temperature limit for terminating reduced mode 25°F (-5°C), refer to example on page 42.
Observe coding “a3”.
f2:1 to f2:12 f8:+10 to f8:–60 f8:–61
Time limit adjustable from 1 to 12 h.
Adjustable from 50°F to -76°F
(+10°C to -60°C).
Function disabled
“Temperature limit for raising the reduced room temperature target” f9:–14 Temperature limit for raising the reduced room temperature target 7°F (-14°C).
Refer to example on page 42.
f9:+10 to f9:–60
Adjustable from 50°F to -76°F
(+10°C to -60°C).
“Raising the set boiler water or supply temperature when changing from operation with reduced room temperature to operation with standard room temperature”
Adjustable from 0 to 50%.
fa:20 Raising the set boiler water or supply temperature when changing from operation with reduced room temperature to operation with standard room temperature by 20%. Refer to example on page 42.
fa:0 to fa:50
“Duration for raising the set boiler water or supply temperature” fb:60 Duration for raising the set supply temperature (see coding “fa”) 60 min.
Refer to example on page 42.
fb:0 to fb:300
Adjustable from 0 to 300 min.
91
92
Coding Level 2
“General” Group
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Coding
Coding in the factory set condition
System design
00:1 System version 1:
One heating circuit without mixing valve
A1 (heating circuit 1), without DHW heating.
Possible change
00:2 to
00:10
For system schemes, see the following table:
3
4
5
Value address
00: ...
2
6
7
Description
One heating circuit without mixing valve A1 (heating circuit 1), with DHW heating; recognized automatically.
One heating circuit with mixing valve M2 (heating circuit 2), without DHW heating.
One heating circuit with mixing valve (heating circuit 2), with DHW heating.
One heating circuit without mixing valve A1 (heating circuit 1), one heating circuit with mixing valve M2 (heating circuit 2), without DHW heating; recognized automatically.
One heating circuit without mixing valve A1 (heating circuit 1), one heating circuit with mixing valve M2 (heating circuit 2), with DHW heating; recognized automatically.
Two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), without DHW heating.
8
9
Two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), with DHW heating.
One heating circuit without mixing valve A1 (heating circuit 1), two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), without DHW heating; recognized automatically.
10
12:5
One heating circuit without mixing valve A1 (heating circuit 1), two heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3), with DHW heating; recognized automatically.
Coding in the factory set condition Possible change
“With EA1 extension: DHW recirculation pump runtime for brief operation”
DHW recirculation pump runtime for brief operation: 5 min.
12:1 to
12:60
Adjustable from 1 to 60 min.
“With EA1 extension: Temperature demand”
1E:0 Analog input 0-10V: Temperatur demand from 32°F to 212°F
(0°C to 100°C):
1V 32°F (0°C)
10 212°F (100°C)
1E:1 Adjustable from 86°F to 248°F
(30°C to 120°C):
1V 86°F (30°C)
10V 248°F (120°C)
2f:0
“AM1 extension”
32:0
Do not adjust!
Without AM1 extension
“Function output A2 at AM1 extension”
33:1 Heating circuit pump, heating circuit without mixing valve A1
(heating circuit 1).
32:1
33:0
33:2
33:3
With AM1 extension
DHW recirculation pump
DHW loading pump
Circulation pump neutralizing system or flue gas/water-heat exchanger.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“General” Group
(continued)
Coding Level 2
Coding in the factory set condition
“Function output A1 at AM1 extension”
34:0 DHW recirculation pump.
Possible change
34:1
34:2
34:3
“Servomotor runtime”
40:125 Servomotor runtime at plug gS A1 125 sec
Do not adjust!
“Sensor 17A”
4a:0 Do not adjust!
“Sensor 17B”
4b:0 No sensor aJ B installed.
40:5 to
40:199
--
4b:1
Heating circuit pump without mixing valve A1
(Heating circuit 1).
Tank loading pump
Circulation pump neutralizing system or flue gas/water-heat exchanger.
Adjustable from 5 sec. to 199 sec.
--
Sensor aJ B installed (e.g. temperature sensor
T2); automatic recognition.
“Connection at plug 20A1”
4c:0 Connection on plug
Heating circuit pump sÖ A1:
“Connection at plug 29”
4d:1
Connection at plug sL : Shunt pump.
4c:1
4c:2
4d:0
4d:2
4d:3
“Connection at plug 52A1”
4e:0 Motor isolation valve.
4e:1
4e:1 to
4e:3
“Delay off time, shunt or system pump”
4f:5 Delay off time system pump 5 min.
4f:0
4f:1 to
4f:60
“Supply temperature sensor for hydraulic low loss header”
52:0 Do not adjust!
“Solar thermal system”
54:0 Without solar thermal system.
54:1 to
54:3
54:4
Primary pump, tank loading system.
Thermal control switch contact .
System pump
Boiler pump
Boiler pump with isolation valve function.
Motor for 3-way mixing valve for return temperature control.
Do not adjust!
No pump delay off.
Adjustable from 1 to 60 min.
Do not adjust!
With solar control module, type SM1, with auxiliary function, e.g. central heating backup; automatic recognition.
“EA1 extension”
5b:0 Without EA1 extension.
5b:1 With EA1 extension; automatic recognition.
93
94
Coding Level 2
“General” Group
(continued)
Coding in the factory set condition
“Function output 157 at EA1 extension”
5c:0 Function output aBJ
Central fault message at EA1 extension:
“Function input DE1 at EA1 extension”
5d:0 No function
“Function input DE2 at EA1 extension”
5e:0 No function
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Possible change
5c:1
5c:2
5c:3
5c:4
5c:5
Feed pump
No function
Heating circuit pump, heating circuit without mixing valve A1 (heating circuit 1), switched to low speed (reduced mode).
Heating circuit pump, heating circuit with mixing valve M2 (heating circuit 2), switched to low speed (reduced mode).
Heating circuit pump, heating circuit with mixing valve M3 (heating circuit 3), switched to low speed (reduced mode).
5d:1
5d:2
5d:3
5d:4
5d:5
5d:6
5e:1
5e:2
5e:3
5e:4
5e:5
5e:6
Operating program changeover
External demand with minimum set supply temperature. Set value adjustment at coding
“9b” in the “General” group.
External blocking
External blocking with fault message.
Fault message input.
Brief operation, DHW recirculation pump (push button function) Set DHW recirculation pump runtime at coding “12” in the “General” group.
Operating program changeover
External demand with minimum set supply temperature Set value adjustment at coding
“9b” in the “General” group.
External blocking
External blocking with fault message.
Fault message input
Brief operation, DHW recirculation pump (push button function) Set DHW recirculation pump runtime at coding “12” in the “General” group.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“General” Group
(continued)
Coding Level 2
Coding in the factory set condition
“Function input DE3 at EA1 extension”
5f:0 No function
“Shutdown delay neutralization system output 1 AM1”
6c:0 Delay off time circulation pump neutralizing system: None
6c:1 to
6c:255
“Shutdown delay neutralization system output 2 AM1”
6d:0 Delay off time circulation pump neutralizing system: None
6d:1 to
6d:255
“Display correction for outdoor temperature”
6e:50 No display correction for outdoor temperature.
6e:0 to
6e:49
6e:51 to
6e:99
“LON communication module”
76:1 With LON communication module; automatic recognition.
“LON participant number”
77:1 LON participant number
Boiler section 1 set to 1, boiler section 2 set to 2 boiler section 3 set to 3.
76:0
77:2 to
77:99
IMPORTANT
If coding is to be set to the factory set condition, the participant number must be reset.
“LON communication”
78:1 LON communication enabled 78:0
Possible change
5f:1
5f:2
5f:3
5f:4
5f:5
5f:6
Operating program changeover.
External demand with minimum set supply temperature Set value adjustment at coding
“9b” in the “General” group.
External blocking
External blocking with fault message.
Fault message input
Brief operation, DHW recirculation pump (push button function) Set DHW recirculation pump runtime at coding “12” in the “General” group.
Adjustable from 1 to 255 sec
Adjustable from 1 to 255 sec
Display correction -9°F (-5 K) to
Display correction -0.2°F (-0.1 K)
Display correction +0.2°F (+0.1 K) to
Display correction +9°F (+4.9 K)
Without LON communication module.
Adjustable from 1 to 99:
1 to 8 = Boiler section
10 - 96 = Vitotronic 200-H
97 = Vitogate 300
98 = Vitogate
99 = Vitocom
LON communication disabled
95
96
Coding Level 2
“General” Group
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Coding in the factory set condition
“With LON communication module”
79:1
7a:0
“LON communication module: Time”
7b:1
7f:1
Control unit is fault manager.
“Central control of heating circuits”
Without central control of heating circuits.
Control unit transmits the time.
“Detached house/apartment building”
Detached house
“Fault message”
80:6 A fault message is issued if a fault occurs for at least 30 sec.
80:0
80:2 to
80:199
“Automatic summer/wintertime changeover”
81:1 Automatic summer/wintertime changeover.
81:0
81:2
81:3
“Summer time starts: Month”
82:3 March 82:1 to
82:12
Possible change
79:0
7a:1
7a:2
7a:3
7b:0
7F:0
Control unit is not fault manager
IMPORTANT
Must be set for boiler section 2/boiler section 3, refer to page 34 .
With central control Heating circuit without mixing valve A1 (heating circuit 1).
Heating circuit with mixing valve M2
(heating circuit 2).
Heating circuit with mixing valve M3
(heating circuit 3).
No time transmission
IMPORTANT
Must be set for boiler section 2/boiler section 3, refer to page 34 .
Apartment building
Separate adjustment of holiday program and time program for DHW heating possible.
Immediate fault message.
Adjustable from
10 to 995 sec,
1 step 5 sec.
Manual summer/wintertime changeover
Do not adjust!
With LON communication module:
The control unit receives the time.
January to December
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“General” Group
(continued)
Coding Level 2
Coding in the factory set condition Possible change
“Summer time starts: Week of the selected month”
83:2 Week 2 of the selected month.
“Summer time starts: Day of the selected week”
84:7 Last Sunday of the selected month.
84:1 to
84:7
“Wintertime starts: Month”
85:11 November 85:1 to
85:12
“Wintertime starts: Week of the selected month”
86:1 Week 1 of the selected month.
86:1 to
86:5
“Wintertime starts: Day of the selected week”
87:7 Last Sunday of the selected month.
87:1 to
87:7
“Temperature displayed”
88:0 Temperature unit °C (Celsius).
“Test display conditions”
8a:175 Do not adjust!
88:1
--
“Identification KM bus combustion controller”
8b:1 ID exists 8b:0
“Operation enabled/blocked”
8f:0 Do not adjust!
--
“Time constant for calculating adjusted outdoor temperature”
90:36 Time constant 6 h.
90:1 to
90:199
83:1 to
83:5
83:6
83:7
83:8
83:9
83:10 to
83:14
Week 1 to week 5 of the selected month.
Last week – 1 week
Last week – 2 week
Last week – 3 week
Last week – 4 week
Special function
Monday to Sunday
January to December
Week 1 to week 5 of the selected month.
Monday to Sunday
Temperature unit °F (Fahrenheit)
--
ID does not exist
--
Fast (low values) or slow (high values) matching of the supply temperature, subject to the set value when the outdoor temperature changes 1 step 10 min.
97
98
Coding Level 2
“General” Group
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Coding in the factory set condition
“Connection at terminals 1 and 2 in plug 143”
91:0 Connection disabled (external operating program changeover).
Possible change
91:1
91:2
91:3
91:4
91:5
91:6
91:7
Contact affects the following heating circuits:
Heating circuit without mixing valve A1
(heating circuit 1).
Heating circuit with mixing valve M2
(heating circuit 2).
Heating circuit without mixing valve A1
(heating circuit 1) and heating circuit with mixing valve M2 (heating circuit 2).
Heating circuit with mixing valve M3
(heating circuit 3).
Heating circuit without mixing valve A1
(heating circuit 1) and heating circuit with mixing valve M3 (heating circuit 3).
Heating circuit with mixing valve M2
(heating circuit 2) and M3
(heating circuit 3).
Heating circuit without mixing valve A1
(heating circuit 1) and heating circuits with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3).
“Central fault message during emissions test function/service display”
93:0 Does not affect central fault.
93:1
“Communication interface”
95:0 Without Vitocom 100 communication interface.
“Extension for heating circuits 2 and 3 with mixing valve”
95:1
96:1 With PCB extension for heating circuits
2 and 3 Heating circuit is recognized automatically.
“With LON communication module: Outdoor temperature”
97:2 The control unit sends the outdoor temperature to the Vitotronic 200-H.
96:0
97:0
97:1
Affects central fault message
With Vitocom 100 communication interface; automatic recognition.
Without PCB extension for heating circuits 2 and 3.
The outdoor temperature of the sensor connected to the control unit is only utilized internally.
The control unit receives the outdoor temperature from the Vitotronic 200-H.
“Viessmann system number”
98:1 Viessmann system number in conjunction with monitoring of several systems within one LON system with
Vitocom 300.
98:1 to
98:5
Adjustable from 1 to 5
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“General” Group
(continued)
Coding in the factory set condition
“Connection at terminals 2 and 3 in plug 143”
99:0 Connection disabled
“Connection at terminals 1 and 2 in plug 143“
9a:0 Connection disabled.
“Set supply temperature for external demand”
9b:70 Set to 158°F (70°C).
