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Viessmann CT3U, Service Instructions Manual, Page: 1 / 64

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Viessmann CT3U Service Instructions Manual Download Page 1

Service instructions

for contractors

VIESMANN

Vitocrossal 300
Type CT3U, 400 to 630 kW

Gas condensing boiler with MatriX cylinder burner
for natural gas E and LL

For applicability, see the last page

VITOCROSSAL 300

5783 337 GB

8/2017

Please keep safe.

Summary of Contents for CT3U

Page 1: ...r contractors VIESMANN Vitocrossal 300 Type CT3U 400 to 630 kW Gas condensing boiler with MatriX cylinder burner for natural gas E and LL For applicability see the last page VITOCROSSAL 300 5783 337 GB 8 2017 Please keep safe ...

Page 2: ...ally applicable standards a ÖNORM EN ÖVGW G K directives ÖVGW TRF and ÖVE c SEV SUVA SVGW SVTI SWKI VKF and EKAS guideline 1942 LPG part 2 Safety instructions for working on the system 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 by removing the separate fuse or by...

Page 3: ...distribution board Danger If water escapes from the appliance there is a risk of scalding Never touch hot heating water Condensate Danger Contact with condensate can be harmful to health Never let condensate touch your skin or eyes and do not swallow it Flue systems and combustion air Ensure that flue systems are clear and cannot be sealed for instance due to accumulation of conden sate or other e...

Page 4: ...rts lists Overview of assemblies 41 Boiler assembly 42 Thermal insulation assembly 44 Burner assembly 46 Parts not shown 48 7 Component overview 49 8 Connection and wiring dia gram Burner control unit connection diagram 50 MatriX cylinder burner 50 Mains filter unit connection diagram 51 9 Water quality requirements 52 10 Reports Water quality 54 Settings and test values 54 11 Specification 56 12 ...

Page 5: ... Not required during inspection Steps required during maintenance Not required during maintenance 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 instruc tions as well as the details in the datasheet It is only designed for the heating u...

Page 6: ...condensate drain system 17 20 Checking the condensate drain and neutralising system if installed 18 21 Checking the burner gauze assembly 18 22 Checking the ignition and ionisation electrodes 19 23 Cleaning the burner 19 24 Installing the burner 20 25 Closing the boiler door 20 26 Automatic tightness test on the two gas train valves 20 27 Checking the filter element in the gas line if installed an...

Page 7: ...age 39 Checking the ventilation air apertures in the installation room only for open flue operation 40 Instructing the system user 23 41 Operating and service documents 24 Commissioning inspection maintenance Steps commissioning inspection and cont 5783 337 GB ...

Page 8: ...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 Record the fill volume water hardness and pH value in the table on page 54 Please note Unsuitable water quality can result in damage to the boiler shell and the heating system Observe the Water quality requirements on page 52 onwards Fi...

Page 9: ...nter a fault state during commis sioning due to a lack of gas in the gas line The fault indicator on the control unit then illuminates Purge the gas line again and reset the burner con trol unit 07 Adjust the codes on the boiler control unit in accordance with the table on page 25 Control unit installation and service instruc tions 08 Check the function of the neutralising system and the hydraulic...

Page 10: ...side the instal lation room or isolate the mains power and secure against unintentional reconnection 04 Pull connecting cables from the gas train 05 Undo fitting A A B C D G F E Fig 3 06 Pull compensation hose G from the gas train 07 Release the gas train from flange E 08 Remove restrictor C with rubber cork gasket D 09 Secure the gas train without restrictor C and without rubber cork gasket D but...

Page 11: ...al 20 mbar 2 kPa The gas pressure switch mini mum GDW 1 is factory set to 10 mbar 1 kPa Never alter this setting 3 Record the actual value in the report on page 54 4 Close the gas shut off valve 5 Remove the pressure tester and close test connec tor A Supply pressure flow pressure Measure 15 mbar 1 5 kPa Do not make any adjustments Notify the gas supply utility 15 to 18 mbar 1 5 to 1 8 kPa Please ...

