Viessmann Vitocrossal 300 Service Instructions Manual
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Viessmann Vitocrossal 300 Service Instructions Manual

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VIESMANN
Service instructions
for contractors
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
Please keep safe.
5783 337 GB
8/2017

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  • Page 1 VIESMANN Service instructions for contractors 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 Please keep safe. 5783 337 GB...
  • Page 2 Hot surfaces can cause burns. Replace faulty components only with genuine ■ Before maintenance and service work, switch Viessmann spare parts. OFF the appliance and let it cool down. Never touch hot surfaces on the boiler, burner, ■ flue system or pipework.
  • Page 3 For replacements, use only original spare parts supplied or approved by Viessmann. Safety instructions for operating the system If you smell gas Condensate Danger...

  • Page 4: Table Of Contents

    Index Index 1. Information Symbols ....................Intended use ..................2. Commissioning, inspec- Steps - commissioning, inspection and maintenance ......tion, maintenance 3. Control unit Setting the codes at the control unit ............25 4. Troubleshooting Diagnosis ....................32 Faults displayed on the display and programming unit (fault codes) .. 32 ■...

  • Page 5: Information Symbols

    Information Symbols The steps in connection with commissioning, inspec- Symbol Meaning tion and maintenance are found in the "Commission- Reference to other document containing ing, inspection and maintenance" section and identified further information as follows: Step in a diagram: Symbol Meaning The numbers correspond to the order in Steps required during commissioning...

  • Page 6: Commissioning, Inspec-Steps - Commissioning, Inspection And Maintenance

    Commissioning, inspection, maintenance Steps - commissioning, inspection and maintenance Commissioning steps Inspection steps Maintenance steps Page • • 1. Information on maintenance work..................• 2. Checking the high limit safety cut-out setting..............• 3. Filling the heating system with water and venting............•...
  • Page 7 Commissioning, inspection, maintenance Steps - commissioning, inspection and… (cont.) Commissioning steps Inspection steps Maintenance steps Page • • 39. Checking the ventilation air apertures in the installation room (only for open flue operation) • 40. Instructing the system user....................23 •...

  • Page 8: Information On Maintenance Work

    Commissioning, inspection, maintenance Information on maintenance work The product contains ceramic fibres. Danger When working with high temperature insulation 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 adapt or replace the insulation.

  • Page 9: Commissioning The System

    Commissioning, inspection, maintenance Filling the trap with water (cont.) 3. Check that the condensate can drain freely. 4. Refit the siphon. Commissioning the system Control unit operating and service instructions, 07. Adjust the codes on the boiler control unit in and neutralising system operating instructions accordance with the table on page 25.

  • Page 10: Checking The Gas Type

    Commissioning, inspection, maintenance Checking the gas type 1. Check with your gas supply utility regarding the 2. In the delivered condition, the burner is preset for gas type and Wobbe index (Wo). natural gas E. If necessary, convert the burner to ■...

  • Page 11: Checking Static Pressure And Supply Pressure

    Commissioning, inspection, maintenance Checking static pressure and supply pressure Static pressure 1. Close the gas shut-off valve. 2. Undo the screw in test connector , but do not remove. 3. Connect the pressure tester at test connector 4. Open the gas shut-off valve. 5.

  • Page 12: Checking The Co2 Content

    Commissioning, inspection, maintenance Checking the CO2 content Preparing the test 1. Open the gas shut-off valve. 2. Start the burner. 3. Press "S" and "-" simultaneously. Display then shows the following: Status: "d" (= control stop) ■ ■ Service: Modulation level in % ("00" = 100 % = upper heating output, "0"...
  • Page 13 Commissioning, inspection, maintenance Checking the CO content (cont.) testing at the lower heating output 1. Press "-" until the service display has decre- mented to "0" (lower heating output). 2. Note The CO content for all natural gases must be between 7.5 and 10.5 %.

  • Page 14: Checking The Flue Gas Temperature

    Commissioning, inspection, maintenance Checking the flue gas temperature Checking the ionisation current Fig. 10 01. Switch OFF the mains isolator. 07. Switch ON the mains isolator and press the reset button. 02. Pull out ionisation cable plug 08. Check the ionisation current. 03.

  • Page 15: Opening The Boiler Door

    Commissioning, inspection, maintenance Opening the boiler door Danger When working with high temperature insulation 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 adapt or replace the insulation.