Coding Level 2
Possible change
99:1
99:2
99:3
99:4
99:5
99:6
99:7
99:8
99:9
99:10
99:11
99:12
99:13
99:14
99:15
No function
External “mixing valve closed”
Heating circuit with mixing valve M2
(heating circuit 2).
No function
External “mixing valve closed”
Heating circuit with mixing valve M3
(heating circuit 3).
No function
External “mixing valve closed”
Heating circuit with mixing valve M2
(heating circuit 2) and M3 (heating circuit 3.
No function
External blocking
No function
External blocking/External “mixing valve closed”
Heating circuit with mixing valve M2
(heating circuit 2) and M3 (heating circuit 3).
No function
External blocking/External “mixing valve closed”
Heating circuit with mixing valve M3
(heating circuit 3).
No function
External blocking/External “mixing valve closed”
Heating circuit with mixing valve M2
(heating circuit 2) and M3 (heating circuit 3).
No function
9a:1
9a:2
9a:3
9a:4
9a:5
9a:6
9a:7
No function
External “mixing valve open”
Heating circuit with mixing valve M2
(heating circuit 2).
No function
External “mixing valve open”
Heating circuit with mixing valve M3
(heating circuit 3)
No function
External “mixing valve open”
Heating circuit with mixing valve M2
(heating circuit 2) and M3 (heating circuit 3).
No function
9b:0 to
9b:127
Adjustable from 32°F to 261°F
(0°C to 127°C)
(limited by boiler specific coding).
99
100
Coding Level 2
“General” Group
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Coding in the factory set condition Possible change
“With LON communication module: Monitoring LON participants”
9c:20 Monitoring LON participants
If there is no response from a participant after 20 min, the values specified inside the control unit are used. Only then will a fault message be issued.
9c:0
9c:5 to
9c:60
“Differential temperature”
9f:8 Differential temperature 8 K only in connection with heating circuit with mixing valve M2 (heating circuit 2) and M3 (heating circuit 3).
9f:0 to
9f:40
No monitoring.
Time adjustable from 5 to 60 min.
Adjustable from 0 to 40 K
“Combustion Controller” Group
Coding
Coding in the factory set condition
“Max operational output”
02:100 100% of rated heating output.
“Gas type”
03:0
“Altitude”
04:0
Natural gas
LA: ≤ 5000 ft. (1500 m)
“Max boiler temperature”
06:95 Set to 203°F (95°C)
“Integral threshold value of controller”
08:30 Set to 30 K min
“Runtime optimization”
09:1 Integral method
“Flue gas damper”
0a:0 Without
Possible change
02:0 to
02:100
03:1
Adjustable from 0% to 100%
(0% represents burner minimum firing rate).
Liquid Propane Gas
04:1 HA: > 5000 ft. (1500 m)
06:5 to
06:127
08:1 to
08:255
Adjustable from 41°F to 261°F (5°C to
127°C)
IMPORTANT
Supply temperature limit switch common supply, set to 210°F (99°C)
[tolerance -11°F (-6K)].
Adjustable from 1 to 255 K min.
09:0
0a:1
Minimum pause.
Do not adjust!
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“Boiler” Group
Coding Level 2
Coding
Coding in the factory set condition
“Single boiler and multi boiler system”
01:2 Multi-boiler system with Viessmann-cascade or LON-cascade.
“Consecutive boiler number in multi boiler systems”
07:1 Consecutive boiler section number in multi boiler systems.
Possible change
01:1
01:3
07:2 to
07:8
“Therm Control”
Od:0 Without Od:1
Od:2
“Flue gas temperature sensor”
1f:0 Do not adjust!
“Service interval”
21:0 No service interval (hours run) selected.
21:1 to
21:100
“Interval for service”
23:0 No interval for service.
23:1 to
23:24
Do not adjust!
Do not adjust!
Adjustable from 1 to 8
7:1 Lead boiler section
7:2-8 Lag boiler sections
Do not adjust!
Do not adjust!
The number of hours run before the burner should be serviced is adjustable from 100 to 10000 h; 1 step 100 h
Interval adjustable from 1 to 24 months.
”Service” display”
24:0 No “Service” display.
24:1 “Service” display.
The address is automatically set and must be manually reset after a service has been carried out.
“Maximum preheating time of isolation valve”
2b:5 Preheating time 5 min.
2b:1 to
2b:60
Maximum preheating time of isolation valve, adjustable from 1 to 60 min.
“Maximum shutdown delay of isolation valve”
2c:5 Shutdown delay 5 min.
2c:1 to
2c:60
Maximum shutdown delay of isolation valve, adjustable from 1 to 60 min.
“Cascade” Group
Coding
Coding in the factory set condition
“Number of boilers connected to the cascade”
35:2 or 3 Boiler sections
Factory set condition:
CA3B 2.5/3.0/3.5/4.0: 2
CA3B 5.0/5.0: 3
Possible change
35:1 to
35:8
1 to 8 sections connected to the lead control
101
102
Coding Level 2
“Cascade” Group
(continued)
Coding in the factory set condition
“Minimum system supply temperature limit”
36:0 Set to 32°F (0°C).
“Maximum system supply temperature limit”
37:80
“Boiler section 1 or boiler sequence changeover”
38:0
39:0
Set to 176°F (80°C).
No boiler section boiler sequence changeover
Do not adjust!
“Permanent boiler section 1”
No permanent lead boiler section.
Do not adjust!
“Permanent last boiler”
3a:0 No permanent last boiler section.
Do not adjust!
“Type of control”
3b:1 Standalone parallel boiler circuit:
With supply temperature sensor
(refer to page 45).
“Control strategy”
3c:0 Condensing strategy (see page 46).
3c:1
3c:2
“Output statement”
3d:1 Output statement for condensing strategy and conventional boiler strategy 1.
3d:0
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
38:2 to
38:200
39:1 to
39:8
3a:1 to
3a:8
3b:0
Possible change
36:1 to
36:127
Adjustable from 32°F to 261°F
(0°C to 127°C) (only when operating with standard room temperature).
37:20 to
37:127
38:1
Adjustable from 68°F to 261°F
(20°C to 127°C).
Note: Value must be lower than the lowest value of coding “06” in the
“Combustion controller” group of every control unit.
Boiler section 1 changeover:
Every first day of the month, the boiler with the shortest number of hours run by its burner becomes the boiler section 1.
Boiler section 1 changeover after 200 to
20,000 hours run
1 step 100 hours run.
Permanent lead boiler section is 1, 2, 3,
4, 5, 6, 7 or 8.
Permanent last boiler section is 1, 2, 3,
4, 5, 6, 7 or 8.
3b:2
3b:3
3b:4
Standalone parallel boiler circuit:
Without supply temperature sensor
(refer to page 45).
Standalone serial boiler circuit:
Without supply temperature sensor
(refer to page 45).
Standalone serial boiler circuit:
With supply temperature sensor
(refer to page 45).
Sequential control method with supply temperature sensor
(refer to page 45).
Conventional boiler strategy 1
(refer to page 47).
Conventional boiler strategy 2
(refer to page 47).
No output statement
Control only in accordance with conventional boiler strategy 2.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“Cascade” Group
(continued)
Coding Level 2
Coding in the factory set condition
“System pump”
3e:0 System pump will only run if there is a heat demand.
“Tank priority control for system pump”
3f:0 Without tank priority control for system pump.
“ECO threshold boiler 1”
41:31 No ECO threshold boiler 1.
Do not adjust!
Possible change
3e:1
3f:1
41: − 30 to
41:+30
“ECO threshold boiler 2”
42:31 No ECO threshold boiler 2.
Do not adjust!
42: to
− 30
42:+30
“ECO threshold boiler 3”
43:31 No ECO threshold boiler 3.
Do not adjust!
43: to
− 30
43:+30
“ECO threshold boiler 4”
44:31 No ECO threshold boiler 4.
Do not adjust!
44: to
− 30
44:+30
“Stop differential”
47:15 Set to 15 K.
47:2 to
47:30
System pump always runs; shutdown through “External blocking” signal.
With tank priority control for system pump.
Adjustable from -22°F to 86°F
(-30°C to +30°C).
Adjustable from -22°F to 86°F
(-30°C to +30°C).
Adjustable from -22°F to 86°F
(-30°C to +30°C).
Adjustable from -22°F to 86°F
(-30°C to +30°C).
Adjustable from 4°F to 54°F
(2 K to 30 K)
Note: One boiler or one burner stage will be shut down if the actual supply temperature exceeds the set supply temperature by this value.
“ECO threshold boiler 5”
65:31 No ECO threshold boiler 5.
Do not adjust!
65: to
− 30
65:+30
Adjustable from -22°F to +86°F
(-30°C to +30°C).
103
104
Coding Level 2
“Cascade” Group
(continued)
Coding in the factory set condition
“ECO threshold boiler 6”
6f:31 No ECO threshold boiler 6.
Do not adjust!
“ECO threshold boiler 7”
74:31 No ECO threshold boiler 7.
Do not adjust!
“ECO threshold boiler 8”
7d:31 No ECO threshold boiler 8.
Do not adjust!
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Possible change
6f: − 30 to
6f:+30
Adjustable from -22°F to 86°F
(-30°C to +30°C).
Adjustable from -22°F to 86°F
(-30°C to +30°C).
74: − 30 to
74:+30
7d: − 30 to
7d:+30
Adjustable from -22°F to 86°F
(-30°C to +30°C).
“DHW” Group
Coding
Coding in the factory set condition
“Storage tank heating, hysteresis”
55:0
Possible change
Tank heating, hysteresis ±5°F (±2.5 K). 55:1
55:2
55:3
Adaptive storage tank heating enabled
(refer to page 44).
Storage tank temperature control with 2 tank temperature sensors
(refer to page 44).
Storage tank temperature control, storage tank loading system.
Do not adjust!
“DHW temperature target”
56:0 Set DHW temperature adjustable from 50°F to 140°F (10 to 60°C).
56:1 Adjustable from 50°F to above 140°F
(10°C to above 60°C).
Note: Observe the max. permissible
DHW temperature.
“Additional function for DHW heating”
58:0 Without additional function for DHW heating.
58:10 to
58:60
Input of a second set DHW temperature; adjustable from 50°F to 203°F
(10°C to 95°C).
(observe coding “56”).
“Tank heating: Set start point”
59:0 Set start point -5°F (-2.5 K)
Set stop point +5°F (+2.5 K)
59:1 to
59:10
Adjustable from 1 K to 10 K below set value.
“For DHW heating”
5a:0 The set supply temperature is determined by the highest system supply temperature demand.
Scan of the temperature in the
“Diagnosis” menu, “General”
(“Common demand temp.”).
5a:1 The supply temperature target is determined by the DHW tank supply temperature demand.
Scan of the temperature in the
“Diagnosis” menu, “General”
(“Common demand temp.”).
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“DHW” Group
(continued)
Coding Level 2
Coding in the factory set condition
“Boiler temperature during DHW heating”
60:20 During DHW heating, the boiler water temperature is up to 36°F (20 K) higher than the set DHW temperature.
Possible change
60:10 to
60:50
The differential between the common supply temperature and the set DHW temperature is adjustable from
11°F to 90°F (10 K to 50 K).
“DHW pump”
61:1 DHW pump starts immediately.
61:0 DHW pump starts subject to boiler temperature.
“DHW pump delay off”
62:10 DHW pump with a delay off time of up to 10 min after tank heating.
62:0 No DHW pump delay off
62:1 to
62:15
67:40 DHW setpoint temperature 104°F
(40°C). Reheating is suppressed above the selected set temperature (DHW heating by the boiler only if solar energy is not sufficient).
“With 2 tank temperature sensors: Tank heating stop point”
67:0
67:10 to
67:95
68:8 With 2 tank temperature sensors (coding
“55:2”): Tank heating stop point at set value x 0.8.
68:2 to
68:10
Delay off time adjustable from 1 to 15 min.
“In comfort mode and after external changeover to constant operation with the standard room temperature”
64:2 Enable constant DHW heating and DHW pump “ON”.
64:0
64:1
No DHW heating; DHW pump “OFF”
DHW heating and DHW pump “ON” according to time program.
“Input of the set DHW temperature”
66:4 At the programming unit of the control unit and all installed Vitotrol 300A remote controls.
66:0
66:1
66:2
66:3
66:5
66:6
66:7
At the programming unit of the control unit.
At the programming unit of the control unit and remote control unit of the heating circuit without mixing valve A1
(heating circuit 1).
At the programming unit of the control unit and remote control unit of the heating circuit with mixing valve M2
(heating circuit 2).
At the programming unit of the control unit and remote control unit of the heating circuit with mixing valve M3
(heating circuit 3).
At the remote control of the heating circuit without mixing valve A1
(heating circuit 1).
At the remote control of the heating circuit with mixing valve M2
(heating circuit 2).
At the remote control of the heating circuit with mixing valve M3
(heating circuit 3).
“For solar DHW heating: DHW temperature target”
No set value 3
DHW setpoint temperature adjustable from 50°F to 203°F (10°C to 95°C)
(limited by boiler-specific coding).
Observe setting of coding “56”.
Factor adjustable from 0.2 to 1
1 step 0.1
105
106
Coding Level 2
“DHW” Group
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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
“55:2”): Tank heating start point at set value x 0.7.
to
69:9
“Runtime, actuator, mixing valve, heat exchanger set
6A:75 Runtime, servomotor, mixing valve, heat exchanger set: 75 sec.