Page 12: ...ust be between 7 5 and 10 5 Check the CO2 content at the flue pipe Rated heating output in kW Permissible CO2 content in 400 8 6 0 3 500 8 6 0 3 630 8 6 0 3 A B Fig 7 3 If the CO2 content needs adjusting Remove cap B Turn setting screw A in small increments 3 mm Allen key until the CO2 content lies within the specified range Turning clockwise CO2 content falls Turning anti clockwise CO2 content ri...

Page 13: ...range Turning clockwise CO2 content rises Turning anti clockwise CO2 content falls 4 Record the actual value in the report on page 54 Please note The CO2 content must always be lower in partial load than it is in full load Rechecking the values Regulate to the upper and lower heating output again using the programming unit in the burner control unit If the values do not match the permis sible CO2 ...

Page 14: ...s the reset button 08 Check the ionisation current Note Approx 2 to 3 s after the gas valve has opened and during operation the ionisation current should be at least 3 µA 09 Record the actual value in the report on page 54 10 Switch OFF the mains isolator remove the test equipment and reconnect the ionisation cable con nectors 11 Switch ON the mains isolator Shutting down the system 1 Switch OFF t...

Page 15: ...ment and safety gog gles A C B E D F Fig 11 1 Undo the quarter turn rotary latches on the sides of burner hood A and remove burner hood A 2 Release burner cables C with plugs fA and lÖ at the burner control unit and remove them from the burner casing 3 Release power cable D with plug fÖ and control unit connecting cable F with plug fÖ aBH at the burner and the strain relief remove them from the bu...

Page 16: ...de the combustion chamber Separating the neutralising system from the boiler connecting the drain hose A B D E C Fig 13 1 Separate hose A to the neutralising system from siphon B 2 Undo siphon B from condensate drain C 3 Connect drain hose D to condensate drain C and route it to drainage system E Commissioning inspection maintenance Opening the boiler door cont 5783 337 GB ...

Page 17: ...g 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 Checking the gaskets and thermal insulation sections 1 Check the gaskets and packi...

Page 18: ...on E 5 Fill lower part D of siphon E with water and refit 6 Fasten the 4 quarter turn rotary latches B and remount lower back panel A 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 the burner gauze assembly...

Page 19: ...gnition electrodes 8 5 1 Fig 16 7 1 5 6 1 Fig 17 Ionisation electrode 15 5 1 Fig 18 Check the ignition electrodes and ionisation electrode for the correct gap to the burner gauze assembly and for possible damage Replace the electrodes if required Cleaning the burner B C E D A F Fig 19 1 Undo fitting C on gas supply pipe B 2 Undo Venturi mixing pipe D from fan E 3 Remove Venturi mixing pipe D with ...

Page 20: ...n casing and the burner flange for gas tight ness Closing the boiler door Note Tighten the boiler door screws evenly and diagonally with a torque of at least 18 Nm Danger Leaks can result in a risk of poisoning through escaping gas Prior to commissioning check the boiler door gasket for correct seating and realign if neces sary Otherwise secondary ventilation may occur with condensate forming on t...

Page 21: ...The use of leak detection spray can result in faulty operation Leak detection spray must not come into contact with electrical contacts 4 Start the burner see page 9 5 Check for tightness Outlet joints of the gas train Joint between the fan and the boiler flange Joint between the fan and the Venturi pipe Checking the rotary damper setting 0 0 Fig 21 1 Open the gas shut off valve Commissioning insp...

Page 22: ... 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 man agement 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 temperat...

Page 23: ...n 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 han dle 2 Check the mixer for ease of operation 3 Check the mixer for leaks Replace the O rings if the mixer is leaking 4 Snap the motorised lever into place Checking the thermal insulation for firm seating ...

Page 24: ...em user their section for safekeep ing Retain the heating contractor s section 2 File all parts lists operating and service instruc tions in the folder and hand this over to the system user Commissioning inspection maintenance Operating and service documents 5783 337 GB ...

Page 25: ...100 type GC1B Vitotronic 200 type GW1B Vitotronic 300 type GW2B Coding address Rated heating output of the MatriX cylinder burner in kW Coding card 400 500 630 02 2 2 2 1042 05 0 0 0 08 70 60 75 09 3 4 5 15 11 13 13 0A 33 33 33 Control unit Setting the codes at the control unit 5783 337 GB Codes ...

