Viessmann VITOCROSSAL 300 Service Instructions For Contractors

Service instructions
VIESMANN
for contractors
Vitocrossal 300
Type CT3U, 400 to 630 kW
Gas condensing boiler with MatriX cylinder burner
for natural gas E and LL
VITOCROSSAL 300
5834360 GB
1/2019
Please keep safe.
Safety instructions
Safety instructions
Please follow these safety instructions closely to
prevent accidents and material losses.
Safety instructions explained
Danger
This symbol warns against the risk of injury.
!
Note
Details identified by the word "Note" contain additional
information.
Please note
This symbol warns against the risk of material
losses and environmental pollution.
Target group
These instructions are exclusively intended for qualified contractors.
■ Work on gas installations may only be carried out by
a registered gas fitter.
■ Work on electrical equipment may 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.
Regulations to be observed
■ National installation regulations
■ Statutory regulations for the prevention of accidents
■ Statutory regulations for environmental protection
■ Codes of practice of the relevant trade associations
■ Relevant country-specific safety regulations
Safety instructions for working on the system
Working on the system
Repair work
■ 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. by
removing the separate fuse or by means of a mains
isolator, and check that it is no longer live.
■ Safeguard the system against reconnection.
■ Wear suitable personal protective equipment when
carrying out any work.
Danger
Hot surfaces and fluids can lead to burns or
scalding.
■ Before maintenance and service work, switch
OFF the appliance and let it cool down.
■ Never touch hot surfaces on the boiler, burner,
flue system or pipework.
Auxiliary components, spare and wearing parts
!
Please note
Spare and wearing parts that have not been tested together with the system can compromise its
function. Installing non-authorised 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.
Please note
Electronic assemblies can be damaged by electrostatic discharge.
Prior to commencing work, touch earthed
objects such as heating or water pipes to discharge static loads.
5834360
!
Please note
Repairing components that fulfil a safety function can compromise the safe operation of the
system.
Replace faulty components only with genuine
Viessmann spare parts.
2
Safety instructions
Safety instructions (cont.)
Safety instructions for operating the system
If you smell gas
Danger
Escaping gas can lead to explosions which may
result in serious injury.
■ Do not smoke. Prevent naked flames and
sparks. Never switch lights or electrical appliances on or off.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Evacuate any people from the danger zone.
■ Notify your gas or electricity supply utility from
outside the building.
■ Have the power supply to the building shut off
from a safe place (outside the building).
If you smell flue gas
Danger
Flue gas can lead to life threatening poisoning.
■ Shut down the heating system.
■ Ventilate the installation site.
■ Close doors to living spaces to prevent flue
gases from spreading.
What to do if water escapes from the appliance
Danger
If water escapes from the appliance there is a
risk of electrocution.
Switch OFF the heating system at the external
isolator (e.g. fuse box, domestic distribution
board).
Flue systems and combustion air
Ensure that flue systems are clear and cannot be
sealed, for instance due to accumulation of condensate or other external causes.
Ensure an adequate supply of combustion air.
Inform system users that subsequent modifications to
the building characteristics are not permissible (e.g.
cable/pipework routing, cladding or partitions).
Danger
Leaking or blocked flue systems, or an inadequate supply of combustion air can cause life
threatening poisoning from carbon monoxide in
the flue gas.
Ensure the flue system is in good working order.
Vents for supplying combustion air must be nonsealable.
Extractors
Operating appliances that exhaust air to the outside
(extractor hoods, extractors, air conditioning units, etc.)
can create negative pressure. If the boiler is operated
at the same time, this can lead to a reverse flow of flue
gas.
Danger
The simultaneous operation of the boiler and
appliances that exhausts air to the outside can
result in life threatening poisoning due to a
reverse flow of flue gas.
Fit an interlock circuit or take suitable steps to
ensure an adequate supply of combustion air.
Danger
If water escapes from the appliance there is a
risk of scalding.
Never touch hot heating water.
Condensate
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Danger
Contact with condensate can be harmful to
health.
Never let condensate touch your skin or eyes
and do not swallow it.
3
Index
Index
1.
Information
Symbols .................................................................................................
Intended use ..........................................................................................
Product information ................................................................................
■ System examples ...............................................................................
Burner ....................................................................................................
5
5
6
6
6
2.
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance ............................
7
3.
Control unit
Setting the codes at the control unit ...................................................... 19
4.
Functions
Air pressure switch ................................................................................ 20
20
21
■ Fan pressure monitoring (LDW1) .......................................................
■ Combustion chamber pressure monitoring (LDW2) ...........................
Parts lists
Overview of assemblies ......................................................................... 23
Boiler assembly ..................................................................................... 24
■ Cable set assembly ............................................................................ 26
Thermal insulation assembly ................................................................. 28
Parts not shown ..................................................................................... 30
6.
Water quality requirements
................................................................................................................ 31
7.