6A:10 to
6A:255
“DHW recirculation pump”
70:0 70:1
71:0
DHW recirculation pump “ON” according to time program when DHW heating is enabled.
DHW recirculation pump “ON” according to time program.
71:1
71:2
Factor adjustable from 0.1 to 0.9
1 step 0.1.
For heat exchanger set: 113 sec.
Runtime adjustable from 10 to 255 sec.
DHW recirculation pump “ON” according to time program.
“OFF” during DHW heating to set value 1.
“ON” during DHW heating to set value 1.
72:0
73:0
75:0
DHW recirculation pump “ON” according to time program.
72:1
72:2
DHW recirculation pump “ON” according to time program.
DHW recirculation pump “ON” according to time program.
73:1 to
73:6
73:7
75:1
“OFF” during DHW heating to set value 2.
“ON” during DHW heating to set value 2.
“ON” from once per hour for 5 min up to
6 times per hour for 5 min during the time program.
Constantly “ON”
DHW recirculation pump “OFF” during economy mode.
“Solar” Group
Only in conjunction with solar control module, type SM1.
Coding in the factory set condition Possible change
“Differential between the actual DHW temperature and the start point for the solar circuit pump”
00:8 Start temperature differential for solar circuit pump 14°F (8 K)
00:2 to
00:30
Adjustable from 4°F to 72°F
(2 K to 30 K).
“Differential between the actual DHW temperature and the stop point of the solar circuit pump”
01:4 Stop temperature differential for solar circuit pump 7°F (4 K)
01:1 to
01:29
Adjustable from 2°F to 52°F
(1 K to 29 K).
“Solar circuit pump speed control”
02:0 Solar circuit pump is not speed-controlled 02:1
02:2
Variable speed solar circuit pump with wave packet control.
Solar circuit pump speed controlled with PWM control.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“Solar” Group
(continued)
Coding Level 2
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 speed control 18°F (10 K).
03:5 to
03:20
Adjustable from 9°F to 36°F
(5 K to 20 K).
“Controller amplification of the speed control”
04:4 Controller amplification of the speed control 4%/K.
04:1 to
04:10
Adjustable from 1% to 10%/K.
“Minimum speed of the solar circuit pump”
05:10 Minimum speed of the solar circuit pump
10% of the maximum speed.
05:2 to
05:100
Adjustable from 2% to 100%.
“Maximum speed of the solar circuit pump”
06:75 Maximum speed of the solar circuit pump 75% of maximum possible speed.
06:1 to
06:100
Adjustable from 1% to 100%.
“Interval function of the solar circuit pump”
07:0 Interval function of the solar circuit pump switched off.
07:1 Interval function of the solar circuit pump switched on.
To capture the collector temperature more accurately, the solar circuit pump starts for short cycles.
“Maximum storage tank temperature”
08:60 DHW setpoint temperature (maximum tank temperature) 140°F (60°C).
08:10 to
08:90
Adjustable from 50°F to 194°F
(10°C to 90°C).
“Maximum collector temperature”
09:130 Maximum collector temperature
(to protect system components)
266°F (130°C).
“Stagnation time reduction”
0a:5 Temperature differential for reducing the stagnation time (reduction in solar circuit pump speed to protect system components and heat transfer medium) 11°F (5 K).
09:20 to
09:200
0a:0
0a:1 to
0a:40
Adjustable from 68°F to 392°F
(20°C to 200°C).
Stagnation time reduction disabled.
Adjustable from 2°F to 72°F
(1 K to 40 K).
“Frost protection function for solar circuit”
0b:0 Frost protection function for solar circuit switched off.
0b:1 Frost protection function for solar circuit switched on (not required with
Viessmann heat transfer medium).
“Delta T monitoring”
0c:1 Delta T monitoring switched on. No flow rate captured in the solar circuit, or flow rate too low.
0c:0 Delta T monitoring switched off.
107
108
Coding Level 2
“Solar” Group
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Coding in the factory set condition
“Night circulation monitoring”
0d:1 Night circulation monitoring switched on.
Unintentional flow in the solar circuit is captured (e.g. at night).
“Calculation of solar yield”
0e:1 Heat statement in conjunction with
Viessmann heat transfer medium
Possible change
0d:0
0e:2
0e:0
“Solar circuit flow rate”
0F:70 Solar circuit flow rate at maximum pump speed 1.8 USG/min (7 L/min)
0f:1 to
0f:255
Night circulation monitoring switched off.
Do not adjust!
No heat statement.
Flow rate adjustable from
0.02 USG/min to 6.7 USG/min
(0.1 L/min to 25.5 L/min)
1 step 0.02 USG/min (0.1 L/min).
“Target temperature control”
10:0 Target temperature control OFF
(see coding address “11”)
“Set solar DHW temperature”
11:50 Set solar DHW temperature 122°F (50°C)
H
Target temperature control switched on (code “10:1”):
Temperature at which the water in the
DHW tank heated by solar energy is to be stratified.
H
Code “20:9” (heating of two DHW tanks) selected:
When one DHW tank reaches its set
DHW temperature, the second DHW tank is heated.
“Minimum collector temperature”
12:20 Minimum collector temperature
(minimum solar circuit pump start temperature) 68°F (20°C).
10:1
11:10 to
11:90
12:0
12:1 to
12:90
Target temperature control switched on.
Adjustable from 50°F to 194°F
(10°C to 90°C).
No minimum limit
Adjustable from 34°F to 194°F
(1°C to 90°C).
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“Solar” Group
(continued)
Coding Level 2
Coding in the factory set condition
“Extended control function”
20:0 No extended control function enabled.
“Start temperature differential for central heating backup”
22:8 Start temperature differential with central heating backup 14°F (8 K)
(code “20:4” must be set).
“Stop temperature differential for central heating backup”
23:4 Stop temperature differential with central heating backup 7°F (4 K)
(code “20:4” must be set).
“Start temperature for thermostat function”
24:40 Start temperature for thermostat function
104°F (40°C) (coding “20:5”or “20:6” must be set).
“Stop temperature for thermostat function”
25:50 Stop temperature for thermostat function
122°F (50°C) (coding “20:5”or “20:6” must be set).
“Priority for DHW storage tank 1”
26:1 Priority for DHW storage tank 1 with cyclical heating (code “20:9” must be set).
22:2 to
22:30
23:2 to
23:30
24:0 to
24:100
25:0 to
25:100
26:0
26:2
Possible change
20:1
20:2
20:3
20:4
20:5
20:6
20:7
20:8
20:9
Additional function for DHW heating.
Differential temperature control 2.
Differential temperature control 2 and auxiliary function.
Differential temperature control 2 for central heating backup.
Thermostat function
Thermostat function and auxiliary function.
Solar heating via external heat exchanger without additional temperature sensor.
Solar heating via external heat exchanger with additional temperature sensor.
Solar heating of two DHW storage tanks
[Solar heating of two DHW tanks].
26:3
26:4
Start temperature differential adjustable from 4°F to 54°F
(2 K to 30 K).
Stop temperature differential adjustable from 2°F to 52°F
(1 to 29 K).
Adjustable from 0°F to 180°F (0 K to
100 K).
Adjustable from 0°F to 180°F
(0 K to 100 K).
Priority for DHW storage tank 1 without cyclical heating.
Priority for DHW storage tank 2 without cyclical heating.
Priority for DHW storage tank 2 with cyclical heating.
Alternate heating without priority for one of the DHW storage tanks .
109
110
Coding Level 2
“Solar” Group
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Coding in the factory set condition
“Alternate heating time”
27:15 Alternate heating time 15 min The
DHW tank without priority is heated at most for the duration of the set cyclical heating duration if the DHW tank with priority is already heated up.
“Alternate pause time”
28:3 Alternate pause time 3 min After the selected cyclical heating duration for the
DHW tank without priority has expired, the rise in collector temperature is captured during the cyclical pause time.
Possible change
27:5 to
27:60
28:1 to
28:60
Adjustable from 5 to 60 min.
Adjustable from 1 to 60 min..
“Heating Circuit ...” Group
Coding
Coding in the factory set condition
“Remote control” a0:0 Without remote control.
Possible change a0:1 a0:2
“Blocking remote control” a1:0 All possible settings at the remote control can be accessed.
“Storage tank priority” a2:2 Tank priority for heating circuit pump and mixing valve.
a1:1 a2:0 a2:1 a2:3 to a2:15
“Temperature limits frost protection function” a3:2 Outdoor temperature below 34°F (1°C):
Heating circ pump switched on.
Outdoor temperature above 37°F (3°C):
Heating circ pump switched off.
a3:–9 to a3:15
With Vitotrol 200, recognized automatically.
Recognized automatically with
Vitotrol 300.
Only comfort mode can be set at the remote control.
Without storage tank priority applicable to heating circuit pump and mixing valve
Storage tank priority only applicable to mixing valve.
Modulating priority applies to mixing valves, i.e. the heating circuit receives a reduced amount of heat.
Heating circuit pump ON/OFF
(see the following table).
CAUTION
If a value below 34°F (1°C) is selected, there is a risk that pipes outside the thermal envelope of the house could freeze up. Standby mode in particular should be taken into consideration, e.g. during holidays.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“Heating Circuit ...” Group
(continued)
Coding Level 2
Coding address a3:...
-1
0
1
-4
-3
-2
2 to
15
-9
-8
-7
-6
-5
Heating circuit pump “ON”
14°F (–10°C)
16°F (–9°C)
18°F (–8°C)
19.5°F (–7°C)
21°F (–6°C)
23°F (–5°C)
25°F (–4°C)
27°F (–3°C)
28.5°F (–2°C)
30°F (–1°C)
32°F (0°C)
34°F (+1°C) to
57 F (+14°C)
Coding in the factory set condition
“Frost protection” a4:0 With frost protection
Possible change a4:1
Heating circuit pump
Heating circuit pump “OFF”
18°F (–8°C)
19.5°F (–7°C)
21°F (–6°C)
23°F (–5°C)
25°F (–4°C)
27°F (–3°C)
28.5°F (–2°C)
30°F (–1°C)
32°F (0°C)
34°F (+1°C)
36°F (+2°C)
27°F (+3°C) to
61°F (+16°C)
No frost protection; this setting is only possible if code a3:-9 has been selected.
Note: “Important” also coding address
“a3”.
“Heating circuit pump logic function (economy control)” a5:5 With heating circuit pump logic function
(economy control): heating circuit pump OFF when the outdoor temperature (OT) is 2°F (1 K) higher than the set room temperature
(RTset) OT > RTset 2°F (1 K).
a5:0 a5:1 to a5:15
Without heating circuit pump logic function.
With heating circuit pump logic function: Heating circuit pump OFF, see the following table.
4
5
6
7 to
15
1
2
3
Coding address a5:...
With heating circuit pump logic function: Heating circuit pump “OFF”
OT > RTset 9°F (+ 5 K)
OT > RTset 7°F (+ 4 K)
OT > RTset 5°F (+ 3 K)
OT > RTset 4°F (+ 2 K)
OT > RTset 2°F (+ 1 K)
OT > RTset
OT > RTset 2°F (– 1 K)
OT > RTset 16°F (– 9 K)
111
112
Coding Level 2
“Heating Circuit ...” Group
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Coding in the factory set condition
“Extended economy mode” a6:36 Extended economy mode disabled.
Possible change a6:5 to a6:35
Extended economy mode enabled, i.e. the burner and heating circuit pump will stop and the mixing valve will be closed at a variable value, adjustable between 41°F to 95°F (5°C and 35°C) plus 2°F (1°C). The base value is the adjusted outdoor temperature. This value is based on the actual outdoor temperature and a time constant, which takes the cooling down of an average building into consideration.
“Mixing valve economy function” a7:0 Only for heating circuits with mixing valve:
Without mixing valve economy function.
a7:1 With mixing valve economy function:
Heating circuit pump also OFF:
H
Mixing valve switched on to heating circuit pump longer than 20 min:
H
Mixing valve in control mode
H
If there is a risk of frost
“Pump idle time” a9:0 Without pump idle time.
a9:1 to a9:15
Pump idle time adjustable from 1 to 15.
1: Short idle time
15: Long idle time
“Output reduction” aa:2 With output reduction through temperature sensor aJ A .
“Room temperature hook-up” b0:0 With remote control:*1
Heating mode/reduced mode:
Weather-compensated.
aa:0 aa:1 b0:1 b0:2 b0:3
Without output reduction.
No function.
Heating mode: Weather-compensated
Reduced mode: with room temperature hook-up
Heating mode: with room temperature hook-up
Reduced mode: Weather-compensated
Heating mode/reduced mode: with room temperature hook-up.
“Room influence factor” b2:8 With remote control and for the heating circuit, operation with room temperature hook-up must be programmed:
Room influence factor 8.
b2:0 b2:1 to b2:31
“Room temperature-dependent heating circuit pump logic function” b5:0 With remote control:
No room temperature-dependent heating circuit pump logic function.
b5:1 to b5:8
Without room influence.
Adjustable from 1 to 31.
For heating circuit pump logic function, refer to the table on page 113.
*1 Only change the coding for the heating circuit without mixing valve A1 for boilers without lower temperature limit or for heating circuits with mixing valve if a remote control is connected to them.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“Heating Circuit ...” Group
(continued)
Coding Level 2
4
5
6
7
8
1
2
3
Coding address b5:...
