Viessmann Vitocrossal 300 CA3 2.5 Installation And Service Instructions Manual Download Page 1

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Installation and Service

Instructions

VITOCROSSAL 300

5790 733 - 07 09/2017

for use by heating contractor

Vitocrossal 300

CA3 Series 2.5, 3.0, 3.5, 4.0, 5.0 and 6.0

Gas condensing boiler with cylinder burners

Read and save these instructions

for future reference.

Please file in Service Binder

Product may not be exactly as shown

IMPORTANT

Heating input:

2500 to 6000 MBH

(733 to 1758 kW)

Summary of Contents for Vitocrossal 300 CA3 2.5

Page 1: ...ng contractor Vitocrossal 300 CA3 Series 2 5 3 0 3 5 4 0 5 0 and 6 0 Gas condensing boiler with cylinder burners Read and save these instructions for future reference Please file in Service Binder Pro...

Page 2: ...ated by chemicals can cause by products in the combustion process which are poisonous to inhabitants and destructive to Viessmann equipment For a listing of chemicals which cannot be stored in or near...

Page 3: ...e 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...

Page 4: ...com 100 LAN 1 Internal Overview 42 Connecting to the Network LAN 42 Vitocom 100 LAN 1 Display and Control Elements 43 Switching on the Vitocom 100 LAN 1 43 Configuring Network Using Static IP 44 Regis...

Page 5: ...Burner 88 Reducing Operational Output if required 90 Checking Static and Connection Pressure 91 Checking the Rotary Damper Setting 92 Checking the Burner Damper Setting 92 Measuring CO2 Content 93 Di...

Page 6: ...e System 122 Operating and Service Documents 122 Boiler Water Temperature Control 123 Cascade Control Unit 123 Heating Circuit Control 128 DHW Tank Temperature Control 132 Calling up Coding Levels 135...

Page 7: ...ut Fault Display 198 Burner Control unit Connection Diagram 199 Boiler Connections 201 Overview 203 PCB Extension for Heating Circuits 2 and 3 with Mixing Valve 204 PCB Low Voltage 204 PCB 120V 205 Pa...

Page 8: ...ce or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision can not...

Page 9: ...ons in all instances to avoid accidental activation of power during service work Technical literature Literature for the Vitocrossal 300 CA3 boiler Technical Data Manual Installation and Service Instr...

Page 10: ...ranty null and void The Vitocrossal 300 CA3 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 swi...

Page 11: ...install the Vitocrossal 300 CA3 boiler in rooms with refrigeration equipment This boiler requires uncontaminated air for safe operation do not install where chemicals are stored For Retrofit Applicat...

Page 12: ...nt sealed combustion operation only Legend A Boiler 1 Clearance for vent pipe installation B Boiler combustion air intake vent To enable convenient installation and maintenance observe the stated clea...

Page 13: ...g the boiler from the side ensure the forks of the lift truck or forklift are centered Refer to the crosshair mark located on the side of the boiler Reducing Boiler Height Reducing the overall height...

Page 14: ...off should be installed directly on the safety header of the boiler or may be installed in the boiler piping above the pressure vessel Note Piping diagrams for specific system layouts are available P...

Page 15: ...nd ANSI 6 in for model 6 0 1 3 Safety header Pressure relief valve low water cutoff automatic air vent and temperature pressure gauge A Hex bushing b in x e in B Air vent with shut off base C Plug b i...

Page 16: ...y factory tested to ASME requirements Safety Header 1 Locate safety header on the main supply header Max allowable working pressure MAWP 160 psi 11 bar Min water pressure 8 psi 0 5 bar Note The minimu...

Page 17: ...plug for each boiler section 2 Install drain valve assembly for each boiler section as shown Legend A 1b in x 10 in nipple B 1b in to c in reducer C c in sediment faucet Installing the isolation valve...

Page 18: ...sing the cable trays provided Legend A Upper cable tray for power supply cables e g boiler power supply B Lower cable tray for low voltage cables e g sensor cables 1 Remove the screws holding the top...

Page 19: ...ation 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...

Page 20: ...3 5 4 0 5 0 and 6 0 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 Pump...

Page 21: ...tem and boiler section 1 controller Legend M2 M3 supply temperature sensor Outdoor temperature sensor Fitting location for outdoor temperature sensor H North or north westerly wall 6 to 8 ft 2 to 2 5...

Page 22: ...vidual terminals are a push in design meaning to install or release a wire the orange button must be pushed in refer to image below for location of orange buttons denoted by B prior to installing or r...

Page 23: ...equires replacement refer to the separate wiring diagram the fuse can be accessed as shown Legend B Push in button C DIN rail typical D Terminal insertion point Main power supply connections The main...

Page 24: ...ircuit pump M3 sA Circulation pump for tank heating sK DHW circulation pump sL Boiler circuit pump g Central fault message gS 3 way mixing valve gSM2 M3 Mixing valve motor 120 V External connections f...