Reports
Water quality .......................................................................................... 33
8.
Specification
................................................................................................................ 34
9.
Final decommissioning
and disposal
................................................................................................................ 35
10.
Certificates
EU Declaration of Conformity ................................................................ 36
Manufacturer's certificate ....................................................................... 36
11.
Keyword index
................................................................................................................ 37
5834360
5.
4
Information
Symbol
Meaning
Reference to other document containing
further information
1.
Step in a diagram:
The numbers correspond to the order in
which the steps are carried out.
The steps in connection with commissioning, inspection and maintenance are found in the "Commissioning, inspection and maintenance" section and identified
as follows:
Symbol
Meaning
Steps required during commissioning
Not required during commissioning
Warning of material losses and environmental pollution
Steps required during inspection
Not required during inspection
Live electrical area
Pay particular attention.
Steps required during maintenance
Not required during maintenance
Component must audibly click into place.
or
■ Acoustic signal
■
Fit new component.
or
■ In conjunction with a tool: Clean the surface.
■
Dispose of component correctly.
Dispose of component at a suitable collection point. Do not dispose of component in
domestic waste.
Intended use
The appliance is only intended to be installed and
operated in sealed unvented heating systems that
comply with EN 12828, with due attention paid to the
associated installation, service and operating instructions as well as the details in the datasheet.
It is only designed for the heating up of heating water.
Every other use will be deemed to be inappropriate.
Any resulting losses are excluded from the manufacturer's liability.
Commercial or industrial usage for a purpose other
than the heating up of heating water shall be deemed
inappropriate.
Intended use also includes the adherence to maintenance and inspection intervals.
Any usage beyond this must be approved by the manufacturer for the individual case.
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Intended use presupposes that a fixed installation in
conjunction with permissible components designed for
this purpose has been carried out.
5
Information
Symbols
Information
Product information
■ Gas condensing boiler
– Rated heating output 400 to 630 kW
– For MatriX cylinder burner for natural gas E and LL
■ Permissible operating pressure 5.5 bar
System examples
Available system examples: See www.viessmannschemes.com.
Burner
Information about commissioning, inspection and maintenance of the burner
Burner service instructions
5834360
Information
Vitocrossal 300, type CT3U
6
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
Commissioning steps
Inspection steps
Maintenance steps
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1. Note on initial commissioning, inspection and maintenance........................................
8
2. Checking the high limit safety cut-out setting................................................................
8
3. Filling the heating system with water and venting.........................................................
8
4. Filling the trap with water..................................................................................................
9
5. Checking the gas type.......................................................................................................
9
6. Changing the gas type.......................................................................................................
9
7. Commissioning the system............................................................................................... 10
8. Checking the flue gas temperature
9. Opening the boiler door..................................................................................................... 11
10. Separating the neutralising system, connecting the drain hose................................... 12
11. Cleaning the combustion chamber and heating surfaces............................................. 13
12. Cleaning and reconnecting the condensate drain pipe.................................................. 14
13. Checking the condensate drain and neutralising system (if installed)......................... 14
14. Checking gaskets and thermal insulation sections........................................................ 14
15. Checking all connections on the heating water side for leaks...................................... 15
16. Closing the boiler door...................................................................................................... 15
17. Checking the filter element in the gas line (if installed); replacing if necessary
18. Checking gas connections for tightness......................................................................... 15
19. Checking the water quality................................................................................................ 16
20. Checking the function of the safety valves
21. Checking the temperature controller setting if a building management system is
used (DCC system)............................................................................................................ 16
22. Checking the expansion vessel and system pressure................................................... 16
23. Checking the gaskets on the flue gas side...................................................................... 17
24. Checking the mixer for ease of operation and leaks...................................................... 17
25. Checking the thermal insulation for firm seating
26. Checking the flue system for leaks
•
27. Checking the ventilation air apertures in the installation room (open flue operation)
28. Instructing the system user.............................................................................................. 17
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•
•
Page
7
Commissioning, inspection, maintenance
Note on initial commissioning, inspection and maintenance
Product contains ceramic fibres
Danger
When working with high temperature insulating
materials that contain zirconium or aluminium
silicate ceramic fibres, fibre dust may
develop. This fibre dust can be harmful to
health.
Only trained personnel may adjust or replace
the insulation. Wear suitable protective clothing,
especially breathing equipment and safety goggles.
Burner inspection and maintenance
Steps and settings that relate to the burner are described in separate instructions.
"MatriX cylinder burner" installation and service
instructions
Removing the burner hood
Remove the burner hood to perform any work or make
any adjustments.
1.
2.
OPN CLOSE
Fig. 1
Checking the high limit safety cut-out setting
The high limit safety cut-out must not be set higher
than 110 °C. If required, set it to a maximum of 110 °C.
Control unit installation and service instructions
Filling the heating system with water and venting
!
Please note
Unsuitable water quality can result in damage to
the boiler shell and the heating system.
