Viessmann VITOCROSSAL 300 Service Instructions Manual Download Page 4 | Manualshive

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Commissioning, inspection, maintenance

Steps

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commissioning, inspection and maintenance ..................................

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Further details regarding the individual steps ..............................................

7

Parts lists

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20

Commissioning/service reports

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28

Specification

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29

Certificates

Declaration of conformity ............................................................................

33

Manufacturer's certificate according to the 1st BImSchV [Germany].............

34

Index

4

Index

56

92

405

GB

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Summary of Contents for VITOCROSSAL 300

Page 1: ...VIESMANN Service instructions for contractors Vitocrossal 300 Type CT3 187 to 635 kW Gas fired condensing boiler VITOCROSSAL 300 5692 405 GB 2 2007 Please keep safe ...

Page 2: ...l legal instructions regarding the prevention of accidents all legal instructions regarding environmental protection the Code of Practice of relevant trade associations all current safety regulations as defined by DIN EN DVGW TRGI TRF VDE and all locally applicable standards If you smell gas Danger Escaping gas can lead to explosions which may result in serious injury Never smoke Prevent naked fla...

Page 3: ... loads Repair work Please note Repairing components which fulfil a safety function can com promise the safe operation of your heating system Replace faulty components only with original Viessmann spare parts Ancillary components spare and wearing parts Please note Spare and wearing parts which have not been tested together with the heating system can compromise its function Instal ling non authori...

Page 4: ...n and maintenance 5 Further details regarding the individual steps 7 Parts lists 20 Commissioning service reports 28 Specification 29 Certificates Declaration of conformity 33 Manufacturer s certificate according to the 1st BImSchV Germany 34 Index 4 Index 5692 405 GB ...

Page 5: ... hose 9 9 Cleaning the combustion chamber and heating surfaces 10 10 Checking gaskets and thermal insulation components 11 11 Checking all heating water connections and the sensor well for leaks 11 12 Checking the function of the safety equipment 11 13 Checking the diaphragm expansion vessel and system pressure 12 14 Checking the flue gas header for soundness 14 15 Cleaning the sight glass in the ...

Page 6: ...ing the boiler room ventilation 22 Checking the function of the flue gas system 23 Adjusting the burner 18 24 Instructing the system user 18 25 Operating and service documents 19 Steps commissioning inspection and cont 6 Commissioning inspection maintenance 5692 405 GB ...

Page 7: ...ition Note For handling the damper see Mini mising pulsation noises page 8 Starting the heating system Operating instructions con trol unit burner and neutralis ing system service instructions control unit and burner manufacturer s docu mentation 1 Check the heating system pres sure Permissible boiler operating pres sure 4 bar 2 Check that the boiler room ventila tion aperture is open 3 Check the ...

Page 8: ...leaks see page 11 9 Check the boiler door and clean out cover a few days after commis sioning and retighten all screws Minimising pulsation noise Whatever the make of boiler burner or flue gas system sound flue systems can still create pulsation noise A change of resonance may be affected by rotating the damper fitted into the flue outlet Further details regarding the individual steps cont 8 Commi...

Page 9: ...lose the gas shut off valve Opening the boiler door 1 Remove the gas supply pipe 2 Undo the screws on the boiler door and open the door Please note Scratches inside the combus tion chamber can lead to corro sion Never put tools or other objects into the combustion chamber Separating the neutralising system from the boiler and con necting the drain hose 1 Separate hose or pipe A to the neutralising...

Page 10: ...leaning agents Ensure that no cleaning agent enters between the boiler body and the thermal insula tion Remove soot deposits with alkaline cleaning agents with additional surfactants e g Fauch 600 Remove coatings and surface discolouration yellow brown with slightly acidic chloride free cleaning agents based on phosphoric acid for example Antox 75 E 2 Remove loose deposits from the boiler flush th...

Page 11: ... on pressurised compo nents Only open the connections on the heating water side after the boiler has been de pres surised Only drain the boiler with a vacuum pump when the boiler air vent valve is open 1 Remove cap A from the back of the boiler 2 Check sensor well B for leaks 3 Fit cap A Checking the function of the safety equipment Check the safety valves the water level and pressure limiters in ...

Page 12: ...80 litres up to 1000 kW 140 litres This diaphragm expansion vessel reduces the frequency and severity of pressure fluctuations the service life of the pressure pump is improved and therefore the operational reliability and service life of system components increased Damage to the boiler or to other system components may result if these recommendations are not fol lowed Carry out all checks in acco...

Page 13: ...cut out For a high limit safety cut out set to 100 ºC 0 2 bar 110 ºC 0 7 bar 2 If the inlet pressure of the dia phragm expansion vessel is lower than the value calculated according to the adjacent formula top up with nitrogen until this value has been achieved 3 Refill with water until the filling pressure is 0 2 bar higher than the inlet pressure of the diaphragm expansion vessel when the system ...

Page 14: ... clean out aperture A on the flue gas collector Traces of conden sate on the outside of the flue gas header indicate a leak 2 If required retighten the gasket at clamping clips B Further details regarding the individual steps cont 14 Commissioning inspection maintenance 5692 405 GB ...

Page 15: ...Checking the thermal insulation Check the thermal insulation fit and adjust if required Checking the mixer for obstructions and leaks 1 Remove the motorised lever from the mixer handle 2 Check the mixer for ease of opera tion 3 Check the mixer for leaks Replace the O rings if the mixer leaks 4 Snap the motorised lever into place Further details regarding the individual steps cont 15 Commissioning ...

