Viessmann VITOCROSSAL 300 Istruzioni operative

VITOCROSSAL 300

Service instructions

for heating engineers

VitocrossalĂ300

typeĂCR3, 186 to 311ĂkW

Gas-fired condensing boiler

5692Ă48 ĂGBăăă9/2 2 Please keep safe

General Information

Safety instructions

Please follow these safety instructions closely to prevent accidents and

material losses.

Work on the equipment

Installation, initial start-up,

inspection, maintenance and repairs

must be carried out by a competent

person (heating engineer/installation

contractor).

Before working on the equipment/

heating system, isolate the mains

electrical supply (e.Ăg. by removing a

separate mains fuse or by means of

a mains electrical isolator) and

safeguard against unauthorised

reconnection.

Close the main gas shut-off valve

and safeguard against unauthorised

reopening.

Work on gas equipment

This must only be carried out by an

approved contractor.

Please observe all commissioning

work specified for gas installations

acc. to TRGI or TRF and all local

regulations.

Repair ork

This must not be carried out on parts

that fulfil a safety function.

Use only original Viessmann spare

parts, or equivalent parts that have

been approved by Viessmann.

Initial start-up

This must be carried out by the

system installer or a commissioning

engineer designated by him; all

actual values should be recorded in a

commissioning/service report.

Instructing the system user

The system installer must hand the

operating instructions to the system

user and instruct him/her in the

operation of the system.

¨ĂSafety instructions

In this instruction manual, this

heading denotes information which

must be observed to prevent

accidents and material losses.

¨This symbol denotes important

information which must be

observed to prevent material

losses.

Operating and service documents

1. Complete and detach the customer

registration card:

HGive the system user this part

for safe-keeping.

HKeep the part for the heating

engineer.

2. Keep all parts lists, operating and

service instructions in the folder

and hand this over to the system

user.

5692Ă48 ĂGB

Contents

Index

Page

General Information

Safety instructionsĂ 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating and service documentsĂ 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Initial start-up, inspection and maintenance

StepsĂ 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Further details of the individual stepsĂ 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parts listsĂ18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix

Water quality requirementsĂ24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Declaration of conformityĂ 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manufacturer's certificateĂ 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Commissioning/service reportĂ 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5692Ă48 ĂGB

Initial start-up, inspection and maintenance

StepsĂćĂinitial start-up, inspection and maintenance

For further instructions concerning the individual steps, see pages indicated.

Commissioning steps

Inspection steps

Maintenance steps Page

C1. Checking the high limit safety cut-out adjustmentĂ 5. . . . . . . .

C2. Filling the heating system ith ater and

ventilating the systemĂ 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C3. Fully opening the flue outlet damper and

locking it openĂ 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C4. Checking the neutralising system connections

and filling ith neutralising agentĂ

C I M 5. System start-upĂ 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C6. Pulsation noisesĂ 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 7. System shutdo n

I M 8. Opening the boiler doorĂ 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M9. Separating the neutralising system from the boiler

and connecting the drain hoseĂ 8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M10. Cleaning the combustion chamber & heating surfacesĂ 9

I11. Checking the boiler door thermal insulation and gaskets

C I M 12. Checking all heating ater connections and

the sensor ell for leaksĂ 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C I 13. Checking the function of all safety equipmentĂ 11. . . . . . . . . . . . .

C I M 14. Checking the expansion vessel and system pressureĂ 11

M15. Cleaning the sight glass in the boiler doorĂ 13. . . . . . . . . . . . . . . . . . . .

I M 16. Closing the boiler doorĂ 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I M 17. Checking the ater qualityĂ 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I18. Checking the thermal insulationĂ 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I19. Checking the flue cover for leaksĂ 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I20. Checking the mixer for easy operation and leaksĂ 15. . . . . . .

M21. Cleaning and reconnecting the condensate drainĂ 16. . . . . . .

I22. Checking the boiler room ventilation

I23. Checking the function of the flue gas system

M24. Burner adjustmentĂ 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5692Ă48 ĂGB

Initial start-up, inspection and maintenance

Further details of the individual steps

Checking the high limit safety cut-out adjustment

The high limit safety cut-out must

not be set higher than 11 ĂºC; set to a

maximum of 11 ĂºC, if necessary.

Control unit installation and

service instructions

Filling the heating system ith ater and ventilating the

system

Record the fill volume of calcium

hydrogen carbonate on pageĂ14.

Please note:

Observe the " ater quality

requirements" on pageĂ24.

Fully opening the flue outlet damper and locking it open

The damper must be in the

horizontal position.

