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Viessmann Vitocrossal 300 Series User Manual

Viessmann Vitocrossal 300 Series
116 pages
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for use by heating contractor
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5673 649 -18 10/2019
Service Instructions
VITOCROSSAL 300
Vitocrossal 300 CU3A
Models 26, 35, 45, 57, 94, 125, 160, 199
Floor mounted, gas-fired condensing boiler with MatriX gas burner and Lambda Pro control
For operation with natural gas and liquid propane gas
Heating input 19 to 199 MBH
5.6 to 58 kW
Read and save these instructions
for future reference.
Product may not be exactly as shown
IMPORTANT
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Table of Contents

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Viessmann Vitocrossal 300 Series Specifications

General IconGeneral
ModelVitocrossal 300 Series
CategoryBoiler
Boiler TypeCondensing Boiler
Heat Exchanger MaterialStainless Steel
Fuel TypeGas
EfficiencyUp to 98%
Installation TypeFloor-standing
Control SystemVitotronic Control
Modulation Range1:10
Water ContentVaries by model, consult product brochure
DimensionsVaries by model, consult product brochure
WeightVaries by model, consult product brochure
Operating PressureUp to 3 bar

Summary

Safety, Installation and Warranty Requirements

Licensed professional heating contractor

Installation, adjustment, service, and maintenance must be performed by a licensed professional heating contractor.

Contaminated air

Air contaminated by chemicals can cause poisonous by-products and damage equipment. Avoid storage of chemicals near the boiler.

Carbon monoxide

Improper installation or maintenance can lead to flue products entering living space, containing poisonous carbon monoxide gas.

Fresh air

Equipment requires adequate combustion and ventilation air for safe operation. Ensure provisions are met.

Equipment venting

Never operate the boiler without an installed venting system. Improper venting can cause carbon monoxide poisoning.

General Information

Important Regulatory and Installation Requirements

Details codes, technical literature, and working on equipment requirements for safe and compliant installation.

Mechanical Room

Guidelines for selecting and preparing the mechanical room for boiler installation, including air quality and temperature.

Start-up

Filling the Heating System

Step-by-step guide on filling the heating system with water, including checking expansion vessel pressure.

Check Power Supply Connection

Verifies the 120VAC power supply connection and neutral conductor requirements.

Start-up Wizard

Guides the installer through initial boiler setup steps like language, time, units, and system configuration.

Select Gas Type

Information on selecting the correct gas type (Natural Gas or LPG) for boiler operation.

Convert Fuel Type to LPG

Step-by-step guide for converting the boiler from natural gas to liquid propane gas operation.

Measure Static Pressure and Running Pressure

Procedures for measuring gas static and running pressures for correct boiler operation.

Setting the Maximum Output

How to limit the maximum output for heating operation via boiler coding card settings.

Check All Primary and Secondary Circuit Connections for Leaks

Ensure all heating and DHW connections are pressure tight to prevent leaks.

Perform Combustion Analysis

Procedure for measuring CO2 and O2 content to ensure optimal combustion quality.

Checking the Direct Vent (coaxial) System Tightness

Performing a leak test on the direct vent system by measuring CO2 in the coaxial gap.

Starting the heating system

Steps to ensure the heating system is ready before initiating boiler operation.

Service

Removing the Burner and Checking the Burner Gasket

Steps for removing the burner and inspecting its gasket for damage or wear.

Checking Burner Mesh Assembly and Refractory

Procedure for checking the burner mesh assembly and refractory for damage and replacement.

Checking and Adjust the Ignition and Ionization Electrodes

Guide for inspecting, cleaning, and adjusting ignition and ionization electrodes for proper operation.

Checking the Diaphragm Expansion Vessel and System Pressure

Verifying the diaphragm expansion vessel's pre-charge pressure and overall system pressure.

Check CO2 Setting

Measuring CO2 and O2 content at the vent pipe to ensure optimal combustion quality.

Check Functioning of Safety Valves

Verifying the proper operation of safety devices like low water cut-offs and pressure relief valves.

Check Gas Pipes and Fittings for Leaks

Performing leak tests on gas piping and fittings to ensure safety and prevent gas escape.

Functional Description

Space heating mode

How the control unit calculates boiler water setpoint based on temperature and heating curve.

Domestic hot water supply with gas-fired space heating boiler

Details DHW heating activation, burner operation, and temperature differentials based on tank temperature.

Adjusting the Heating Curves

Changing the slope and shift

Explains how to adjust the heating curve slope and shift for optimal system performance.

Coding 1

Coding 2

Heating Circuit 1, 2 and 3

Coding settings for heating circuits, including frost protection, economy modes, and pump logic.

Heating Circuit 1, 2 and 3 (continued)

Advanced coding parameters for heating circuits, covering economy functions and pump control logic.

Zone Circuit 1, 2 and 3

Configuration of heating curve slopes and levels for individual zone circuits.

Diagnosis and Service Scans

Diagnosis

Accessing and scanning operating data, system versions, and connected components.

Troubleshooting

Checking Outputs (relay tests)

Performing relay tests to control and verify the output functions of system components.

Fault Codes

How to identify and interpret fault codes displayed by the control unit, including their system behavior and causes.

Fault Codes (continued)

Detailed table of fault codes, their system behavior, causes, and corrective actions.

Corrective Action

Checking the outdoor temperature sensor

Procedure for testing the resistance of the outdoor temperature sensor and replacing it if faulty.

Checking the DHW / low loss header / heating circuit / room temperature sensor

Testing resistance of various temperature sensors (DHW, low loss header, heating circuit, room) against provided curves.

Checking the boiler temperature sensor

Procedure to test the boiler temperature sensor's resistance and replace it if necessary.

Checking the flue gas temperature sensor

Testing the flue gas temperature sensor's resistance and its role in locking out the boiler.

Function Description

Control Functions

Explains various control functions like heating program changeover, external blocking, and demand, and their coding.

Additional Information

Burner Program Sequence of Operation

Detailed breakdown of the burner's operational phases, timings, and safety checks.

Technical Data

Comprehensive table of technical specifications for boiler models, including input, output, pressures, and temperatures.

Technical Data (continued)

Continuation of technical data, including dimensions, flue gas temperatures, and sound ratings.

Lighting and Operating Instructions

Critical safety warnings and step-by-step procedures for starting and operating the boiler.

OPERATING INSTRUCTIONS

Step-by-step guide for safe start-up, operation, and setting of controls for the boiler.

TO TURN OFF GAS TO APPLIANCE

Procedure for safely shutting off the gas supply to the appliance, including steps for service.

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