Observe the "Water quality requirements" on
page 31 onwards.
5834360
Record the fill volume, water hardness and pH value in
the table on page 33.
8
Commissioning, inspection, maintenance
Filling the trap with water
A
B
Fig. 2
1. Remove lower back panel A. To do so, undo the 4
quarter-turn rotary latches B.
2. Undo the siphon and fill with water, otherwise flue
gas may escape.
3. Check that the condensate can drain freely.
4. Refit the siphon.
Danger
Flue gas escaping from the trap can cause
potentially fatal carbon monoxide poisoning.
Always fill the trap with water before commissioning.
Checking the gas type
1. Check with your gas supply utility regarding the
gas type and Wobbe index (Wo). The boiler can be
operated in the following Wobbe index ranges:
■ With natural gas E:
Wobbe index range 12.0 to 16.1 kWh/m3 (43.2 to
58.0 MJ/m3)
■ With natural gas LL:
Wobbe index range 10.0 to 13.1 kWh/m3 (36.0 to
47.2 MJ/m3) (not in a and c).
2. If required, convert the burner to a different gas
type in accordance with details provided by your
gas supply utility.
"MatriX cylinder burner" service instructions
Changing the gas type
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"MatriX cylinder burner" service instructions
9
Commissioning, inspection, maintenance
Commissioning the system
■ Burner service instructions
■ Vitotronic operating instructions and service
07. Adjust the codes on the boiler control unit in
accordance with the table on page 19.
instructions
■ Neutralising system operating instructions
01. Check the heating system pressure. Permissible
boiler operating pressure: 5.5 bar (550 kPa)
Vitotronic installation and service instructions
08. Check the function of the neutralising system and
the hydraulic seal in the trap.
02. With open flue operation: Check whether the ventilation measures for the installation room are
designed and open in accordance with regulations.
03. Check the gas supply pressure.
Neutralising system operating instructions
09. Check all gaskets and plugs, and retighten if necessary.
Note
We recommend checking all connections on the
heating water side for leaks approx. every 500
hours run. See page 15.
04. Open the gas line shut-off valves.
05. Switch ON the mains isolator (outside the installation room).
06.
A
B
10. Check the boiler door and flue gas collector a few
days after commissioning and retighten all screws.
Torque: Boiler door 18 Nm
Torque: Flue gas collector 7 Nm
Danger
For safe operation, a minimum operating pressure of 0.5 bar (50 kPa) is absolutely essential.
A minimum pressure switch/limiter can be used
to safeguard this.
C
D
Fig. 3
Turn on ON/OFF switch B at the programming
unit of the control unit. If fault indicator A on the
control unit illuminates and display C on the
burner control unit flashes, first reset the system.
For this, press reset button D on the burner control unit.
Note
During commissioning, the appliance can enter a
fault state if there are still airlocks in the gas line.
■ Purge the gas line again.
■ Reset burner.
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Checking the flue gas temperature
10
Commissioning, inspection, maintenance
Opening the boiler door
Danger
When working with high temperature insulating
materials that contain zirconium or aluminium
silicate ceramic fibres, fibre dust may
develop. This fibre dust can be harmful to
health.
Only trained personnel may adjust or replace
the insulation. Wear suitable protective clothing,
especially breathing equipment and safety goggles.
Disconnecting cables
2.
fA
lÖ
1.
A / aB]
B
fÖ aB]
fÖ / aBH
D
C
B
A
3.
Fig. 4
A Burner cables with plugs fA and lÖ
B Power cable with plug fÖ
C Control unit connecting cable with plug fÖ/aBH
D Flue gas temperature sensors aGA/aGB
1. Disconnect burner cables A from the burner control unit. Route the cables out of the burner casing.
3. Remove the gas supply pipe.
4. If available, remove the hose for room sealed operation.
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2. Disconnect cables B to D from the burner and
strain relief, and remove from the burner casing.
11
Commissioning, inspection, maintenance
Opening the boiler door (cont.)
Opening the boiler door
5.
6.
Fig. 5
!
Please note
Scratches inside the combustion chamber can
lead to corrosion.
Never place tools or other objects inside the
combustion chamber.
Separating the neutralising system, connecting the drain hose
C
D
A
B
E
1. Separate hose A to the neutralising system from
siphon B.
3. Connect drain hose D to condensate drain C and
route it to drainage system E.
2. Undo siphon B from condensate drain C.
4. Clean the combustion chamber and heating surfaces.
12
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Fig. 6
Commissioning, inspection, maintenance
Separating the neutralising system, connecting… (cont.)
5. Remove drain hose D. Clean condensate
drain C on the inside using a plastic brush.
7. Fill trap B with water (see page 9).
6. Connect siphon B and hose A.
Cleaning the combustion chamber and heating surfaces
Thoroughly clean the combustion chamber and heating surfaces with a water jet. For this, separate the
neutralising system (if installed) from the boiler and
connect the drain hose. See page 12.