Page 25: ...ump A1 s M2 Heating circuit pump M2 s M3 Heating circuit pump M3 sA Circulation pump for tank heating sK DHW circulation pump sL Boiler circuit pump g Central fault message gS 3 way mixing valve gSM2...

Page 26: ...pump sA DHW pump sK DHW recirculation pump sL Boiler pump system pump Available connections Connections on extension for heating circuit with mixing valve HC2 M2 HC3 M3 Plug Terminal Component s M2 5...

Page 27: ...nnecting Pumps continued 120V pumps with an amperage draw of 2FLA Contactor specification 120VAC 1A Legend A DIN rail located in the junction box B Contactor relay field supplied C Pump D Power supply...

Page 28: ...120VAC 1A Legend A DIN rail located in the junction box B Contactor relay field supplied C Pump D Power supply w disconnect and protection 208 460 575V 3 phase pumps Contactor specification 120VAC 1A...

Page 29: ...wires to the DIN terminals as shown based on desired functionality Legend A DIN Rail in junction box B 120V Valve Actuator C Valve Available connections gSM2 For heating circuit 2 gSM3 For heating cir...

Page 30: ...bles BK1 BK2 and BK3 of the 24V valve adaptor 3 Connect BK1 BK2 and BK3 to DIN terminals for desired valve application Refer to the chart below 4 Connect black wire E of the mixing valve adaptor to an...

Page 31: ...water cut off LWCO device Refer to the manual specific to the device for interconnection details Legend A Low water cut off typical 1 Remove jumper between terminals 15 L and 16 L 2 Make connection fo...

Page 32: ...st be potential free 1 Remove jumper from terminals 17 L and 18 L 19 L and 20 L or 21 L and 22 L 2 Make connection of the safety equipment to 17 L and 18 L 19 L and 20 L or 21 L and 22 L Legend A Mini...

Page 33: ...Terminal bridge must be removed on site for 240VAC connection WARNING Incorrectly executed electrical installations can lead to injuries from electrical current and result in appliance damage WARNING...

Page 34: ...sion Coding EA1 extension Set 5D DE1 5E DE2 or 5F DE3 in the General group to 3 or 4 Electrical Connections continued CAUTION The external connection must be potential free IMPORTANT Installation Conn...

Page 35: ...al heating off DHW heating off d5 0 in the Heating circuit group factory set condition Constant operation with reduced room temperature DHW heating off w or Central heating off DHW heating on d5 1 in...

Page 36: ...for heating circuits 1 to 3 H External blocking H External blocking with fault message input H External demand with minimum boiler water temperature H Fault message input H Brief operation of the DHW...

Page 37: ...on site cable and LON junction box Installation distance 3000 ft 900 m with LON junction box Legend A Vitocrossal 300 CA3 control unit B LON connecting cable 23 ft 7 m long C Terminal end resistor D...

Page 38: ...com 100 establishes communication via the internet between the connected Vitotronic control unit and the user interfaces e g Vitodata 100 or Vitotrol app Technical details on the control functions and...

Page 39: ...et connection Message designations H Terminal device for receiving mail e g computer H Mobile phone for receiving SMS only with internet service Vitodata 100 fault management H Fax for receiving messa...

Page 40: ...to the Vitocom 100 The Vitocom 100 transmits these messages to the Vitodata server The Vitotrol app scans the status of the heating system cyclically and displays the messages Note Heating system mes...

Page 41: ...nits via IP networks Functions Vitodata 100 control functions H Setting set temperature values heating curve slope and shift H Setting operating programs holiday programs and switching times H Setting...

Page 42: ...preinstalled A Rating plate T1 Maintenance button T2 No function T3 LON key only when integrating the Vitocom 100 into a BMS send service PIN T4 Reset button 1 LON service indicator green LED 2 No fu...

Page 43: ...d Flashes green quickly Software update is being installed The device must not be isolated from the mains Explanation of displays Switching on the Vitocom 100 LAN 1 Initialization When the Vitocom 100...

Page 44: ...h servers are used in the internal network 8 Store the settings using Save A web page appears confirming that the process has been successful Configuring Network Using Static IP Version 2 Network stil...

Page 45: ...ith internet browser http www vitodata100 viessmann com 2 On the start page press Register and complete all fields on the registration form Note In the Password field assign a new password min 6 chara...

Page 46: ...was not pressed before maintenance work then a fault message may be sent depending on the activity 2 Briefly press the maintenance button again once the maintenance work has been carried out approx 1...

Page 47: ...s yellow Internet connection available but the Vitodata server cannot be reached Disconnect plug in power supply unit and reconnect again after approx 15 sec Connection attempt is repeated see page 42...

Page 48: ...ight rise min 2 3 Avoid sharp bends 2 Connect flue system Size 10 in 250 mm for models 2 5 and 3 0 12 in 300 mm for models 3 5 and 4 0 16 in 400 mm for models 5 0 and 6 0 Note Support all venting comp...

Page 49: ...utralization system 4 Connect drain hose D to the condensate drain of the neutralization system and install at drainage E WARNING Escaping flue gas can cause severe personal injury or loss of life Alw...

