Service instructions for contractors VIESMANN Vitocrossal 300 Type CR3 and CR37, 787 and 978 kw Gas condensing boiler For applicability, see the last page VITOCROSSAL 300 4/2009 Please keep safe.
Safety instructions Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained Danger This symbol warns against the risk of injury.! Please note This symbol warns against the risk of material losses and environmental pollution. Note Details identified by the word "Note" contain additional information. Target group These instructions are exclusively designed for qualified personnel. Work on gas equipment must only be carried out by a qualified gas fitter. Work on electrical equipment must only be carried out by a qualified electrician. The system must be commissioned by the system installer or a qualified person authorised by the installer. Regulations Observe the following when working on this system all 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, Gas Safety (Installation & Use) Regulations the appropriate Building Regulation either the Building regulations, the Building Regulation (Scotland), Building Regulations (Northern Ireland), the Water Fittings Regulation or Water Bylaws in Scotland, the current I.E.E. Wiring Regulations. If you smell gas Danger Escaping gas can lead to explosions which may result in serious injury. Never smoke. Prevent naked flames and sparks. Never switch lights or electrical appliances ON or OFF. Close the gas shut-off valve. Open windows and doors. Remove all people from the danger zone. Notify your gas or electricity supplier from outside the building. Shut off the electricity supply to the building from a safe place (outside the building). 2
Safety instructions Safety instructions (cont.) If you smell flue gas Danger Flue gas can lead to life-threatening poisoning. Shut down the heating system. Ventilate the boiler room. Close all doors leading to the living space. Working on the system When using gas as fuel, also close the main gas shut-off valve and safeguard against unauthorised reopening. Isolate the system from the power supply and check that it is no longer 'live', e.g. by removing a separate fuse or by means of a main isolator. Safeguard the system against unauthorised reconnection. Please note! Electronic modules can be damaged by electro-static discharges. Touch earthed objects, such as heating or water pipes, to discharge static loads. Repair work! Please note Repairing components which fulfil a safety function can compromise 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. Installing non-authorised components and non-approved modifications/conversion can compromise safety and may invalidate our warranty. For replacements, use only original spare parts from Viessmann or those which are approved by Viessmann. 3
Index Index Commissioning, inspection, maintenance Steps commissioning, inspection and maintenance... 5 Further details regarding the individual steps... 7 Parts lists... 18 Commissioning/service reports... 23 Specification... 24 Certificates Declaration of conformity... 27 Manufacturer's certificate according to the 1st BImSchV [Germany]... 28 4
Commissioning, inspection, maintenance Steps commissioning, inspection and maintenance For further information regarding the individual steps, see the page indicated Commissioning steps Inspection steps Maintenance steps Page 1. Checking the high limit safety cut-out setting... 7 2. Filling the heating system with water and venting the system... 7 3. Fully opening the flue outlet damper and locking it open... 7 4. Starting the system... 7 5. Minimising pulsation noise... 8 6. Shutting down the system... 9 7. Opening the boiler door... 9 8. Separating the neutralising system from the heat exchanger module and connecting the drain hose... 9 9. Cleaning the combustion chamber and heating surfaces... 9 10. Checking gaskets and thermal insulation components... 10 11. Checking all heating water connections and the sensor well for leaks... 11 12. Checking the function of the safety equipment... 12 13. Checking the diaphragm expansion vessel and system pressure... 12 14. Cleaning the sight glass in the boiler door... 13 15. Closing the boiler door... 13 16. Checking the thermal insulation... 13 17. Checking the mixer for obstructions and leaks... 13 18. Checking the water quality... 14 19. Cleaning and reconnecting the condensate drain system... 14 20. Checking the installation room ventilation 5
Commissioning, inspection, maintenance Steps commissioning, inspection and (cont.) Commissioning steps Inspection steps Maintenance steps Page 21. Checking the flue gas system for leaks 22. Adjusting the burner... 15 23. Checking the gaskets/seals on the flue gas side... 16 24. Instructing the system user... 17 25. Operating and service documents... 17 6