!
Please note
Contact with unalloyed iron and scratches on
parts in contact with flue gases can lead to corrosion.
Only use plastic brushes, not wire brushes or
sharp objects.
1. Clean the combustion chamber and heating surfaces.
■ For normal cleaning, flush the heating surfaces
thoroughly with a jet of water.
■ You may use cleaning agents if you notice stubborn residues, surface discolouration or soot
deposits.
For this, observe the following:
– Only use solvent-free cleaning agents. Ensure
that no cleaning agent gets between the boiler
shell and the thermal insulation.
– Remove soot deposits with an alkaline cleaning agent with surfactant additive (e.g. Fauch
condensing boiler cleaner or Sotin 300).
– Remove coatings and surface discolouration
(yellow-brown) with slightly acidic, chloride-free
cleaning agents based on phosphoric acid (e.g.
Antox 75 E).
2. Remove loosened deposits from the boiler. Thoroughly flush heating surfaces and the flue gas collector with a jet of water.
Danger
Loose residues and residual cleaning agents
can lead to injury.
Wear goggles, protective gloves and protective
clothing.
!
Please note
Scratches on parts that come into contact with
flue gas can lead to corrosion.
Only use plastic brushes, no wire brushes or
sharp objects.
For normal cleaning, flush the heating surfaces thoroughly with a jet of water. For stubborn residues, surface discolouration or soot deposits cleaning agents
may be used.
For this, observe the following:
■ Only use solvent-free cleaning agents. Ensure that
no cleaning agent gets between the boiler body and
the thermal insulation.
■ Remove soot deposits with an alkaline cleaning
agent with surfactant additive (e.g. Fauch 600).
■ Remove coatings and surface discolouration (yellowbrown) with slightly acidic, chloride-free cleaning
agents based on phosphoric acid (e.g. Antox 75 E).
■ Remove loose deposits from the boiler; thoroughly
flush the heating surfaces and the flue gas collector
with a water jet.
Cleaning agent manufacturer's instructions
Note
"Fauch 600" and "Antox 75 E"
Manufacturer:
Hebro Chemie GmbH
Rostocker Strasse 40
D-41199 Mönchengladbach
5834360
Cleaning agent manufacturer's details
Note
"Fauch" and "Antox 75 E"
Manufacturer: Hebro Chemie GmbH, Mönchengladbach
www.hebro-chemie.de
"Sotin 300"
Manufacturer: Sotin Chemische und technische Produkte GmbH & Co., Bad Kreuznach
www.sotin.de
13
Commissioning, inspection, maintenance
Cleaning and reconnecting the condensate drain pipe
Note
Clean the inside of the condensate drain pipe at least
once a year.
C
E
D
A
Fig. 7
B
1. Disconnect drain hose C.
4. Undo and flush lower part D of siphon E.
2. Clean the inside of the condensate drain pipe
(hose, pipes).
5. Fill lower part D of siphon E with water and refit.
Check the trap for leaks.
3. Clean the neutralising system (if installed) in
accordance with the manufacturer's instructions.
6. Insert 4 quarter-turn rotary latches B. Refit lower
back panel A.
Neutralising system operating instructions
Note
The neutralising agent can be ordered with part
no. 9521702.
Checking the condensate drain and neutralising system (if installed)
Fill water into the combustion chamber.
Note
The water must flow from the condensate drain pipe
without backing up.
If necessary, clean the condensate drain pipe again.
Checking gaskets and thermal insulation sections
1. Check the gaskets and packing cords in the boiler
door for damage.
3. Replace any damaged components.
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2. Check the thermal insulation components on the
boiler door for damage.
14
Commissioning, inspection, maintenance
Checking all connections on the heating water side for leaks
Danger
There is a risk of injury when working on pressurised components.
The connections on the heating water side must
only be opened after the boiler has been depressurised.
Only drain the boiler with a suction pump when
the boiler air vent valve is open.
Note
Also check the connections for the control equipment
and the minimum pressure switch (low water indicator)
for tightness.
Closing the boiler door
18 Nm
2.
1.
Fig. 8
Danger
Leaks can result in a risk of poisoning through
escaping gas.
Before commissioning
■ Clean the sealing faces.
■ Check gaskets for damage and replace if
required.
■ Check the boiler door gasket is seated correctly and realign the boiler door if necessary.
Checking the filter element in the gas line (if installed); replacing if
necessary
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Checking gas connections for tightness
Danger
Escaping gas leads to a risk of explosion.
Always carry out the following steps.
1. Insert new gaskets in all gas fittings that have been
opened and retighten them.
15
Commissioning, inspection, maintenance
Checking gas connections for tightness (cont.)
2. Open the gas shut-off valve.
4. Start the burner (see page 10).
3. Check the joints in the gas train for leaks using a
gas leak detector.
!