With heating circuit pump logic function:
Heating circuit pump “OFF” Heating circuit pump “ON”
RTactual > RTset +9°F (+5 K)
RTactual > RTset +7°F (+4 K)
RTactual < RTset +7°F (+4 K)
RTactual < RTset +5°F (+3 K)
RTactual > RTset +5°F (+3 K) RTactual < RTset +4°F (+2 K)
RTactual > RTset +4°F (+2 K)
RTactual > RTset +2°F (+1 K)
RTactual > RTset
RTactual > RTset –2°F (–1 K)
RTactual > RTset –4°F (–2 K)
RTactual < RTset +2°F (+1 K)
RTactual < RTset
RTactual < RTset –2°F (–1 K)
RTactual < RTset –4°F (–2 K)
RTactual < RTset –5°F (–3 K)
Coding in the factory set condition
“Quick heat-up/quick setback” b6:0 With remote control:
Without quick heat-up/quick setback.
“Start optimization” b7:0 With remote control and for the heating circuit, operation with room temperature.
hook-up must be programmed:
Without start optimization.
“Heat-up gradient start optimization” b8:10 With remote control and for the heating circuit, operation with room temperature hook-up must be programmed:
Heat-up gradient start optimization
10 min/K.
“Learning start optimization” b9:0 With remote control and for the heating circuit, operation with room temperature hook-up must be programmed:
Without learning start optimization.
“Shutdown time optimization” c0:0 With remote control:
Without shutdown time optimization.
Possible change b6:1 b7:1 b7:2 b8:11 to b8:255 b9:1 c0:1 c0:2
With quick heat-up/quick setback.
(refer to function description on page 39).
With start optimization, max. heat-up time offset 2 h 30 min.
With start optimization, max. heat-up time offset 15 h 50 min.
Adjustable from 11 min/K to 255 min/K
With learning start optimization
With stop optimization, max. setback time offset 1 h.
With stop optimization, max. setback time offset 2 h.
“Stop optimization of setback time offset” c1:0 With remote control:
Without shutdown time optimization.
c1:1 to c1:12
With stop optimization of setback time offset adjustable from 10 min. to 120 min.
1 step 10 min.
“Learning shut-down time optimization” c2:0 With remote control:
Without learning shutdown time optimization.
c2:1 With learning shut-down time optimization.
113
114
Coding Level 2
“Heating Circuit ...” Group
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Coding in the factory set condition
“Mixing valve runtime” c3:125
“System dynamics mixing valve” c4:1
Only for heating circuits with mixing valve:
Mixing valve runtime 125 sec.
System dynamics:
Mixing valve control characteristics.
“Minimum supply temperature limit” c5:20 Electronic minimum supply temperature limit 68°F (20°C) (only when operating with standard room temperature).
“Maximum supply temperature limit” c6:75 Electronic maximum supply temperature limit set to 167°F (75°C).
c5:1 to c5:127 c6:10 to c6:127
“Room influence limit” c8:31 With remote control and for the heating circuit, operation with room temperature hook-up must be programmed:
No room influence limit
“External operating program changeover” d5:0 With external operating program changeover (observe setting of coding
“5d”, “5e”, “5f” and “91” in the
“General” group). Changeover “Constant central heating with reduced room temperature” or “Standby mode”
(subject to set reduced room temperature).
“EA1 extension: Operating program changeover” d8:0 No operating program changeover.
c8:1 to c8:30 d5:1 d8:1 d8:2 d8:3
“Day temperature target” e1:1 Do not adjust!
“Display correction of the actual room temperature” e2:50 With remote control:
No display correction of the actual room temperature.
e2:0 to e2:49 e2:51 to e2:99
Possible change c3:10 to c3:255 c4:0 to c4:3
Adjustable from 10 sec. to 255 sec.
Controller responds too quickly (cycles between “Open” and “Closed”):
Select a lower value.
Controller responds too slowly
(temperature is not held sufficiently): select a higher value.
Adjustable from 34°F to 261°F
(1°C to 127°C)
(limited by boiler specific coding).
Adjustable from 50°F to 261°F
(10°C to 127°C)
(limited by boiler specific coding).
Adjustable from 2°F to 54°F
(1 K to 30 K).
Changeover to “Constant operation with standard room temperature”.
Operating program changeover via input
DE1.
Operating program changeover via input
DE2.
Operating program changeover via input
DE3.
Display correction -9°F (-5 K) to
Display correction -0.2°F (-0.1 K)
Display correction +0.2°F (+0.1 K) to
Display correction +9°F (+4.9 K)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
“Heating Circuit ...” Group
(continued)
Coding Level 2
Coding in the factory set condition
“Slab curing” f1:0 Slab curing function not active.
Do not adjust!
“Time limit for comfort mode” f2:8 Time limit for comfort mode or external operating program changeover via pushbutton: 8 h.
Possible change f2:0 No time limit*2
Note: Observe setting of coding “5d”,
“5e”, “5f” in the “General” group, as well as “d5” and “d8” in the “Heating circuit...” group.
“Temperature limit for terminating reduced mode” f8:–5 Temperature limit for terminating reduced mode 23°F (-5°C), see example on page 42.
Observe coding “a3”.
f2:1 to f2:12 f8:+10 to f8:–60
Time limit adjustable from 1 h to 12 h*2.
Adjustable from +50°F to -76°F
(+10°C to -60°C).
f8:–61 Function disabled
“Temperature limit for raising the reduced room temperature target” f9:–14 Temperature limit for raising the reduced room temperature target 7°F (-14°C), refer to example on page 42.
f9:+10 to f9:–60
“Duration for raising the set boiler water or supply temperature” fb:60 Duration for raising the set supply temperature (see coding “fa”) 60 min.
Refer to example on page 42.
fb:0 to fb:300
Limit for raising the set room temperature to the value selected for standard mode, adjustable from +50°F to -76°F
(+10°C to -60°C).
“Raising the set boiler water or supply temperature when changing from operation with reduced room temperature to operation with standard room temperature” fa:20 Raising the set boiler water or supply temperature when changing from operation with reduced room temperature to operation with standard room temperature by 20%.
Refer to example on page 42.
fa:0 to fa:50
Adjustable from 0 to 50%.
Adjustable from 0 to 300 min.
115
116
Service Scans
Calling up the Service Menu
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
From the home screen tap the following buttons:
1.
2. “Service”
3. Enter “viservice” password.
4. Select the required menu range.
Overview of menu structure
“Service main menu”
“Diagnosis”
“General”
“Cascade”
“DHW”
“Heating circuit 1/2/3”
“Solar energy”
“Short query”
“Reset data”
“Actuator test”
“System configuration”
“Coding level 1”
“Coding level 2”
“History of faults”
“Service functions”
“LON participant check”
“System log”
“Vitocom PIN input”
“Startup”
“The heating system is reset to the factory state”
“Change passwords”
“Service level”
“Coding level 2”
“Reset all passwords”
“Exit service”
Note:
H
“Coding level 2” is only displayed if this level has been enabled: Enter “viexpert” password.
H
Tap to return to the “Service main menu”
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Leaving the Service Menu
Service Scans
From the service main menu tap the following buttons:
1. “Exit service”
Note: The system exits the service menu automatically after 30 min.
Change Passwords
In the factory set condition, the following passwords have been assigned:
H
“ viservice” for access to the “Service main menu”
H
“viexpert” for access to “Coding level 2”
From the home screen tap the following buttons:
1.
2. “Service”
3. Enter “viservice” password.
4. “Change passwords”
5. “Service level” or “Coding level 2”
6. Enter current password.
7. Confirm with .
8. Enter new password.
9. .
Resetting all Passwords to Factory Settings
From the home screen tap the following buttons:
1.
Request the master password from the Technical
Service at the Viessmann Group.
2.
3. “Service”
4. Enter “viservice” password.
5. “Change passwords”
6. “Reset all passwords”
7. Enter master password. This must be requested from the service hotline.
8. Confirm with .
Scanning Operating Data
Operating data can be scanned in various areas.
Operating data on heating circuits with mixing valves and a solar thermal system can only be scanned if the relevant components are installed in the system.
For further information on operating data, see chapter
“Brief scan”.
Note:
“- - -” appears on the display if a scanned sensor is faulty.
From the home screen tap the following buttons:
1.
2. “Service”
3. Enter “viservice” password.
4. “Diagnosis”
5. Select required group, e.g. “General”.
Resetting Operating Data
Saved operating data (e.g. hours run) can be reset to 0.
The value "Dampened outdoor temp" is reset to the actual value.
From the home screen tap the following buttons:
1.
2. “Service”
3. Enter “viservice” password.
4. “Diagnosis”
5. “Reset data”
6. Select required value or “All data”.
117
Service Scans
Brief Scan
From the home screen tap the following buttons:
1.
2. “Service”
3. Enter “viservice” password.
4. “Diagnosis”
5. “Brief scan”
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
6 . An overview of brief scans appears with 11 lines and 6 fields. for the required brief scan in line with the following tables.
118
1:
2:
3:
4:
5:
1 2
System schemes 01 to 10
0
0
0
0
0
0
0
0
3
0
0
4
Control unit software version
0
Number of KM BUS participants
0
0
5 6
Software version, programming unit
Appliance identification CU-ID
Software version
Solar control module type SM1
0 0
Software version,
AM1 extension
Software version,
EA1 extension
6:
7:
8:
Connection on plug aVD .1/2
0: Contact open
1: Contact closed
Connection on plug aVD .2/3
0: Contact open
1: Contact closed
0
LON subnet address/system number LON node address
SNVT config.
0: Auto
1: Tool
Software version
Communic.
coproc.
Neuron Chip
Software version
9:
10: 0
11: 0
Heating circuit HC1
Remote control
0: Without
1: Vitotrol 200A
2: Vitotrol 300A
Software version
Remote control
0
0
Heating circuit HC2
Remote control
0: Without
1: Vitotrol 200A
2: Vitotrol 300A
0
Software version, extension for heating circuits 2 and 3 with mixing valve
0
0
0
Software version
Remote control
0
0
Participant number
0
0
Heating circuit HC3
Remote control
0: Without
1: Vitotrol 200A
2: Vitotrol 300A
Software version
Remote control
0
Software version,
0
0 extension for heating circuits 2 and 3 with mixing valve
Note: The displays in fields 3 and 5 are the same.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Carrying Out an Actuator Test
From the home screen tap the following buttons:
1.
2. “Service”
3. Enter “viservice” password.
4. “Actuator test”
Service Scans
Note: Before an actuator is selected, all actuators are off.
The actuators listed in the table can be tested at the relay outputs subject to system equipment level and control unit configuration (lead control or service control).
Display
“All actuators”
“Output 20”
“Output 52”
“Output 52”
“Output 29”
“Central fault message”
“Htg circ pump HC2”
“Mixing valve HC2”
OFF
ON
Open
Neutral
“Output 52” Close
“DHW tank primary pump” ON
“DHW circ pump” ON
ON
ON
ON
Open
Close
“Htg circ pump HC3”
“Mixing valve HC3”
“EA1 output 1”
“AM1 output 1”
“AM1 output 2”
“Solar circuit pump”
ON
Open
Close
ON
ON
ON
ON
Explanation
All actuators have been switched off.
Actuator at output
Actuator at output sÖ gS
A1
A1
Actuator at output sA
Actuator at output sK
Actuator at output sL
Central fault message facility at output gÖ
Actuator at output sÖ M2
Actuator at output gS M2
Actuator at output gS M3
Actuator at output gS M3
“Solar circ pump min”
“Solar circ pump max”
“SM1 output 22”
ON
ON
ON
Contact “P - S” on plug aBJ of EA1 extension closed.
Actuator at output A1
Actuator at output A2
“Solar circuit pump” On Solar circuit pump at output sF at solar control module, type SM1
“Solar circ pump min” On Solar circuit pump at output sF at solar control module, type SM1 set to min. speed.
“Solar circ pump min” On Solar circuit pump at output sF at solar control module, type SM1 set to max. speed.
Actuator at output sS at solar control module type SM1
Information regarding the mixing valve motor rotational direction.
The supply temperature must rise when the mixing valve opens. If the temperature drops, either the motor is turning in the wrong direction or the mixing valve set is incorrectly fitted (observe the mixing valve installation instructions).
119
120
Service Scans
Checking Sensors
Maintenance Display
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
From the home screen tap the following buttons:
1.
2. “Service”
3. Enter “viservice” password.
4. “Diagnosis”
5. Select group.
6. Scan actual temperature of the relevant sensor.
Set limits in coding “21” and “23” in the “Boiler” group.
Once these values have been reached, “Service” and symbol appear on the display.
Tap the following buttons:
1. “Confirm” The footer shows .
2.
Note: After tapping the following will be displayed
if your heating system has several fault messages
simultaneously:
3. “Service messages”
The service messages appear orange in a list.
After maintenance has been carried out
From the home screen tap the following buttons:
1.
2. “Service”
3. Enter “viservice” password.
4. “Service functions”
“Reset service” The set service coding for hours run and interval restart at 0 and coding “24” in the
“Boiler” group is set to “24:0”.
Note: If a service is carried out prematurely, set coding
“24:1” in the “Boiler” group to “24:0”. The selected maintenance coding for hours run and time intervals restart at 0. If coding “24” is not reset, “Service” will be displayed again on the
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Fault Display
Troubleshooting
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.