Page 50: ...ground install a condensing drain above the ground max 2 in 50 mm Note The amount of condensate and the flue gas temperature gross graphs are independent of each other The Vitocrossal 300 CA3 boiler...

Page 51: ...b in for Vitocrossal 300 CA3 models 2 5 3 0 3 5 and 4 0 7 3 in for Vitocrossal 300 CA3 models 5 0 and 6 0 Honeywell combination gas valve assembly model V4734C1010 1100 1 Additional components may be...

Page 52: ...get damaged WARNING Escaped gas may lead to explosion which could cause severe injuries Do not vent gas pipe above combustion chamber of boiler CAUTION If gas pipe contains dirt it is recommended to i...

Page 53: ...ify shutoff valves as such with a tab and familiarize operator ultimate owner of boiler with these valves Legend A Manual gas shutoff valve supplied B Nipple field supplied C Ground joint union recomm...

Page 54: ...the top of the boiler or the safety supply of the boiler see page 15 No valve shut off device or obstruction of any kind and no construction must be used between boiler and relief valve or on the dis...

Page 55: ...to 0 in refer to local gas codes CAUTION For underfloor heating applications an additional immersion or strap on aquastat must be installed in the low temperature underfloor loop downstream of the mi...

Page 56: ...th mixing valve System separation is required of underfloor heating systems employing non oxygen diffusion barrier tubing All components on the secondary side of the heat exchanger must be made of cor...

Page 57: ...echnical documentation and contact your local Viessmann Sales Representative for further assistance This installation example depicts a possible piping layout for multiple Vitocrossal 300 CA3 boilers...

Page 58: ...nnected to the heating coils located in the air handling units The boiler piping system may be exposed to refrigerated air circulation and must be equipped with flow control valves or other automatic...

Page 59: ...nt ends of the vent pipe collar and if used the air intake pipe collar Slide pipes into each other with a gentle twisting motion Condensate must drain from the flue pipe to the boiler Ensure a suitabl...

Page 60: ...D1785 CSA B137 3 B181 2 ANSI ASTM F441 CPVC Schedule 40 ANSI ASTM D2661 CSA B181 1 ULC S102 2 ANSI ASTM D2665 D1785 CSA B137 3 B181 2 ANSI ASTM F441 ABS DWV Schedule 40 ANSI ASTM D2661 CSA B181 1 ULC...

Page 61: ...ing 10 within 3 ft 0 9 m to the property line advisable not mandatory please check with local building authorities and municipal bylaws 11 at a location where ice formation on the ground can present a...

Page 62: ...daptor supplied by others Combustion air intake If using room air independent venting system the combustion air intake kit must be used Connect the air intake pipe from outdoors to the adaptor provide...

Page 63: ...Z223 1 or NFPA Standard 54 To ensure safe operation of the appliance Viessmann recommends that the system be inspected once a year by a qualified service technician Every venting system must be plann...

Page 64: ...and exhaust vents as described in this section Ensure the vent and combustion air supply comply with these instructions The Vitocrossal 300 CA3 boiler location should never be under negative pressure...

Page 65: ...nation in such a way that it cannot be blocked by snow Min 2 in 50 mm Max 36 in 915 mm Min 12 in 305 mm Min 2 in 50 mm Air Vent Combustion Air Intake Filter field supplied A combustion air inlet filte...

Page 66: ...level Flue Min 2 in Max 36in 50 mm 915 mm Venting Component Installation Guide Flashing and storm collar installation Flashings and storm collars are field supplied Flashings and storm collars suitab...

Page 67: ...distance b less than 18 in 450 mm Legend a minimum 18 in 450 mm b 18 in 450 mm The venting system must be securely supported by a support system suitable for the weight and design of the materials em...

Page 68: ...Boiler model 5 0 6 0 Combustion air intake diameter in mm 16 400 16 400 Exhaust vent diameter in mm 16 400 16 400 Max combustion air intake length b ft m 198 60 164 50 Max total equivalent length a b...

Page 69: ...l PP s vent termination elbows must be secured in place as specified by manufacturer IMPORTANT For PP s systems all exhaust vent and air intake piping and elbows exposed outside must be UV resistant p...

Page 70: ...149 45 198 60 Horizontal intake and exhaust Vitocrossal 300 CA3 Boiler model 5 0 6 0 Combustion air intake diameter in mm 16 400 16 400 Exhaust vent diameter in mm 16 400 16 400 Max combustion air int...

Page 71: ...ake and vertical exhaust Vitocrossal 300 CA3 Boiler model 5 0 6 0 Combustion air intake diameter in mm 16 400 16 400 Exhaust vent diameter in mm 16 400 16 400 Max combustion air intake length b ft m 1...

Page 72: ...length must be calculated based on the single combustion air intake pipe with the longest equivalent length as shown in the illustration with grey fill Refer to pages 66 68 70 and 71 to determine max...

Page 73: ...m 12 300 14 350 12 300 14 350 Max vent equivalent length ft m 198 60 198 60 198 60 198 60 Vertical exhaust room air dependant Vitocrossal 300 CA3 Boiler model 5 0 6 0 Exhaust vent diameter in mm 16 40...