Please note
The use of leak detection spray can result in
faulty operation.
Leak detection spray must not come into
contact with electrical contacts.
Checking the water quality
Enter the amount of top-up water, the total hardness
and the pH value in the table on page 33.
For water quality requirements, see page 31.
The pH value should be between 8.2 and 9.5.
Checking the function of the safety valves
Checking the temperature controller setting if a building management system
is used (DCC system)
!
Please note
Shutting down from full load can result in high
material stress and material damage.
If a system with a higher ranking building management system takes over the temperature
control of the boiler, adjust the settings at the
temperature controller TR. Set the electronic
temperature controller to at least 10 K below the
mechanical temperature controller.
Checking the expansion vessel and system pressure
Note
Observe the manufacturer's instructions for the diaphragm expansion vessel (MAG).
Carry out this test on a cold system.
3. Top up with water until the charge pressure of the
cooled system is 0.1 to 0.2 bar (10 to 20 kPa)
higher than the pre-charge pressure of the expansion vessel.
Permiss. operating pressure: 5.5 bar (550 kPa)
1. Drain the system until the pressure gauge indicates "0" or close the cap valve on the expansion
vessel and reduce the pressure in the expansion
vessel.
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2. If the pre-charge pressure of the expansion vessel
is lower than the static system pressure, top up
with nitrogen until the pre-charge pressure is 0.1 to
0.2 bar (10 to 20 kPa) higher.
16
Commissioning, inspection, maintenance
Checking the gaskets on the flue gas side
1. Check the flue gas collector seals for tightness.
Danger
Escaping flue gas poses a risk to health.
Check gaskets on the flue gas collector and
adjust if required.
A
Note
Check the gaskets at full load operation, for example using an inspection mirror, dew point indicator
or thermal image camera. If required, remove the
thermal insulation sections. Traces of condensate
on the outside of the flue gas collector also indicate
a leak.
C
B
2. If required, retighten the flue gas collector at the
clamping clips. Tighten screws diagonally to 7 Nm.
Replace the lip seal in the case of leaks.
3. Check the flue gas temperature sensor and plug-in
connection for correct seating.
Fig. 9
A Clamping clips
B Actuator damper
C Flue gas temperature sensor
Note
Repeat the tightness test after approx. 500 hours run;
retighten the screws if necessary. Ensure that the gasket and clamping clip are seated correctly.
Checking the mixer for ease of operation and leaks
1. Remove the motorised lever from the mixer handle.
3. Check the mixer for tightness. In the event of a
leak, replace the O-ring.
2. Check the mixer for ease of operation.
4. Snap the motorised lever into place.
Checking the thermal insulation for firm seating
Checking the flue system for leaks
Checking the ventilation air apertures in the installation room (open flue
operation)
Instructing the system user
This includes all components installed as accessories,
e.g. remote control units. In addition, the system installer must make the user aware of the required maintenance work.
5834360
The system installer should hand the operating instructions to the system user and instruct the user in operating the system.
17
Commissioning, inspection, maintenance
Instructing the system user (cont.)
Operating and service documents
2. File all parts lists, operating and service instructions in the folder and hand this over to the system
user.
5834360
1. Complete and detach the customer registration
card:
■ Hand system users their section for safekeeping.
■ Retain the heating contractor's section.
18
Control unit
Setting the codes at the control unit
Vitotronic service instructions
In conjunction with the following control units:
■ Vitotronic 100, type CC1E
■ Vitotronic 200, type CO1E
■ Vitotronic 300, type CM1E
Parameter
Boiler group
Rated heating output of the MatriX cylinder burner in kW
Coding card
500
630
2
2
2
05
0
0
0
08
70
60
75
09
3
4
5
15
11
13
13
0A
33
33
33
1042
5834360
Codes
400
02
19
Functions
Air pressure switch
Fan pressure monitoring (LDW1)
A
B
The air pressure switch triggers a fault shutdown of the
burner control unit under the following circumstances:
■ If the static pressure check was unsuccessful after
approx. 5 minutes
■ If the air pressure is outside the permiss. range in
the pre-purge phase (tolerance time approx. 5 min.)
■ If the air pressure switch fails in control mode or the
air pressure lies outside the permissible range
The fault shutdown is indicated by fault codes "F F5"
and "F F7" on the burner control unit display. Reset
the burner control unit by pressing reset button R.
"MatriX cylinder burner" service instructions
Fig. 10
Rated heat in- LDW1 setting value
put
Qmax (Hi)
[net cv]
in kW
in mbar (kPa)
400
381
500
474
630
593
2 (0.2) ↑
A Reset button R
B Air pressure switch 1
The switching threshold of air pressure switch 1
(LDW1) is monitored in the fan ramp-up phases and
checked in modulating burner operation. This ensures
a minimum pre-purge.
5834360
Functions
Rated heating output
Pmax
(50/30 °C)
in kW
20
Functions
Air pressure switch (cont.)