For an explanation of fault messages, see chapter “Fault messages”.
Calling up acknowledged fault messages
Tap the following buttons:
1.
Note: After tapping the following will be displayed if your heating system has several fault simultaneously:
2.
“Faults” The fault messages appear in red and in
chronological order in a list.
Calling up fault codes from the fault memory
(fault history)
The 10 most recent faults (including those remedied) are saved and can be scanned. Faults are sorted by date.
From the home screen tap the following buttons:
1.
2. “Service”
3. Enter “viservice” password.
4. “Fault history”
5. Call up further information in the relevant fault with .
6. to delete the list.
121
122
Troubleshooting
Boiler System Fault Codes
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Displayed fault code
0f
10
18
20
28
30
38
40
44
48
System characteristics
Control mode.
Operates as if the outdoor temperature was 32°F (0°C).
Operates as if the outdoor temperature was 32°F (0°C).
Standalone control unit without supply temperature sensor
(possibly supply temperature not high enough)
Standalone control unit without supply temperature sensor
(possibly supply temperature not high enough)
H
With DHW tank: DHW pump
ON, boiler is maintained at set tank temperature.
H
Without DHW tank: Boiler is regulated by the temperature controller.
H
With DHW tank: DHW pump
ON, boiler is maintained at set tank temperature.
H
Without DHW tank: Boiler is regulated by the temperature controller.
Mixing valve is being closed.
Mixing valve is being closed.
Mixing valve is being closed.
Cause
Service “0f” is only displayed in the fault history.
Short circuit, outdoor temperature sensor.
Lead break, outdoor temperature sensor.
Short circuit, common supply temperature sensor
Lead break, common supply temperature sensor
Short circuit, boiler water temperature sensor
Lead break, boiler water temperature sensor
Measures
Service required
Note: After servicing, set code
“24:0”.
Check outdoor temperature sensor.
Check outdoor temperature sensor.
Check the supply temperature sensor.
Check the supply temperature sensor.
Check boiler water temperature sensor.
Check boiler water temperature sensor.
Short circuit, supply temperature sensor, heating circuit with mixing valve M2 (heating circuit 2).
Short circuit, supply temperature sensor, heating circuit with mixing valve M3 (heating circuit 3).
Lead break, supply temperature sensor, heating circuit with mixing valve M2 (heating circuit 2).
Check supply temperature sensor.
Check supply temperature sensor.
Check supply temperature sensor.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Boiler System Fault Codes
(continued)
Displayed fault code
4c
50
52
58
5a
60
68
70
78
80
81
Troubleshooting
System characteristics Cause Measures
Mixing valve is being closed.
Tank loading pump on:
DHW temperature target = set supply temperature
Priority control is cancelled.
Control mode
Lead break, supply temperature sensor, heating circuit with mixing valve M3 (heating circuit 3).
Short circuit, tank temperature sensor 1
Check supply temperature sensor.
Check tank temperature sensor.
Tank loading pump on:
DHW temperature target = set supply temperature
Priority control is cancelled.
Control mode
Short circuit, supply temperature sensor low loss header.
Lead break, DHW tank temperature sensor 1.
Check supply temperature sensor.
Check DHW tank temperature sensor.
Lead break, low loss header supply temperature sensor.
Boiler with maximum temperature, no output reduction, mixing valve return temperature control open
Boiler with maximum temperature, no output reduction, mixing valve return temperature control open
Shunt pump constantly ON.
With tank loading system: close 3-way mixing valve; no DHW heating
Shunt pump constantly ON
With tank loading system: close 3-way mixing valve; no DHW heating
Short circuit, temperature sensor aJ aJ
A
Lead break, temperature sensor aJ B .
.
Lead break, temperature sensor
A .
Short circuit, temperature sensor aJ B .
If a fault occurs 3 x in 15 min., fault is displayed. Burner control unit goes into a fault state, system cools down, burner control unit locked out.
Short circuit, boiler water temperature sensor, burner control unit
Burner control unit in a fault sate Sensor drift, boiler water temperature sensor, burner control unit
Check supply temperature sensor (see page 57).
Without supply temperature sensor:
Set code “52:0” in the
“General” group.
Check temperature sensor.
Check temperature sensor.
Without temperature sensor:
Set coding “4a:0” in the
“General” group.
Check temperature sensor.
Check temperature sensor.
Without temperature sensor:
Set code “4b:0” in the
“General” group.
Check connection cable and dual sensor; replace sensor if required.
Check connection cable and dual sensor; replace sensor if required.
123
124
Troubleshooting
Boiler System Fault Codes
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Displayed fault code
88
90
91
92
93
94
98
99
9a
System characteristics
Control mode
Control mode
No solar DHW heating.
Control mode.
No solar DHW heating.
Control mode
Control mode
No solar DHW heating.
Cause
Burner control unit in a fault state Lead break, boiler water temperature sensor, burner control unit
Short circuit, temperature sensor
/ connection at solar control module, type SM1.
Short circuit, temperature sensor aÖ , connection at solar control module, type SM1.
Short circuit, collector temperature sensor, connection of temperature sensor & at solar control module, type SM1 or sensor at S1 of the Vitosolic.
Short circuit, temperature sensor, connection at S3 of the Vitosolic.
Measures
Short circuit, DHW tank temperature sensor, connection of temperature sensor % at solar control module, type SM1 or sensor at S2 of the Vitosolic.
Lead break, temperature sensor
/ , connection at solar control module, type SM1.
Check sensor at the solar control unit (see separate installation and service instructions).
Check sensor at the solar control unit (see separate installation and service instructions).
Check temperature sensor /
(see separate installation and service instructions).
Check coding address “20” in the “Solar” group.
Lead break, temperature sensor aÖ , connection at solar control module, type SM1.
Lead break, collector temperature sensor, connection of temperature sensor & at solar control module, type SM1 or sensor at S1 of the Vitosolic.
Check connection cable and dual sensor; replace sensor if required.
Check temperature sensor
(see separate installation and service instructions).
Check temperature sensor aÖ
(see separate installation and service instructions).
Check sensor at the solar control unit (see separate installation and service instructions).
Check temperature sensor service instructions).
/ aÖ
(see separate installation and
Check coding address “20” in the “Solar” group.
Check sensor at the solar control unit (see separate installation and service instructions).
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Boiler System Fault Codes
(continued)
Troubleshooting
Displayed fault code
9b
System characteristics
9c
9e
9f a0 a1 a2 a3 a7 ab b1 b5
Cause Measures
Control mode
No solar DHW heating.
Control mode
Control mode
Boiler cools down
Boiler cools down
Boiler cools down
Boiler cools down
Control mode
Control mode, DHW tank may be cold
Control mode
Control mode
Lead break, temperature sensor, connection to S3 of the Vitosolic.
Lead break, DHW tank temperature sensor, connection of temperature sensor % at solar control module, type SM1 or sensor at S2 of the Vitosolic.
No supply rate in solar circuit or flow rate too low, or temperature limiter has responded.
Check sensor at the solar control unit (see separate installation and service instructions).
Check sensor at the solar control unit (see separate installation and service instructions).
Check solar circuit. Acknowledge fault message (see separate installation and service instructions).
Check solar control unit (see separate installation and service instructions).
Fault, solar control module, type
SM1 or Vitosolic.
Displayed if a fault occurs at these devices that has no fault message in the Vitotronic.
Fault, safety equipment at “X7” of plug-in adapter 2 for external safety equipment
Fault, safety equipment at “X3” of plug-in adapter 2 for external safety equipment
Fault, safety equipment at “X2” of plug-in adapter 2 for external safety equipment
Fault, safety equipment at “X1” of plug-in adapter 2 for external safety equipment
Programming unit fault
Tank loading system configuration fault:
Coding “55:3” in the “DHW” group has been set, but plug aJ B is not plugged in and/or codes “4c:1” and “4e:2” in the
“General” group have not been set.
Communication error, programming unit
Internal fault
Check safety equipment, reset if required.
Check safety equipment, reset if required.
Check safety equipment, reset if required.
Check safety equipment, reset if required.
Replace the programming unit.
Insert plug aJ B and check codes.
Check connections, and replace the programming unit if required.
Check PCB is plugged in correctly.
125
126
Troubleshooting
Boiler System Fault Codes
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Displayed fault code b6 b7 b8 ba bc bd be bf c1 c2 c3 c8
System characteristics
Constant mode
Boiler water temperature control
Control mode
Mixing valve close
Control mode without remote control.
Control mode without remote control
Control mode without remote control
Control mode
No communication via LON
Boiler cools down
Control mode
Control mode
Boiler cools down.
Cause
Invalid hardware recognition
Coding card fault
Lead break, flue gas temperature sensor
Communication error, PCB, extension for heating circuits 2 and 3 with mixing valve.
Communication error, Vitotrol remote control unit, heating circuit without mixing valve A1
(heating circuit 1).
Communication error, Vitotrol remote control unit, heating circuit with mixing valve M2
(heating circuit 2)
Communication error, Vitotrol remote control unit, heating circuit with mixing valve M3
(heating circuit 3)
Incorrect LON communication module.
External safety equipment at plug aBÖ .
Lead break, KM BUS to solar control module, type SM1 or
Vitosolic.
Communication error, AM1 extension
Fault, low water indicator at
“X7” of plug-in adapter 1 for external safety equipment.
Measures
Check coding address “92” in the “General” group;
H
161: Single boiler system
H
190: Cascade control unit
H
166: Boiler section 2/boiler section 3 control unit
Note: Coding “8a:176” in the
“General” group must be set in order for coding “92” to be able to be displayed.
Plug in or replace the boiler coding card.
Replace temperature sensor.
Set code “1F:0” in the “Boiler” group.
Check that the PCB and ribbon cable are plugged in correctly, and replace PCB if required.
Check connections, lead (see separate installation and service instructions) and coding address
“a0” in the “Heating circuit...” group.
Check connections, lead (see separate installation and service instructions) and coding address
“a0” in the “Heating circuit...” group.
Check connections, lead (see separate installation and service instructions) and coding address
“a0” in the “Heating circuit...” group.
Replace LON communication module.
Check connection and external safety equipment.
Check KM BUS cable and appliance.
Without solar control unit:
Set code “54:0” in the “General” group.
Check connections.
Without AM1 extension:
Set coding “32:0” in the
“General” group.
Check system water level, reset low water indicator.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Boiler System Fault Codes
(continued)
Troubleshooting d6 d7 d8 da
Displayed fault code c9 cA cB cF d1 d2 d3 d4 d5 db
System characteristics Cause Measures
Boiler cools down.
Boiler cools down.
Boiler cools down.
Control mode
No communication via LON, boiler at a configurable temperature set point
Boiler cools down.
Control mode
Control mode
Boiler cools down
Boiler ramps up to the electronic maximum boiler water temperature limit.
Control mode
Control mode
Control mode
Control mode without room influence.
Control mode without room influence
Fault, maximum pressure limiter at “X3” of plug-in adapter 1 for external safety equipment
Fault, minimum pressure limiter or maximum pressure limiter 2 at “X2” of plug-in adapter 1 for external safety equipment
Fault at additional safety temperature limiter or temperature monitor at “X1” of plug-in adapter 1 for external safety equipment
Communication error, control unit LON communication module.
Burner in fault mode
Communication fault, Plug-in adapter 2 for external safety equipment
Communication error, extension
EA1.
MCB F2 has responded.
Connection plug aBA
No communication between boiler circuit control unit and cascade control unit.
broken.
Input DE1 at extension EA1 reports a fault.
Input DE2 at extension EA1 reports a fault.
Input DE3 at extension EA1 reports a fault.
Short circuit, room temperature sensor, heating circuit without mixing valve A1 (heating circuit 1).
Short circuit, room temperature sensor, heating circuit with mixing valve M2 (heating circuit 2).
Check system pressure, reset maximum pressure limiter.
Check system pressure, reset minimum pressure limiter or maximum pressure limiter 2.
Check system temperature, reset safety temperature limiter.
Check LON communication module and replace if required.
If no LON communication module is installed, set code “76:0” in the “General” group.
Check burner
Check plug-in adapter , if no plug-in adapter is available, adjust coding “31:0” in
“General” group.
Check connections (refer to the installation manual). Without extension EA1:
Set code “5b:0” in the
“General” group.
Check MCB F2 and jumper on plug aBA .
Fuse F2 has tripped or check connection to Plug aBA , possibly plug aBA not inserted.
Check communication via participants check.
Check configuration of cascade participants.
Remove fault at appliance concerned.
Remove fault at appliance concerned.
Remove fault at appliance concerned.
Check room temperature sensor (refer to page 77).
Check room temperature sensor (refer to page 77).
127
128
Troubleshooting
Boiler System Fault Codes
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Displayed fault code dc dd de df
System characteristics
Control mode without room influence.
Control mode without room influence.
Control mode without room influence.
Control mode without room influence.
Cause Measures
Short circuit, room temperature sensor, heating circuit with mixing valve M3 (heating circuit 3).
Lead break, room temperature sensor, heating circuit without mixing valve A1 (heating circuit 1).
Lead break, room temperature sensor, heating circuit with mixing valve M2 (heating circuit 2).
Lead break, room temperature sensor, heating circuit with mixing valve M3 (heating circuit 3).
Check room temperature sensor
(refer to page 77).