Page 74: ...00 14 350 12 300 14 350 Max vent equivalent length ft m 164 50 198 60 115 35 198 60 Horizontal exhaust room air dependant Vitocrossal 300 CA3 Boiler model 5 0 6 0 Exhaust vent diameter in mm 16 400 16...

Page 75: ...Steel PP s Multiple Boiler Installations Horizontal vent termination Vertical vent termination 36 in min 915 mm min Note 36 in 915 mm minimum distance apart for horizontal vent terminations 6 in min 1...

Page 76: ...les to calculate efficiency Stack thermometer dial settings range 0 F to 250 F 0 C to 121 C d in NPT male to in barb adaptor fitting as well as tubing for pressure measurement Technical information Th...

Page 77: ...ssal 300 CA3 Technical Data Manual Installation and Service Instructions Operating Instructions Wiring diagrams The following topics must be covered Proper system operation sequence Explain the equipm...

Page 78: ...a safe place outside the building If you smell flue gas WARNING Escaping gas can lead to explosions which may result in serious injury WARNING Flue gas can lead to life threatening poisoning Auxiliary...

Page 79: ...setting burner control will have a hard lock out with F F1 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...

Page 80: ...tion Filling Condensate Trap with Water IMPORTANT See page 221 for water quality requirements Checking the Type of Gas IMPORTANT The heating system is equipped for operation with natural gas Switching...

Page 81: ...rs 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 button R B on the burner control...

Page 82: ...Operating the System continued IMPORTANT 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 Activat...

Page 83: ...oding Levels Check the following coding addresses in Coding level 2 and adjust accordingly If the fault indicator lights up on the control unit and the display on the burner control unit is blinking r...

Page 84: ...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 Legend A Boiler water temperature or supply temperature B Outdoor temperature C Set ro...

Page 85: ...rature Adjustment of the reduced set room temperature from 37 F to 52 F 3 C to 14 C Legend A Changing the slope B Changing the shift vertical parallel offset of the heating curve Outdoor temperature B...

Page 86: ...r temperature Set coding 97 1 in the General group Viessmann system number coding 98 1 in the General group Viessmann system number coding 98 1 in the General group Viessmann system number coding 98 1...

Page 87: ...the fault manager must be up to date From the home screen tap the following buttons 1 Menu 2 Service 3 Enter viservice password 4 Service functions 5 LON participant check The list of all connected LO...

Page 88: ...T 1 Remove top panels 2 Remove panels on the right side service side of the boiler In order to remove the burner dismantle the following 3 remove upper frame profile 4 Remove upper side frame profile...

Page 89: ...er and Burner continued Burner Combinations Burner Input MBH Boiler model Section 1 lead Section 2 lag 1 Section 3 lag 2 2 5 1250 1250 3 0 1500 1500 3 5 1500 2000 4 0 2000 2000 5 0 1500 1500 2000 6 0...

Page 90: ...onger 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 und...

Page 91: ...oys a direct spark ignition system A CO2 measurement see page 93 must be taken before and after working on gas appliances to eliminate risks to health and to guarantee the satisfactory condition of th...

Page 92: ...be set as follows during this time Service Checking the Rotary Damper Setting Boiler model Burner model Rotary damper setting 2 5 and 3 0 1 25 MMBTU Not equipped 1 5 MMBTU Not equipped 3 5 to 6 0 1 5...

Page 93: ...he specified range Turning clockwise CO2 level falls less gas Turning counter clockwise CO2 level rises more gas 4 Record the actual value in the report on page 222 Checking the CO2 level Preparing th...

Page 94: ...ecord measurement reading in record on page 222 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 permis...

Page 95: ...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 appears again IMPORTANT Ionization current mus...

Page 96: ...isconnect the burner gas line 2 Disconnect the connector from the burner control unit 3 Pull off the ignition electrode connectors 1 Remove 2 screws on the ignition electrode block Lift the electrode...

Page 97: ...ner section to the side Refer to the Installation Instructions for lifting device IMPORTANT A lifting mechanism is required to dismantle the burner A lifting mechanism that can be mounted to the boile...

Page 98: ...ixing tube L Burner fan M Burner gauze assembly N Ignition electrode block O Burner control unit P Mains filter unit Service Legend A Burner frame B Air pressure switch 1 C Air pressure switch 2 D Dis...

Page 99: ...b7 is displayed check the coding card Refer to the Service Instructions Coding Card on Burner Control Unit Display and Programming Unit of Burner Control Unit 1 Disconnect KM BUS connector avG 2 Undo...

Page 100: ...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 di...

Page 101: ...Leak test the reconnected gas line and gas valve connections CAUTION Usage of leak detection spray may lead to a malfunction Avoid contact between leak detection spray and electrical contacts Boiler m...

Page 102: ...s type will be displayed under Service window 0 NG or 1 LPG 7 Press buttons Y E or B G to set 0 for NG and 1 for LPG 8 Press button S F to confirm Upon successful completion 1 will be displayed under...