Further details regarding the individual steps Checking the high limit safety cut-out setting Commissioning, inspection, maintenance The high limit safety cut-out must not be set higher than 110 C; if required, set it to a maximum of 110 C. Control unit installation and service instructions Filling the heating system with water and venting the system Record the fill volume, water hardness and ph value on page 14. Permissible boiler operating pressure: 4 bar.! Please note Unsuitable water qualities can result in damage to the boiler body and the heating system. According to VDI Directive 2035, the heating system must be filled and operated with water with a sum of alkaline earths not exceeding 0.02 mol/m 3 (overall hardness 0.11 dh). Observe the "Water quality requirements" on page 25. Fully opening the flue outlet damper and locking it open The damper must be in the horizontal position. Note For handling the damper, see "Minimising pulsation noises", page 8. Starting the system Operating instructions control unit, burner and neutralising system, service instructions control unit and burner manufacturer's documentation 1. Check the heating system pressure. Permissible boiler operating pressure: 4 bar 3. Check the gas supply pressure. 4. Check that the cleaning aperture on the flue outlet is closed. 5. Open the gas line shut-off valves. 2. Check that the installation room ventilation aperture is open. 7
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 6. Switch ON the main isolator, the switch for the heating circuit pump and the burner control switch, in that 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, and retighten if necessary. Note We recommend you check all heating water connections for leaks after approx. 500 hours (see page 11). 9. Check the boiler door and clean-out cover a few days after commissioning 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. 1. Undo M 10 nut A on lever B of rotary damper C. 2. Adjust the lever until all pulsating noises have ceased (the lever mirrors the damper position). B A 3. Lock the rotary damper with M 10 nut. 4. Readjust the burner, if required. BC 8
Shutting down the system Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 1. Switch OFF the main isolator or the power supply and safeguard against unauthorised reconnection. 2. Pull plugs fa and lö from the burner. 3. Close the gas shut-off valve. Opening the boiler door 1. Remove the gas supply pipe. 2. Undo the four screws on the boiler door and open the door.! Please note Scratches inside the combustion chamber can lead to corrosion. Never put tools or other objects into the combustion chamber. Separating the neutralising system from the heat exchanger module and connecting the drain hose C B A D 2. Remove siphon B from condensate drain C. 3. Clean the inside of condensate drain C with a plastic brush. 4. Connect drain hose D to condensate drain C and run to a sewer. 1. Separate hose or pipe A to the neutralising system from siphon B. Cleaning the combustion chamber and heating surfaces! Please note Contact with unalloyed iron and scratches on parts in contact with flue gases can lead to corrosion. Only use plastic brushes, NOT wire brushes or sharp objects. 1. Clean the combustion chamber and heating surfaces. 9
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) For normal cleaning, flush the heating surfaces thoroughly with a water jet. However, you may use cleaning agents if you notice stubborn residues, surface discolouration or soot deposits. For this, observe the following: Only use solvent-free cleaning agents. Ensure that no cleaning agents enter between the boiler body and the thermal insulation. 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 (e.g. Antox 75 E). 2. Remove loose deposits from the boiler; flush the heating surfaces and the flue gas collector thoroughly with a water jet. Danger Loose residues and residual cleaning agents can lead to injury. Wear goggles, protective gloves and protective clothing. Cleaning agent manufacturer's details. Note "Fauch 600" and "Antox 75 E" Manufacturer: Hebro Chemie GmbH Rostocker Straße 40 D -41199 Mönchengladbach Checking gaskets and thermal insulation components 1. Check gaskets and the packing cord in the boiler door for damage. 3. Replace any damaged parts. 2. Check the thermal insulation components of the boiler door for possible damage. 10