Combustion chamber pressure monitoring (LDW2)
To monitor the combustion chamber pressure, the
switching threshold of air pressure switch 2 (LDW2) is
monitored in all operating phases (except during the
safety and stabilising time).
A
B
The air pressure switch triggers a fault shutdown of the
burner control unit under the following circumstances:
■ If the combustion chamber pressure is outside the
permissible range (> 5 mbar) in the pre-purge phase,
in control mode or in the post-purge phase after
2 attempts
The fault shutdown is indicated by fault code "F FB"
on the burner control unit display. Reset the burner
control unit by pressing reset button R.
Fig. 11
Rated heat in- LDW2 setting value
put
Qmax (Hi)
[net cv]
in kW
in mbar (kPa)
400
381
500
474
630
593
5 (0.5) ↑
5834360
A Reset button R
B Air pressure switch 2
Rated heating output
Pmax
(50/30 °C)
in kW
21
Functions
"MatriX cylinder burner" service instructions
Functions
5834360
Functions
Air pressure switch (cont.)
22
Parts lists
Overview of assemblies
The following details are required when ordering
parts:
■ Serial no. (see type plate A)
■ Assembly (from this parts list)
■ Position number of the individual part within the
assembly (from this parts list)
A
B
C
Fig. 12
5834360
Components
A Type plate
B Thermal insulation assembly
C Boiler assembly
23
Parts lists
Boiler assembly
0008
0003
0005
0003
0006
0009
0008
0010
0002
0011
0010
0007
0012
0005
0001
0004
5834360
Components
Fig. 13
0003
0005
0006
0011
24
Parts lists
Boiler assembly (cont.)
Flue gas collector
0002
Boiler door
0003
Thermal insulation block and mat for boiler door
0004
Stench trap
0005
Mounting bracket
0006
Packing GF 20 x 15 x 2040
0007
Bolt
0008
Gasket DN 100
0009
Gasket DN 80
0010
Viessmann logo
0011
Door panel (with pos. 0010)
0012
Flue gas temperature sensor
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Components
0001
25
Parts lists
Boiler assembly (cont.)
Cable set assembly
0001
0003
0005
0006
Fig. 14
5834360
Components
0004
0002
26
Parts lists
Boiler assembly (cont.)
Dual temperature sensor
0002
Burner cable 41
0003
Cable KM-BUS 145
0004
Power cable 40
0005
Cable 40/156
0006
Flue gas temperature sensor connecting cable 15A/15B
5834360
Components
0001
27
Parts lists
Thermal insulation assembly
0012
0010
0029
0007
0011
0017
0015
0013
0005
0018
0009
0036
0030
0016
0019
0033
0032
0037
0031
0002
0007
0022
0008
0024
0027
0001
0025
0023
0027
0004
0003
0028
0014
0006
0036
0026
0034
0035
0020
0026
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Components
Fig. 15
0021
0033
28
Parts lists
Front panel, bottom
0002
Thermal insulation mat, upper front
0003
Thermal insulation mat, lower front
0004
Thermal insulation strip
0005
Rail, front left
0006
Rail, front right (with pos. 0036)
0007
Side panel
0008
Side panel, control unit
0009
Thermal insulation jacket
0010
Flashing, left
0011
Flashing, right
0012
Top panel
0013
Rail, back left
0014
Rail, back right
0015
Thermal insulation mat, upper back
0016
Thermal insulation mat, lower back
0017
Back panel, top
0018
Back panel, centre
0019
Back panel, bottom
0020
Mounting bracket rear panel
0021
Mounting bracket
0022
Trunking retainer
0023
Cable trunking, lower section
0024
Cable trunking, upper section
0025
2-fold strain relief
0026
Edge protector
0027
Brace
0028
Mounting bracket fascia
0029
Front panel, top
0030
Back panel, adaptor
0031
Back panel, flue gas collector, left
0032
Back panel, flue gas collector, right
0033
Sealing clip
0034
Quarter-turn rotary latch with toggle
0035
Damping washer
0036
Vitocrossal 300 logo
0037
Reinforcement, flue gas collector
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0001
Components
Thermal insulation assembly (cont.)
29
Parts lists
Parts not shown
Fixings
0004
Decorative strip
0005
Touch-up spray paint, Vitosilver
0006
Touch-up paint stick, Vitosilver
0007
Installation instructions
0008
Service instructions
5834360
Components
0003
30
Water quality requirements
Water quality requirements
Note
Observation of the following requirements is a necessary condition for safeguarding your warranty rights.
The warranty excludes damage due to corrosion and
scaling.
Prevention of damage due to scaling
Total heating output
kW
Total alkaline earths
mol/m3
Total hardness
°dH
> 50 to ≤ 200
≤ 2.0
≤ 11.2
> 200 to ≤ 600
≤ 1.5
≤ 8.4
> 600
< 0.02
< 0.11
The standard values assume the following:
■ The total volume of fill and top-up water will not
exceed 3 times the water capacity of the heating system during its service life.