Page 103: ...Remove the boiler left side panels see page 88 4 Disconnect power cable with plug f Then disconnect the burner cables with plugs A B aGA aGB fA gD l and in addition to plug avG from the burner contro...

Page 104: ...o 6 0 Installation Service Service 3A and 3B Boiler Temperature Sensor Description 3A sensor NTC 10k terminals 1 2 3B sensor NTC 20k terminals 3 4 Temperature Resistance in k ohms Temperature Resistan...

Page 105: ...oiler 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 well 3 Disconnect sen...

Page 106: ...ove the boiler secondary temperature sensor from the sensor well 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...

Page 107: ...tion 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 ac...

Page 108: ...eak detection spray must not come into contact with electrical contacts Fan pressure monitoring function LDW1 The switching threshold of the air pressure switch 1 LDW1 is monitored in all fan start up...

Page 109: ...ing 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 purge phase The fault shutdown is...

Page 110: ...150 230 C d 4 1e 35 D d 4 10f 270 E d 4 15 17 380 430 F d 4 15 13c 380 350 G a 6 13c 350 Compensation lines for CA3 2 5 and 3 0 Replacement lines must be cut to length See following table for require...

Page 111: ...e replaced air pressure switch Legend A Air pressure switch fan LDW1 compensation line on connector marked B Air pressure switch combustion chamber LDW2 compensation line on connector marked C Air pre...

Page 112: ...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 r...

Page 113: ...is cold 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...

Page 114: ...ismantling the burners see from page 96 Legend A Combination gas valve B Gas connector pipe C Fitting at gas connector pipe D Venturi mixing tube E Fan F Flame tube 1 Disconnect Venturi mixing tube D...

Page 115: ...For normal cleaning flush the heating surfaces thoroughly with a water jet You may use cleaning agents if you notice stubborn residues surface discoloration or soot deposits For this observe the follo...

Page 116: ...5 replace granulate 2 If contaminated rinse the neutralization unit with tap water 3 Add granulate as marked IMPORTANT The granulate is consumed as it neutralizes the condensate The red marking indica...

Page 117: ...combination gas valve should be replaced WARNING Risk of explosion due to gas leakage Check for gas leakage at the gauge connections Further Assembly and Commissioning 1 Position the burner tile with...

Page 118: ...th electrical contacts Taking Final Measurement Reading 1 Take CO2 measurement reading after each burner dismantling in accordance with the items beginning from pages 79 and 80 2 Record measurement re...

Page 119: ...soften the water down to a total of alkaline earths of 2 ppm of CaCO3 Operating information During expansion or repair work only drain the pipework sections which are crucial Check clean and activate...

Page 120: ...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 includi...

Page 121: ...if these recommendations are not followed 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 CA...

Page 122: ...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 long...

Page 123: ...hed 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...

Page 124: ...nventional boiler strategy 2 coding 3c 2 in the Cascade group see page 157 H The cascade control specifies the set boiler water temperature for all currently active boilers Every boiler control unit r...

Page 125: ...oiler 1 100 rated heating output base load set to 33 Boiler 2 100 rated heating output base load set to 33 Starting criterion An output statement causes the boilers to start Coding 3d 1 in the Cascade...

Page 126: ...e 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 Starting criterion The boilers are s...

Page 127: ...5 to 6 0 Installation Service Conventional boiler strategy 1 coding 3c 1 in the Cascade group Starting Shutdown Cascade Control Unit continued Function Description Starting Shutdown Conventional boile...

Page 128: ...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...

Page 129: ...oor 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 Heat...

Page 130: ...et 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 wi...

Page 131: ...n 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 valv...

Page 132: ...rculation pump can be adjusted individually for each heating circuit Priority control H With priority control coding a2 2 in the Heating circuit group The set supply temperature will be adjusted to 32...

Page 133: ...61 1 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...

Page 134: ...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 DH...

Page 135: ...s 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 indi...

Page 136: ...it 2 and M3 heating circuit 3 without DHW heating 8 Two heating circuits with mixing valve M2 heating circuit 2 and M3 heating circuit 3 with DHW heating 9 One heating circuit without mixing valve A1...

Page 137: ...lected month 83 6 Last week 1 week 83 7 Last week 2 weeks 83 8 Last week 3 weeks 83 9 Last week 4 weeks 83 10 to 83 14 Special function Summer time starts Day of the selected week 84 7 Last Sunday of...

Page 138: ...e of controller 08 30 Set to 30 Kmin 08 1 to 08 255 Adjustable from 1 to 255 K min Runtime optimization 09 1 Integral method 09 0 Minimum pause Coding in the factory set condition Possible change Sing...

Page 139: ...st value of coding 06 in the Combustion controller group of every control unit Boiler section 1 or boiler sequence changeover 38 0 No boiler section boiler sequence changeover Do not adjust 38 1 Boile...