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking all heating water connections and the sensor well for leaks Danger There is a risk of injury when working on pressurised components. Only open the connections on the heating water side after the boiler has been de-pressurised. Only drain the boiler with a vacuum pump when the boiler air vent valve is open. D C A A B A 1. Undo the screws of top panels A and remove the panels. 2. Open thermal insulation C of the heat exchanger module until connecting flange D is freely accessible. 3. Check connecting flange D, sensor well B and all connections on the heating water side for leaks. 4. Close the thermal insulation of the heat exchanger module. 5. Position the top panels and secure with screws. 11
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the function of the safety equipment Check the safety valves, the water level and pressure limiters in accordance with manufacturer's details. Checking the diaphragm expansion vessel and system pressure Note Observe the diaphragm expansion vessel manufacturer's instructions. Carry out this test on a cold system. Pump controlled pressure maintaining systems Note In heating systems with automatic pressure maintaining systems and/or deaerating systems (operating according to the pressure reduction method for deaerating), we recommend the installation of a diaphragm expansion vessel (DEV) as individual boiler protection. The diaphragm expansion vessel must be able to hold the heating water expansion volume inside the boiler and provide a capacity of at least 35 l. 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 followed. Carry out all checks in accordance with manufacturer's instructions. Limit pressure fluctuations to the lowest possible differential. Cyclical pressure fluctuations and more significant pressure differentials point towards a system fault. Immediately remedy such faults, otherwise other heating system components may become faulty. Diaphragm expansion vessel 1. Drain the system or close the cap valve on the diaphragm expansion vessel and reduce the pressure, until the pressure gauge indicates"0". Note The pre-charge pressure of the diaphragm expansion vessel (p 0 ) comprises the static system pressure (p St ) (= static head) and a supplement (p 0 = p St + supplement). The supplement is subject to the adjustment of the high limit safety cutout. For a high limit safety cut-out set to 100 ºC: 0.2 bar 110 ºC: 0.7 bar 12
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 2. If the pre-charge pressure of the diaphragm expansion vessel is lower than the value calculated according to the adjacent formula, top up with sufficient nitrogen to achieve this value. 4. Mark this value on the pressure gauge as the minimum filling pressure. 3. Refill with water until the filling pressure is 0.2 bar higher than the precharge pressure of the diaphragm expansion vessel when the system is cold. Cleaning the sight glass in the boiler door Check gaskets A and hose connection B for leaks. A B Closing the boiler door 1. Tighten the screws on the boiler door evenly and diagonally. 2. Install the gas supply pipe and check for tightness. 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 operation. 13
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) 3. Check the mixer for leaks. Replace the O-rings if the mixer leaks. 4. Snap the motorised lever into place. Checking the water quality Enter the amount of top-up water and the total hardness of the feed and boiler water into the following table. For water quality requirements, see page 25. Meter readinup Fill and top- Total water Total hardness ph value Date water volume Feedwater Boiler water m 3 m 3 m 3 dh dh The total hardness of the feed and top-up water must not exceed the guidelines specified by the VDI 2035 (see page 25). The ph value should be between 8.2 and 9.5. Cleaning 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. 14
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Note Clean the inside of the condensate drain system at least annually. A B C D E 1. Pull drain or cleaning hose C off. 2. Clean the inside of condensate drain A once more with the plastic brush. 3. Release and flush lower part E of siphon B; clean the inlet connector of siphon B with a brush. 4. Secure siphon B on condensate drain A and seal in, if required. 6. Clean the inside of the pipes of the condensate drain system and the neutralising system. Neutralising system operating instructions 7. Connect the supply of the neutralising system with line D and siphon B (if required seal in) and ensure that the condensate is draining correctly to the sewer system. 5. Fill lower part E of the siphon with water and reassemble. Note There is a risk of flue gas escaping if the siphon is not filled with water. Adjusting the burner Observe the burner manufacturer's instructions. 15
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Checking the gaskets/seals on the flue gas side 18x 6x A B C D 1. Check the gasket/seal on flue gas collector C between flue gas collector B and boiler body D for tightness. 16 2. Check gaskets A of the clean-out cover for tightness.