Page 16: ...ardness and the pH value in the tables For water quality requirements see page 30 Fill water Top up water Count Total water volume Date m3 m3 m3 m3 Max fill volume m3 Further details regarding the individual steps cont 16 Commissioning inspection maintenance 5692 405 GB ...

Page 17: ...eaning and reconnecting the condensate drain system The condensate drain siphon neutralising system and all intermediate hoses and pipes are part of the condensate drain system Note Clean the inside of the condensate drain system at least annually Further details regarding the individual steps cont 17 Commissioning inspection maintenance 5692 405 GB ...

Page 18: ... drain and fill with water or fit a siphon and fill that with water Note There is a risk of flue gas escaping if the U bend or siphon is not filled with water 6 Connect the supply line to the neu tralising system and make a proper connection between the conden sate drain and the sewer entry Adjusting the burner Observe the burner manufacturer s instructions Instructing the system user The installe...

Page 19: ... the system user this part for safekeeping Retain the heating engineer s part 2 File all parts lists operating and service instructions in the folder and hand this over to the system user Further details regarding the individual steps cont 19 Commissioning inspection maintenance 5692 405 GB ...

Page 20: ... Lower thermal insulation mat back panel 206 Spacer stud 207 Threaded stud 208 Front panel top 209 Front panel centre 210 Front panel bottom 211 Back panel top 214 Side panel bottom 215 Side panel top 216 Side panel l h and r h 217 Finned panel r h front bottom 220 Finned panel l h front bottom 221 Cap 222 6 fold strain relief 223 Mounting panel back 224 Mounting panel 225 Edge protector 226 Cable...

Page 21: ...A Type plate optionally on the r h or l h side B Boiler circuit control see separate parts list C Burner cable see separate parts list Parts lists cont 21 Parts lists 5692 405 GB ...

Page 22: ...Parts lists cont 22 Parts lists 5692 405 GB ...

Page 23: ...Parts lists cont 23 Parts lists 5692 405 GB ...

Page 24: ...Parts lists cont 24 Parts lists 5692 405 GB ...

Page 25: ...Parts lists cont 25 Parts lists 5692 405 GB ...

Page 26: ...Parts lists cont 26 Parts lists 5692 405 GB ...

Page 27: ...Parts lists cont 27 Parts lists 5692 405 GB ...

Page 28: ...ce Service date by Service Service Service date by Service Service Service date by Service Service Service date by Service Service Service date by Commissioning service reports 28 Commissioning service reports 5692 405 GB ...

Page 29: ... according to EnEV Efficiency η at 100 of rated output 97 6 97 6 97 8 97 5 97 6 97 6 at 60 of rated out put 107 5 108 2 108 2 107 2 107 5 107 3 Standby loss qB 70 0 4 0 3 0 3 0 3 0 28 0 25 Power consump tion 1 at 100 of rated output W 529 606 678 769 854 950 at 60 of rated out put W 176 202 226 256 285 317 Water quality requirements Note Maintaining the following requirements is necessary to safeg...

Page 30: ...est boiler All measures to prevent corrosion on the water side in accordance with VDI 2035 Sheet 2 have been implemented Soften the fill top up water in heat ing systems operating under the fol lowing conditions The total of alkaline earths in the fill top up water exceed the standard value Higher fill top up water volumes are expected The specific system volume is less than 20 l kW output In mult...

Page 31: ...systems start all boi lers simultaneously to prevent the entire lime deposit settling in the heat transfer area of just one boiler Where water treatment is required treat even the first fill of the heating systems prior to commissioning This also applies to any subsequent filling e g when adding top up water or after a repair or after sys tem expansion The formation of lime deposits on the heating...

Page 32: ... pressure of the diaphragm expansion vessel should be checked at least during the annual service For pressure maintaining systems see page 12 The use of permeable components e g plastic pipes that are permeable to gas in underfloor heating systems should be avoided Provide system separation if such components are nevertheless used This must sepa rate the water flowing through the plastic pipes fro...

Page 33: ... meets the requirements of the Efficiency Directive 92 42 EEC for condensing boilers The product characteristics determined as system values for the product Vitocrossal 300 as part of EC type testing according to the Efficiency Directive see specification table can be utilised to assess the energy consumption of heating and ventilation equipment to DIN V 4701 10 which is specified by the EnEV Germ...

Page 34: ... by the 1st BImSchV paragraph 7 3 Germany Boiler and burner unit Boiler Vitocrossal 300 type CT3 with MatriX radiant burner type VM III Vitocrossal 300 type CT3 Allendorf 30 January 2007 Viessmann Werke GmbH Co KG pp Manfred Sommer Manufacturer s certificate according to the 1st BImSchV Germany 34 Certificates 5692 405 GB ...

Page 35: ...35 5692 405 GB ...

Page 36: ...GB Subject to technical modifications Viessmann Werke GmbH Co KG D 35107 Allendorf Telephone 49 6452 70 0 Fax 49 6452 70 2780 www viessmann com Viessmann Limited Hortonwood 30 Telford Shropshire TF1 7YP GB Telephone 44 1952 675000 Fax 44 1952 675040 E mail info uk viessmann com ...

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