Page 140: ...ing in the factory set condition Possible change Type of control 3b 1 Standalone parallel boiler circuit With supply temperature sensor see page 124 3b 0 Standalone parallel boiler circuit Without sup...

Page 141: ...No ECO threshold boiler 6 Do not adjust 6F 30 to 6F 30 Adjustable from 22 F to 86 F 30 C to 30 C ECO threshold boiler 7 74 31 No ECO threshold boiler 7 Do not adjust 74 30 to 74 30 Adjustable from 22...

Page 142: ...s not speed controlled 02 1 Variable speed solar circuit pump with wave packet control 02 2 Solar circuit pump speed controlled with PWM control Maximum storage tank temperature 08 60 DHW setpoint tem...

Page 143: ...ossible change Storage tank priority a2 2 Tank priority control for heating circuit pump and mixing valve a2 0 Without storage tank priority applicable to heating circuit pump and mixing valve a2 1 St...

Page 144: ...circuit pump ON H Mixing valve in control mode H If there is a risk of frost Pump idle time a9 0 Without pump idle time a9 7 With pump idle time heating circuit pump turned off Function description pa...

Page 145: ...ration with standard room temperature c5 1 to c5 127 Adjustable from 34 F to 261 F 1 C to 127 C limited by boiler specific coding Maximum supply temperature limit c6 75 Electronic maximum supply tempe...

Page 146: ...tion 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 see example on page 131 f9 10 to f9 60...

Page 147: ...g valve M2 heating circuit 2 and M3 heating circuit 3 with DHW heating 9 One heating circuit without mixing valve A1 heating circuit 1 two heating circuits with mixing valve M2 heating circuit 2 and M...

Page 148: ...ug s A1 Heating circuit pump 4c 1 Primary pump tank loading system 4c 2 Thermal control switch contact Connection at plug 29 4d 1 Connection at plug sL Shunt pump 4d 0 System pump 4d 2 Boiler pump 4d...

Page 149: ...e Function input DE1 at EA1 extension 5d 0 No function 5d 1 Operating program changeover 5d 2 External demand with minimum set supply temperature Set value adjustment at coding 9b in the General group...

Page 150: ...2 AM1 6d 0 Delay off time circulation pump neutralizing system None 6d 1 to 6d 255 Adjustable from 1 to 255 sec Display correction for outdoor temperature 6e 50 No display correction for outdoor tempe...

Page 151: ...valve M3 heating circuit 3 LON communication module Time 7b 1 Control unit transmits the time 7b 0 No time transmission IMPORTANT Must be set for boiler section 2 boiler section 3 see page 87 Detached...

Page 152: ...starts Week of the selected month 86 1 Week 1 of the selected month 86 1 to 86 5 Week 1 to week 5 of the selected month Wintertime starts Day of the selected week 87 7 Last Sunday of the selected mont...

Page 153: ...eating 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...

Page 154: ...M2 heating circuit 2 and M3 heating circuit 3 99 11 No function 99 12 External blocking External mixing valve closed Heating circuit with mixing valve M3 heating circuit 3 99 13 No function 99 14 Exte...

Page 155: ...f 40 Adjustable from 0 to 40 K Coding Level 2 General Group continued Coding Coding in the factory set condition Possible change Max operational output 02 100 100 of rated heating output 02 0 to 02 10...

Page 156: ...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 Interval adjustable from 1 to 24 months Service disp...

Page 157: ...n Permanent boiler section 1 39 0 No permanent lead boiler section Do not adjust 39 1 to 39 8 Permanent lead boiler section is 1 2 3 4 5 6 7 or 8 Permanent last boiler 3a 0 No permanent last boiler se...

Page 158: ...o 86 F 30 C to 30 C ECO threshold boiler 2 42 31 No ECO threshold boiler 2 Do not adjust 42 30 to 42 30 Adjustable from 22 F to 86 F 30 C to 30 C ECO threshold boiler 3 43 31 No ECO threshold boiler 3...

Page 159: ...erature sensors see page 134 55 3 Storage tank temperature control storage tank loading system Do not adjust DHW temperature target 56 0 Set DHW temperature adjustable from 50 to 140 F 10 to 60 C 56 1...

Page 160: ...the programming unit of the control unit 66 1 At the programming unit of the control unit and remote control unit of the heating circuit without mixing valve A1 heating circuit 1 66 2 At the programm...

Page 161: ...am 72 1 OFF during DHW heating to set value 2 72 2 ON during DHW heating to set value 2 73 0 DHW recirculation pump ON according to time program 73 1 to 73 6 ON from once per hour for 5 min up to 6 ti...

Page 162: ...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 tempera...

Page 163: ...stable 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 10 1 Target temperatu...

Page 164: ...K code 20 4 must be set 22 2 to 22 30 Start temperature differential adjustable from 4 F to 54 F 2 K to 30 K Stop temperature differential for central heating backup 23 4 Stop temperature differential...

Page 165: ...0 recognized automatically a0 2 Recognized automatically with Vitotrol 300 Blocking remote control a1 0 All possible settings at the remote control can be accessed a1 1 Only comfort mode can be set at...