Check room temperature sensor
(refer to page 77).
Check room temperature sensor
(refer to page 77).
Check room temperature sensor
(refer to page 77).
Burner Fault Codes
Fault display on the display interface of the control unit, to service burner refer to burner section starting on page 28.
Displayed fault code
E1
E2
System characteristics
Burner control unit in a fault state.
Burner control unit in a fault state.
Shortage of gas to gas pressure switch 2; valve leak test.
Cause
Valve 1 not tight / gas pressure switch 2 does not open.
Valve 2 not tight; gas pressure switch 2 does not close.
Measures
Check setting of gas pressure switch 2; check connecting cable; replace gas valve.
Check setting of gas pressure switch 2; check connecting cable; replace gas valve.
Replace gas valve.
E4
E5
EE
EF
F0
Burner shuts down
Burner control unit in a fault state.
Burner control unit in a fault state.
Burner control unit in a fault state.
Operation according to internal burner control unit defaults.
Gas valve does not open; gas valve leaking; gas pressure switch 2 faulty.
Multiple detection of undervoltage with return and renewed undervoltage.
Internal fault of the burner control unit and during test of ionization input.
Internal error in feedback from gas safety valves; output relay does not respond.
Internal error in feedback from gas safety valves; output relay does not respond.
Communication error, burner control unit.
Check the power supply.
Replace burner control unit.
Reset burner control unit; replace burner control unit.
Reset burner control unit; replace burner control unit.
Check plug and KM BUS to burner control unit.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Burner Fault Codes
(continued)
Troubleshooting
Displayed fault code
F2
F3
F4
System characteristics Cause Measures
Burner control unit in a fault state; system cools down.
Ionization flame monitor reports faulty flame signal during startup or after the post-purge.
No flame formation during safety time; ionization flame monitor reports no flame signal.
No flame formation during safety time; ionization flame monitor reports no flame signal.
No flame formation during safety time; ionization flame monitor reports no flame signal.
Poor start-up characteristics; rotary damper does not close.
Flame does not build during the safety time, no signal captured by the ionization flame monitor.
Flame does not build during the safety time, no signal captured by the ionization flame monitor.
Flame does not build during the safety time, no signal captured by the ionization flame monitor.
Excessive boiler water temperature.
Gas valve not gas tight (gas is escaping and burning); incorrect coding card.
Ionization electrode incorrectly adjusted; ionization electrode not plugged in. Ground leakage of electrode or cable.
Ignition electrodes incorrectly adjusted, electrodes grounded, faulty ignition unit, faulty burner control unit.
Insulation body of ignition or ionization electrode cracked.
Servomotor faulty, servomotor connecting cable faulty, output relay faulty (burner control unit).
Incorrect gas type selected.
Gas valve does not open.
Combustion characteristics not ideal.
Wait until the boiler water temperature falls below the maximum permissible boiler water temperature. If the burner fan is active check sensor
3A/3B. If the burner fan is not active check sensor 15A/15B.
Reset burner control unit.
Check ionization path; replace coding card; replace gas valve.
Insert plug of ionization electrode; check cables; adjust ionization electrode (see boiler service instructions)
Adjust ignition electrodes (see boiler service instructions); replace ignition unit; replace burner control unit.
Replace ignition or ionization electrode
Replace connecting cable; replace servomotor; replace burner control unit.
Select gas type (see boiler service instructions).
Check connecting cable; check gas valve and replace if required.
Adjust the burner (see boiler service instructions); if necessary also adjust the setting screws when the burner is off to be able to start the burner).
129
130
Troubleshooting
Burner Fault Codes
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Displayed fault code
F5
System characteristics
F6
F7
F8
F9
Fa
Fd
Cause Measures
Air pressure switch shows no air pressure, fan not running.
Air pressure switch switches off during operation.
Gas pressure switch notifies no gas pressure.
Fan pressure is produced during the air pressure switch idle state check.
Air pressure switch contact is not in the idle state.
Flame extinguishes during operation.
Flame extinguishes during operation.
Fan not running; fan speed not reached.
Status duration too long, fan ramp-up.
Varying fan speed
No fan feedback.
Fan runs without demand; burner control unit in a fault state.
Burner control unit in a fault state; system cools down; burner control unit locked out.
Air pressure switch is faulty, incorrectly connected or incorrectly set.
Flue gas back pressure; condensate backed up; air pressure switch hose faulty; connecting hose leaking.
Gas shut-off valve closed; gas pressure switch faulty; multiple problems with gas supply.
Wind influence on fan.
Air pressure switch faulty.
Burner gauze assembly faulty.
Combustion characteristics not ideal.
Fan faulty; cables are faulty or broken.
Internal fault; fan cannot reach its set value.
Fan faulty, cable a-Ö A faulty or broken. Check cable a-Ö A ; check external power supply; replace the cable or fan; remove foreign bodies.
Fan faulty, external fan power supply not connected or faulty cable a-Ö A or cable broken, fan blocked (poss. by foreign bodies).
Fan does not reach idle state, cable a-Ö A faulty, fan faulty, faulty burner control unit.
Burner control unit in a fault state.
Replace air pressure switch, connect or set correctly.
Remove flue gas back pressure; check if condensate backed up; reset burner control unit; replace hose.
Open gas shut-off valve; check gas flow pressure; replace gas filter if required; reset burner control unit; replace gas valve.
Check the flue draught (chimney)
Replace the air pressure switch.
Check burner gauze assembly; replace if damaged.
Adjust burner
(see boiler service instructions).
Check cables and replace the fan if required
Replace fan or burner control unit.
Check cable; replace cable a-Ö A or fan.
Check cable a-Ö A ; check external power supply; replace cable or fan; remove foreign bodies.
Fan subject to wind influence, check flue outlet and fan, replace cable a-Ö A , replace fan, replace burner control unit.
Read off fault at the burner control unit display and programming unit (boiler service instructions).
Fault message to the burner control unit:
Note: If LON participant faults occur, “Fault participant”... is displayed.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Burner Control Unit Connection Diagram
Connection and Wiring Diagrams
WARNING
Disconnect power inside the boiler junction box, before servicing boiler.
CAUTION
Provide disconnect means and overload protection as required.
Legend
A Boiler temperature sensor 1 § A
B Boiler temperature sensor 2 § B
C Secondary boiler water temperature sensor 1 aG A
D Secondary boiler water temperature sensor 2 aG B
E Overfire pressure switch acA A (APS2)
F Fan motor with PWM control and feedback a=Ö A
G Inlet gas pressure switch ayA GDW1
H Inlet fan pressure switch acA (APS1)
K Gas pressure switch (outlet pressure at first valve
seat) GDW2
L Burner display and programming unit
M Flame
N valve
O Burner damper
P Ignition unit gF
Q Gas valve V1 dG
R Gas valve V2 dH
S Vitotronic control unit
T AC-EMI suppression filter device
U Message: Air damper open
F1/F2 Fuse
131
Connection and Wiring Diagrams
Boiler Connections
Connection overview for CA3B 2.5 to 4.0 models
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
132
Legend
A Supply temperature sensors heating circuits M2/M3
B External LON participants (i.e. Vitotronic 200-H)
C Low voltage/sensor connections
D Boiler power supply connection
E Pumps/mixing valve connections
F Disconnect switch with lockout provision
G EA1 extension
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Boiler Connections
(continued)
Connection overview for CA3B 5.0 to 6.0 models
Connection and Wiring Diagrams
Legend
A Supply temperature sensors heating circuits M2/M3
B External LON participants (i.e. Vitotronic 200-H)
C Low voltage/sensor connections
D Boiler power supply connection
E Pumps/mixing valve connections
F Internal disconnect switch (with lockout provision)
G EA1 extension
133
Connection and Wiring Diagrams
Overview
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
134
Legend
A1 mixing valve, boiler section 1 control only
A2 PCB, low voltage
A3 PCB, 120 V~
A6 Programming unit connection PCB
A7 Optolink PCB / emissions test switch
A8 PCB
A9 Coding card
A10 LON communication module
A11 Power supply unit PCB
A12 Programming unit ON/OFF switch
A13 Programming unit
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Connection and Wiring Diagrams
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 Heating circuit pumps fÖ gS M2/M3 Mixing valve motors
K1-K6
X
Power supply
Relay
Electrical interfaces
PCB, Low Voltage
Legend
!
?
/
Outdoor temperature sensor
Supply temperature sensor / common system supply temperature
% A DHW Tank temperature sensor
% B DHW tank temperature sensor for tank loading
system aJ B Temperature sensor, DHW tank loading system avD External avG KM-BUS avH External
LON
S3
V1
Emissions test switch
Fault display (red)
V2 Operating mode display (green)
X Electrical interfaces
135
Connection and Wiring Diagrams
PCB 120V~
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
136
Legend sÖ Heating circuit pump
or sA sL primary pump, tank loading system
Circulation pump for DHW tank heating
(accessory) sK DHW recirculation pump (on-site)
Boiler circuit pump or distributor pump (on-site) fÖ fA gÖ gS
Power supply, 120 V/60 Hz
Burner
Output for central fault message
Motor for 3-way mixing valve, primary store
system aBÖ External connections (remove jumper when connecting) aBA Safety chain (potential free) aBH
F MCB/fuse
K2-K10 Relays switch
X Electrical interfaces
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.
Order replacement components from your Viessmann distributor.
Parts for CA3B 2.5 and 3.0
0001 Vitocrossal 300 CA3B boiler
0002 Vitotronic 300 GW6C control panel
0003 Boiler enclosure assembly
0004 Other Parts
A Rating Plate
Parts
137
138
Parts
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.
Order replacement components from your Viessmann distributor.
Parts for Enclosure Assembly
0001 Side panel, right top front
0002 Side panel, right top rear
0004 Side panel, left top
0006 Side panel, right bottom
0008 Front panel, top
0009 Nameplate, “Vitocrossal 300”
0010 Nameplate, “Viessmann”
0011 Front panel, bottom
0012 Rear panel 1, bottom
0013 Rear panel 2, bottom
0014 Rear panel, top
0015 Cover plate
0018 Top panel
0020 Insulation blanket
0021 Cable channel, front
0022 Cable channel, rear
0024 Cable clasp
0025 Side panel, left front bottom
0027 Side panel, left rear bottom panel
0029 Filter, grill
0030 Filter, air
0031 Accessory pack, fasteners
0032 Access key for control panel
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
Order replacement components from your Viessmann distributor.
Parts for CA3B 2.5 and 3.0 Boiler Assembly
0002 Boiler section
0003 Gasket, 30 x 20 L=1500
0004 Support bracket 1
0005 Support bracket 2
0006 Plug, 1½ in.
0007 Fiber rope seal, 18x2100 mm
0008 Sensor well, G½ L=100 with clip
0009 Sensor well, G½ L=150 with clip
0010 Accessory pack, boiler sections,
1.25 MMBH and 1.5 MMBH
0012 Boiler stand
0013 Cover with tension gasket
0014 Locking band, 10 in. with gasket
0015 Boiler supply header
0016 Gasket, PN10 DN2”
0017 Accessory pack for supply, DN65
0024 Boiler return header
0025 Accessory pack for return, DN65
0026 Servomotor, SR230A-5
0027 Connection pipe 1, NG/LP with gaskets
0028 Connection pipe 2, NG/LP with gaskets
0029 Gasket, A46x62x2
0030 Connection pipe 3, NG/LP
0032 Condensate syphon, G1 1/4 x G1 1/2
0033 CA3B Cylinder Burner 1.25 MMBH
Parts
139
140
Parts
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.
Order replacement components from your Viessmann distributor.
Parts for CA3B 3.5 and 4.0 Boilers
0001 Vitocrossal 300 CA3B boiler
0002 Vitotronic 300 GW6C control panel
0003 Boiler enclosure assembly
0004 Other Parts
A Rating
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
Order replacement components from your Viessmann distributor.
Parts for Enclosure Assembly
0001 Side panel, right top front
0002 Side panel, right top rear
0004 Side panel, left top
0006 Side panel, right bottom
0008 Front panel, top
0009 Nameplate, “Vitocrossal 300”
0010 Nameplate, “Viessmann”
0011 Front panel, bottom
0012 Edge protection
0013 Rear panel, bottom
0014 Rear panel, top
0015 Edge protection
0017 Top panel
0019 Thermal insulation jacket
0020 Cable channel, front
0021 Cable channel, rear
0023 Side panel, left front bottom
0025 Side panel, left-hand rear bottom
0026 Cover panel
0027 Filter, grill
0028 Filter, air
0029 Other parts
Parts
141
142
Parts
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.