Commissioning, inspection, maintenance Further details regarding the individual steps (cont.) Note The seals/gaskets can also be checked under full load with an inspection mirror. If required, remove the thermal insulation components. Traces of condensate on the outside of flue gas collector B or on parts of the thermal insulation also point towards leaks. 3. If required, retighten flue gas collector seal C and seal A or replace. Instructing the system user The installer must instruct the user in the operation of the system. Operating and service documents 1. Complete and detach the customer registration card: Hand the system user this part for safekeeping. Retain the heating contractor's part. 2. File all parts lists, operating and service instructions in the folder and hand this over to the system user. 17
Parts lists Parts lists When ordering spare parts: Quote the type and serial no. (see type plate) and the pos. no. of the required part (as per this parts list). Obtain standard parts from your local supplier. 003 Gasket set (gaskets and sealant) 004 Flue gas collector cover (incl. pos. 006, 007 and 008) 006 Inspection cover 007 Gasket, inspection cover 008 Gasket, flue gas collector cover 009 Gasket 010 Gasket 011 Gasket 012 Boiler door 013 Sight and test pipe cover 014 Sight glass (incl. gasket) 015 Hose ferrule 016 Hose 017 Thermal insulation mat 018 Thermal insulation block 019 Packing 25 x 15 020 Packing 7 25 021 Packing 9 x 7 022 Burner plate 023 Siphon 025 Burner cable, see separate parts list 026 Sensor well 200 Bezel 201 Front left top panel 202 Front right top panel 203 Centre top panel 204 Top front panel 205 Bottom front panel 206 Top back panel 207 Bottom back panel 208 Back panel, left and right 209 Top side panel 210 Bottom side panel 211 Front l.h. rail 212 Front r.h. rail 213 Back l.h. rail 214 Back r.h. rail 215 Centre rail 216 Back retaining bracket 217 Thermal insulation jacket, front 218 Thermal insulation jacket, centre 219 Thermal insulation jacket, back 220 Thermal insulation mat, front 221 2-fold strain relief 222 Vitocrossal 300 logo 223 Edge protector 224 Thermal insulation mat, back Parts not shown 024 Coding card 027 Flame tube gasket 300 Thermal insulation pack 301 Decorative adhesive tape 302 Touch-up spray, Vitosilver 303 Touch-up paint stick, Vitosilver 304 Installation instructions 305 Service instructions A Type plate, optionally left or right B Boiler circuit control, see separate parts list 18
Parts lists Parts lists (cont.) 201 209 209 202 213 216 215 210 211 210 B 204 217 221 205 222 200 220 19
Parts lists Parts lists (cont.) 206 223 203 208 224 207 218 219 216 214 209 215 212 A 209 210 210 20
Parts lists Parts lists (cont.) 018 017 015 012 013 014 018 016 022 021 014 015 011 026 009 019 020 21
Parts lists Parts lists (cont.) 006 007 009 010 004 003 008 023 003 025 22
Commissioning/service reports Commissioning/service reports date: by: Commissioning Service Service date: by: Service Service Service date: by: Service Service Service date: by: Service Service Service date: by: Service Service Service 23
Specification Specification Rated output T V/ T R = 50/30 C kw 787 978 T V /T R = 80/60 C kw 720 895 Rated thermal load kw 742 923 Product ID CE-0085 AU 0315 Product parameters (according to EnEV) Efficiency η at 100% of rated output % 97.0 97.1 at 30% of rated output % 108.3 108.5 Standby loss q B,70 % 0.25 0.25 Power consumption at 100% of rated output W 1059 1175 at 30% of rated output W 353 140 24
Water quality requirements Heating systems with rated operating temperatures up to 100 ºC (VDI 2035) Prevent excessive scale build-up (calcium carbonate) on the heating surfaces. For heating systems with operating temperatures up to 100 C, the VDI Directive 2035 sheet 1 "Prevention of heating system damage in hot water heating systems - scaling in DHW and hot water heating systems" applies [in Germany; check local regulations]: At an output in excess of 600 kw, the total of alkaline earths in the fill and topup water must not exceed 0.02 mol/m³. Operating information: Take the system into use step by step, starting with the lowest boiler output and at a high heating water flow rate. This prevents a localised concentration of lime deposits on the boiler heating surfaces. During expansion or repair work, only drain the necessary pipework sections. Filters, dirt traps and other blow-down or separating facilities in the heating water circuit must be checked, cleaned and activated more frequently after commissioning or new installations, and later on subject to the water treatment applied (e.g. water softening). The build-up of lime deposits on the heating surfaces will be minimised if these instructions are