Page 166: ...frost protection a4 1 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 W...

Page 167: ...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 aJA aa 0 Without output reduction aa 1 N...

Page 168: ...imization b7 1 With start optimization max heat up time offset 2 h 30 min b7 2 With start optimization max heat up time offset 15 h 50 min Heat up gradient start optimization b8 10 With remote control...

Page 169: ...om 50 F to 261 F 10 C to 127 C limited by boiler specific coding Room influence limit c8 31 With remote control and for the heating circuit operation with room temperature hook up must be programmed N...

Page 170: ...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 see example on...

Page 171: ...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 le...

Page 172: ...n 7 Confirm with OK 8 Enter new password 9 Tap OK twice New password for Service main menu New password for Coding level 2 5 Change passwords 6 Reset all passwords 7 Enter master password This must be...

Page 173: ...0 0 6 Code An overview of brief scans appears with 11 lines and 6 fields for the required brief scan in line with the following tables 7 LON subnet address system number LON node address 0 0 8 SNVT co...

Page 174: ...d in the table can be tested at the relay outputs subject to system equipment level and control unit configuration lead control or service control EA1 output 1 ON Contact P S on plug aBJ of EA1 extens...

Page 175: ...From the home screen tap the following buttons 1 Menu 2 Service 3 Enter viservice password 4 Service functions 5 Reset service The set service coding for hours run and interval restart at 0 and coding...

Page 176: ...Tap the following buttons 1 Note After tapping the following will be displayed if your heating system has several fault messages simultaneously 2 Faults The fault messages appear in red and in chronol...

Page 177: ...not high enough Lead break common supply temperature sensor Check the supply temperature sensor 30 H With DHW tank DHW pump ON boiler is maintained at set tank temperature H Without DHW tank Boiler i...

Page 178: ...sor aJA Check temperature sensor 68 Boiler with maximum temperature no output reduction mixing valve return temperature control open Lead break temperature sensor aJA Check temperature sensor Without...

Page 179: ...Short circuit collector temperature sensor connection of temperature sensor at solar control module type SM1 or sensor at S1 of the Vitosolic Check sensor at the solar control unit see separate instal...

Page 180: ...Vitotronic Check solar control unit see separate installation and service instructions a0 Boiler cools down Fault safety equipment at X7 of plug in adapter 2 for external safety equipment Check safet...

Page 181: ...and service instructions and coding address a0 in the Heating circuit group bd Control mode without remote control Communication error Vitotrol remote control unit heating circuit with mixing valve M...

Page 182: ...Plug in adapter 2 for external safety equipment Check plug in adapter if no plug in adapter is available adjust coding 31 0 in General group d3 Control mode Communication error extension EA1 Check co...

Page 183: ...eck setting of gas pressure switch 2 check connecting cable replace gas valve E2 Burner control unit in a fault state Valve 2 not tight gas pressure switch 2 does not close Check setting of gas pressu...

Page 184: ...ions No flame formation during safety time ionization flame monitor reports no flame signal Ignition electrodes incorrectly adjusted electrodes grounded faulty ignition unit faulty burner control unit...

Page 185: ...e assembly replace if damaged Flame extinguishes during operation Combustion characteristics not ideal Adjust burner see boiler service instructions F9 Fan not running fan speed not reached Fan faulty...

Page 186: ...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 sen...

Page 187: ...operating levels A Status display B Service display C Reset button D LEDs from left heat demand flame maintenance and fault F Selection button E G Cursor button Operating display In standard mode the...

Page 188: ...ablished Pre ignition Flame stabilization Operation with flame Reheat Post purge Maintenance program no air pressure Maintenance program no gas pressure or mains under voltage Forced ventilation when...

Page 189: ...ps and hours run 2 Meters for start ups and hours run that can be reset 3 Software version 4 Fault history for the last 10 fault codes Example to delete the hours run meter press the following buttons...

Page 190: ...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 A 6 To exit th...

Page 191: ...wing 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 Serv...

Page 192: ...rement Gas valve V1 Gas valve V2 Auxiliary valve Servomotor Flue gas damper Ignition Fan Fault message output Relay test Start up Operation Shutdown Wait state Error state Subsequent state depends on...

Page 193: ...amplifier test max 50 seconds Gas fan air pressure switch and boiler water temperature sensor test max 20 seconds 2 Fan ramp up max 20 seconds 3 Pre purge 10 seconds Adjusting start up load test WD1...

Page 194: ...y 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 c...

Page 195: ...down burner control unit locked out Coding card not inserted in the burner control unit incorrect or faulty coding card Insert coding card check coding card replace if required F b7 Type of coding ca...

Page 196: ...error in feedback from gas safety valves output relay does not respond Reset burner control unit replace burner control unit F EF Burner control unit in a fault state Internal error in feedback from...

Page 197: ...safety time ionization flame monitor reports no signal Combustion characteristics not ideal Adjust the burner see pages 93 and 94 if necessary also adjust the setting screws when the burner is OFF to...