  • Page 16: Separating The Neutralising System From The Boiler, Connecting The Drain Hose

    Commissioning, inspection, maintenance Opening the boiler door (cont.) Fig. 12 5. Undo 6 screws on boiler door and open it. 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 from the boiler, connecting the drain hose Fig.

  • Page 17: Cleaning The Combustion Chamber And Heating Surfaces

    Commissioning, inspection, maintenance Separating the neutralising system from the… (cont.) 4. Clean the combustion chamber and heating surfa- 6. Connect siphon and hose ces. 7. Fill trap with water (see page 8). 5. Remove drain hose and clean the inside of con- densate drain with a plastic brush.

  • Page 18: Checking The Condensate Drain And Neutralising System (If Installed)

    Commissioning, inspection, maintenance Cleaning and reconnecting the condensate drain… (cont.) Fig. 14 1. Disconnect drain hose 4. Undo and flush lower part of siphon 2. Clean the inside of the condensate drain system 5. Fill lower part of siphon with water and refit. (hose, pipes).

  • Page 19: Checking The Ignition And Ionisation Electrodes

    Commissioning, inspection, maintenance Checking the burner gauze assembly (cont.) 1. Check the wire mesh and cover of burner gauze assembly for damage. Slight wavy deforma- tions in burner gauze assembly are not prob- lematic. 2. Replace burner gauze assembly if required. 3.

  • Page 20: Installing The Burner

    Commissioning, inspection, maintenance Cleaning the burner (cont.) 4. Disconnect the connecting cables from fan 5. Clean the fan housing and impeller with com- Remove the fan. pressed air. Danger 6. If required, vacuum the inside of burner gauze Mains voltage can be life threatening. assembly For maintenance work, isolate the gas fan from the power supply.

  • Page 21: Checking All Gas Connections For Tightness

    Commissioning, inspection, maintenance Checking the filter element in the gas line (if installed) and replacing if required Checking all gas connections for tightness Danger 4. Start the burner (see page 9). Escaping gas leads to a risk of explosion. Always carry out the following steps. 5.

  • Page 22: Performing Final Checks

    Commissioning, inspection, maintenance Checking the rotary damper setting (cont.) 2. Check the position of the rotary damper in burner 5. Check the position of the rotary damper during the idle mode. Rotary damper windows must be start-up phase. Rotary damper windows must fully opened.

  • Page 23: Checking The Flue Gas Collector For Tightness

    Commissioning, inspection, maintenance Checking the flue gas collector for tightness 1. Traces of condensate on the outside of the flue gas collector indicate a leak. In full load operation, the gaskets can be checked with an inspection mir- ror. If required, remove the thermal insulation com- ponents.
  • Page 24 Commissioning, inspection, maintenance Operating and service documents 1. Complete and detach the customer registration card: ■ Hand the system 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.

  • Page 25: Control Unit Setting The Codes At The Control Unit

    Control unit Setting the codes at the control unit Vitotronic service instructions In conjunction with the following control units: ■ Vitotronic 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 1042...
  • Page 26 Air pressure switch Function The signal of air pressure switch is evaluated in the following operating situations: ■ Prior to the fan start (idle state check) ■ In the pre-purge phase ■ In control mode, subject to the output being no lower than the starting output.
  • Page 27 Burner control unit (cont.) The display screen comprises three digits consisting of Status Service seven segments each. 4 keys serve to make adjust- ments at the different operating levels. Fig. 24 Reset button LED: left heat demand; centre flame; right –...
  • Page 28 Burner control unit (cont.) Safety time Status Service Flame formation Fig. 31 Status Service Flame stabilisation Fig. 32 Operation with flame Status Service Fig. 33 Post-purge Status Service Fig. 34 Standby Status Service Fig. 35 Display Status Service (1-digit) (2-digit) Operating display in standard For the current operating con- "FL"...
  • Page 29 Burner control unit (cont.) Quality of the ionisation current Status Service Note A value 50 for the quality of the ionisation current is > Fig. 36 very good. If the value is lower, measure the ionisation current. If the ionisation current is A, check the ≤...
  • Page 30 Burner control unit (cont.) 3. Set the upper heating output: Press until the display shows "d 00". 4. Press simultaneously; the burner returns to modulating mode. The burner continues at the original modulation level at which status "d" = controlled stop was initiated. Fault display If the burner control unit switches to a fault state, the Status Service...
  • Page 31 Burner control unit (cont.) Status Service 2. Press to call up the second most recent fault, up to the tenth most recent fault. Display under "Status" Fault Fig. 47 Most recent fault Tenth most recent fault The fault code is displayed under "Service". 3.