Parts for CA3B 3.5 Boiler Assembly
0001 Boiler section, 1.5 MMBH
0002 Boiler section, 2.0 MMBH
0003 Fiber rope seal, 25x15x1500 mm
0004 Support bracket 1
0005 Support bracket 2
0006 Plug, 1½ in.
0007 Fiber rope seal, 18x2100 mm
0008 Sensor well, G½ L=100 with clip
0009 Sensor well, G½ L=150 with clip
0010 Accessory pack, boiler section,
1.25 MMBH and 1.5 MMBH
0011 Accessory pack, boiler section,
2.0
0012 Boiler stand
0013 Cover with tension gasket
0014 Locking band, 12 in. with gasket
0015 Boiler supply header
0016 Gasket, PN10 DN2”
0018 Accessory pack, DN65
0019 Flow regulator 1, DN65
0020 Accessory pack, DN65
0021 Flow regulator 2, DN65
0024 Boiler return header
0025 Accessory pack for return, DN65
0026 Servomotor, SR230A-5
0027 Connection pipe 1, NG/LP with gasket
0028 Connection pipe 2, NG/LP with gasket
0029 Gasket, A46x62x2
0030 Connection pipe 3, NG/LP with gasket
0031 CA3B Burner Harness and Sensors
0032 Condensate syphon, G1 1/4 x G1 1/2
0034 CA3B Cylinder Burner 2.0 MMBH
0035 CA3B Cylinder Burner 1.5 MMBH
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
Parts for CA3B 4.0 Boiler Assembly
0002 Boiler section, 2.0 MMBH
0003 Fiber rope seal, 25x15x1500 mm
0004 Support bracket 1
0005 Support bracket 2
0006 Plug, 1½ in.
0007 Fiber rope seal, 18x2100 mm
0008 Sensor well, G½ L=100 with clip
0009 Sensor well, G½ L=150 with clip
0011 Accessory pack boiler section, 2.0 MMBH
0012 Boiler stand
0013 Cover with tension gasket
0014 Locking band, 12 in. with gasket
0015 Boiler supply header
0016 Gasket, PN10 DN2”
0017 Accessory pack for supply, DN65
0024 Boiler return header
0025 Accessory pack for return, DN65
0026 Servomotor, SR230A-5
0027 Connection pipe 1, NG/LP with gaskets
0028 Connection pipe 2, NG/LP with gaskets
0029 Gasket, A46x62x2
0030 Connection pipe 3, NG/LP with gaskets
0031 CA3B Burner Harness and Sensors
0032 Condensate syphon, G1 1/4 x G1 1/2
0034 CA3B Cylinder Burner 2.0 MMBH
Parts
143
144
Parts
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.
Order replacement components from your Viessmann distributor.
Parts for CA3B 5.0 and 6.0 Boilers
0001 Vitocrossal 300 CA3B boiler
0002 Vitotronic 300 GW6C control panel
0003 Boiler enclosure assembly
0004 Other Parts
A Rating
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
Order replacement components from your Viessmann distributor.
Parts for Enclosure Assembly
0001 Side panel, right top front
0002 Side panel, right top rear
0003 Side panel, right top mid
0004 Side panel, left top
0005 Side panel, left top mid
0006 Side panel, right bottom
0007 Side panel, right mid bottom
0008 Front panel, top
0009 Nameplate, “Vitocrossal 300”
0010 Nameplate, “Viessmann”
0011 Front panel, bottom
0012 Gas pipe edge protection
0013 Rear panel 1, bottom
0014 Rear panel 2, top
0015 Cover plate 2
0016 Cover plate 1
0017 Top panel
0018 Top panel, mid
0019 Insulation blanket
0020 Cable channel 1
0021 Cable channel 2
0022 Cable channel 3
0023 Side panel, left front bottom
0024 Side panel, left mid bottom
0025 Side panel, left rear bottom
0026 Cover panel
0027 Filter, grill
0028 Filter, air
0029 Accessory pack, fasteners
Parts
145
146
Parts
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.
Parts for CA3B 5.0 Boiler Assembly
0001 Boiler section, 1.5 MMBH
0002 Boiler section, 2.0 MMBH
0003 Fiber rope seal, 25x15x1500mm
0004 Support bracket 1
0005 Support bracket 2
0006 Plug, 1½ in.
0007 Fiber rope seal, 18x2100 mm
0008 Sensor well, G½ L=100 with clip
0009 Sensor well, G½ L=150 with clip
0010 Accessory pack boiler section,
1.25 MMBH and 1.5 MMBH
0011 Accessory pack boiler section,
2.0
0012 Boiler stand
0013 Cover with tension gasket
0014 Locking band, 16 in. with gasket
0015 Boiler supply header
0016 Gasket, PN10 DN2”
0018 Accessory pack, DN65
0019 Flow regulator, DN65
0022 Accessory pack, DN65
0023 Orifice, DN65
0024 Boiler return header
0025 Accessory pack for return, DN65
0026 Servomotor, SR230A-5
0027 Connection pipe 1, NG/LP with gaskets
0028 Connection pipe 2, NG/LP with gaskets
0029 Gasket, A46x62x2
0030 Connection pipe 3, NG/LP with gaskets
0031 CA3B Burner Harness and Sensors
0032 Condensate syphon, G1 1/4 x G1 1/2
0034 CA3B Cylinder Burner 2.0 MMBH
0035 CA3B Cylinder Burner 1.5 MMBH
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
Parts for CA3B 6.0 Boiler Assembly
0002 Boiler section, 2.0 MMBH
0003 Fiber rope seal, 25x15x1500 mm
0004 Support bracket 1
0005 Support bracket 2
0006 Plug, 1½ in.
0007 Fiber rope seal, 18x2100 mm
0008 Sensor well, G½ L=100 with clip
0009 Sensor well, G½ L=150 with clip
0011 Accessory pack boiler section,
MMBH
0012 Boiler stand
0013 Cover with tension gasket
0014 Locking band, 16 in. with gasket
0015 Boiler supply header
0016 Gasket, PN10 DN2”
0017 Accessory pack for supply, DN65
0024 Boiler return header
0025 Accessory pack for return, DN65
0026 Servomotor, SR230A-5
0027 Connection pipe 1, NG/LP with gaskets
0028 Connection pipe 2, NG/LP with gaskets
0029 Gasket, A46x62x2
0030 Connection pipe 3, NG/LP with gaskets
0031 CA3B Burner Harness and Sensors
0032 Condensate syphon, G1 1/4 x G1 1/2
0034 CA3B Cylinder Burner 2.0 MMBH
Parts
147
148
Parts
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.
Order replacement components from your Viessmann distributor.
Parts for Burner Assembly, 1.25 and 1.5 MMBH, compact
0001 Burner plate
0002 Burner gasket
0003 Burner chassis, compact
0004 Combustion chamber door refractory
0005 Accessory pack, small burner parts
0006 Burner tube
0007 Gasket, burner tube
0008 Electrodes
0009 Ignition cable
0010 Ignition transformer
0011 Coding plug, burner
0012 CA3B Burner Control
0013 Fan, G3G200 120/1/60
0014 Gasket, fan
0015 Venturi mixing pipe
0016 Gas valve, V4734C1010-1100
0017 Servomotor, burner damper STA
0018 Linkage M5, burner damper
0019 Flange, 1¼ in., gas valve
0020 O-ring, gas valve, 52x3.5
0021 Connection pipe, fuel NG/LP
0022 Gasket, triple-electrode
0023 Hose set
0025 Orifice with gasket, NG
0026 Gasket, fan
0027 Fan adaptor
0028 Burner tube kit, D245
0029 Flange, 1¼ in., gas valve
0030 2/2 way solenoid valve
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
Order replacement components from your Viessmann distributor.
Parts for Burner Control Unit 1.25 and 1.5 MMBH, compact
0001 Burner control, VUC310-C10.004
0002 Programming unit, HI201-C01.001 with LED
0003 Harness “11”, ionization/ground
0004 Cable, gas pressure switch “2”
0005 Harness “54”, ignition transformer
0006 Harness, step motor
0007 Harness “111”, gas pressure
0008 Harness “35/36”, gas valve
0009 Harness “100A”, motor
0010 Harness “100”, fan
0011 Cable, “131A”, sensors and air pressure switch
0012 Air pressure switch 1 with cable
0013 Air pressure switch with 131A cable
0014 Cable, fuel conversion
0015 Harness, burner shut-off
0016 Accessory pack, plugs #41,90,151,191
0017 Suppression filter device AC EMI
0018 Plug, 3-pole, RST25I3 (each)
0019 Harness “38”, bypass
Parts
149
150
Parts
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.
Order replacement components from your Viessmann distributor.
Parts for Burner Assembly, 1.5 MMBTU
0001 Burner plate
0002 Burner gasket
0003 Burner chassis
0004 Combustion chamber door refractory
0005 Accessory pack, small burner parts
0006 Burner tube
0007 Gasket, burner tube
0008 Electrodes
0009 Ignition cable
0010 Ignition transformer
0011 Coding plug, burner
0012 CA3B Burner Control
0013 Servomotor, inlet damper STA
0014 Fan, G3G200 120/1/60
0015 Gasket, fan
0016 Inlet damper
0017 Linkage M5, inlet damper
0018 Venturi mixing pipe
0019 Gas valve, V4734C1010-1100
0020 Servomotor, burner damper STA
0021 Linkage M5, burner damper
0022 Flange, 1¼ in., gas valve
0023 O-ring, gas valve, 52x3.5
0024 Connection pipe 2, with shut-off
0025 Gasket, triple-electrode
0026 Compensation hose set, air pressure
0027 Installation instruction compact burner
0028 Orifice with gasket, NG
0029 Gasket, fan
0030 Fan adaptor
0031 Burner tube kit, D245
0032 Flange, 1¼ in., gas valve
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
Order replacement components from your Viessmann distributor.
Parts for Burner Control Unit, 1.5 MMBTU
0001 Burner control, VUC310-C10.004
0002 Programming unit with LED
0003 Harness “11”, ionization/ground
0004 Harness “VPS87”, gas pressure
0005 Harness “54”, ignition transformer
0006 Harness, step motor/inlet damper
0007 Harness “111”, gas pressure
0008 Harness “35/36”, gas valve
0009 Harness “100A”, motor
0010 Harness “100”, fan
0011 Harness sensors
0012 Air pressure switch 1 with cable
0013 Air pressure switch 2 with cable
0014 Air pressure switch with cable
0015 Harness, step motor/burner damper
0016 Accessory pack, plugs #41,90,151,191
0017 Suppression filter device AC EMI
0018 Plug, 3-pole, RST25I3 (each)
Parts
151
152
Parts
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.
Order replacement components from your Viessmann distributor.
Parts for Burner Assembly, 2.0 MMBH
0001 Burner plate
0002 Burner gasket
0003 Burner chassis
0004 Combustion chamber door refractory
0005 Accessory pack, small burner parts
0006 Burner tube
0007 Gasket, burner tube
0008 Electrodes
0009 Ignition cable
0010 Ignition transformer
0011 Coding plug, burner
0012 CA3B Burner Control
0013 Servomotor, inlet damper STA
0014 Fan,120/1/60
0015 Gasket, fan
0016 Inlet damper
0017 Linkage M5, inlet damper)
0018 Venturi mixing pipe
0019 Gas valve, V4734C1010-1100
0020 Servomotor, burner damper STA
0021 Linkage M5, burner damper
0022 Flange, 1¼ in., gas valve
0023 O-ring, gas valve, 52x3.5
0024 Connection pipe 1 with shut-off
0025 Gasket triple-electrode
0026 Compensation hose set, air pressure
0027 Installation instructions compact burner
0028 Burner tube kit, D245
0029 Flange, 1¼ in., gas valve
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
Order replacement components from your Viessmann distributor.
Parts for Burner Control Unit, 2.0 MMBTU
0001 Burner control, VUC310-C10.004
0002 Programming unit with LED
0003 Harness “11”, ionization/ground
0004 Harness “VPS87”, gas pressure
0005 Harness “54”, ignition transformer
0006 Harness, step motor/inlet damper
0007 Harness “111”, gas pressure
0008 Harness “35/36”, gas valve
0009 Harness “100A”, motor
0010 Harness “100”, fan
0011 Harness sensors
0012 Air pressure switch 1 with cable
0013 Air pressure switch 2 with cable
0014 Air pressure switch with cable
0015 Harness, step motor/burner damper
0016 Accessory pack, plugs #41, 90, 151, 191
0017 Suppression filter device AC EMI
0018 Plug, 3-pole, RST25I3 (each)
Parts
153
154
Parts
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.
Order replacement components from your Viessmann distributor.
Parts for Control Panel, Vitotronic 300, GW6C
0001 Master-Display
0002 Vitotronic 300, GW6C boiler and system control
0003 Junction Box
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
Order replacement components from your Viessmann distributor.
Parts for Control Panel, Vitotronic 300, GW6C
0001 Master-Display
0002 Vitotronic 300, GW6C boiler and system control
0003 Junction Box
Parts
155
156
Parts
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.
Order replacement components from your Viessmann distributor.
Parts for Master-Display Assembly
0001 Control console, GW6C
0002 Rear housing, master display
0003 Programming unit, Vitotronic 200 HI932
0004 Circuit board, SA168 A10
0005 Flat cable, 16-pole
0006 Harness, master power
0007 Harness, relay
0008 Covers, sliding, left/right
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
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.
Order replacement components from your Viessmann distributor.