Page 198: ...fault state Flue gas path or condensate path blocked off Excessive combustion chamber pressure air pressure switch 2 LDW2 Check flue gas path or condensate path and clean if required F Fb Burner not...

Page 199: ...and feedback a 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 kJ GDW2 L Burner display and programming unit M Fla...

Page 200: ...ition burner inlet damper E Ignition unit gF F Gas valve V1 dG G Gas valve V2 dH H Fan motor with PWM control and feedback a A I Boiler temperature sensor 1 A J Boiler temperature sensor 2 B K AC EMI...

Page 201: ...rams 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...

Page 202: ...Connection overview for CA3 3 5 to 6 0 models 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 pow...

Page 203: ...th 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 modul...

Page 204: ...emperature sensor DHW tank loading system avD External connections avG KM BUS participants avH External connections LON Connecting cable for data exchange accessory S3 Emissions test switch V1 Fault d...

Page 205: ...pump on site sL Boiler circuit pump or distributor pump on site f Power supply 120 V 60 Hz fA Burner g Output for central fault message gS Motor for 3 way mixing valve primary store system aB External...

Page 206: ...Number from ASME rating plate A when ordering replacement parts Order replacement components from your Viessmann distributor CA3 Parts for CA3 3 5 4 0 0001 Vitocrossal 300 CA3 boiler 0002 Vitotronic 3...

Page 207: ...op 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 Panel door 0012 Rear pan...

Page 208: ...1 0007 Fiber rope seal 18x2100 mm 0008 Sensor well G l 100 mm with clip 0009 Sensor well G l 150 mm with clip 0010 Accessory pack boiler section 0011 Boiler stand 0012 Cover with tension gasket 0013 C...

Page 209: ...erial Number from ASME rating plate when ordering replacement parts Order replacement components from your Viessmann distributor CA3 Parts for CA3 5 0 6 0 0001 Vitocrossal 300 CA3 boiler 0002 Vitotron...

Page 210: ...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 Panel door 0012 R...

Page 211: ...rope seal 18x2100 mm 0008 Sensor well G l 100 mm with clip 0009 Sensor well G l 150 mm with clip 0010 Accessory pack boiler section 0011 Boiler stand 0012 Cover with tension gasket 0013 Connection pi...

Page 212: ...fractory 0005 Accessory pack of small burner parts 0006 Burner tube 0007 Gasket for burner tube 0008 Electrodes 0009 Ignition cable 0010 Ignition transformer 0011 Coding plug for burner 5090 0012 Prog...

Page 213: ...003 Burner chassis 0004 Combustion chamber door refractory 0005 Accessory pack for small burner parts 0006 Burner tube 0007 Gasket for burner tube 0008 Electrodes 0009 Ignition cable 0010 Ignition tra...

Page 214: ...4 0 Boiler 7769873 CA3 5 0 Boiler 7769874 CA3 6 0 Boiler 7769875 Ordering Replacement Parts Please provide Model and Serial Number from ASME rating plate when ordering replacement parts Order replacem...

Page 215: ...75 Ordering Replacement Parts Please provide Model and Serial Number from ASME rating plate when ordering replacement parts Order replacement components from your Viessmann distributor Master Display...

Page 216: ...rcuit 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...

Page 217: ...nt parts Order replacement components from your Viessmann distributor Junction Box Assembly 0001 Vitocom 100 LAN1 without communication module 0002 Disconnect switch 0003 Sealing grommet M63 0004 Rece...

Page 218: ...00 39e 1000 39e 1000 and jacketing Overall Boiler Height 4 including insulation and jacketing in mm 78c 2000 78c 2000 84 2131 84 2131 84 2131 84 2131 Concrete boiler base 3 Length in mm 74 1900 74 190...

Page 219: ...4 254 306 8 306 8 408 4 408 4 Combustion Air Internal diameter for direct vent sealed combustion using the combustion air intake kit optional accessory in mm 10 254 10 254 12 306 8 12 306 8 16 408 4 1...

Page 220: ...e gas outlet vent pipe connection Dimensions Boiler Model 2 5 and 3 0 3 5 and 4 0 5 0 and 6 0 A in mm 90c 2305 101f 2581 138 3503 B in mm 33b 851 39e 1000 39e 1000 C 1 in mm 78 1981 84 2131 84 2131 D...

Page 221: ...CA3 Series 2 5 to 6 0 Installation Service Inspection and Maintenance Counter reading USG Fill and make up water USG Total quantity of water USG Total hardness Feed water Boiler water pH value Date Re...

Page 222: ...by a qualified heating technician or service agency IMPORTANT Setting and Test Values Commissioning Maintenance Service Static Pressure mbar w c Section 1 Section 2 Section 3 Section 1 Section 2 Sect...

Page 223: ...afety 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 p...

Page 224: ...ocrossal 300 CA3 Series 2 5 to 6 0 Installation Service Technical information subject to change without notice Printed on environmentally friendly recycled and recyclable paper Scan for digital copy o...

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Viessmann Vitocrossal 300 CA3 2.5, Installation And Service Instructions Manual

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