Page 26: ...n The air pressure switch fails in control mode or the air pressure lies outside the permissible range The fault shutdown is indicated with fault codes F AA and F AB on the burner control unit display To acknowledge the fault display press the reset button min s This indicates a serious fault The fault shutdown by the air pressure switch is displayed as a fault in the control unit The air pressure...

Page 27: ...nt operating status The same applies after pressing reset following a fault The following displays are shown automatically If a fault occurs see the fault codes on page 32 onwards You can exit at any time by pressing reset button A hold for 5 to 10 s Status Service Fig 25 Standby Status Service Fig 26 Start Heat demand System tests Status Service Fig 27 Idle state check Fan ramp up Status Service ...

Page 28: ...s Page 28 Service display For fault message d see page 29 Current modulation level Page 29 Fault indicator For fault message F see ta ble on page 32 For fault code displays see page 32 Table on page 32 Fault memory Status 0 to 9 Calling up the last 10 faults Page 31 Information display The information display is activated from the operating display Information regarding current meter readings such...

Page 29: ...g 40 Hours run meter with reset 1 digit Status Service Fig 41 Hours run meter with reset 100 digit Status Service Fig 42 Hours run meter with reset 1000 digit Manual mode and service display To call up the service display and for manual mode the control unit must be issuing a heat demand The service display shows the current modulation level in Display d 0 Lower heating output d 00 Upper heating o...

Page 30: ...hart on page 38 2 Press b While the key is held down additional fault infor mation is displayed under Service 3 Hold down the reset button for longer than s The operating display appears again The burner control unit is reset Fault memory The 10 most recent faults are saved and can be called up The most recent fault code is shown first followed by the preceding codes If no key or the reset button ...

Page 31: ...ss S The operating display appears again 2 Specification of each individual fault Status Service Fig 48 1 Press a While this key is held down the status number operating phase in which the fault occurred is dis played under Service Value between 01 and 36 See flowchart on page 38 2 Press b For as long as this key is held down additional fault information is displayed under Service Burner control u...

Page 32: ... starts automatical ly after 2 min after 5 min and then after 1 h Reset by holding down the reset button until 9 flashes General process errors Fault code 1 Shown on display System characteristics Cause of fault Measure F AA F AA Fan pressure is produced during the air pressure switch idle state check Wind influence on fan Check the flue draught chimney F AA F AA Air pressure switch con tact is no...

Page 33: ...orts external light in gress during start up or after post purge Gas train is leaking Gas is escaping and burning off Replace gas train F A7 F A7 No flame reported during safety time ionisation flame monitor reports no flame signal Ionisation electrode set incorrectly ionisation ca ble not plugged in Adjust ionisation elec trode setting see page 19 plug in ionisa tion electrode F A7 F A7 No flame ...

Page 34: ...Flame extinguishes dur ing stabilising time Incorrect gas type Set correct gas type F A9 F A9 Flame extinguishes dur ing stabilising time Burner gauze assembly faulty Check burner gauze as sembly replace if dam aged F A9 F A9 Flame extinguishes dur ing stabilising time Incorrect parameter memory stick inserted Replace and enable pa rameter memory stick F A9 F A9 Flame extinguishes dur ing stabilis...

Page 35: ... Replace memory stick I Danger Plug in terminals on the burner control unit are live Only replace memory stick when burner control unit has been isolated from power supply F 41 F 41 Fan speed deviation Fan faulty cable 100A faulty or broken fan un suitable for the required speed Check the cable and re place cable 100A or fan if required F 42 F 42 No feedback from fan Fan faulty external pow er sup...

Page 36: ...er be guaranteed Fault code 1 Shown on display System characteristics Cause of fault Steps to take 01 02 05 to 0d 0F 14 15 17 1A to 1c 1E 45 47 Ac b0 01 02 05 to 0d 0F 14 15 17 1A to 1c 1E 45 47 Ac b0 Fault in burner control unit area Internal system fault and EMC Replace burner control unit Measure against EMC Try connecting to another phase F 0E F F 0E F Fault in burner control unit area EEPROM ...