Parts for Connection Enclosure Assembly
0001 Control unit, module
0002 Cover, motherboard
0003 Extension module, MV 2+3
0004 Motherboard, low voltage, MB200
0005 Circuit board, CU102-A60.XXX touch
0006 Motherboard, 120/1/60, MB201
0007 Circuit board, power supply, SP102
0008 Circuit board, LON, IU100-B10
0009 Rear housing connection enclosure
0010 Control panel, without AHL+FHL,
120/1/60
0011 Switch, 2-pole, on/off
0012 Fuse holder cover
0013 Fuse holder
0014 Fuse, T6.3A/250V, (set of 10)
0015 Sensor #1, outdoor, NTC
0016 Sensor #5, DHW, immersion NTC
0017 Sensor #2/#17, supply/return,
strap-on NTC
0018 Harness heating circuit expansion
156/40A
0019 Cable, 1M shielded,
2 x RJ45-steward
0020 Connecting cable (7M), LON RJ45
0021 LON terminal end resistor (set of 2)
0022 Accessory pack, low voltage plugs
0023 3-Pole plug, male, #20 (set of 3)
0024 4-Pole plug, #52 (set of 3)
0025 3-Pole plug, #156 (set of 3)
0026 3-Pole plug, #40 (set of 3)
0027 3-Pole plug, #50 (set of 3)
0028 Accessory pack, plugs #143,145,146
0030 Coding plug
0031 Programming unit,
Vitotronic 200 HI932
0032 Control, with sub-base, adaptor and cabling
0033 Connecting cable, ETS
0034 Switch, 1-pole, ETS
0035 Flat cable, 16-pole
Parts
157
158
Parts
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.
Order replacement components from your Viessmann distributor.
Parts for Junction Box Assembly
0001 EA1 extension 120VAC
0002 Switch-disconnector, 690/3/40
0003 Sealing grommet, M50
0005 Relay, K3-14ND10 120V
0006 Terminal block, 3-pole
0007 Terminal block, PT 2.5
0008 Terminal block, PT 16
0009 Fuse holder
0010 Fuse, 2.0A/250V (set of 10)
0011 Circuit breaker, 16A
0012 Circuit breaker, 10A
0013 Relay, 24-240V 8A SPDT time delay
0014 Power relay, 120V 30A
0015 Power relay, 120V 10A 3PDT
0016 Power relay, 120V 10A DPDT
0017 Vitogate 300 BN (optional accessory)
0018 Power supply, 24VDC 0.75A
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Technical Data
Specifications
Boiler Model
Input
Minimum Input NG
Minimum Input LPG
Output (thermal efficiency)
Output (combustion efficiency)
Net AHRI Rating
Combustion efficiency *
1
Thermal efficiency *
1
NG Supply Pressure
LPG Supply Pressure
Power Supply
”w.c. (max.)
”w.c. (min.)
”w.c. (max.)
”w.c. (min.)
Voltage
Phase
Hz
Amp.
in.
(mm)
CA3B
MBH
(kW)
MBH
(kW)
MBH
(kW)
MBH
(kW)
MBH
(kW)
MBH
(kW)
%
%
14
4
14
10
120
1
60
20
88 c
(2251)
2.5
2500
(733)
250
(73)
495
(145)
2402
(703)
2352
(689)
2089
(611)
94.1
96.1
14
4
14
10
120
1
60
20
88 c
(2251)
3.0
3000
(879)
300
(88)
495
(145)
2883
(844)
2832
(830)
2506
(734)
94.1
96.1
14
4
14
10
120
1
60
20
99 b
(2526)
3.5
3500
(1026)
300
(88)
495
(145)
3363
(985)
3294
(965)
2924
(856)
94.1
96.1
14
4
14
10
120
1
60
20
99 b
(2526)
4.0
4000
(1172)
400
(117)
660
(193)
3844
(1126)
3764
(1103)
3342
(979)
94.1
96.1
14
4
14
10
208 *
2
3
60
20
136
(3449)
5.0
5000
(1465)
300
(88)
495
(145)
4805
(1408)
4705
(1379)
4178
(1224)
94.1
96.1
Overall Boiler Length
(including insulation and jacketing)
Overall Boiler Width
(including insulation and jacketing)
Overall Boiler Height *
4
(including insulation and jacketing)
Concrete boiler base *
3
Length in.
(mm) in.
(mm)
34
(860)
78 c
(2000)
34
(860)
78 c
(2000)
39 b
(1000)
84
(2131)
39 b
(1000)
84
(2131)
39 b
(1000)
84
(2131)
39 b
(1000)
84
(2131)
Width
Thickness in.
(mm) in.
(mm) in.
(mm)
74 c
(1900)
34
(860)
4
(100)
74 c
(1900)
34
(860)
4
(100)
82 c
(2100)
39 b
(1000)
4
(100)
82 c
(2100)
39 b
(1000)
4
(100)
114 a
(2900)
39 b
(1000)
4
(100)
114 a
(2900)
39 b
(1000)
4
(100)
Weight
Complete with the burners, control, thermal insulation and jacketing lb.
(Kg)
4233
(1920)
4233
(1920)
4696
(2130)
4806
(2180)
6261
(2840)
6894
(3127)
*
1
Tested to ANSI/AHRI standard 1500 Performance Rating of Commercial Space Heating Boilers / DOE Test
Procedure 81 FR 89276 / U.S. Standards ANSI Z21.13/CSA 4.9 / AHRI, BTS-2000 Testing Standard Method to determine the efficiency of Commercial Heating Boilers.
*
2
Requires 208Y/120VAC - 3
phase
- 60 Hz - 4 wire (L1, L2, L3, N, G) power supply.
*
3
Concrete boiler pad is required for all installations (refer to the Installation Instructions).
* 4
Does not include the concrete boiler pad or seismic brackets.
Note: For altitude operation up to 4,999 feet, derate the input capacity by 3%/1000 ft.
For operation from 5,000 to 10,000 feet, with the electronic altitude adjustment made, derate the input capacity by an additional 0.6%/1000 ft. for a total derate of 18%.
14
4
14
10
208 *
2
3
60
20
136
(3449)
6.0
6000
(1758)
400
(117)
660
(193)
5766
(1689)
5646
(1655)
5013
(1469)
94.1
96.1
A
A Input capacity after electronic altitude adjustment is made.
159
160
Specifications
Technical Data
(continued)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Boiler Model
Boiler Water Content
Heat Exchanger Surface
Maximum Operating Temperature
Maximum Adjustable High Limit
Maximum Operating Pressure
CA3B
USG
(L)
2.5
108
(410) ft.
2 142.7
(m 2) (13.3)
°F
(°C)
°F
(°C) psig
(bar)
210
(99)
203
(95)
160
(11)
3.0
108
(410)
142.7
(13.3)
210
(99)
203
(95)
160
(11)
3.5
151
(570)
170.2
(15.8)
210
(99)
203
(95)
160
(11)
4.0
143
(540)
192.5
(17.9)
210
(99)
203
(95)
160
(11)
Boiler Connections
B oiler supply and return
(BS), (BR) (ANSI flanges)
Safety supply
Boiler drain
Condensate drain (barbed fitting)
Gas connection
Boiler flue collar
Internal diameter in.
(mm) in.
in.
2@1 b in.
in.
4
(100)
2 c
2 b
4
(100)
2
2@1 b c
2 b
4
(100)
2
2@1 b c
2 b
4
(100)
2
2@1 b c
2 b
4
(100)
2
3@1 b c
3
Combustion Air
Internal diameter
(for direct vent sealed combustion using the combustion air intake kit optional accessory)
Flue Gas Values
Temperature (at a return temperature of 86°F (30°C) at rated input in.
(mm) in.
(mm)
10
(254)
10
(254)
10
(254)
10
(254)
12
(306.8)
12
(306.8)
12
(306.8)
12
(306.8)
16
(408.4)
16
(408.4) at partial load
°F
(°C)
°F
(°C)
113
(45)
91
(33)
113
(45)
91
(33)
117
(47)
91
(33)
117
(47)
91
(33)
122
(50)
91
(33)
Temperature (at a return temperature of 140°F (60°C) at rated input °F
(°C)
167
(75)
167
(75)
162
(72)
162
(72)
167
(75)
Mass flow rate (of flue gas) at rated input at partial load lbs/h 2216
(kg/h) (1007) lbs/h
(kg/h)
USG/h
(L/h)
267
(121)
24
(91)
2656
(1205)
320
(145)
29
(109)
3109
(1410)
320
(145)
34
(129)
3549
(1610)
425.5
(193)
38
(144)
4442
(2015)
320
(145)
48
(182)
Max. Condensate Flow Rate for NG and LPG
Pressure at boiler flue outlet at rated input
Standby Loss
At boiler water temperature
158°F (70°C) [room temperature 68°F (20°C)]
NOx @3% O 2
* 5 pa
(max.)
“w.c.
(max.)
BTU/h
(W)
%
100
0.4
6227
(1825)
0.25
100
0.4
7469
(2197)
0.25
100
0.4
8750
(2564)
0.25
10000
(2931)
0.25
<20 ppm
100
0.4
100
0.4
12500
(3663)
0.25
*
5
For operation with natural gas, field setup and adjustment is required to achieve the stated value.
Adjustment may cause a boiler derate of up to 20%.
5.0
227
(860)
244.1
(22.7)
210
(99)
203
(95)
160
(11)
122
(50)
91
(33)
15000
(4396)
0.25
167
(75)
5324
(2415)
425.5
(193)
58
(220)
100
0.4
6.0
218
(825)
288.8
(26.8)
210
(99)
203
(95)
160
(11)
6
(150)
2
3@1 b c
3
16
(408.4)
16
(408.4)
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Requirements for Water Conditions
Inspection and Maintenance
USG
Counter reading
USG
Fill and make-up water
USG
Total quantity of water Total hardness
Feed water Boiler water pH-value Date
161
162
Inspection and Maintenance
Maintenance Record
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Setting and Test Values
Static Pressure
Supply Pressure (running pressure)
for natural gas NG mbar (”w.c.)
for liquid propane gas LPG
Check gas type
mbar (”w.c.)
Carbon Dioxide Content CO
2
■ at the upper rated heating output actual set
% by vol.
% by vol.
% by vol.
■ at the lower rated heating output actual set
Oxygen Content O
2
■ at the upper rated heating output actual set
■ at the lower rated heating output actual set
Carbon Monoxide Content CO actual set
% by vol.
% by vol.
% by vol.
% by vol.
% by vol.
ppm
ppm
Commissioning Maintenance/Service
mbar (”w.c.) Section 1 Section 2 Section 3 Section 1 Section 2 Section 3
Flue Gas Temperature (gross) actual °F (°C) set °F (°C)
Ionization Current
■ at the upper rated heating output μ A
■ at the lower rated heating output μ A
Draught actual hPa (”w.c.) set hPa (”w.c.)
Maintenance Schedule
The following is an overview of scheduled service steps.
Regular service work ensures reliable, energy-efficient, and environmentally friendly operation.
IMPORTANT
Keep boiler and boiler room clear and free from combustible materials, gasoline and other flammable vapors and liquids.
Do not obstruct the flow of combustion and ventilation air.
All inspection, maintenance, and service must be performed by a qualified heating technician.
IMPORTANT
The boiler must be cleaned at least once a year by a qualified heating technician or service agency.
Vitocrossal 300 CA3B Series 2.5 to 6.0 Service
Maintenance Schedule
(continued)
Inspection and Maintenance
Frequency Performed by
Monthly Owner /
Operator
Annually Owner /
Operator
Heating
Technician
Periodically Heating
Technician
Service
Check the system pressure frequently.
Ensure proper operation of the boiler control. Refer to operating instructions of the control.
Inspect all seals; retighten or replace as necessary.
Ensure an adequate supply of combustion air and ventilation air into and out of the mechanical room is being maintained at all times.
Ensure that nothing is obstructing the flow of combustion ventilation air, and no chemicals, garbage, gasoline, combustible materials, flammable vapors, or liquids are stored, not even temporarily, in the vicinity of the boiler.
Check for water on the floor from the discharge pipe of pressure relief valve or any other pipe, pipe joint, valve, or air vent.
Test pressure relief valve and check for proper operation. See instructions attached to pressure relief valve.
Check all operational high limits for proper operation.
Check for proper operation of the condensate neutralization system (if used).
Check the condition and fill status of the neutralization media.
Check the pH value of the flue gas condensate (min. 6.5).
Check for moisture water on external vent pipe joints and appearance of ice on the vent pipe or chimney outlet in the winter time.
Ensure service work/test is conducted at least annually by qualified personnel, and that any deficiencies are corrected immediately.
Test functionality of safety high limits.
Test and establish proper chemical makeup of system water.
Check flue pipe condition, chimney connection and chimney itself.
Check pressure relief valve and system pressure, and verify proper operation.
Check heating pipe joints, valves, air vents, etc. System leaks must be corrected immediately to avoid further defects.
The cause of defect must also be determined in order to avoid further problems.
Check for proper combustion air supply and ventilation to boiler / mechanical room.
Test high limits by dialing lower settings, then switching burners on/off to verify function. Test low water cut-off, check and verify proper function according to manufacturer’s instructions.
Check requirements for maintenance or lubrication of the circulation pumps according to manufacturer’s instructions.
Check for gas-tight connection of gas piping, unions, gas valve and manifold.
Check proper ignition of the burners.
Combustion test must be performed by a qualified heating technician.
Ensure functionality of low water cutoffs, including flushing of float types (if used) during operation. Refer to the manufacturer’s instructions.
Inspect low- and/or high pressure gas switch (if used).
Inspect main burner flame and follow the instruction manual for detailed service and maintenance guidelines.
All boilers and the boiler room must be kept free of high dust levels, high humidity, aggressive vapors and/or chemicals containing chlorine.
Ensure proper boiler room ventilation.
Valves, fittings and pipes not pressure tight must be repaired.
Combustion chamber door, clean-out opening covers, and flanges may need to be retightened and resealed. Do not over tighten.
163
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