  • Page 32: Troubleshooting Diagnosis

    Troubleshooting Diagnosis Faults displayed on the display and programming unit (fault codes) Message codes Message code System characteristics Cause Measures Burner does not start Gas supply pressure too Check gas flow pressure; check low; gas pressure switch gas pressure switch. switches off Burner does not start.
  • Page 33 Troubleshooting Diagnosis (cont.) Fault code Shown on System characteristics Cause of fault Measure display F AE F AE Burner control unit in a Valve 1 leaking Replace gas train. fault state F AF F AF Burner control unit in a Valve 2 leaking Replace gas train.
  • Page 34 Troubleshooting Diagnosis (cont.) Fault code Shown on System characteristics Cause of fault Measure display F A7 F A7 No flame reported during Connections "L 1" and Check core assignment safety time; ionisation "N" interchanged at the and alter if required. flame monitor reports no power supply terminal of flame signal.
  • Page 35 Troubleshooting Diagnosis (cont.) Fault code Shown on System characteristics Cause of fault Measure display F 4b F 4b Parameter memory stick Parameter set enabled, Plug memory stick into not found but memory stick not burner control unit; re- plugged into burner con- place memory stick.
  • Page 36 Troubleshooting Diagnosis (cont.) Fault code Shown on System characteristics Cause of fault Measure display F 54 F 54 PWM values incorrect EEPROM of memory Replace memory stick. stick modified or deleted; Danger memory stick faulty Plug-in terminals on the burner control unit are live.

  • Page 37: Faults Without Fault Display

    Troubleshooting Diagnosis (cont.) Faults without fault display Fault Cause of fault Measure Combustion faults due to Excessive gas throughput Adjust gas throughput in accordance with the rated pulsation boiler heating output. Insufficient or excessive air Adjust gas throughput in accordance with the rated boiler heating output.

  • Page 38: Burner Control Unit Flow

    Burner control unit flow chart Burner control unit flow chart Fig. 49 After the controller issues a heat demand, the following program sequence runs: Phase Duration Fault 0 ... Waiting for heat demand 0 ... Fan idle state check max. 2 min Air pressure switch idle state check max.
  • Page 39 Burner control unit flow chart Burner control unit flow chart (cont.) Phase Duration VPS decision: Valve leak test 0.1 s VPS: Empty intermediate valve space 1 to 3 s VPS test time: Valve 1 1 to 240 s VPS: Fill intermediate valve space 1 to 3 s VPS detection: Gas pressure 0.1 s...
  • Page 40 Burner control unit flow chart Burner control unit flow chart (cont.)

  • Page 41: Parts Lists Overview Of Assemblies

    Parts lists Overview of assemblies Ordering parts Standard parts are available from your local supplier. The following information is required: ■ Serial no. (see type plate Assembly (from this parts list) ■ Position number of the individual part within the ■...

  • Page 42: Boiler Assembly

    Parts lists Boiler assembly 0008 0006 0003 0009 0008 0010 0011 0007 0002 0010 0003 0005 0005 0004 0001 0006 0011 Fig. 51...
  • Page 43 Thermal insulation 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)

  • Page 44: Thermal Insulation Assembly

    Parts lists Thermal insulation assembly 0012 0010 0011 0029 0017 0015 0013 0018 0007 0005 0009 0036 0030 0016 0019 0033 0032 0037 0031 0002 0007 0022 0008 0024 0023 0027 0027 0001 0004 0025 0028 0033 0003 0014 0021 0034 0026 0006...
  • Page 45 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...

  • Page 46: Burner Assembly

    Parts lists Burner assembly 2f 007 Fig. 53 MatriX burner type plate Label "Set to ..."...
  • Page 47 Parts lists Burner assembly (cont.) Pos. Part Burner frame Small and fixing parts Threaded connector R ⅛ Oval head screw A M4 x 45 Screw EJOT-PT KBL 40 Hose 6 x 1.5, 320 mm long Stud M8 x 20 Cheese head screw Z4 M4 x 12 Hexagon nut M8 Cheese head screw M6 x 20 Cable ties 114.7 x 2.5...