Please note:

For handling the damper, see chapter

"Pulsation noises" (pageĂ7).

5692Ă48 ĂGB

Initial start-up, inspection and maintenance

Further details of the individual steps (cont.)

System start-up

Operating instructions ć control unit, burner and neutralising system

Service instructions ć control unit and burner manufacturer's

documentation

1. Check the system pressure.

Permissible boiler operating

pressure: 4Ăbar

2. Check that the boiler room

ventilation duct is unobstructed.

3. Check the mains gas supply

pressure.

4. Check whether the cleaning

aperture on the flue outlet is

closed.

5. Open the gas main shut-off valves.

6. Switch on the mains isolator, the

heating circuit pump switch and

the burner control switch in this

order.

Burner manufacturer's

operating instructions

7. Check the function of the

neutralising system.

Neutralising system

operating instructions

8. Check all gaskets/seals and plugs

for leaks and re-tighten, if

necessary.

Please note:

In addition, we recommend you

check all heating water

connections after approx.

500Ăhours operation for leaks

(see pageĂ10).

9. Check the boiler door and

clean-out cover a few days after

commissioning and re-tighten all

screws.

5692Ă48 ĂGB

Initial start-up, inspection and maintenance

Further details of the individual steps (cont.)

Pulsation noises

Independent of the make of boiler, burner or flue gas system, gas-tight flue

systems can create pulsation noises.

A change of resonance may be effected by rotating the damper fitted into the

flue outlet.

1. Loosen MĂ1 nutĂA in handleĂB

of damperĂC.

2. Adjust the handle until all

pulsation noises have ceased

(the handle mirrors the damper

position).

3. Lock the damper with MĂ1 nutĂA.

4. If necessary, readjust the burner.

5692Ă48 ĂGB

Initial start-up, inspection and maintenance

Further details of the individual steps (cont.)

Opening the boiler door

1. Remove the gas supply pipe.

2. Loosen the screws on the boiler

door and open it.

¨Do not insert tools or other

objects into the combustion

chamber.

Separating the neutralising system from the boiler and

connecting the drain hose

1. Pull hoseĂD to the neutralising

system off stench trap plugĂE.

2. Unscrew stench trap plugĂE from

condensate drainĂF.

3. Clean the inside of condensate

drainĂF with a plastic brush.

4. Connect drain hoseĂGĂto

condensate drainĂFĂand run to a

sewer.

5692Ă48 ĂGB

Initial start-up, inspection and maintenance

Further details of the individual steps (cont.)

Cleaning the combustion chamber and heating surfaces

Thoroughly clean the combustion

chamber and heating surfaces with a

water jet.

¨Do not use a wire brush or sharp

objects.

Scratches or other damage to

components which are in contact

with flue gases should be avoided.

Components which are in contact

with flue gases should not come

into contact with pure iron,

otherwise corrosion damage will

result. Use plastic brushes, if

necessary.

For normal cleaning, rinse the

heating surfaces with a water jet.

However, you may use cleaning

agents if you notice stubborn

residues, surface discolouration

or soot deposits.

When doing so, please observe the

following:

HOnly use solvent-free cleaning

agents. Ensure that no solvent

enters between the heat exchanger

and the thermal insulation.

HRemove soot deposits with alkaline

agents containing surfactants (e.Ăg.

FauchĂ6 *1).

HCombustion residues may create

thin, yellow-brown surface

discolouration as well as hard

deposits, which may only become

visible after removing the soot

deposits. Use slightly acidic,

chlorine-free cleaning agents

based on phosphoric acid to

remove surface discolouration and

hard deposits (e.Ăg. Antox Ă75ĂE*1).

HRemove loosened deposits from

the heat exchanger and thoroughly

rinse the heating surfaces and the

flue gas collector with a water jet.

¨ĂSafety instructions

ear goggles, protective gloves and

protective clothing, if necessary.

Cleaning agent

manufacturer's details.

*1Manufacturer:

Hebro Chemie GmbH

Rostocker StraßeĂ40

DĆ41199ĂMönchengladbach

5692Ă48 ĂGB

Initial start-up, inspection and maintenance

Further details of the individual steps (cont.)

Checking all heating ater connections and the sensor ell for

leaks

¨ĂSafety instructions

Only open the heating water connections after the boiler has been

depressurised.

Only drain the boiler with a vacuum pump when the boiler vent is open.

1. Loosen the screws of top

panelsĂHand remove the panels.

2. Check sensor wellĂK and all

heating water connections for

leaks.

3. Position the top panels and secure

with screws.

5692Ă48 ĂGB

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