Page 37: ...etails on page 12 onwards CO2 content too low Incorrect setting Check whether the burner has been adjusted to the correct gas type change gas restrictor if required see page 10 onwards Adjust burner in accordance with the details on page 12 onwards CO formation or burner is very sooty Insufficient or excessive air Correct the settings Check ventilation in installation room Insufficient draught in ...

Page 38: ...Output Output Output Output 10 11 12 13 14 16 17 18 19 20 21 23 24 25 32 33 34 1 35 36 0 1 3 4 6 7 8 9 Output Input Output same or steady Input same or steady Fig 49 After the controller issues a heat demand the following program sequence runs Phase Duration 00 Fault 0 01 Waiting for heat demand 0 03 Fan idle state check max 2 min 04 Air pressure switch idle state check max 5 s 06 Fan ramp up max ...

Page 39: ...h 0 18 Pre ignition time 0 to 1 min 19 Ignition safety time SZA 0 5 to 9 4 s 20 SZA flame detection 0 5 s 21 Flame stabilising time 1 to 200 s 23 Transition to control mode max 2 min 24 Control mode 0 25 Transition after controlled shutdown 1 to 30 s 32 Burner run on time 1 to 60 s 33 Post purge time 0 to 1 h 34 Restart blocking time 0 to 1 h 01 Waiting for heat demand 0 In the case of fault shutd...

Page 40: ...40 Burner control unit flow chart Burner control unit flow chart cont 5783 337 GB Diagnosis ...

Page 41: ...parts list Position number of the individual part within the assembly from this parts list Standard parts are available from your local supplier A B C Fig 50 A Type plate B Thermal insulation assembly C Boiler assembly D Burner assembly not shown Parts lists Overview of assemblies 5783 337 GB Components ...

Page 42: ...42 0005 0011 0010 0011 0002 0010 0006 0005 0003 0007 0004 0001 0008 0009 0008 0006 0003 Fig 51 Parts lists Boiler assembly 5783 337 GB Components ...

Page 43: ...block and mat for boiler door 0004 Stench trap 0005 Mounting bracket 0006 Packing GF 20 x 15 x 2040 0007 Stud bolt B 12H11 x 85 0008 Gasket DN 100 0009 Gasket DN 80 0010 Viessmann logo 0011 Door panel with pos 0010 Parts lists Boiler assembly cont 5783 337 GB Components ...

Page 44: ...27 0014 0024 0028 0021 0026 0020 0023 0022 0029 0009 0033 0034 0008 0007 0016 0004 0027 0003 0002 0007 0005 0013 0010 0012 0011 0015 0019 0030 0017 0018 0035 0031 0032 0037 Fig 52 Parts lists Thermal insulation assembly 5783 337 GB Components ...

Page 45: ...ack 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 pan...

Page 46: ...012 2h 019 2c 027 017 2h B 018 020 2a 2i 2i 2g 2e 2g 2e 008 010 028 013 009 029 029 016 030 005 025 2b 014 015 031 032 2f 007 006 004 003 033 Fig 53 A MatriX burner type plate B Label Set to Parts lists Burner assembly 5783 337 GB Components ...

Page 47: ...ion cable 010 Burner control unit 011 Display and programming unit for burner control unit 012 Cable entry for burner control unit 013 Connecting cable ignition transformer 014 Connecting cable servomotor 015 Connecting cable min gas pressure switch 016 Connecting cable gas valve 017 Air pressure switch with connecting cable 018 Actuator 019 Gas fan 020 Gasket gas fan 021 Rotary damper 022 Toggle ...

Page 48: ...ixings 0004 Decorative strip 0005 Touch up spray paint Vitosilver 0006 Touch up paint stick Vitosilver 0007 Installation instructions 0008 Service instructions Parts lists Parts not shown 5783 337 GB Components ...

Page 49: ...rvomotor G Venturi mixing pipe H Mains filter unit with contactor N P L K M O D B H Fig 55 B Air pressure switch D Display and programming unit H Mains filter unit with contactor K Ignition electrodes L Ionisation electrode M Gas supply pipe N Burner control unit O Ignition unit p Burner gauze assembly Component overview Component overview 5783 337 GB Components ...