■ The specific system volume is less than 20 l/kW
heating output. In multi boiler systems, apply the output of the smallest boiler.
■ All measures to prevent corrosion on the water side
in accordance with VDI 2035 Part 2 have been
implemented.
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.
■ The specific system volume is greater than 20 l/kW
heating output. In multi boiler systems, apply the output of the smallest boiler.
■ In systems > 50 kW, install a water meter to record
The build-up of limescale deposits on the heating surfaces will be minimised if these instructions are followed.
5834360
the volume of fill and top-up water. Enter the volume
of fill water and the water hardness into the boiler
maintenance checklists.
■ For systems with a specific system volume greater
than 20 l/kW heating output, apply the requirements
of the next higher category of total heating output (in
accordance with the table). In multi boiler systems,
apply the output of the smallest boiler. In the case of
severe excess (> 50 l/kW) soften down to a total
amount of alkaline earths ≤ 0.02 mol/m3.
Operating information:
■ During expansion or repair work, only drain the necessary pipework sections.
■ Check, clean and activate filters, dirt traps and other
blow-down or separating facilities in the heating
water circuit more frequently after commissioning or
in the case of new installations; later on subject to
the water treatment applied (e.g. water softening).
■ No further steps are required during commissioning
if you fill the heating system with fully softened
water.
If the heating system is charged, not with fully softened water, but with water that meets the requirements in the above table, also observe the following during commissioning:
■ Commission the system step by step, starting with
the lowest boiler output and a high heating water
flow rate. This prevents localised concentration of
limescale deposits on the boiler heating surfaces.
■ In multi boiler systems, start all boilers simultaneously to prevent the total amount of limescale deposits settling in the heat exchanger of just one boiler.
■ Where water treatment is required, treat even the
first fill of the heating system prior to commissioning.
This also applies to any subsequent filling, e.g. when
adding top-up water or after a repair, or for any system expansion.
31
Appendix
Prevent excessive scale build-up (calcium carbonate)
on the heating surfaces. For heating systems with
operating temperatures up to 100 °C, guideline
VDI 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 relevant explanations in the original text
of the guideline.
Water quality requirements
Water quality requirements (cont.)
Any limescale deposits that have formed because of a
failure to observe the requirements of guideline
VDI 2035 will in most cases already have caused a
reduction in the service life of the installed heating
appliances. Removing the limescale deposits is one
option for restoring operational viability.
This measure must be carried out by a qualified contractor. Inspect the heating system for possible damage prior to returning it into use. It is essential that the
incorrect operating parameters are corrected to prevent renewed formation of excessive scale deposits.
The corrosion resistance of ferrous materials on the
heating water side of heating systems and heat generators depends on the absence of oxygen in the heating
water. Oxygen introduced into the heating system with
the first fill and subsequent top-ups reacts with the system materials without causing damage.
The characteristic blackening of the water after a certain time in operation indicates that there is no more
free oxygen present. The technical rules and in particular Directive VDI 2035-2 therefore recommend that
heating systems are designed and operated so that a
constant ingress of oxygen into the heating water is
prevented.
During operation, oxygen can enter due to:
■ Open expansion vessels receiving a flow
■ Negative pressure in the system
■ Gas-permeable components
Sealed unvented systems – e.g. with an expansion
vessel – offer good protection against the ingress of
airborne oxygen into the system, if correctly sized and
operating at the correct pressure. Under all operating
conditions and at all points in the heating system,
including the intake side of the pump, the pressure
must be higher than atmospheric pressure. Check the
pre-charge pressure of the expansion vessel at least
during the annual service. The use of gas-permeable
components, e.g. permeable plastic pipes in underfloor
heating systems, should be avoided. Provide system
separation if such components are nevertheless used.
This 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 further anti-corrosion measures are required for
sealed unvented hot water heating systems, subject to
the above points being observed. However, take additional precautions where there is a risk of oxygen
ingress. For example, add sodium sulphite as an oxygen binder (5 - 10 mg/litre into the excess). The pH
value of the heating water should be between
8.2 and 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 the other heating system components. We recommend you refer questions regarding water treatment to a relevant qualified contractor.
For further details, see VDI 2035-2 and EN 14868
guidelines.