  • Page 48: Parts Not Shown

    Parts lists Parts not shown 0003 Fixings 0004 Decorative strip 0005 Touch-up spray paint, Vitosilver 0006 Touch-up paint stick, Vitosilver 0007 Installation instructions 0008 Service instructions...

  • Page 49: Component Overview

    Component overview Component overview MatriX cylinder burner Fig. 54 Burner frame Gas train Air pressure switch Rotary damper with servomotor Gas fan Venturi mixing pipe Display and programming unit Mains filter unit with contactor Fig. 55 Air pressure switch Gas supply pipe Display and programming unit Burner control unit Mains filter unit with contactor...

  • Page 50: Connection And Wiring Dia-Burner Control Unit Connection Diagram

    Connection and wiring diagram Burner control unit connection diagram MatriX cylinder burner Fig. 56 Burner control unit MPA 5113 Solenoid valve, stage 1 (BV 1) Vitotronic control unit Servomotor for rotary damper Fan motor with PWM control and feedback B2 Safety chain jumper Flame monitor with ionisation current F1 MCB/fuse Display unit with reset function...

  • Page 51: Mains Filter Unit Connection Diagram

    16 A. Make the power supply (230 V~/50 Hz) via a permanent connection. 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.

  • Page 52: Water Quality Requirements

    Water quality requirements Water quality requirements Note Observation of the following requirements is a neces- sary condition for safeguarding your warranty rights. The warranty excludes damage due to corrosion and scaling. Prevention of damage due to scaling Prevent excessive scale build-up (calcium carbonate) on the heating surfaces.
  • Page 53 Water quality requirements Water quality requirements (cont.) Any limescale deposits that have formed because of a This measure must be carried out by a qualified con- failure to observe the requirements of guideline tractor. Inspect the heating system for possible dam- VDI 2035 will in most cases already have caused a age prior to returning it into use.

  • Page 54: Reports Water Quality

    Reports Water quality Meter reading Fill and top-up water Total water volume Total hardness pH value Date Feedwater Boiler water Settings and test values Settings and test values Commissioning Maintenance/service Static pressure mbar Supply pressure (flow pressure) For natural gas E mbar For natural gas LL mbar...
  • Page 55 Reports Settings and test values (cont.) Settings and test values Commissioning Maintenance/service Ionisation current At the upper rated heat- μ ■ ing output At the lower rated heat- μ ■ ing output Draught actual Note The CO content for all natural gases must be between 7.5 and 10.5 %.

  • Page 56: Specification

    Specification Specification Gas boiler, category I 2ELL Rated heating output = 50/30 °C 135 to 400 168 to 500 209 to 630 = 80/60 °C 123 to 370 153 to 460 192 to 575 Rated heat input 127 to 381 158 to 474 198 to 593 Product ID...

  • Page 57: Final Decommissioning

    Final decommissioning and disposal Final decommissioning and disposal Viessmann products can be recycled. Components and substances from the system are not part of ordi- nary household waste. For decommissioning the system, isolate the system from the power supply and allow components to cool down where appropriate.

  • Page 58: Certificates Eu Declaration Of Conformity

    This product 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, type CT3U, as part of EC type testing can be used to assess the energy efficiency of heating and ventilation systems in buildings to DIN V 4701-10, as specified by the EnEV [Germany] (see Specification table).

  • Page 59: Manufacturer's Certificate

    Certificates 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): ■ limits according to paragraph 6 (1).

  • Page 60: Keyword Index

    Keyword index Keyword index Air pressure switch.............26 Ignition and ionisation electrodes, checking....19 Assembly Information display............. 28 – Boiler............... 42 Information on maintenance.........8 – Burner..............46 Internal system faults..........36 – Overview..............41 Ionisation current check..........14 – Thermal insulation...........44 Ionisation electrode, checking........19 Boiler water requirements..........
  • Page 64 Applicability Serial No.: 7519062 7519063 7519064 7311947 7311948 7311949 Viessmann Werke GmbH & Co. KG Viessmann Limited D-35107 Allendorf Hortonwood 30, Telford Telephone: +49 6452 70-0 Shropshire, TF1 7YP, GB Fax: +49 6452 70-2780 Telephone: +44 1952 675000 www.viessmann.com Fax: +44 1952 675040...

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