Page 50: ... Air pressure switch H VPS gas pressure switch K Gas pressure switch min L Ignition unit M Solenoid valve stage 2 BV 2 N Solenoid valve stage 1 BV 1 O Servomotor for rotary damper B2 Safety chain jumper F1 MCB fuse F2 MCB fuse F6 High limit safety cut out F7 Temperature controller H1 Hours run meter modulation H2 Fault message H3 Hours run meter modulation S1 ON OFF switch Connection and wiring di...

Page 51: ...ower supply 230 V 50 Hz via a permanent connection fÖ Power supply 230 V 50 Hz fÖ aBH Control unit power supply plug fÖ Switched phase for controlling contactor B plug aBH gD Flue gas damper Note Make the power supply 230 V 50 Hz via a perma nent connection The faulty power cable should only be replaced with an original Viessmann power cable Connection and wiring diagram Mains filter unit connecti...

Page 52: ...r and the water hardness into the boiler maintenance checklists For systems with a specific system volume in excess of 20 l kW heating output in multi boiler systems apply the output of the smallest boiler apply the requirements of the next higher category of total out put in accordance with the table In the case of severe excess 50 l kW soften down to a total amount of alkaline earths 0 02 mol m3...

Page 53: ...el 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 ...

Page 54: ...gas E mbar For natural gas LL mbar Tick gas type Carbon dioxide content CO2 At the upper rated heat ing output actual by vol set by vol At the lower rated heat ing output actual by vol set by vol Oxygen content O2 At the upper rated heat ing output actual by vol set by vol At the lower rated heat ing output actual by vol set by vol Carbon monoxide con tent CO actual ppm set ppm Flue gas temperatur...

Page 55: ...ated heat ing output μA At the lower rated heat ing output μA Draught actual hPa set hPa Note The CO2 content for all natural gases must be between 7 5 and 10 5 The CO2 content must always be lower in partial load than it is in full load Reports Settings and test values cont 5783 337 GB Appendix ...

Page 56: ...ated heating output W 585 630 890 Lower rated heating output W 90 95 105 MatriX cylinder burner Rated boiler heating output TF TR 50 30 C kW 135 to 400 168 to 500 209 to 630 TF TR 80 60 C kW 123 to 370 153 to 460 192 to 575 Burner type VM IV 1 VM IV 2 VM IV 3 Voltage V 230 Frequency Hz 50 Power consumption W 575 620 880 Motor speed rpm 5340 4130 4300 Modulation range 33 to 100 33 to 100 33 to 100 ...

Page 57: ...rt of ordi nary household waste 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 Final decommissioning and disposal Final decommissioning and disposal 5783 337 GB Appendix ...

Page 58: ...0 3 2 2014 EN 15502 2 1 2012 4 EN 61000 3 3 2013 EN 50491 5 2 2010 EN 62233 2008 AC 2008 EN 55014 1 2006 A1 2009 A2 2011 EN 301489 1 V2 1 1 EN 55014 2 2015 EN 301489 17 V2 2 1 EN 60335 1 2012 AC 2014 A11 2014 EN 300328 V2 1 1 EN 60335 2 102 2016 In accordance with the listed directives this product is designated with Allendorf 1 August 2017 Viessmann Werke GmbH Co KG Authorised signatory Reiner Ja...

Page 59: ...s 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 1 August 2017 Viessmann Werke GmbH Co KG Authorised signatory Reiner Jansen Head of Strategic Quality Management Certificates Manufacturer s certificate 5783 337 GB Appendix ...

Page 60: ...g for tightness 23 G Gas type check 10 H Heating system Filling 8 High limit safety cut out 8 I Ignition and ionisation electrodes checking 19 Information display 28 Information on maintenance 8 Internal system faults 36 Ionisation current check 14 Ionisation electrode checking 19 M Manufacturer s certificate 59 N Neutralising system 16 O Operating display 27 P Parts list 41 R Report Settings test...

Page 61: ...61 5783 337 GB ...

Page 62: ...62 5783 337 GB ...

Page 63: ...63 5783 337 GB ...

Page 64: ...mann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com 5783 337 GB Subject to technical modifications ...

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