5834360
Appendix
Prevention of damage due to corrosion on the water side
32
Reports
Water quality
Fill and top-up water
Total water volume
m3
m3
m3
Total hardness
Feedwater Boiler water
pH value
Date
5834360
Appendix
Meter reading
33
Specification
Specification
Rated heating output
Pcond: TF/TR = 50/30 °C
kW
135 to 400
168 to 500
209 to 630
Pn: TF/TR = 80/60 °C
kW
123 to 370
153 to 460
192 to 575
Rated heat input
kW
127 to 381
158 to 474
198 to 593
CE-0085AQ0257
Permiss. operating temperature
°C
95
95
95
Permiss. flow temperature
(= safety temperature)
°C
110
110
110
Permiss. operating pressure
bar
MPa
5.5
0.55
5.5
0.55
5.5
0.55
mm
mm
mm
mm
mm
1220
1725
1046
1221
1987
1295
1800
1046
1221
1987
1450
1960
1046
1221
1987
mm
mm
mm
1250
900
100
1300
900
100
1500
900
100
600
645
755
740
795
935
litres
261
325
406
PN 6 DN
PN 6 DN
100
100
100
100
100
100
PN 6 DN
80
80
80
1½
1
32/20
1½
1
32/20
250
250
Boiler body dimensions
Boiler length
Length incl. burner hood
Width
Width incl. control unit
Height
Foundation
Length
Width
Height
Weight
■ Boiler body
kg
Total weight
■ Boiler incl. burner, thermal insulation and boiler kg
control unit
Capacity boiler water
Boiler connections
Boiler flow
Boiler return 1
*1
Boiler return 2*1
Safety connection (safety valve) (male thread)
Drain (male thread)
Condensate drain, flue gas collector/trap
R
R
7 mm
1½
1
32/20
Flue gas connection
7 mm
250
*1
34
When connecting 2 heating circuits, connect the heating circuit with the lowest temperature level to boiler return 1.
5834360
Product ID
Final decommissioning and disposal
Final decommissioning and disposal
Appendix
For decommissioning the system, isolate the system
from the power supply and allow components to cool
down where appropriate.
All components must be disposed of correctly.
5834360
Viessmann products can be recycled. Components
and substances from the system are not part of ordinary household waste.
35
Certificates
We, Viessmann Werke GmbH & Co. KG, D-35107
Allendorf, declare as sole responsible body that the
named product complies with the European directives
and supplementary national requirements in terms of
its design and operational characteristics.
Conformity has been verified with the CE designation.
Using the serial number, the full Declaration of Conformity can be found on the following website:
www.viessmann.co.uk/eu-conformity
Manufacturer's certificate
We, Viessmann Werke GmbH & Co. KG, D-35107 Allendorf, confirm that the product Vitocrossal 300, type
CT3U, complies with the following conditions stipulated by the 1st German Immissions Order (BImSchV):
■ NOx limits according to paragraph 6 (1).
■ Flue gas loss of no more than 9 % according to paragraph 10 (1).
■ Standard seasonal efficiency [to DIN] of at least 94 % in accordance with paragraph 6 (2)
Allendorf, 4 July 2018
Viessmann Werke GmbH & Co. KG
Authorised signatory Reiner Jansen
Head of Strategic Quality Management
5834360
Appendix
EU Declaration of Conformity
36
Keyword index
Keyword index
A
Air pressure switch
– Combustion chamber pressure monitoring (LDW2)21
– Fan pressure monitoring (LDW1)............................20
Assembly
– Boiler....................................................................... 24
– Cable set................................................................. 26
– Overview................................................................. 23
– Thermal insulation...................................................28
B
Boiler door
– Closing.................................................................... 15
– Opening...................................................................11
Burner cables............................................................. 11
C
Codes.........................................................................19
Combustion chamber, cleaning..................................13
Condensate drain pipe......................................... 12, 14
D
Drain hose............................................................12, 14
E
Expansion vessel....................................................... 16
G
Gaskets, checking......................................................14
Gas type check............................................................ 9
H
Heating surfaces, cleaning.........................................13
Heating system
– Filling.........................................................................8
High limit safety cut-out................................................8
M
Manufacturer's certificate........................................... 36
N
Neutralising system..............................................12, 14
Note on maintenance................................................... 8
O
Operating and service documents............................. 18
Overview of steps.........................................................7
P
Parts list..................................................................... 23
R
Requirements for boiler water.................................... 31
S
Specification...............................................................34
Steps, overview............................................................7
System commissioning.............................................. 10
System pressure check..............................................16
System user instruction..............................................17
T
Temperature controller............................................... 16
Thermal insulation sections, checking....................... 14
Tightness
– Flue gas side...........................................................17
– Gas connections..................................................... 15
Trap........................................................................ 9, 14
W
Water quality
– Checking................................................................. 16
– Requirements..........................................................31
– Table........................................................................33
I
Instructing the system user........................................ 17
5834360
L
Leaks
– Heating water side connections.............................. 15
37
38
5834360
39
5834360
40
Subject to technical modifications.
Viessmann Limited
Hortonwood 30, Telford
Shropshire, TF1 7YP, GB
Telephone: +44 1952 675000
Fax: +44 1952 675040
E-mail: [email protected]
5834360
Viessmann Werke GmbH & Co. KG
D-35107 Allendorf
Telephone: +49 6452 70-0
Fax: +49 6452 70-2780
www.viessmann.com