observed. Any scale deposits that have formed because the requirements to VDI Directive 2035 have not been observed, will in most cases already have caused a reduction in the service life of the installed heating equipment. Removing the lime deposits is one option to restore the operational viability. This measure must be carried out by a specialist. Inspect the heating system for possible damage prior to returning it into use. It is essential that the faulty operating parameters are corrected to prevent renewed formation of excessive scale deposits. Prevention of damage due to corrosion on the water side The corrosion resistance of ferrous materials on the heating water side of heating systems and boilers depends on the absence of oxygen in the heating water. The oxygen introduced into the heating system with both the first fill and with topup water reacts with the system materials without causing damage. 25
Water quality requirements (cont.) The characteristic blackening of the water after some time in use indicates that free oxygen is no longer present. The technical rules and in particular VDI Directive 2035-2 therefore recommend that heating systems are designed and operated so that a constant ingress of oxygen into the heating water is prevented. During use, oxygen can normally only enter due to: open expansion vessels overflowing, negative pressure in the system, gas-permeable components. Sealed unvented systems, e.g. those equipped with a diaphragm expansion vessel, offer good protection against the ingress of airborne oxygen into the system, if correctly sized and operating at the correct pressure. At every part of the heating system, even at the suction side of the pump and under all operating conditions, the system pressure should be above ambient atmospheric pressure. The inlet 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 separate the water flowing through the plastic pipes from other heating circuits, e.g. from the boiler, by the provision of a corrosion-resistant heat exchanger. No further anti-corrosion measures are required for sealed hot water heating systems, subject to the above points being observed. However, take additional precautions where there is a risk of oxygen ingress, for example by adding oxygen binder sodium sulphite (5-10 mg/ litre into the excess). The heating water should have a ph value between 8.2 and 9.5. Different conditions apply to systems that contain aluminium components. Where chemicals are used as part of the corrosion protection, we recommend that the manufacturer of the chemicals issues a certificate of suitability of the additives with regard to the boiler materials and the materials of the other heating equipment components. We recommend you refer questions of water quality/treatment to an appropriate specialist. For further details, see VDI Directive 2035-2 and in DIN EN 14868. 26
Certificates Declaration of conformity We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, declare as sole responsible body, that the product Vitocrossal 300, type CR3 and CR37 with the Vitotronic boiler control unit conforms to the following standards: DIN EN 297 DIN EN 55 014-1 DIN EN 303 DIN EN 55 014-2 DIN EN 676 DIN EN 60 335 DIN EN 677 DIN EN 61 000-3-2 DIN EN 50 010-2-2 DIN EN 61 000-3-3 DIN EN 50 165 TRD 702 DIN EN 50 366 This product is designated _-0085 in accordance with the following directives: 2006/95/EC 2004/108/EC 90/396/EEC This boiler meets the requirements of all current TRD regulations. The Declaration of Conformity for the pressure-jet gas burner is contained in the burner manufacturer s documentation. Allendorf, 16 February 2009 Viessmann Werke GmbH&Co KG pp. Manfred Sommer 27
Certificates Manufacturer's certificate according to the 1st BImSchV [Germany] We, Viessmann Werke GmbH&Co KG, D-35107 Allendorf, confirm that the following product meets the NO x limits specified by the 1st BImSchV paragraph 7 (2): Vitocrossal 300, type CR3 and CR37 Allendorf, 16 February 2009 Viessmann Werke GmbH&Co KG pp. Manfred Sommer Printed on environmentally friendly, chlorine-free bleached paper Applicability Applicable to the relevant boilers with burner from the respective serial number. Boiler 7247 420 6 00001, 7247 421 6 00001, 7247 422 6 00001, 7247 423 6 00001, 7247 424 6 00001, 7247 425 6 00001, 28 Viessmann Werke GmbH&Co KG D-35107 Allendorf Telephone: +49 6452 70-0 Fax: +49 6452 70-2780 www.viessmann.com Burner 7185 861 5 00001, 7185 862 5 00001, 7185 863 5 00001, 7185 864 5 00001, 7185 865 5 00001, 7185 866 5 00001, Viessmann Limited Hortonwood 30, Telford Shropshire, TF1 7YP, GB Telephone: +44 1952 675000 Fax: +44 1952 675040 E-mail: info-uk@viessmann.com Subject to technical modifications.